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Cat Bucyrus Terex SKS-W Infinity Blasthole Drill Service Manual SN 1A66K53 – PDF DOWNLOAD
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Cat Bucyrus Terex SKS-W Infinity Blasthole Drill Service Manual SN 1A66K53 – PDF DOWNLOAD
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Description
Cat Bucyrus Terex SKS-W Infinity Blasthole Drill Service Manual SN 1A66K53 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus Terex SKS-W Infinity Blasthole Drill Service Manual SN 1A66K53 – PDF DOWNLOAD
Language : English
Pages : 563
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Cat Bucyrus Terex SKS-W Infinity Blasthole Drill Service Manual SN 1A66K53 – PDF DOWNLOAD
Safety Information:
- This manual is furnished with your Infinity Series rotary blasthole drill to aid you in performing
the necessary service work to maintain your drill in good operating condition. - This manual contains repair and adjustment information for all major operating systems on the
machine. In some cases such as hydraulic pumps and motors it is better to replace the unit with a
new or rebuilt unit than to perform major repairs. Should further information be desired or should
particular problems arise which are not covered sufficiently in this manual, the matter should be
referred to manufacturer. - The descriptions and specifications contained in this manual were in effect at the time of printing.
The right is reserved to make changes at any time without notice and without obligation. - It is YOUR responsibility to understand and follow manufacturer’s instructions on machine operation
and service, and to observe pertinent safety precautions, laws and regulations. Failure to read and
understand this manual and all safety, capacity and instruction placards on the machine before
operating the unit, constitutes a misuse of the machine. - It is your responsibility to know the
manufacturer’s specific requirements, government regulations, required precautions and any work
hazards which may exist. You must make these known to all personnel working with the equipment or
in the area, so that all may take the necessary and required safety precautions. Keep all children,
visitors, and untrained personnel away from the equipment. - It is also your responsibility to
operate your equipment with skill, good judgment, and caution. Following recognised safety
procedures will help you avoid accidents. Failure to heed these instructions can result in property
damage, serious injury or death.
TABLE OF CONTENTS:
Cat Bucyrus Terex SKS-W Infinity Blasthole Drill Service Manual SN 1A66K53 – PDF DOWNLOAD
Section 1 – Safety 1-1
Section 1 Contents 1-3
Safety 1-5
Personal Protective Equipment 1-5
Noise 1-5
Electrical Contact 1-5
Overhead and Buried Utilities 1-5
Contact with Electric Wires 1-6
Contaminated Air 1-6
Machine Stability 1-7
Moving and Rotating Parts 1-8
High Pressure Air or Fluid 1-8
Before Operation 1-8
During Operation 1-9
Maintenance 1-11
Safety Locator 1-12
Notes 1-14
Section 2 – Operator’s Cab / Controls 2-1
Section 2 Contents 2-3
Graphic Symbol Legend 2-5
Warning Decals 2-8
Operators Controls and Indicators 2-10
Right Hand Control Panel 2-10
Instrument Panel 2-12
Circuit Breakers 2-13
Light Switches 2-13
Pressure Gauge Panel 2-14
Left Hand Control Panel 2-16
Cab Foot Controls 2-20
Thread Grease Switch 2-20
Air Conditioner 2-21
T7 Series Split System Air Conditioning Manual 2-21
Section 1 0 Technical Data and Control Settings 2-22
Section 2 0 Installation and Commissioning 2-24
Section 3 0 Routine Maintenance Procedures 2-30
Section 4 0 Fault Diagnosis 2-31
Section 5 0 Reference Drawings 2-40
Notes 2-45
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
Weld Inspection Schedule 3-6
Main Frame 3-6
BI620444
Int-6 SKS-W Introduction
Contents
Levelling Jacks 3-7
Levelling Jacks Cylinder 3-7
Levelling Jacks 3-8
Limit Switch 3-8
Levelling Jack Cylinders 3-8
Mast Elevating Cylinders 3-9
Mast Elevating Cylinders 3-9
Internal Counterbalance Valve 3-10
Crawler Assembly 3-12
Crawler Assembly 3-13
Parts List 3-13
Crawler Component Repair 3-13
Metric Bolt Torque Specifications 3-14
Track Tension Adjustment 3-15
Before Operating the Machine 3-15
General Maintenance 3-15
Track Assembly 3-16
Idler Unit Description 3-17
Hydraulic Tensioner 3-18
Repair 3-18
Nitrogen Tensioner 3-19
Nitrogen Tensioner – Filling Instructions 3-20
Nitrogen Tensioner – Pressure Check 3-21
Nitrogen Tensioner – Pressure Release 3-21
Hydraulic Tensioner 3-22
Hydraulic Tensioner Assembly 3-22
Repair 3-22
Track Chain 3-23
Track Chain – Separate 3-23
Track Chain Repair 3-24
Track Shoes Installation 3-26
Track Link Position 3-26
Track Shoe – Mounting to Track Chain 3-26
Track Shoe Bolt Torque (Direct Torque Method) 3-28
Bolt Torque KN111 3-28
Track Shoe Bolt Torque (Torque Turn Method) 3-29
Bolt Torque KN111 3-29
Track Chain and Shoe Installation 3-30
Track Chain with Shoes 3-30
Track Chain and Shoe – Assembly and Installation 3-30
Final Drive Unit 3-32
General Description 3-32
Removal from Track Frame 3-33
Installation into Track Frame 3-34
Final Drive Maintenance 3-35
Final Drive Oil 3-36
BI620444
SKS-W Introduction Int-7
Contents
Final Drive Assembly 3-37
Parts List 3-38
Final Drive – Disconnect and Parking Brake 3-39
Towing Procedure – Gear Drive Disconnect 3-39
Parking Brake – Description 3-40
Parking Brake – Removal and Installation 3-40
Idler Unit 3-41
Idler Unit – Assembly 3-41
Idler Unit – Removal 3-44
Track and Support Rollers 3-45
Track Roller Assembly 3-45
General Description 3-45
Track Roller – Removal and Disassembly 3-46
Support Roller – Removal and Disassembly 3-46
Track and Support Roller – Assembly 3-47
Track and Support Roller – Test and Install 3-48
Track and Sprocket Inspection 3-50
Track Inspection and Wear Limit Guide 3-50
Sprocket Wear Patterns 3-54
Auxiliary Crane 3-60
Rear Deck Crane Palfinger Crane PC 1300 Service Information 3-60
Warranty Provisions 3-61
Checking Bolted Connections 3-61
Maintenance Chart 3-62
Lubrication 3-64
Hydraulic Fluids 3-67
Oil Change / Oil Maintenance 3-68
Cleaning Agents and Equipment 3-69
Repairing Paint Damage 3-70
Removal From Service and Disposal 3-70
Notes 3-71
Section 4 – Engine / Drive Train / Compressor 4-1
Section 4 Contents 4-3
Power Group Locator 4-5
Caterpillar C27 Engine 4-6
Caterpillar C27 Engine 4-6
Engine Mounts – Installation 4-7
Engine and Compressor Air Cleaner 4-8
Engine and Compressor Air Cleaner Service Assembly 4-8
Engine and Compressor Air Cleaner Service 4-9
Flexible Drive Coupling 4-12
Flexible Drive Coupling Service 4-12
Pump Drive 4-14
Pump Identification and Parts List 4-14
Pump Drive Assembly – Removal and Replacement 4-15
BI620444
Int-8 SKS-W Introduction
Contents
Pump Drive Gearbox 4-16
Pump Drive Gearbox 4-16
Pump Drive Gearbox – Repair 4-17
Pump Drive Gear Box Input Shaft Assembly 4-18
Hydraulic Pumps 4-20
Hydraulic Pumps – Removal and Replacement 4-20
Compressor Installation 4-21
Safety 4-21
Compressor Installation 4-24
Compressor Drive Coupling 4-26
Compressor Alignment 4-27
Compressor Shaft Seal 4-28
Compressor Shaft Seal 4-28
Low Pressure Compressor 4-30
Description 4-30
Compressed Air Functions 4-30
Inlet Valve 4-34
Compressor Regulation 4-36
Compressor Regulation Closed Poppet Inlet 4-37
Running Blowdown Valves 4-38
Relieving Regulators 4-39
Compressor Control Set-up Closed Poppets Inlet 4-41
Compressor Functional Description 4-50
Compressor Operation 4-51
Compressor Operation 4-51
Compressor Maintenance 4-53
General Maintenance 4-53
Compressor Receiver Tank Assembly 4-54
Parts List 4-55
Separator Elements 4-56
Separator Elements – Remove and Replace 4-57
Scavenge Line 4-58
Compressor Discharge Temperature Gauge, Switch and Sender 4-60
Minimum Pressure Valve 4-61
Minimum Pressure / Check Valve Maintenance 4-61
Thermal Bypass Valve 4-62
Thermal Bypass Valve Maintenance 4-63
Compressor Fluid Filter 4-64
Changing Filter Elements 4-65
Troubleshooting 4-66
Coolers 4-68
Hydraulic Oil / Hydraulic Cooler Assembly 4-68
Compressor Oil Cooler 4-69
Fan Speed 4-69
Aluminium Tube Air to Oil Cooler 4-70
Aluminium Tube Air to Oil Cooler – Standard Parts 4-70
BI620444
SKS-W Introduction Int-9
Contents
Removal Replacement 4-71
Oil Cooler – Internal Cleaning 4-73
Radiator Cooler 4-75
Typical Radiator Core – Standard Parts 4-75
Cleaning 4-76
Tube Removal 4-76
Seal Installation 4-77
Tube Installation 4-78
Notes 4-80
Section 5 – Dust Control System 5-1
Section 5 Contents 5-3
Dust Control System 5-5
Dust Control Systems 5-5
Water Injection 5-6
Water Tanks 5-6
Water Injection Relief Valve 5-7
Water Injection Control 5-8
Water Injection Basic Circuit 5-10
Water Pump 5-11
Pump Specifications 5-11
Servicing Instructions 5-11
Water Injection Pump and Parts List 5-12
Replacing Piston Cup Seals 5-13
Replacing Suction and Discharge Valves 5-14
Replacing Power End Bearings 5-15
Servicing the Wrist Pin Bearings 5-16
Fastener Torque Requirements 5-16
Recommended Lubricants 5-17
Water Pump Motor Repair 5-17
Water Injection Hydraulic Control Valve Repair 5-17
Water Pump Drive Coupling 5-17
Level and Flow Transducer 5-17
Notes 5-18
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Weld Inspection Schedule 6-6
Mast Inspection 6-6
Mast Assembly and Installation 6-7
Mast Assembly 10m 6-7
Mast Weldment 6-8
Mast Pivot 6-8
Mast Locking 6-8
BI620444
Int-10 SKS-W Introduction
Contents
Mast / Drill Without Mast 6-9
Mast Assembly 6-10
Raising the Mast 6-10
Hoist / Pulldown Cylinder 6-12
Hoist / Pulldown Cylinder and Parts List 6-12
Removal From Mast Assembly 6-13
Repair 6-14
Installation 6-14
Hoist / Pulldown Cable 6-16
Adjustment 6-16
Replacement 6-18
Rotary Drive 6-20
Rotary Head Assembly 6-20
Rotary Head Guide Alignment 6-21
Rotary Head – Drive System 6-23
Rotary Drive – Removal from Mast 6-24
Rotary Drive – Installation 6-24
Rotary Drive Gearbox – Repair 6-25
Rotary Head Bull Shaft Bearing Nut 6-26
Air Swivel 6-27
Deck Wrench 6-28
Deck Wrench 6-28
H O B O Wrench 6-29
H O B O Wrench 6-29
Breakout System – H O B O 6-30
Optional Hydraulic Operated Bit Basket – H O B B 6-30
Pipe Positioner 6-31
Pipe Positioner 6-31
Carousel Pipe Rack 6-32
Major Components 6-32
Rod Handling – Carousel Indexing 6-33
Pipe Rack Assembly 6-34
General Information 6-35
Pipe Rack Bearings – Removal 6-35
Pipe Rack Components – Inspection 6-37
Pipe Rack – Assembly and Installation 6-38
Pipe Rack Roller – Remove and Replace 6-39
Pipe Rack Roller – Disassembly and Assembly 6-40
Top Sub Saver 6-42
Replacement Procedure 6-42
Notes 6-43
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-7
BI620444
SKS-W Introduction Int-11
Contents
Pressure Setting Sequence 7-9
Pressure Setting Sequence 7-9
Hydraulic System 7-9
Hydraulic Tank 7-10
Hydraulic Tank 7-10
Return Hydraulic Filters 7-11
Main Return and Case Drain Filters 7-12
Routine Maintenance 7-13
Changing Filter Elements 7-13
Main Hydraulic Pumps 7-14
Pump Identification and Parts List 7-14
Right Track / Pulldown, Left Track / Rotation Pumps 7-15
Hydraulic Piston Pumps – Removal and Replacement 7-15
Main Pumps 7-16
AA4VG180 Hydraulic Pump EP2 Control 7-16
AA4VG EP Controller 7-18
EP (24V DC) Control 7-19
Technical Data 7-20
Main Hydraulic Pumps 7-21
Setting Procedure 7-22
Port Locations 7-23
Charge Pressure, High Pressure, P O R and Zero Position Settings 7-24
Set Charge Pressure – 320psi (22bar) 7-24
Set Crossover Relief (High Pressure) – 5500psi (380bar) 7-25
Set Pressure Override (P O R) – 5000psi (345bar) 7-26
Set Mechanical Zero Position – EP Pump Control 7-27
Set Hydraulic Zero Position – EP Pump Control 7-28
Removal and Inspection of Charge Pump 7-29
Removal and Installation of Shaft Seal 7-30
Routine Maintenance 7-31
Troubleshooting Procedure 7-32
Charge Circuit 7-34
Charge Circuit 7-34
Charge Filter 7-35
Routine Maintenance 7-35
Changing Filter Elements 7-36
Main Pumps Circuit 7-37
Main Pumps Circuit 7-37
Loop Filters 7-38
Routine Maintenance 7-38
Filter Assembly Loop 7-40
Changing Filter Elements 7-41
Rotation Circuit 7-42
Rotation Circuit 7-42
Rotary Drive Gearbox Motor 7-44
Rotary Drive Gearbox Motor – Test and Repair 7-44
BI620444
Int-12 SKS-W Introduction
Contents
Shaft Seal Replacement 7-45
Troubleshooting 7-47
Tram Circuit 7-49
Tram Circuit 7-49
Main Closed Loop Circuits 7-51
Diverter Valve 7-51
Operation 7-51
Diverter Valve 7-51
Right Track / Pulldown and Hoist Circuit 7-52
Basic Right Track / Pulldown and Hoist Circuit 7-52
Basic Right Track / Pulldown and Hoist 7-52
Pulldown and Hoist Circuit 7-53
Hoist / Pulldown Cylinder Counterbalance Valve 7-53
Left Track / Rotation Pump 7-54
Basic Left Track / Rotation Pump Circuit 7-54
Basic Left Track / Rotation Pump 7-54
Pilot Control Manifold 7-55
Pilot Control Manifold 7-55
Pilot Control Manifold Parts List 7-56
Electro Proportional Valves 7-64
Proportional Valve Set-up 7-65
Proportional Pulldown 7-66
Auto Pulldown Card 7-67
Reduced Pulldown Potentiometer ‘Pot’ 7-68
Auxiliary Pump Circuit 7-69
Auxiliary Pump Circuit 7-69
Spools 7-70
Electro – Hydraulic Kit (24V DC) 7-70
Auxiliary Pump 7-72
Auxiliary Functions 7-72
Auxiliary Pump Operation 7-73
Auxiliary Circuit 7-76
Counterbalance Valves 7-78
Counterbalance Valves Adjustment 7-78
Jack Control and Mast Elevating Circuit 7-79
OEM Controllers / EP Levers 7-80
Jack Control and Mast Elevating Control Valve 7-81
OEM Electro Proportional Mast Raise / Jacks Valve 7-81
Levelling Jack Cylinders 7-82
Jack Leg Cylinder 7-82
Counterbalance Valve Test Procedure 7-82
Mast Elevating Cylinders 7-83
Internal Counterbalance Valve 7-83
Internal Counterbalance Valve Test Procedure 7-84
Hydraulic Operated Breakout Wrench 7-85
H O B O Wrench circuit 7-85
BI620444
SKS-W Introduction Int-13
Contents
Operation 7-86
Setting of H O B O Sequence Valves 7-87
Fan Speed Adjustment 7-87
Cooler Fan Circuit 7-88
Fan Motor Circuit 7-88
Cooler Fan Motor 7-91
Hydraulic Motor 7-91
Hydraulic Thermostatic Valve 7-95
Hydraulic Cooler – Thermal Valve 7-95
Water Injection Circuit 7-96
Water Injection Circuit 7-96
Water Injection Valve 7-97
Introduction 7-99
Valve Stack Assembly 7-100
Segment Alterations 7-101
Pulsar™ Solenoid Removal and Plug 7-103
Work Port Option Exchange 7-103
Assembly Drawing – VBL By-pass Inlet Segment Parts List 7-105
Assembly Drawing – VPL Work Segment Parts List 7-107
Water Pump Motor 7-109
Water Pump Motor Repair Information 7-109
Shaft Seal Repair 7-110
Hydraulic Cylinder Repair 7-113
Hydraulic Cylinders 7-113
General Information 7-114
H Head 7-116
N Head 7-117
Z Head 7-118
Z Head (Two Piece) 7-119
K Head 7-120
M Head 7-121
Z Piston 7-122
Z Piston (Threaded) 7-123
H and K Piston 7-124
M Piston 7-125
N Piston 7-128
Notes 7-129
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-5
Electrical Locator 8-5
Electrical Locator (cont ) and Parts List 8-6
Solenoid Banks 8-7
Main Junction Box Label 8-9
Jump Starting 8-10
Jump Starting 8-11
BI620444
Int-14 SKS-W Introduction
Contents
Batteries 8-12
Batteries 8-12
Welding Precautions 8-13
Welding Precautions 8-13
Electrical Components 8-14
Electrical Circuits 8-14
Transducers 8-14
EP Levers 8-15
Joystick Adjustments 8-16
Vigilante Guide 8-18
Important Information 8-18
PLC 8-19
Touchscreen 8-22
Laser Depth System 8-23
Start Up and Shutdown 8-26
Alarms 8-26
Solenoid Control 8-27
Auto Lube 8-29
Gauges 8-29
Level Switches 8-31
Dust Suppression 8-31
N B: For further information on specific electronic components, please refer to
Electronic Components Section on Service Manual CD
Acknowledgements 8-32
Disclaimers 8-32
Notes 8-33
Section 1 Contents 1-3
Safety 1-5
Personal Protective Equipment 1-5
Noise 1-5
Electrical Contact 1-5
Overhead and Buried Utilities 1-5
Contact with Electric Wires 1-6
Contaminated Air 1-6
Machine Stability 1-7
Moving and Rotating Parts 1-8
High Pressure Air or Fluid 1-8
Before Operation 1-8
During Operation 1-9
Maintenance 1-11
Safety Locator 1-12
Notes 1-14
Section 2 – Operator’s Cab / Controls 2-1
Section 2 Contents 2-3
Graphic Symbol Legend 2-5
Warning Decals 2-8
Operators Controls and Indicators 2-10
Right Hand Control Panel 2-10
Instrument Panel 2-12
Circuit Breakers 2-13
Light Switches 2-13
Pressure Gauge Panel 2-14
Left Hand Control Panel 2-16
Cab Foot Controls 2-20
Thread Grease Switch 2-20
Air Conditioner 2-21
T7 Series Split System Air Conditioning Manual 2-21
Section 1 0 Technical Data and Control Settings 2-22
Section 2 0 Installation and Commissioning 2-24
Section 3 0 Routine Maintenance Procedures 2-30
Section 4 0 Fault Diagnosis 2-31
Section 5 0 Reference Drawings 2-40
Notes 2-45
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
Weld Inspection Schedule 3-6
Main Frame 3-6
BI620444
Int-6 SKS-W Introduction
Contents
Levelling Jacks 3-7
Levelling Jacks Cylinder 3-7
Levelling Jacks 3-8
Limit Switch 3-8
Levelling Jack Cylinders 3-8
Mast Elevating Cylinders 3-9
Mast Elevating Cylinders 3-9
Internal Counterbalance Valve 3-10
Crawler Assembly 3-12
Crawler Assembly 3-13
Parts List 3-13
Crawler Component Repair 3-13
Metric Bolt Torque Specifications 3-14
Track Tension Adjustment 3-15
Before Operating the Machine 3-15
General Maintenance 3-15
Track Assembly 3-16
Idler Unit Description 3-17
Hydraulic Tensioner 3-18
Repair 3-18
Nitrogen Tensioner 3-19
Nitrogen Tensioner – Filling Instructions 3-20
Nitrogen Tensioner – Pressure Check 3-21
Nitrogen Tensioner – Pressure Release 3-21
Hydraulic Tensioner 3-22
Hydraulic Tensioner Assembly 3-22
Repair 3-22
Track Chain 3-23
Track Chain – Separate 3-23
Track Chain Repair 3-24
Track Shoes Installation 3-26
Track Link Position 3-26
Track Shoe – Mounting to Track Chain 3-26
Track Shoe Bolt Torque (Direct Torque Method) 3-28
Bolt Torque KN111 3-28
Track Shoe Bolt Torque (Torque Turn Method) 3-29
Bolt Torque KN111 3-29
Track Chain and Shoe Installation 3-30
Track Chain with Shoes 3-30
Track Chain and Shoe – Assembly and Installation 3-30
Final Drive Unit 3-32
General Description 3-32
Removal from Track Frame 3-33
Installation into Track Frame 3-34
Final Drive Maintenance 3-35
Final Drive Oil 3-36
BI620444
SKS-W Introduction Int-7
Contents
Final Drive Assembly 3-37
Parts List 3-38
Final Drive – Disconnect and Parking Brake 3-39
Towing Procedure – Gear Drive Disconnect 3-39
Parking Brake – Description 3-40
Parking Brake – Removal and Installation 3-40
Idler Unit 3-41
Idler Unit – Assembly 3-41
Idler Unit – Removal 3-44
Track and Support Rollers 3-45
Track Roller Assembly 3-45
General Description 3-45
Track Roller – Removal and Disassembly 3-46
Support Roller – Removal and Disassembly 3-46
Track and Support Roller – Assembly 3-47
Track and Support Roller – Test and Install 3-48
Track and Sprocket Inspection 3-50
Track Inspection and Wear Limit Guide 3-50
Sprocket Wear Patterns 3-54
Auxiliary Crane 3-60
Rear Deck Crane Palfinger Crane PC 1300 Service Information 3-60
Warranty Provisions 3-61
Checking Bolted Connections 3-61
Maintenance Chart 3-62
Lubrication 3-64
Hydraulic Fluids 3-67
Oil Change / Oil Maintenance 3-68
Cleaning Agents and Equipment 3-69
Repairing Paint Damage 3-70
Removal From Service and Disposal 3-70
Notes 3-71
Section 4 – Engine / Drive Train / Compressor 4-1
Section 4 Contents 4-3
Power Group Locator 4-5
Caterpillar C27 Engine 4-6
Caterpillar C27 Engine 4-6
Engine Mounts – Installation 4-7
Engine and Compressor Air Cleaner 4-8
Engine and Compressor Air Cleaner Service Assembly 4-8
Engine and Compressor Air Cleaner Service 4-9
Flexible Drive Coupling 4-12
Flexible Drive Coupling Service 4-12
Pump Drive 4-14
Pump Identification and Parts List 4-14
Pump Drive Assembly – Removal and Replacement 4-15
BI620444
Int-8 SKS-W Introduction
Contents
Pump Drive Gearbox 4-16
Pump Drive Gearbox 4-16
Pump Drive Gearbox – Repair 4-17
Pump Drive Gear Box Input Shaft Assembly 4-18
Hydraulic Pumps 4-20
Hydraulic Pumps – Removal and Replacement 4-20
Compressor Installation 4-21
Safety 4-21
Compressor Installation 4-24
Compressor Drive Coupling 4-26
Compressor Alignment 4-27
Compressor Shaft Seal 4-28
Compressor Shaft Seal 4-28
Low Pressure Compressor 4-30
Description 4-30
Compressed Air Functions 4-30
Inlet Valve 4-34
Compressor Regulation 4-36
Compressor Regulation Closed Poppet Inlet 4-37
Running Blowdown Valves 4-38
Relieving Regulators 4-39
Compressor Control Set-up Closed Poppets Inlet 4-41
Compressor Functional Description 4-50
Compressor Operation 4-51
Compressor Operation 4-51
Compressor Maintenance 4-53
General Maintenance 4-53
Compressor Receiver Tank Assembly 4-54
Parts List 4-55
Separator Elements 4-56
Separator Elements – Remove and Replace 4-57
Scavenge Line 4-58
Compressor Discharge Temperature Gauge, Switch and Sender 4-60
Minimum Pressure Valve 4-61
Minimum Pressure / Check Valve Maintenance 4-61
Thermal Bypass Valve 4-62
Thermal Bypass Valve Maintenance 4-63
Compressor Fluid Filter 4-64
Changing Filter Elements 4-65
Troubleshooting 4-66
Coolers 4-68
Hydraulic Oil / Hydraulic Cooler Assembly 4-68
Compressor Oil Cooler 4-69
Fan Speed 4-69
Aluminium Tube Air to Oil Cooler 4-70
Aluminium Tube Air to Oil Cooler – Standard Parts 4-70
BI620444
SKS-W Introduction Int-9
Contents
Removal Replacement 4-71
Oil Cooler – Internal Cleaning 4-73
Radiator Cooler 4-75
Typical Radiator Core – Standard Parts 4-75
Cleaning 4-76
Tube Removal 4-76
Seal Installation 4-77
Tube Installation 4-78
Notes 4-80
Section 5 – Dust Control System 5-1
Section 5 Contents 5-3
Dust Control System 5-5
Dust Control Systems 5-5
Water Injection 5-6
Water Tanks 5-6
Water Injection Relief Valve 5-7
Water Injection Control 5-8
Water Injection Basic Circuit 5-10
Water Pump 5-11
Pump Specifications 5-11
Servicing Instructions 5-11
Water Injection Pump and Parts List 5-12
Replacing Piston Cup Seals 5-13
Replacing Suction and Discharge Valves 5-14
Replacing Power End Bearings 5-15
Servicing the Wrist Pin Bearings 5-16
Fastener Torque Requirements 5-16
Recommended Lubricants 5-17
Water Pump Motor Repair 5-17
Water Injection Hydraulic Control Valve Repair 5-17
Water Pump Drive Coupling 5-17
Level and Flow Transducer 5-17
Notes 5-18
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Weld Inspection Schedule 6-6
Mast Inspection 6-6
Mast Assembly and Installation 6-7
Mast Assembly 10m 6-7
Mast Weldment 6-8
Mast Pivot 6-8
Mast Locking 6-8
BI620444
Int-10 SKS-W Introduction
Contents
Mast / Drill Without Mast 6-9
Mast Assembly 6-10
Raising the Mast 6-10
Hoist / Pulldown Cylinder 6-12
Hoist / Pulldown Cylinder and Parts List 6-12
Removal From Mast Assembly 6-13
Repair 6-14
Installation 6-14
Hoist / Pulldown Cable 6-16
Adjustment 6-16
Replacement 6-18
Rotary Drive 6-20
Rotary Head Assembly 6-20
Rotary Head Guide Alignment 6-21
Rotary Head – Drive System 6-23
Rotary Drive – Removal from Mast 6-24
Rotary Drive – Installation 6-24
Rotary Drive Gearbox – Repair 6-25
Rotary Head Bull Shaft Bearing Nut 6-26
Air Swivel 6-27
Deck Wrench 6-28
Deck Wrench 6-28
H O B O Wrench 6-29
H O B O Wrench 6-29
Breakout System – H O B O 6-30
Optional Hydraulic Operated Bit Basket – H O B B 6-30
Pipe Positioner 6-31
Pipe Positioner 6-31
Carousel Pipe Rack 6-32
Major Components 6-32
Rod Handling – Carousel Indexing 6-33
Pipe Rack Assembly 6-34
General Information 6-35
Pipe Rack Bearings – Removal 6-35
Pipe Rack Components – Inspection 6-37
Pipe Rack – Assembly and Installation 6-38
Pipe Rack Roller – Remove and Replace 6-39
Pipe Rack Roller – Disassembly and Assembly 6-40
Top Sub Saver 6-42
Replacement Procedure 6-42
Notes 6-43
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-7
BI620444
SKS-W Introduction Int-11
Contents
Pressure Setting Sequence 7-9
Pressure Setting Sequence 7-9
Hydraulic System 7-9
Hydraulic Tank 7-10
Hydraulic Tank 7-10
Return Hydraulic Filters 7-11
Main Return and Case Drain Filters 7-12
Routine Maintenance 7-13
Changing Filter Elements 7-13
Main Hydraulic Pumps 7-14
Pump Identification and Parts List 7-14
Right Track / Pulldown, Left Track / Rotation Pumps 7-15
Hydraulic Piston Pumps – Removal and Replacement 7-15
Main Pumps 7-16
AA4VG180 Hydraulic Pump EP2 Control 7-16
AA4VG EP Controller 7-18
EP (24V DC) Control 7-19
Technical Data 7-20
Main Hydraulic Pumps 7-21
Setting Procedure 7-22
Port Locations 7-23
Charge Pressure, High Pressure, P O R and Zero Position Settings 7-24
Set Charge Pressure – 320psi (22bar) 7-24
Set Crossover Relief (High Pressure) – 5500psi (380bar) 7-25
Set Pressure Override (P O R) – 5000psi (345bar) 7-26
Set Mechanical Zero Position – EP Pump Control 7-27
Set Hydraulic Zero Position – EP Pump Control 7-28
Removal and Inspection of Charge Pump 7-29
Removal and Installation of Shaft Seal 7-30
Routine Maintenance 7-31
Troubleshooting Procedure 7-32
Charge Circuit 7-34
Charge Circuit 7-34
Charge Filter 7-35
Routine Maintenance 7-35
Changing Filter Elements 7-36
Main Pumps Circuit 7-37
Main Pumps Circuit 7-37
Loop Filters 7-38
Routine Maintenance 7-38
Filter Assembly Loop 7-40
Changing Filter Elements 7-41
Rotation Circuit 7-42
Rotation Circuit 7-42
Rotary Drive Gearbox Motor 7-44
Rotary Drive Gearbox Motor – Test and Repair 7-44
BI620444
Int-12 SKS-W Introduction
Contents
Shaft Seal Replacement 7-45
Troubleshooting 7-47
Tram Circuit 7-49
Tram Circuit 7-49
Main Closed Loop Circuits 7-51
Diverter Valve 7-51
Operation 7-51
Diverter Valve 7-51
Right Track / Pulldown and Hoist Circuit 7-52
Basic Right Track / Pulldown and Hoist Circuit 7-52
Basic Right Track / Pulldown and Hoist 7-52
Pulldown and Hoist Circuit 7-53
Hoist / Pulldown Cylinder Counterbalance Valve 7-53
Left Track / Rotation Pump 7-54
Basic Left Track / Rotation Pump Circuit 7-54
Basic Left Track / Rotation Pump 7-54
Pilot Control Manifold 7-55
Pilot Control Manifold 7-55
Pilot Control Manifold Parts List 7-56
Electro Proportional Valves 7-64
Proportional Valve Set-up 7-65
Proportional Pulldown 7-66
Auto Pulldown Card 7-67
Reduced Pulldown Potentiometer ‘Pot’ 7-68
Auxiliary Pump Circuit 7-69
Auxiliary Pump Circuit 7-69
Spools 7-70
Electro – Hydraulic Kit (24V DC) 7-70
Auxiliary Pump 7-72
Auxiliary Functions 7-72
Auxiliary Pump Operation 7-73
Auxiliary Circuit 7-76
Counterbalance Valves 7-78
Counterbalance Valves Adjustment 7-78
Jack Control and Mast Elevating Circuit 7-79
OEM Controllers / EP Levers 7-80
Jack Control and Mast Elevating Control Valve 7-81
OEM Electro Proportional Mast Raise / Jacks Valve 7-81
Levelling Jack Cylinders 7-82
Jack Leg Cylinder 7-82
Counterbalance Valve Test Procedure 7-82
Mast Elevating Cylinders 7-83
Internal Counterbalance Valve 7-83
Internal Counterbalance Valve Test Procedure 7-84
Hydraulic Operated Breakout Wrench 7-85
H O B O Wrench circuit 7-85
BI620444
SKS-W Introduction Int-13
Contents
Operation 7-86
Setting of H O B O Sequence Valves 7-87
Fan Speed Adjustment 7-87
Cooler Fan Circuit 7-88
Fan Motor Circuit 7-88
Cooler Fan Motor 7-91
Hydraulic Motor 7-91
Hydraulic Thermostatic Valve 7-95
Hydraulic Cooler – Thermal Valve 7-95
Water Injection Circuit 7-96
Water Injection Circuit 7-96
Water Injection Valve 7-97
Introduction 7-99
Valve Stack Assembly 7-100
Segment Alterations 7-101
Pulsar™ Solenoid Removal and Plug 7-103
Work Port Option Exchange 7-103
Assembly Drawing – VBL By-pass Inlet Segment Parts List 7-105
Assembly Drawing – VPL Work Segment Parts List 7-107
Water Pump Motor 7-109
Water Pump Motor Repair Information 7-109
Shaft Seal Repair 7-110
Hydraulic Cylinder Repair 7-113
Hydraulic Cylinders 7-113
General Information 7-114
H Head 7-116
N Head 7-117
Z Head 7-118
Z Head (Two Piece) 7-119
K Head 7-120
M Head 7-121
Z Piston 7-122
Z Piston (Threaded) 7-123
H and K Piston 7-124
M Piston 7-125
N Piston 7-128
Notes 7-129
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-5
Electrical Locator 8-5
Electrical Locator (cont ) and Parts List 8-6
Solenoid Banks 8-7
Main Junction Box Label 8-9
Jump Starting 8-10
Jump Starting 8-11
BI620444
Int-14 SKS-W Introduction
Contents
Batteries 8-12
Batteries 8-12
Welding Precautions 8-13
Welding Precautions 8-13
Electrical Components 8-14
Electrical Circuits 8-14
Transducers 8-14
EP Levers 8-15
Joystick Adjustments 8-16
Vigilante Guide 8-18
Important Information 8-18
PLC 8-19
Touchscreen 8-22
Laser Depth System 8-23
Start Up and Shutdown 8-26
Alarms 8-26
Solenoid Control 8-27
Auto Lube 8-29
Gauges 8-29
Level Switches 8-31
Dust Suppression 8-31
N B: For further information on specific electronic components, please refer to
Electronic Components Section on Service Manual CD
Acknowledgements 8-32
Disclaimers 8-32
Notes 8-33
Section 9 – Lubrication and Preventive Maintenance 9-1
Section 9 Contents 9-3
Central Lube System 9-5
Auto Lube Basic Operation 9-5
Central Lube Tank Assembly 9-6
Auto Lube Lincoln Pneumatic Pump Owners Manual 9-7
Central Lube System Circuit 9-17
Basic Operational Principles of Auto Lube Injectors 9-18
BI620444
SKS-W Introduction Int-15
Contents
SL-V and SL-V XL Injectors 9-18
SL-1 and Sl-11 Injectors 9-19
SL-32 Injectors 9-20
Typical Grease System Circuit 9-21
First 50 Hours Service 9-22
Lube Faults / Operation 9-23
Auto Lube Timer 9-24
Lube Pressure Screen 9-24
Air Service Units 9-25
Filter Regulator 9-25
Air Line Oiler 9-26
Soft Start Dump Valve 9-27
Pipe Thread Lubricator 9-28
Air Service Unit 9-28
High Pressure Stripped Pump 9-29
Filter Locator 9-37
Filter Locator Assembly 9-37
Lubrication and Preventive Maintenance 9-38
General Lubrication 9-38
Equipment Lubrication 9-38
Care of Lubrication Points 9-38
Safety 9-39
Track Gear 9-40
Engine Maintenance 9-41
Air Cleaners 9-42
Air Filter Elements 9-42
Alternator Maintenance 9-42
Pump Drive and Drive Shaft Maintenance 9-43
Compressor Maintenance 9-43
Cooler Packs 9-43
A-frame and Pivot Point Maintenance 9-45
Pull Down and Hoist Ropes and Sheaves Maintenance 9-45
Rotary Head Maintenance 9-45
Hydraulic System Maintenance 9-47
Hydraulic Maintenance 9-47
Water Pump Maintenance 9-47
Cab Maintenance 9-47
Air Conditioner Maintenance 9-49
Battery Maintenance 9-49
Lubrication System Maintenance 9-49
Fire Suppression Maintenance 9-49
Weld Inspection Schedule 9-51
Weld Inspection Schedule SK Series 9-51
Track and Sprocket Inspection 9-52
Track Inspection and Wear Limit Guide 9-52
Sprocket Wear Patterns 9-56
BI620444
Int-16 SKS-W Introduction
Contents
Lubrication and Maintenance Chart – 250hr 9-62
Lubrication and Maintenance Chart – 500hr 9-70
Lubrication and Maintenance Chart – 1000hr 9-79
Lubrication and Maintenance Chart – 2000hr 9-88
Lubricant Specifications 9-98
Hydraulic System 9-98
Hydraulic Tank Capacity 9-98
Compressor Lubrication 9-99
Compressor Lubricant Specifications 9-99
Lubricating Grease 9-100
Gear Lubricant 9-100
Scheduled Oil Sampling Analysis 9-100
Torque Values for Split Flange Connections 9-101
Torque Values for Split Flange Connections 9-101
Procedure No 1-87 Revision A 9-103
Notes 9-104
Section 9 Contents 9-3
Central Lube System 9-5
Auto Lube Basic Operation 9-5
Central Lube Tank Assembly 9-6
Auto Lube Lincoln Pneumatic Pump Owners Manual 9-7
Central Lube System Circuit 9-17
Basic Operational Principles of Auto Lube Injectors 9-18
BI620444
SKS-W Introduction Int-15
Contents
SL-V and SL-V XL Injectors 9-18
SL-1 and Sl-11 Injectors 9-19
SL-32 Injectors 9-20
Typical Grease System Circuit 9-21
First 50 Hours Service 9-22
Lube Faults / Operation 9-23
Auto Lube Timer 9-24
Lube Pressure Screen 9-24
Air Service Units 9-25
Filter Regulator 9-25
Air Line Oiler 9-26
Soft Start Dump Valve 9-27
Pipe Thread Lubricator 9-28
Air Service Unit 9-28
High Pressure Stripped Pump 9-29
Filter Locator 9-37
Filter Locator Assembly 9-37
Lubrication and Preventive Maintenance 9-38
General Lubrication 9-38
Equipment Lubrication 9-38
Care of Lubrication Points 9-38
Safety 9-39
Track Gear 9-40
Engine Maintenance 9-41
Air Cleaners 9-42
Air Filter Elements 9-42
Alternator Maintenance 9-42
Pump Drive and Drive Shaft Maintenance 9-43
Compressor Maintenance 9-43
Cooler Packs 9-43
A-frame and Pivot Point Maintenance 9-45
Pull Down and Hoist Ropes and Sheaves Maintenance 9-45
Rotary Head Maintenance 9-45
Hydraulic System Maintenance 9-47
Hydraulic Maintenance 9-47
Water Pump Maintenance 9-47
Cab Maintenance 9-47
Air Conditioner Maintenance 9-49
Battery Maintenance 9-49
Lubrication System Maintenance 9-49
Fire Suppression Maintenance 9-49
Weld Inspection Schedule 9-51
Weld Inspection Schedule SK Series 9-51
Track and Sprocket Inspection 9-52
Track Inspection and Wear Limit Guide 9-52
Sprocket Wear Patterns 9-56
BI620444
Int-16 SKS-W Introduction
Contents
Lubrication and Maintenance Chart – 250hr 9-62
Lubrication and Maintenance Chart – 500hr 9-70
Lubrication and Maintenance Chart – 1000hr 9-79
Lubrication and Maintenance Chart – 2000hr 9-88
Lubricant Specifications 9-98
Hydraulic System 9-98
Hydraulic Tank Capacity 9-98
Compressor Lubrication 9-99
Compressor Lubricant Specifications 9-99
Lubricating Grease 9-100
Gear Lubricant 9-100
Scheduled Oil Sampling Analysis 9-100
Torque Values for Split Flange Connections 9-101
Torque Values for Split Flange Connections 9-101
Procedure No 1-87 Revision A 9-103
Notes 9-104
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