CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X14 – PDF DOWNLOAD

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CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X14 – PDF DOWNLOAD

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CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X14 – PDF DOWNLOAD

Language : English
Pages : 841
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X14 – PDF DOWNLOAD

Safety Information

This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

WARNING: BEFORE STARTING ENGINE:
Study Operator and Service Manuals
Study Engine Operator and Maintenance Manual
Practice All Safety Precautions
Make Pre-Operation Check
Learn Controls Before Operating

• 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 recognized safety procedures will help you avoid accidents. Failure to heed these instructions can result in property damage, serious injury or death.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus Terex SKSS-15 Infinity Blasthole Drill Service Manual SN1K67X14 – PDF DOWNLOAD

Introduction Int-2
Safety Information Int-2
Parts Ordering and Product Support Int-3
Table of Contents iv
General Locator xvi
Section 1 – Safety 1-1
Section 1 Contents 1-3
Safety 1-4
Personal Protective Equipment 1-4
Noise 1-4
Electrical Contact 1-4
Overhead and Buried Utilities 1-4
Contact with Electric Wires 1-5
Contaminated Air 1-5
Machine Stability 1-6
Moving and Rotating Parts 1-7
High Pressure Air or Fluid 1-7
Before Operation 1-7
During Operation 1-8
Maintenance 1-10
Safety Locator 1-11
Section 2 – Operator’s Cab / Controls 2-1
Section 2 Contents 2-3
Graphic Symbol Legend 2-4
Warning Decals 2-8
Operators Controls and Indicators 2-10
Control Panels 2-10
Right Hand Control Panel 2-11
Instrument Panel and Circuit Breakers 2-12
Circuit Breakers 2-12
Light Switches 2-13
Instrument Panel 2-13
System Pressure Guage Panel 2-14
Left Hand Control Panel 2-16
Foot Control Pedals 2-22
Cab Foot Controls 2-22
Thread Grease Switch 2-22
Pipe Safety Arm Override Switch 2-22
Air Conditioner 2-23
T8 Series Split System Air Conditioning Manual 2-23
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
BI620425
SKSS Introduction v
Contents
Main Frame Repair 3-5
Leveling Jacks 3-6
Leveling Jacks 3-6
Leveling Jack Cylinders 3-7
Mast Elevating Cylinders 3-8
Mast Elevating Cylinders 3-9
Remove 3-10
Repair 3-10
Replace 3-10
Crawler Assembly 3-11
Crawler Component Repair 3-12
Metric Bolt Torque Specifications 3-13
Track Maintenance 3-14
Before Operating the Machine 3-14
General Maintenance 3-14
Track Tension Adjustment 3-15
Hydraulic Tensioner 3-16
Description 3-17
Nitrogen Tensioner 3-18
Hydraulic Tensioner 3-19
Repair 3-19
Nitrogen Tensioner Assembly 3-20
Nitrogen Tensioner – Fitting Instructions 3-21
Nitrogen Tensioner – Pressure Check 3-23
Nitrogen Tensioner – Pressure Release 3-23
Track Chain – Separate 3-24
Track Chain – Repair 3-25
Track Link – Repair & Replace 3-25
Track Link – Description 3-26
Track Shoes Installation 3-27
Track Link Position 3-27
Track Shoe – Mounting to Tracsk Chain 3-28
Track Shoe Bolt Torque (Direct Torque Method) 3-29
Track Shoe Bolt Torque (Torque Turn Method) 3-30
Track Chain and Shoe Installation 3-31
Track Chain with Shoes 3-31
Track Chain & Shoe – Assembly & Installation 3-31
Final Drive 3-33
Removal from Track Frame 3-33
Final Drive Assembly 3-34
Final Drive Service 3-36
Final Drive Installation 3-58
Idler Unit Assembly 3-59
Idler Unit – Assembly 3-61
Idler Unit Removal 3-65
Idler Unit – Removal 3-65
BI620425
vi SKSS Introduction
Contents
Track and Support Rollers 3-67
General Description 3-67
Track Roller – Removal & Disassembly 3-69
Track and Support Roller – Assembly 3-71
Track and Support Roller – Test and Install 3-72
Auxiliary Crane 3-74
Hydraulic Crane (Auxiliary Crane) 3-74
Load Lift Capacities 3-74
Maintenance 3-75
Section 4 – Engine / Drive Train / Compressor 4-1
Section 4 Contents 4-3
Power Group Locator 4-6
Cummins Engine 4-7
Engine Fuel System 4-8
Construction 4-9
Combo Fuel Filter Head & Pump Manifold 4-10
FS1006 Fuel Filter with Water Separator 4-10
Fuel Manifold with Integrated FSO Valve 4-11
Fuel Connections 4-11
Pre Filters 4-12
Wiring with EFS Power Relay 4-12
Pressure and Temperature Sensors 4-12
Operation 4-13
QST30 Electric Fuel Supply System 4-14
Oil Reserve Systems 4-16
Engine Oil Reserve System (Basic Circuit) 4-16
LED Monitor Readings 4-17
Adjustment of Running Oil Level 4-17
Oil Reserve Basic Circuit 4-18
Oil Pressure Switch 4-18
Oil Reserve System 4-18
Troubleshooting 4-19
Maintenance 4-19
Engine and Compressor Air Cleaner 4-20
Engine and Compressor Air Cleaner Service 4-21
Compressor Assembly 4-24
Flexible Drive Coupling 4-25
Flexible Drive Coupling Service 4-25
Pump Drive 4-27
Pump Identification 4-27
Pump Drive Assembly – Removal and Replacement 4-28
Pump Drive Gearbox 4-29
Pump Drive Gearbox Repair 4-30
3″ Input Shaft Assembly 4-32
Hydraulic Pump 4-33
BI620425
SKSS Introduction vii
Contents
Hydraulic Pumps – Removal and Replacement 4-33
Compressor Installation 4-34
Compressor Drive Coupling 4-34
Compressor Drive Coupling – Removal and Replacement 4-38
Compressor Shaft Seal 4-40
Compressor Shaft Seal 4-40
High Pressure Compressosr 4-43
Safety 4-43
Description 4-46
Compressed Air Functions 4-46
Compressor Oil Circuit 4-50
Diagram Legend 4-50
Compressor Oil Circuit – COLD 4-51
Compressor Oil Circuit – HOT 4-52
Compressor Condensation Table 4-53
Compressor Air Circuit 4-54
Compressor Air Circuits – 1475cfm @ 500psi 4-54
Compressor Functional Description 4-69
Compressor Operation 4-72
Operation 4-72
Compressor Maintenance 4-75
General Maintenance 4-75
Interstage Tube 4-77
Discharge Check Valve 4-78
Separator/Receiver Tank 4-79
Scavenge Line 4-81
Compressor Discharge Temperature Gauge, Switch and Sender 4-82
Minimum Pressure Valve 4-83
Minimum Pressure / Check Valve Maintenance 4-83
Thermal Bypass Valve 4-84
Thermal Bypass Valve Maintenance 4-85
Oil Stop Valve 4-86
Compressor Fluid Filter 4-88
Changing Filter Elements 4-89
Inlet Valve 4-90
Relieving Regulators 4-92
Reducing Regulators 4-95
System Blowdown Valve 4-97
Running Blowdown Valve 4-98
Running Blowdown Maintenance 4-99
Moisture Separator Maintenance 4-100
System Air Dryer 4-101
Airodyn Compressed Air Drain Trap Installation 4-102
Airodyn Compressed Air Drain Trap Operation 4-102
Airodyn Compressed Air Drain Trap Maintenance 4-103
Auxiliary Regulators 4-104
BI620425
viii SKSS Introduction
Contents
Auxiliary Regulator Maintenance 4-106
Troubleshooting 4-108
Cooler Locator 4-111
Compressor Oil Cooler Assembly 4-112
Hydraulic Oil / Radiator Cooler Assembly 4-113
Coolers Maintenance 4-114
Compressor Oil / Hydraulic Oil Cooler Service Manual 4-115
Radiator Cooler Service Manual 4-122
Section 5 – Dust Control System 5-1
Dust Control System 5-4
Dust Control Systems 5-4
Water Injection 5-5
Water Tanks 5-5
Water Tank Top up Soleniod Valve 5-6
Water Injection Relief Valve 5-8
Water Injection Control 5-9
Water Injection Basic Circuit 5-11
Water Pump 5-12
Pump Specifications 5-12
Servicing Instructions 5-12
Parts List 5-13
Replacing Piston Cup Seals 5-14
Replacing Suction and Discharge Valves 5-15
Replacing Power End Bearings 5-16
Servicing the Wrist Pin Bearings 5-17
Fastener Torque Requirements 5-17
Recommended Lubricants 5-18
Water Pump Motor Repair 5-18
Water Injection Hydraulic Control Valve Repair 5-18
Water Pump Drive Coupling 5-18
Level and Flow Transducer 5-18
High Pressure Cleaner 5-19
High Pressure Wash down (Motor and Pump) 5-19
Water Injection Valve 5-25
Water Injection Ball valve assembly 5-25
Water Injection Ball valve 5-25
Actuator – Installation Operation and Maintenance Manual 5-27
Actuator – Contents 5-28
Actuator – Air Connections 5-29
Actuator – Installation 5-30
Actuator – Dis-assembly 5-31
Actuator – Removing Endcaps type ES 5-32
Actuator – Removing Pistons/Spindle 5-33
Actuator – Re-assembly guide band and shaft 5-33
Actuator – Reassembly Pistons 5-34
BI620425
SKSS Introduction ix
Contents
Actuator – Re-assembly Endcaps single acting actuators 5-35
Actuator – Re-assembly of springclip and insert 5-36
Actuator – Parts List 5-37
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-4
Mast Repair 6-4
Mast Assembly 6-5
Mast Assembly 6-5
Mast Pivot 6-6
Feed Cylinders 6-7
Feed Cylinder – Removal 6-9
Feed Cylinder Assembly 6-11
Repair 6-12
Installation 6-12
Hoist / Pulldown Cable Adjustment 6-13
Hosit / Pulldown Cable Adjustment 6-14
Hoist / Pulldown Cable Replacement 6-17
Rotary Drive Assembly 6-18
Rotary Head Guide Alignment 6-19
Rotary Head – Drive System 6-20
Rotary Drive – Removal from Mast 6-21
Rotary Drive – Installation 6-21
Rotary Drive Gearbox 6-22
Rotary Drive Gearbox – Item Listing 6-23
Rotary Head Bull Shaft Bearing Nut 6-23
Rotary Drive Gearbox – Repair 6-24
Air Swivel 6-25
Winch Assembly 6-26
Precautions on the use of Winches 6-26
Wedge Socket 6-28
Grooved Drums 6-29
Plain (Smooth) Drums 6-29
Drums – Multiple Layers 6-29
Winch Assembly Service 6-30
BG8A and BG8B Hydraulic Winch Service Manual 6-31
Deck Wrench 6-62
H O B O Wrench 6-63
Breakout System – HOBO 6-64
Pipe Safety Arm 6-64
Pipe Positioner 6-65
Carousel Pipe Rack 6-66
Major Components 6-66
Rod Handling – Carousel Indexing 6-67
Carousel Pipe Rack Assembly 6-68
BI620425
x SKSS Introduction
Contents
General Information 6-69
Pipe Rack Bearings – Removal 6-69
Pipe Rack Componetns – Inspection 6-72
Pipe Rack – Assembly and Installation 6-73
Pipe Rack Roller – Remove and Replace 6-74
Pipe Rack Roller – Disassembly and Assembly 6-75
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-6
Pressure Setting Sequence 7-8
Pressure Setting Sequence 7-8
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 7-14
Right Track, Left Track / Rotation Pumps 7-15
Hydraulic Piston Pumps – Removal and REplacement 7-15
AA4VG 180 Hydraulic Pump HD/D Control 7-16
Technical Data 7-18
Port Locations 7-22
Setting Procedure 7-23
Charge Pressure, High Pressure, P O R and Zero Position Settings 7-24
Set Charge Pressure – 450psi (31 bar) 7-24
Set Crossover Relief (High Pressure) – 5500psi (380 bar) 7-25
Set Pressure Override (P O R) – 5000psi (345 bar) 7-26
Set Mechanical Zero Position – HD Pump Control 7-27
Set Hydraulic Zero Position – HD Pump Control 7-28
Removal and Inspection of Charge Pump 7-29
Removal and Installation of Shaft Seal 7-30
Routine Maintenance 7-31
Charge Filter 7-34
Routine Maintenance 7-34
Changing Filter Elements 7-34
Main Pumps Circuit 7-36
Main Pumps Circuit 7-36
Rotation/Tram Motor Circuit 7-37
Loop Filters 7-38
Routine Maintenance 7-38
Changing Filter Elements 7-41
Rotation Circuit 7-42
Rotation Circuit 7-42
BI620425
SKSS Introduction xi
Contents
Rotary Drive Gearbox Motor 7-44
Rotary Drive Gearbox Motor – Test and Repair 7-44
Shaft Seal Replacement 7-45
Trouvle Shooting 7-47
Tram Circuit 7-49
Tram Circuit 7-49
Feed and Auxiliary Pump Circuit 7-51
Hydraulic Piston Pumps – Removal and Replacement 7-51
Feed and Auxiliary Functions Pump 7-54
Repair Instructions 7-55
Pump Replacement – Start Up 7-56
Hydraulic Systems 7-58
Auxiliary and Feed Circuits 7-58
Main Control Valves 7-59
Valve Stand Assembly 7-59
Pilot Control Manifold 7-60
Control Valve Assembly 7-62
Auxiliary Pump Load Solenoid Valve 7-62
Hydraulic Feed Circuit 7-68
MP22 Valve – Hoist and Pulldown Control 7-70
Feed Valve Assembly 7-73
Holdback Control 7-76
Jack Control and Mast Elevating Circuit 7-77
Jack Control and Mast Elevating Circuit 7-78
MP18 Valve – Jack and Mast Raise Valve 7-79
Counterbalance Valves 7-81
Counterbalance Valve Adjustment 7-81
Leveling Jack Cylinders 7-82
Counterbalance Valve Test Procedure 7-83
Mast Elevating Cylinders 7-84
Counterbalance Valve Test Procedure 7-85
Auxiliary Functions Circuit 7-86
Auxiliary Functions Circuit 7-86
4WE6 – Aux Functions and Mast Valves 7-88
Repair Kits 7-90
Exploded View of 4WE6 7-91
Hydraulic Operated Breakout Wrench 7-92
Setting of HOBO Sequence Valves 7-93
Hydraulic Systems 7-94
Pipe Safety Arm 7-95
Hydraulic Gear Pumps – Removal and Relpacement 7-96
Hydraulic Gear Pumps – Repair 7-96
Hydraulic Gear Pumps – Shaft Seal Removal and Replacement 7-97
Cooler Fan Circuit 7-99
Fan Motor Circuit 7-99
Cooler Fan Motor 7-102
BI620425
xii SKSS Introduction
Contents
Hydraulic Motor 7-102
Hydraulic Thermostatic Valve 7-106
Hydraulic Cooler – Thermal Valve 7-106
Central Lube 7-107
Hydraulic Circuit 7-108
Air Conditioner Compressor Drive Circuit 7-109
Air Conditioner Drive Motor 7-110
Design 7-110
Operational Check 7-110
Shaft Seal Replacement 7-111
Screw Tightening Torque 7-111
Gear Backlash 7-111
Specifications 7-111
Parts List 7-112
Water Injection / Foam Injection Circuit 7-113
Water Injection / Foam Injection Valve 7-114
Water Injection / Foam Injection Valve 7-116
Introduciton 7-116
Valve Stack Assembly 7-117
Segment Alterations 7-118
Pulsar Solenoid Removal and Plug 7-120
Recommended Test Stand 7-121
Final Stack Adjustment 7-124
Assembly Drawing – VBL Bypass Inlet Segment Parts List 7-130
Assembly Drawing – VPL Work Segment Parts List 7-132
Water Pump Motor 7-134
Water Pump Motor Repair Information 7-134
Shaft Seal Repair 7-135
Foam Injection Unit 7-138
Hydraulic Cylinder Repair 7-139
General Information 7-140
H Head 7-142
N Head 7-143
Z Head 7-144
Z Head ( Two Piece) 7-145
K Head 7-146
M Head 7-147
Z Piston 7-148
Z Piston (Threaded) 7-149
H & K Piston 7-150
M Piston 7-151
N Piston 7-154
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-4
BI620425
SKSS Introduction xiii
Contents
Electrical Locator Parts List 8-6
Jump Starting 8-7
Batteries 8-9
Welding Precautions 8-10
Vigilante Guide 8-11
Important Information 8-11
PLC 8-12
EEPROM 8-13
Output Card 8-14
Touchscreen 8-15
Laser Depth System 8-16
Safety Instructions & Precautions 8-17
Pipe in Hole Detection 8-18
Distance Meter 8-18
Start Up and Shut Down 8-19
Hydraulic Function Enable 8-19
Alarms 8-19
Solenoid Control 8-20
Auto Lube 8-23
Hammer Oiler System 8-23
Gauges 8-24
Pressure Transducer 8-24
Level Transducer 8-24
Hammer Oil Level Transducer 8-24
Temperature Transducer 8-25
Water Flow Transducer 8-27
Inclinometers 8-28
Head Speed Module 8-29
Level Switches 8-30
Dust Suppression 8-30
Turkey Spray 8-30
Water Suppression Tank – Top Up 8-30
Vigilante System Component Information 8-31
Head Speed Module 8-31
Rotary Head Speed Flowmeter 8-33
Inclinometer 8-37
Ladder Prox Switch 8-40
LDM 40 A Laser 8-41
Level Switches – Capacitive Level Switch (Hydraulic Oil Level) 8-53
Radiator Level Switch 8-57
Level Transducer – Electronic Level Sensor 8-61
Hammer Oil Level Transducer 8-71
Pressure Transducer – Combined Pressure Sensor 8-73
Temperature Transducer – Control Monitor for Temperature Sensors 8-82
Temperature Sensor 8-94
Water Flow Transducer – Flow Sensor Analog 8-95
Water Control Module 8-109
Rod Counter Switch 8-138
Remote Fuel Level Display 8-139
Section 9 – Lubrication and Preventive Maintenance 9-1
Section 9 Contents 9-3
Central Lube System 9-5
Hydraulic Control Schematic 9-6
Auto Lube 9-6
Central Lube Pump Module 9-10
Central Lube Pump 9-23
Hammer Oiler Tank Assembly 9-49
Hammer Oil Circuit 9-50
Hammer Oil System 9-51
Air Service Unit Components 9-51
Filter Regulator 9-52
Air Line Oiler 9-53
Fire Ball 425 Pump – Instructions 9-54
Pipe Thread Lubricator 9-71
Air Service Unit 9-71
Filter Regulator 9-72
Air Line Lubricator 9-73
Pipe Thread Pump 9-74
Filter Locator 9-82
Lubrication General 9-84
Equipment Lubrication 9-84
Care of Lubrication Points 9-84
Torque Valves for Split Flange Connections 9-85
Lubrication and Preventive Maintenance 9-88
Safety 9-88
Track Gear 9-88
Engine Maintenance 9-90
Air Cleaners 9-91
Air Filter Elements 9-91
Alternator Maintenance 9-91
Pump Drive and Drive Shaft Maintenance 9-92
Compressor Maintenance 9-92
Cooler Packs 9-92
A-Frame and Pivot Point Maintenance 9-94
Pull Down and Hoist Ropes and Sheaves Maintenance 9-94
Hydraulic System Maintenance 9-96
Hydraulic Maintenance 9-96
Water Pump Maintenance 9-96
Cab Maintenance 9-96
Air Conditioner Maintenance 9-98
Battery Maintenance 9-98
Lubrication System Maintenance 9-98
Fire Suppression Maintenance 9-98
Lubrication and Maintenance Chart 250hr 9-100
Lubrication and Maintenance Chart 500hr 9-110
Lubrication and Maintenance Chart 1000hr 9-121
Lubrication and Maintenance Chart 2000hr 9-132
Lubricant Specifications 9-144
Hydraulic System 9-144
Hydraulic Tank Capacity 9-144
Compressor Lubrication 9-145
Compressor Lubricant Specifications 9-145
Lubricating Grease 9-146
Gear Lubricant 9-146
Scheduled Oil Sampling Analysis 9-14

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