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Cat Bucyrus Terex SKSS-12 Infinity Blasthole Drill Service Manual SN 1D67F08 – PDF DOWNLOAD
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Cat Bucyrus Terex SKSS-12 Infinity Blasthole Drill Service Manual SN 1D67F08 – PDF DOWNLOAD
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Description
Cat Bucyrus Terex SKSS-12 Infinity Blasthole Drill Service Manual SN 1D67F08 – PDF DOWNLOAD
FILE DETAILS:
Cat Bucyrus Terex SKSS-12 Infinity Blasthole Drill Service Manual SN 1D67F08 – PDF DOWNLOAD
Language : English
Pages : 745
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Cat Bucyrus Terex SKSS-12 Infinity Blasthole Drill Service Manual SN 1D67F08 – 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 SKSS-12 Infinity Blasthole Drill Service Manual SN 1D67F08 – PDF DOWNLOAD
SKSS-12_F08 Service Manual.pdf................................................... 0 Introduction................................................................. 3 Safety Information....................................................... 3 Parts Ordering and Product Support....................................... 4 Table of Contents........................................................ 5 Section 1 - Safety........................................................... 16 Personal Protective Equipment............................................ 17 Noise.................................................................... 17 Electrical Contact....................................................... 17 Overhead and Buried Utilities............................................ 17 Contact with Electric Wires.............................................. 18 Contaminated Air......................................................... 18 Machine Stability........................................................ 19 Moving and Rotating Parts................................................ 20 High Pressure Air or Fluid............................................... 20 Before Operation......................................................... 20 During Operation......................................................... 21 Maintenance.............................................................. 23 Safety Locator........................................................... 24 Section 2 - Operator's Cab / Controls........................................ 26 Graphic Symbol Legend.................................................... 27 Warning Decals........................................................... 31 Operators Controls and Indicators........................................ 33 Control Panels....................................................... 33 Right Hand Control Panel................................................. 34 Instrument Panel and Circuit Breakers.................................... 35 Circuit Breakers..................................................... 35 Light Switches....................................................... 36 Instrument Panel..................................................... 36 System Pressure Guage Panel.............................................. 37 Left Hand Control Panel.................................................. 39 Air Conditioner.......................................................... 45 T8 Series Split System Air Conditioning Manual....................... 45 Section 3 - Main Frame / Crawlers............................................ 76 Main Frame Repair - General.............................................. 77 Main Frame Repair.................................................... 77 Leveling Jacks........................................................... 78 Leveling Jacks....................................................... 78 Leveling Jack Cylinders.............................................. 79 Mast Elevating Cylinders................................................. 80 Mast Elevating Cylinders............................................. 81 Remove............................................................... 82 Repair............................................................... 82 Replace.............................................................. 82 Crawler Assembly......................................................... 83 Crawler Component Repair............................................. 84 Metric Bolt Torque Specifications........................................ 85 Track Maintenance........................................................ 86 Before Operating the Machine......................................... 86 General Maintenance.................................................. 86 Track Tension Adjustment................................................. 87 Hydraulic Tensioner.................................................. 88 Description.......................................................... 89 Nitrogen Tensioner................................................... 90 Hydraulic Tensioner...................................................... 91 Repair............................................................... 91 Nitrogen Tensioner Assembly.............................................. 92 Nitrogen Tensioner - Fitting Instructions................................ 93 Nitrogen Tensioner - Pressure Check.................................. 95 Nitrogen Tensioner - Pressure Release................................ 95 Track Chain - Separate................................................... 96 Track Chain - Repair..................................................... 97 Track Link - Repair & Replace........................................ 97 Track Link - Description............................................. 98 Track Shoes Installation................................................. 99 Track Link Position.................................................. 99 Track Shoe - Mounting to Tracsk Chain................................100 Track Shoe Bolt Torque (Direct Torque Method)............................101 Track Shoe Bolt Torque (Torque Turn Method)..............................102 Track Chain and Shoe Installation........................................103 Track Chain with Shoes...............................................103 Track Chain & Shoe - Assembly & Installation.........................103 Final Drive..............................................................105 Final Drive - General Description....................................105 Final Drive Unit Removal.................................................106 Removal from Track Frame.............................................106 Final Drive Unit Installation............................................107 Installation into Track Frame........................................107 Final Drive Maintenance..................................................108 Oil Check / Change...................................................108 Final Drive Oil..........................................................109 Specifications.......................................................109 Recommended Oil......................................................109 Final Drive Assembly.....................................................110 Final Drive - Disconnect & Parking Brake.................................134 Towing Procedure - Gear Drive Disconnect.............................134 Parking Brake - Removal & Installation...............................135 Idler Unit Assembly......................................................136 Idler Unit - Assembly................................................138 Idler Unit Removal.......................................................142 Idler Unit - Removal.................................................142 Track and Support Rollers................................................144 General Description..................................................144 Track Roller - Removal & Disassembly.................................146 Track and Support Roller - Assembly..................................148 Track and Support Roller - Test and Install..........................149 Auxiliary Crane..........................................................151 Hydraulic Crane (Auxiliary Crane)....................................151 Load Lift Capacities.................................................151 Maintenance..........................................................152 Section 4 - Engine / Drive Train / Compressor................................154 Power Group Locator......................................................155 Cummins Engine...........................................................156 Engine Fuel System...................................................157 Construction.........................................................158 Combo Fuel Filter Head & Pump Manifold...............................159 FS1006 Fuel Filter with Water Separator..............................159 Fuel Manifold with Integrated FSO Valve..............................160 Fuel Connections.....................................................160 Pre Filters..........................................................161 Wiring with EFS Power Relay..........................................161 Pressure and Temperature Sensors.....................................161 Operation............................................................162 QST30 Electric Fuel Supply System....................................163 Oil Reserve Systems..................................................165 Engine Oil Reserve System (Basic Circuit)............................165 LED Monitor Readings.................................................166 Adjustment of Running Oil Level......................................166 Oil Reserve Basic Circuit............................................167 Oil Pressure Switch..................................................167 Oil Reserve System...................................................167 Troubleshooting......................................................168 Maintenance..........................................................168 Engine and Compressor Air Cleaner........................................169 Engine and Compressor Air Cleaner Service............................170 Compressor Assembly......................................................173 Flexible Drive Coupling..................................................174 Flexible Drive Coupling Service......................................174 Pump Drive...............................................................176 Pump Identification..................................................176 Pump Drive Assembly - Removal and Replacement........................177 Pump Drive Gearbox.......................................................178 Pump Drive Gearbox Repair............................................179 3" Input Shaft Assembly..............................................181 Hydraulic Pump...........................................................182 Hydraulic Pumps - Removal and Replacement............................182 Compressor Installation..................................................183 Compressor Drive Coupling............................................183 Compressor Installation..............................................185 Compressor Drive Coupling - Removal and Replacement..................187 Compressor Shaft Seal....................................................188 Compressor Shaft Seal................................................188 Low Pressure Compressosr.................................................191 Safety...............................................................191 Description..........................................................194 Compressed Air Functions.............................................194 Compressor Oil Circuit...................................................198 Diagram Legend.......................................................198 Compressor Oil Circuit - COLD........................................199 Compressor Oil Circuit - HOT.........................................200 Compressor Oil Circuit - Shut Down...................................201 Compressor Air Circuits - 2400cfm @ 100psi...............................202 Diagram Legend.......................................................204 Shutdown.............................................................205 Start Up.............................................................206 Run Loaded...........................................................207 Drilling Air On......................................................208 Compressor Functional Description........................................209 Compressor Operation.....................................................211 Operation............................................................211 Compressor Maintenance...................................................213 General Maintenance..................................................213 Discharge Check Valve................................................215 Compressor Receiver Tank Assembly....................................216 Separator Elements...................................................218 Separator Elements - Remove & Replace................................219 Scavenge Line........................................................220 Compressor Discharge Temperature Gauge, Switch and Sender............221 Minimum Pressure Valve...............................................222 Minimum Pressure / Check Valve Maintenance...........................222 Thermal Bypass Valve.................................................223 Thermal Bypass Valve Maintenance.....................................224 Oil Stop Valve.......................................................225 Compressor Fluid Filter..............................................227 Changing Filter Elements.............................................228 Bearing Oil Filter...................................................229 Compressor Inlet Valve Control System................................230 Compressor Inlet Valve Control System................................231 Relieving Regulators.................................................232 System Blowdown Valve................................................235 Running Blowdown Valve...............................................236 Running Blowdown Maintenance.........................................237 Moisture Separator Maintenance.......................................238 Auxiliary Regulators.................................................239 Auxiliary Regulator Maintenance......................................240 Troubleshooting......................................................243 Aluminum Tube Air to Oil Cooler..........................................247 Compressor Oil Cooler................................................247 Radiator Cooler..........................................................248 Radiator Hydraulic Oil Cooler Assembly...............................248 Radiator / Oil Cooler Repair.........................................257 Section 5 - Dust Control System..............................................264 Dust Control System......................................................265 Dust Control Systems.................................................265 Water Injection..........................................................266 Water Tanks..........................................................266 Water Tank Top up Soleniod Valve.....................................267 Water Injection Relief Valve.........................................269 Water Injection Control..............................................270 Water Injection Basic Circuit........................................272 Water Pump...............................................................273 Pump Specifications..................................................273 Servicing Instructions...............................................273 Parts List...........................................................274 Replacing Piston Cup Seals...........................................275 Replacing Suction and Discharge Valves...............................276 Replacing Power End Bearings.........................................277 Servicing the Wrist Pin Bearings.....................................278 Fastener Torque Requirements.........................................278 Recommended Lubricants...............................................279 Water Pump Motor Repair..............................................279 Water Injection Hydraulic Control Valve Repair.......................279 Water Pump Drive Coupling............................................279 Level and Flow Transducer............................................279 Section 6 - Mast / Rotary Drive / Pipe Rack..................................280 Mast Weldment............................................................281 Mast Repair..........................................................281 Mast Assembly............................................................282 Mast Assembly........................................................282 Mast Pivot...........................................................283 Feed Cylinders...........................................................284 Feed Cylinder - Removal..............................................286 Feed Cylinder Assembly...............................................288 Repair...............................................................289 Installation.........................................................289 Hoist / Pulldown Cable Adjustment........................................290 Hosit / Pulldown Cable Adjustment....................................291 Hoist / Pulldown Cable Replacement...................................294 Rotary Drive Assembly....................................................295 Rotary Head Guide Alignment..........................................296 Rotary Head - Drive System...........................................297 Rotary Drive - Removal from Mast.....................................298 Rotary Drive - Installation..........................................298 Rotary Drive Gearbox.....................................................299 Rotary Drive Gearbox - Item Listing..................................300 Rotary Head Bull Shaft Bearing Nut...................................300 Rotary Drive Gearbox - Repair........................................301 Air Swivel...........................................................302 Winch Assembly...........................................................303 Precautions on the use of Winches....................................303 Wedge Socket.........................................................305 Grooved Drums........................................................306 Plain (Smooth) Drums.................................................306 Drums - Multiple Layers..............................................306 Winch Assembly Service...............................................307 BG8A and BG8B Hydraulic Winch Service Manual.........................308 Deck Wrench..............................................................339 H.O.B.O. Wrench..........................................................340 Breakout System - HOBO...............................................341 Pipe Safety Arm......................................................341 Pipe Positioner..........................................................342 Carousel Pipe Rack.......................................................343 Major Components.....................................................343 Rod Handling - Carousel Indexing.....................................344 Carousel Pipe Rack Assembly..........................................345 General Information..................................................346 Pipe Rack Bearings - Removal.........................................346 Pipe Rack Componetns - Inspection....................................349 Pipe Rack - Assembly and Installation................................350 Pipe Rack Roller - Remove and Replace................................351 Pipe Rack Roller - Disassembly and Assembly..........................352 Section 7 - Hydraulic Systems................................................354 Hydraulic Symbols........................................................355 Pressure Setting Sequence................................................357 Pressure Setting Sequence............................................357 Hydraulic Tank...........................................................359 Hydraulic Tank.......................................................359 Return Hydraulic Filters.............................................360 Main Return and Case Drain Filters.......................................361 Routine Maintenance..................................................362 Changing Filter Elements.............................................362 Main Hydraulic Pumps.....................................................363 Pump Identification..................................................363 Right Track, Left Track / Rotation Pumps.................................364 Hydraulic Piston Pumps - Removal and REplacement.....................364 AA4VG 180 Hydraulic Pump HD/D Control................................365 Technical Data.......................................................367 Port Locations.......................................................371 Setting Procedure....................................................372 Charge Pressure, High Pressure, P.O.R. and Zero Position Settings....373 Set Charge Pressure - 450psi (31 bar)................................373 Set Crossover Relief (High Pressure) - 5500psi (380 bar).............374 Set Pressure Override (P.O.R) - 5000psi (345 bar)....................375 Set Mechanical Zero Position - HD Pump Control.......................376 Set Hydraulic Zero Position - HD Pump Control........................377 Removal and Inspection of Charge Pump................................378 Removal and Installation of Shaft Seal...............................379 Routine Maintenance..................................................380 Charge Circuit...........................................................383 Charge Filter............................................................385 Routine Maintenance..................................................385 Changing Filter Elements.............................................385 Main Pumps Circuit.......................................................387 Main Pumps Circuit...................................................387 Loop Filters.............................................................389 Routine Maintenance..................................................389 Changing Filter Elements.............................................392 Rotation Circuit.........................................................393 Rotation Circuit.....................................................393 Rotary Drive Gearbox Motor...............................................395 Rotary Drive Gearbox Motor - Test and Repair.........................395 Shaft Seal Replacement...............................................396 Trouvle Shooting.....................................................398 Tram Circuit.............................................................400 Tram Circuit.........................................................400 Feed and Auxiliary Pump Circuit..........................................402 Hydraulic Piston Pumps - Removal and Replacement.....................402 Feed and Auxiliary Functions Pump....................................405 Repair Instructions..................................................406 Pump Replacement - Start Up..........................................407 Hydraulic Systems........................................................409 Auxiliary and Feed Circuits..........................................409 Main Control Valves......................................................410 Valve Stand Assembly.................................................410 MP18 Valve - Jack and Mast Raise Valve...................................411 MP22 Valve - Hoist and Pulldown Control..................................413 4WE6 - Aux. Functions and Mast Valves....................................416 Repair Kits..........................................................418 Exploded View of 4WE6................................................419 Counterbalance Valves....................................................420 Counterbalance Valve Adjustment......................................420 Pilot Control Manifold...................................................421 Control Valve Assembly...................................................423 Auxiliary Pump Load Solenoid Valve...................................423 Hydraulic Feed Circuit...................................................429 Feed Valve Assembly......................................................434 Jack Control and Mast Elevating Circuit..................................437 Jack Control and Mast Elevating Circuit..............................438 Leveling Jack Cylinders..................................................439 Counterbalance Valve Test Procedure..................................440 Mast Elevating Cylinders.................................................441 Counterbalance Valve Test Procedure..................................442 Auxiliary Functions Circuit..............................................443 Auxiliary Functions Circuit..........................................443 Hydraulic Operated Breakout Wrench.......................................445 Setting of HOBO Sequence Valves......................................446 Cooler Fan Circuit.......................................................447 Fan Motor Circuit....................................................447 Cooler Fan Motor.........................................................450 Hydraulic Motor......................................................450 Hydraulic Thermostatic Valve.............................................454 Hydraulic Cooler - Thermal Valve.....................................454 Central Lube.............................................................455 Hydraulic Circuit....................................................456 Air Conditioner Compressor Drive Circuit.................................457 Air Conditioner Drive Motor..............................................458 Design...............................................................458 Operational Check....................................................458 Shaft Seal Replacement...............................................459 Screw Tightening Torque..............................................459 Gear Backlash........................................................459 Specifications.......................................................459 Parts List...........................................................460 Water Injection Circuit..................................................461 Water Injection Valve................................................462 Water Injection Valve....................................................464 Introduciton.........................................................464 Valve Stack Assembly.................................................465 Segment Alterations..................................................466 Pulsar Solenoid Removal and Plug.....................................468 Recommended Test Stand...............................................469 Final Stack Adjustment...............................................472 Assembly Drawing - VBL Bypass Inlet Segment Parts List...............478 Assembly Drawing - VPL Work Segment Parts List.......................480 Water Pump Motor.........................................................482 Water Pump Motor Repair Information..................................482 Shaft Seal Repair....................................................483 Hydraulic Cylinder Repair................................................486 General Information..................................................487 H Head...............................................................489 N Head...............................................................490 Z Head...............................................................491 Z Head ( Two Piece)..................................................492 K Head...............................................................493 M Head...............................................................494 Z Piston.............................................................495 Z Piston (Threaded)..................................................496 H & K Piston.........................................................497 M Piston.............................................................498 N Piston.............................................................501 Section 8 - Electrical Components............................................504 Electrical Locator.......................................................505 Electrical Locator Parts List........................................507 Jump Starting............................................................508 Batteries................................................................510 Welding Precautions......................................................511 Vigilante Guide..........................................................512 Important Information................................................512 PLC..................................................................513 EEPROM...............................................................514 Output Card..........................................................515 Touchscreen..........................................................516 Laser Depth System...................................................517 Safety Instructions & Precautions....................................518 Pipe in Hole Detection...............................................519 Distance Meter.......................................................519 Start Up and Shut Down...............................................520 Hydraulic Function Enable............................................520 Alarms...............................................................520 Solenoid Control.....................................................521 Auto Lube............................................................524 Hammer Oiler System..................................................524 Gauges...............................................................525 Pressure Transducer..................................................525 Level Transducer.....................................................525 Hammer Oil Level Transducer..........................................525 Temperature Transducer...............................................526 Water Flow Transducer................................................528 Inclinometers........................................................529 Head Speed Module....................................................530 Level Switches.......................................................531 Dust Suppression.....................................................531 Turkey Spray.........................................................531 Water Suppression Tank - Top Up......................................531 Vigilante System Component Information...................................532 Head Speed Module....................................................532 Inclinometer.........................................................534 Ladder Prox Switch...................................................537 LDM 40 A Laser.......................................................538 Level Switches - Capacitive Level Switch (Hydraulic Oil Level).......550 Radiator Level Switch................................................554 Level Transducer - Electronic Level Sensor...........................558 Hammer Oil Level Transducer..........................................568 Pressure Transducer - Combined Pressure Sensor.......................570 Temperature Transducer - Control Monitor for Temperature Sensors.....579 Temperature Sensor...................................................591 Water Flow Transducer - Flow Sensor Analog...........................592 Water Control Module.................................................606 Section 9 - Lubrication and Preventive Maintenance...........................616 Central Lube System......................................................617 Hydraulic Control Schematic..........................................618 Auto Lube............................................................618 Central Lube Pump Module.............................................622 Central Lube Pump....................................................635 Bit Oiler Tank Assembly..................................................661 Bit Oil Circuit..........................................................662 Bit Oil System...........................................................663 Air Service Unit Components..........................................663 Filter Regulator.....................................................664 Air Line Oiler.......................................................665 Fire Ball 425 Pump - Instructions....................................666 Pipe Thread Lubricator...................................................683 Air Service Unit.....................................................683 Filter Regulator.....................................................684 Air Line Lubricator..................................................685 Pipe Thread Pump.....................................................686 Filter Locator...........................................................694 Lubrication General......................................................696 Equipment Lubrication................................................696 Care of Lubrication Points...........................................696 Lubrication and Preventive Maintenance...................................697 Safety...............................................................697 Track Gear...........................................................697 Engine Maintenance...................................................699 Air Cleaners.........................................................700 Air Filter Elements..................................................700 Alternator Maintenance...............................................700 Pump Drive and Drive Shaft Maintenance...............................701 Compressor Maintenance...............................................701 Cooler Packs.........................................................701 A-Frame and Pivot Point Maintenance..................................703 Pull Down and Hoist Ropes and Sheaves Maintenance....................703 Hydraulic System Maintenance.........................................705 Hydraulic Maintenance................................................705 Water Pump Maintenance...............................................705 Cab Maintenance......................................................705 Air Conditioner Maintenance..........................................707 Battery Maintenance..................................................707 Lubrication System Maintenance.......................................707 Fire Suppression Maintenance.........................................707 Lubrication and Maintenance Chart 250hr..................................709 Lubrication and Maintenance Chart 500hr..................................719 Lubrication and Maintenance Chart 1000hr.................................730 Lubricant Specifications.................................................739 Hydraulic System.....................................................739 Hydraulic Tank Capacity..............................................739 Compressor Lubrication...............................................740 Compressor Lubricant Specifications..................................740 Lubricating Grease...................................................741 Gear Lubricant.......................................................741 Scheduled Oil Sampling Analysis......................................741 Torque Valves for Split Flange Connections...............................742
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