Cat Bucyrus Terex Series SKSS-15 Infinity Blasthole Drill Service Manual SN 1H67C05 & 1H67C43 – PDF DOWNLOAD

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Cat Bucyrus Terex Series SKSS-15 Infinity Blasthole Drill Service Manual SN 1H67C05 & 1H67C43 – PDF DOWNLOAD

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Cat Bucyrus Terex Series SKSS-15 Infinity Blasthole Drill Service Manual SN 1H67C05 & 1H67C43 – PDF DOWNLOAD

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Pages : 854
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Cat Bucyrus Terex Series SKSS-15 Infinity Blasthole Drill Service Manual SN 1H67C05 & 1H67C43 – PDF DOWNLOAD

Safety:

• The Rotary Drill is a heavy moving machine with a mast which raises vertically for drilling. Like
  all moving objects and reach extending devices, there are potential hazards associated with its
  use. These hazards will be minimised if the machine is properly inspected and maintained. The
  maintainers must read this manual and have been trained to use the machine in an appropriate and
  safe manner. Should any ques- tions arise concerning the maintenance or operation of the machine
  contact Reedrill in your state or territory.
• There are many personal hazards and dangers associated with working on and around a drill rig. If
  the safety instructions outlined in this section are adhered to, risk of injury or harm to yourself
  and others will be significantly reduced.

In this section and those that follow, the word:

* DANGER means that severe injury or death will result from failure to follow instruction
* WARNING means that severe injury or death can result from failure to follow instruction
* CAUTION means that minor injury or property damage can result from failure to follow
instruction
* NOTE means that special attention should be given to the instruction

Personal Protective Equipment:
Ensure that the minium PPE is worn at all times when operating or maintaining the machine. Specific
PPE may be required when undertaking some tasks or repairs. For example working at height, welding
or grinding repairs.
Noise:
The Rotary Drill generates high noise while it is in operation there- fore, hearing protection is
mandatory whenever working in the vicinity of the drill.

Electrical Contact:
The Mines Regulation 5.28 states that unless minimum clearances under and in the vicinity of
overhead power lines in accordance with AS 3007.5 can be assured, no drilling activity can take
place within 10 meters any electrical power-line.

Overhead and Buried Utilities:
* Should be located, noted and emphasised on all drilling location plans and drilling assignment
sheets.
* Whenever overhead power lines exist on or near a drilling site or project, consider all wires
to be live and dangerous.
* Watch for sagging power lines before entering a site. Do not lift power lines to gain entrance

TABLE OF CONTENTS:

Cat Bucyrus Terex Series SKSS-15 Infinity Blasthole Drill Service Manual SN 1H67C05 & 1H67C43 – PDF DOWNLOAD

Introduction
Parts Ordering & Product Support i
Safety Information ii
Product Description iii
Manual Contents iii
Table of Contents iv
General Locators xvi
Section 1
Safety 1-1
Personal Protective Equipment 1-2
Noise 1-2
Electrical Contact: 1-2
Overhead and Buried Utilities 1-2
Contact With Electric Wires 1-3
Contaminated Air 1-3
Machine Stability 1-4
Moving and Rotating Parts 1-5
High Pressure Air or Fluid 1-5
Before Operation 1-5
During Operation 1-6
Maintenance 1-8
Safety Locators 1-9
Section 2
Operator’s Cab/ Controls 2-1
Operator’s Controls and Indicators 2-2
Control Panels 2-2
Right Hand Control Panel 2-3
Instrument Panel and Circuit Breakers 2-4
Circuit Breakers 2-4
Light Switches 2-5
Instrument Panel 2-5
System Pressure Guage Panel 2-6
Left Hand Control Panel 2-8
Foot Control Pedals 2-14
Thread Grease Switch 14
Pipe Safety Arm Override Switch 14
Foot Control Pedals 14
Air Conditioner 15
Contents 2-17
Introduction 2-19
Unit Specification 2-20
Technical Data and Control Settings 2-23
Installation and Commissioning 2-25
BI620428
SKSS Introduction v
Table of Contents
Operating Instructions 2-32
Routine Maintenance Proceedures 2-34
Fault Diagnosis 2-38
Warranty 2-48
Basic Spare Parts Listing 2-49
Reference Drawings 2-51
Section 3
Main Frame – Crawlers 3-1
Main Frame Repair 3-2
Leveling Jacks 3-3
Leveling Jack Cylinders 3-4
Remove 3-4
Repair 3-4
Replace 3-4
Mast Elevating Cylinders 3-5
Remove 3-7
Repair 3-7
Replace 3-7
Crawler Assembly 3-8
Crawler Component Repair 3-9
Metric Bolt Torque Specifications 3-10
Track Maintenance 3-11
Before Operating Machine: 3-11
General Maintenance 3-11
Track Tension Adjustment 3-12
Hydraulic Tensioner 3-13
Correct Track Tension 3-13
Description 3-14
Nitrogen Tensioner 3-15
Hydraulic Tensioner 3-16
Repair 3-16
Nitrogen Tensioner Assembly 3-17
Track Tension Adjustment 3-18
Nitrogen Tensioner – Filling Instructions 3-18
Nitrogen Tensioner – Pressure Check 3-20
Nitrogen Tensioner – Pressure Release 3-20
Track Chain – Separate 3-22
Track Chain Repair 3-24
Track Link – Repair & Replace 3-24
Track Link – Description 3-25
Track Shoes Installation 3-26
Track Link Position 3-26
Track Shoe – Mounting to Track Chain 3-26
Track Shoe – Mounting to Track Chain 3-27
Direct Torque Method 3-27
BI620428
vi SKSS Introduction
Table of Contents
Torque Turn Method 3-27
Track Shoe – Retightening 3-27
Track Shoe Bolt Torque (Direct Torque Method) 3-28
Track Shoe Bolt Torque (Torque Turn Method) 3-29
Track Chain and Shoe Installation 3-30
Track Chain with Shoes 3-30
Track Chain & Shoe – Assembly & Installation 3-30
Final Drive 3-32
Final Drive – General Description 3-32
Final Drive Unit Removal 3-33
Removal from Track Frame 3-33
Installation into Track Frame 3-34
Final Drive Maintenance 3-35
Oil Check / Change 3-35
Final Drive Oil 3-36
Specifications 3-36
Recommended Oil 3-36
Final Drive Assembly 3-37
Parking Brake – Description 3-38
Final Drive Disconnect 3-39
Final Drive – Disconnect & Parking Brake 3-40
Towing Procedure – Gear Drive Disconnect 3-40
Parking Brake – Removal & Installation 3-40
Idler Assembly 3-41
Idler Unit Removal 3-43
Idler Unit – Assembly 3-45
Track and Support Rollers 3-49
General Description 3-49
Track Roller – Removal & Disassembly 3-51
Support Roller – Removal & Disassembly 3-52
Track and Support Roller – Assembly 3-53
Track and Support Roller – Test and Install 3-54
Auxiliary Crane 3-56
Palfinger Hydraulic Crane Operators Manual 3-57
Contents 3-58
Before Operation of Crane 3-64
Start Operation of Crane 3-65
Section 4
Engine / Drive Train / Compressor 4-1
Power Group Locator 4-2
Engine 4-3
Engine Fuel System 4-4
Engine Oil Reserve System Circuit 4-12
Engine Oil Reserve System 4-12
Oil Reserve Systems 4-14
LED Monitor Readings 4-15
BI620428
SKSS Introduction vii
Table of Contents
Signals 4-15
Adjustment of Running Oil Level 4-15
Servicing 4-16
Troubleshooting 4-16
Oil Reserves Systems – Maintenance 4-17
Engine and Compressor Air Cleaners 4-18
Engine and Compressor Air Cleaner Service 4-19
Inspection and General Service 4-19
Engine and Compressor Air Cleaner Service 4-21
Safety Element Service 4-21
Flexible Drive Coupling Service 4-22
Adaptor Flanges 4-22
Centering Flanges 4-22
Rubber Element 4-22
Tube Assembly 4-22
Mounting Screws and Adhesive 4-23
Pump Drive Assembly – Removal and Replacement 4-25
Pump Drive 4-25
Pump Identification 4-26
Pump Drive Gearbox 4-27
Pump Drive Gearbox – Repair 4-28
3″ Input Shaft Assembly 4-30
Hydraulic Piston Pumps 4-31
Hydraulic Piston Pumps – Removal and Replacement 4-31
Hydraulic Piston Pumps – Repair 4-31
Tram and Rotation Pumps 4-32
Hydraulic Piston Pumps 4-69
Hydraulic Piston Pumps – Removal and Replacement 4-69
Hydraulic Piston Pumps – Repair 4-69
Feed and Auxiliary Pump 4-70
Hydraulic Gear Pumps 4-101
Hydraulic Gear Pumps – Removal and Replacement 4-101
Hydraulic Gear Pumps – Repair 4-101
Compressor Installation 4-115
Compressor Replacement and Drive Coupling Maintenance 4-116
Disassembly 4-116
Before Installation of New or Rebuilt Compressor: 4-117
Reassembly 4-118
Before Start-Up of New or Rebuilt Compressor: 4-118
Drill Compressor 4-119
High Pressure Compressor 4-120
Section 1 Safety 4-120
General 4-120
Pressure Release 4-120
Fire and Explosion 4-121
Moving Parts 4-121
Toxic and Irritating Substances 4-121
Electrical Shock 4-122
BI620428
viii SKSS Introduction
Table of Contents
Lifting 4-122
Section 2 Description 4-123
Introduction 4-123
Compressed Air Functions 4-123
Sullair Compressor Unit 4-124
Compressor Discharge System 4-125
Compressor Cooling and Lubrication System 4-126
Compressor Fluid Circuit 4-127
Compressor Condensation Table 4-130
Compressor Air Circuit 1475cfm @ 500psi 4-131
Compressor Description 4-143
Air Inlet System 4-143
Instrument Group 4-145
Protection System 4-145
Compressor Operation 4-146
Section 3 Operation 4-146
General 4-146
Purpose Of Controls 4-146
Initial Start-up Procedure 4-148
Subsequent Start-up Procedure 4-149
Shutdown Procedure 4-149
General Operating Instructions 4-149
Compressor Maintenance 4-150
Section 4 General Maintenance 4-150
General 4-150
Daily Operation 4-150
Maintenance After Initial 50 Hours Of Operation 4-151
Maintenance Every 250 Hours 4-151
Maintenance Every 500 Hours 4-151
Maintenance Every 1000 Hours 4-151
Main Drive Shaft Seal Replacement 4-152
Interstage Tube 4-155
Discharge Check Valve 4-156
Separator/Receiver Tank 4-157
Minimum Pressure / Check Valve 4-159
Scavenge Line 4-160
Scavenge Line Sight Glass 4-160
Scavenge Line Oriface 4-160
Compressor Discharge Temperature Switches, Senders and Gauges 4-161
Thermal/Bypass Valve 4-162
Fluid Stop Valve 4-164
Compressor Fluid Filter 4-166
Inlet Valve 4-168
Compressor Regulation 4-170
Relieving Regulators 4-170
Reducing Regulators 4-173
System Blowdown Valve 4-175
Running Blowdown Valve 4-176
BI620428
SKSS Introduction ix
Table of Contents
Moisture Separator Maintenance 4-178
Auxiliary Regulator 4-179
Troubleshooting 4-181
Compressor Oil Cooler Assembly 4-185
Compressor oil cooler 4-185
Radiator/Hydraulic Oil Cooler Assembly 4-186
Radiator/Oil Cooler Repair 4-187
High Pressure Compressor Fluid Cooler 4-189
Radiator Cooler 4-197
Section 5
Dust Control Systems 5-1
Water Injection 5-3
Water Injection Control 5-4
Basic Water Injection System – SKSS-15 5-6
Water Pump 5-7
Recommended Lubricants 9
Water Pump Motor Repair 9
Water Pump Motor 10
Foam Injection System 18
Foam Injection Pump 20
Section 6
Mast / Rotary Drive / Pipe Rack 6-1
Mast Weldment 6-2
Mast Repair 6-3
Mast Assembly 6-3
Mast Pivot 6-4
Feed Cylinders 6-5
Feed Cylinder – Removal 6-7
Feed Cylinder Assembly 6-9
Repair 6-10
Installation 6-10
Hoist/Pulldown Cable Adjustment 6-11
Hoist/Pulldown Cable Replacement 6-14
Rotary Head Guide Alignment 6-16
Rotary Drive Assembly 6-18
Rotary Drive – Removal from Mast 6-19
Rotary Drive – Installation 6-19
Rotary Drive Gearbox 6-20
Rotary Drive Gearbox – Item Listing 6-21
Rotary Head Bull Shaft Bearing 6-21
Rotary Drive Gearbox – Repair 6-22
Main Shaft Bearing Preload 6-22
Air Swivel 6-23
BI620428
x SKSS Introduction
Table of Contents
Winch Assembly 6-24
Precautions on the Use of Winches 6-24
Wire Rope 6-24
Wedge Sockets 6-26
Grooved Drums 6-27
Plain (Smooth) Drums 6-27
Drums – Multiple Layers 6-27
Winch Assembly Service Manual 6-28
Deck Wrench 6-57
H O B O Wrench 6-58
Breakout System – HOBO 6-59
Pipe Safety Arm 6-59
Pipe Positioner 6-60
Carousel Pipe Rack 6-61
Major Components 6-6-61
Carousal Indexing 6-62
Pipe Rack Bearings – Removal 6-64
Pipe Rack Components – Inspection 6-67
Pipe Rack – Assembly and Installation 6-68
Pipe Rack Roller – Remove and Replace 6-69
Pipe Rack Roller – Disassembly and Assembly 6-71
Section 7
Hydraulic Systems 7-1
Hydraulic Symbols 7-2
Pressure Setting Sequence 7-4
Hydraulic Tank 7-6
Main Return and Case Drain Filter 7-8
Main Hydraulic Pumps 7-10
Pump Identification 7-11
Right Track, Left Track/Rotation Pumps 7-11
Hydraulic Piston Pumps – Repair 7-11
AA4VG 180 Hydraulic Pump 7-13
HD/D Control 7-13
Port Locations 7-15
Setting Procedure 7-15
Mechanical Zero Position – HD Pump Control 7-16
Hydraulic Zero Position – HD Pump Control 7-17
Charge Pressure, High Pressure and P O R Relief Settings 7-18
Set Charge Pressure 7-19
Set Crossover Relief (High Pressure) 7-19
Set Pressure Override (P O R ) 7-21
Charge Filter 7-22
Tram/Rotation Pump Circuit 7-24
Tram/Rotation Pump Circuit 7-25
Rotation Circuit 7-26
BI620428
SKSS Introduction xi
Table of Contents
Rotation/Tram Motor Circuit 7-27
Loop Filters 7-28
Rotary Drive Gearbox Motor 7-32
Rotary Drive Gearbox Motor – Repair 7-32
Case leakage bypass test 7-32
Shaft Seal Replacement 7-32
Trouble Shooting 7-34
Feed and Auxiliary Pump Circuit 7-36
Hydraulic Piston Pumps – Repair 7-36
Feed & Auxiliary Functions Pump 7-37
Function of Load Sensing Control (DRS) 7-37
Adjustment Procedure 7-37
Standby Pressure: 7-37
Main Pressure: 7-37
Auxiliary and Feed Circuits 7-38
Main Control Valves 7-39
Valve Stand Assembly 7-39
MP18 Valve – Jack and Mast Raise Valve 7-40
MP22 Valve – Hoist and Pulldown Control 7-42
MP22 Valve 7-44
4WE6 – Aux Functions and Mast Valves 7-45
Exploded View of 4WE6 7-49
Counterbalance Valve 7-49
Counterbalance Valve Adjustments 7-49
Pilot Control Manifold 7-50
Control Valve Assembly 7-52
Auxiliary Pump Load Solenoid Valve – V03 7-52
Shuttle Valve – V04 7-52
Auxiliary Pump Load Sense Relief – V05 7-52
Jacks/Mast raise Load Sense relief – V06 7-53
Drill/Tram Interlock Solenoid Valve – V07 7-53
Drill/Tram Solenoid Valve – V08 7-54
Auto Pulldown Solenoid Valve – V09 7-54
Pilot Operated Directional Valve – V10 7-54
Set-up Interlock Solenoid Valve – V11 7-54
Auto Pulldown Pressure Reducing Valve – V12 7-55
Shuttle Valve – V13 7-55
Surge Protection Relief Valve – V14 7-55
Maximum Pulldown Pressure Relief – V15 7-56
2nd Maximum Pulldown Relief Valve – V16 7-56
Reduced Pulldown Relief Valve – V17 7-56
Reduced Pulldown Solenoid Valve – V18 7-57
Shuttle Valve – V19 7-57
Orifice – V20 7-57
Maximum Rotation Pressure Relief – V21 7-57
Surge Protection Pressure Reducing/Relieving Valve – V22 7-57
Hydraulic Feed Circuit 7-58
Hoist/Pulldown Control Valve 410665 MP22 7-59
BI620428
xii SKSS Introduction
Table of Contents
Set Max Pulldown Relief Valve (V15) 7-59
Feed Control Valve 7-61
Holdback Control 7-67
Feed Valve Assembly 7-68
Jack Control and Mast Elevating Circuit 7-69
Pressure Adjustment 7-70
Leveling Jack Cylinders 7-71
Counterbalance Valve Test Procedure 7-72
Mast Elevating Cylinders 7-73
Counterbalance Valve Test Procedure 7-74
Auxiliary Functions Circuit 7-75
Hydraulic Operated Breakout Wrench 7-77
Setting of HOBO Sequence Valves 7-78
Pipe Positioner Sequence Valves 7-79
Setting of Pipe Positioner Sequence Valves 7-79
Pipe Safety Arm Sequence Valves 7-80
Setting of Pipe Safety Arm Sequence Valves 7-80
Cooler Fan Circuit 7-81
Fan Motor Circuit 7-81
Adjustment 7-81
Cooler Fan Motor 7-84
Hydraulic Thermostatic Valve 7-88
Central Lube 7-89
Hydraulic Circuit 7-90
Air Conditioner Compressor Drive Circuit 7-91
Air Conditioner Drive Motor 7-92
Water Injection Circuit 7-96
Water Injection valve 7-97
Toc-2 Controller 7-99
Water Injection Valve 7-99
Hydraulic Cylinders Repair 7-116
Hydraulic Cylinders List 7-116
Section 8
Vigilante Guide and Electrical Components 8-1
Electrical Locator 8-2
Batteries 8-5
Jump Starting 8-6
Welding Precautions 8-8
Vigilante Guide 8-9
Contents 8-9
Important Information 8-10
PLC 8-11
Eeprom 8-12
Output Card 8-13
Touchscreen 8-14
Laser Depth System 8-15
BI620428
SKSS Introduction xiii
Table of Contents
Pipe in Hole Detection 8-17
Tram Protection 8-17
Mast and Jack Lowering Protection 8-17
Pipe Rack Swing Interlock 8-17
Distance Meter 8-17
Start Up and Shut Down 8-18
Hydraulic Function Enable 8-18
Drill Tram Enable Function 8-18
Alarms 8-18
Solenoid Control 8-19
Auto Lube 8-22
Hammer Oiler System 8-22
Gauges 8-23
Pressure Transducer 8-23
Level Transducer 8-23
Temperature Transducer 8-24
Water Flow Transducer 8-24
Inclinometers 8-25
Head Speed Module 8-26
Level Switches 8-27
Dust Suppression 8-27
Turkey Spray 8-27
Water Suppression Tank Top Up 8-27
Vigilante System Component Information 8-28
Contents 8-28
Head Speed Module 8-29
Inclinometer 8-31
Ladder Prox Switch 8-34
Laser 8-35
Level Switches 8-47
Radiator Level Switch 8-51
Level Transducers 8-55
Pressure Transducers 8-65
Temperature Transducer 8-74
Water Flow Transducer 8-83
Water Control Module 8-97
Rod Counter Prox Switch 8-104
Remote Fuel Level Display 8-105
Section 9
Lubrication and Preventive Maintenance 9-1
Central Lube System 9-2
Hydraulic Control Schematic 9-3
Auto Lube 9-3
Central Lube System Circuit Drawing 9-5
Central Lube Tank Assembly 9-6
Central Lube System 9-7
BI620428
xiv SKSS Introduction
Table of Contents
Central Lube Pump Module 9-8
Central Lube Pump 9-21
SL-1 Injector Assembly 9-46
SL-1 Injector Specifications 9-46
Hammer Oiler Tank Assembly 9-48
Hammer Oil Circuit 9-49
Hammer Oil System 9-50
Air Service Unit Components 9-50
Pipe Thread Lubricator 9-63
Air Service Unit 9-63
Filter Regulator 9-64
Air Line Lubricator 9-65
Pipe Thread Pump 9-66
Filter Locator 9-74
Lubrication And Maintenance 9-76
Safety 9-76
Track Gear 9-76
Engine Maintenance 9-77
Air Cleaners 9-78
Air Filter Elements 9-78
Alternator Maintenance 9-78
Pump Drive And Drive Shaft Maintenance 9-79
Compressor Maintenance 9-79
Cooler Packs 9-80
A-Frame And Pivot Point Maintenance 9-80
Pull Down And Hoist Ropes And Sheaves Maintenance 9-81
Rotary Head Maintenance 9-81
Hydraulic System Maintenance 9-82
Hydraulic Maintenance 9-82
Water Pump Maintenance 9-83
Cab Maintenance 9-83
Air Conditioner Maintenance 9-83
Battery Maintenance 9-84
Lubrication System Maintenance 9-84
Fire Suppression Maintenance 9-84
Lubrication – General 9-85
Equipment Lubrication 9-85
Lubrication & Maintenance Chart – 250hr 9-86
Lubrication & Maintenance Chart – 500hr 9-96
Lubrication & Maintenance Chart – 1000hr 9-107
Lubrication & Maintenance Chart – 2000hr 9-118
Lubrication and Maintenance 9-130
Lubricant Specifications 9-131
Hydraulic System 9-131
Hydraulic Tank Capacity 9-131
Compressor Lubrication 9-132
Lubricating Grease 9-133
BI620428
SKSS Introduction xv
Table of Contents
Gear Lubricant 9-133
Scheduled Oil Sampling Analysis 9-133
Torque Values for Split Flange Connections 9-134
Torque Values for Hydraulic Tubes & Fittings 9-135
Torque Values for Standard Fasteners 9-136

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