Cat Rotary Track Drill MD6420 SKSS-12 Series Terex Infinity Blasthole Drill Operator & Maintenance Manual – PDF DOWNLOAD

Description

Cat Rotary Track Drill MD6420 SKSS-12 Series Terex Infinity Blasthole Drill Operator & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Rotary Track Drill MD6420 SKSS-12 Series Terex Infinity Blasthole Drill Operator & Maintenance Manual – 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
● 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.

TABLE OF CONTENTS:

Cat Rotary Track Drill MD6420 SKSS-12 Series Terex Infinity Blasthole Drill Operator & Maintenance Manual – PDF DOWNLOAD

SKSS-12_C81_Service Manual.pdf..........................................................  0
	ServiceManual.......................................................................  2
		Parts Ordering & Product Support................................................  4
		Safety Information..............................................................  5
		Product Description.............................................................  6
		Table of Contents...............................................................  7
		General Locator................................................................. 19
	Section 1 - Safety.................................................................. 23
		Safety.......................................................................... 24
			Personal Protective Equipment............................................... 24
			Noise....................................................................... 24
			Electrical Contact.......................................................... 24
			Overhead and Buried Utilities............................................... 24
			Contact With Electric Wires................................................. 25
			Contaminated Air............................................................ 25
			Machine Stability........................................................... 26
			Moving and Rotating Parts................................................... 27
			High Pressure Air or Fluid.................................................. 27
			Before Operation............................................................ 27
			During Operation............................................................ 28
			Maintenance................................................................. 30
			Safety Locator.............................................................. 31
	Section 2 Operators Cab/Controls.................................................... 33
		Operator’s Controls and Indicators.............................................. 34
			Control Panels.............................................................. 34
		Right Hand Control Panel........................................................ 35
		Instrument Panel and Circuit Breakers........................................... 36
			Circuit Breakers............................................................ 36
			Light Switches.............................................................. 37
			Instrument Panel............................................................ 37
		System Pressure Guage Panel..................................................... 38
		Left Hand Control Panel......................................................... 40
		Foot Control Pedals............................................................. 46
			Cab Foot Controls........................................................... 46
			Thread Grease Switch........................................................ 46
			Pipe Safety Arm Override Switch............................................. 46
		Air Conditioner................................................................. 47
	Section 3 - Main Frame/Crawlers..................................................... 97
		Main Frame Repair............................................................... 98
		Leveling Jacks.................................................................. 99
			Leveling Jack Cylinders.....................................................100
		Mast Elevating Cylinders........................................................101
		Crawler Assembly................................................................104
			Crawler Component Repair....................................................105
		Metric Bolt Torque Specifications...............................................106
		Track Maintenance...............................................................107
			Before Operating the Machine:...............................................107
			General Maintenance.........................................................107
		Track Tension Adjustment........................................................108
			Hydraulic Tensioner.........................................................109
			Description.................................................................110
			Nitrogen Tensioner..........................................................111
		Hydraulic Tensioner.............................................................112
			Repair......................................................................112
		Nitrogen Tensioner Assembly.....................................................113
			Nitrogen Tensioner - Filling Instructions...................................114
			Nitrogen Tensioner - Pressure Check.........................................116
			Nitrogen Tensioner - Pressure Release.......................................116
		Track Chain - Separate..........................................................118
		Track Chain Repair..............................................................120
			Track Link - Repair & Replace...............................................120
			Track Link - Description....................................................121
		Track Shoes Installation........................................................122
			Track Link Position.........................................................122
			Track Shoe - Mounting to Track Chain........................................122
		Track Shoe Bolt Torque (Direct Torque Method)...................................124
		Track Shoe Bolt Torque (Torque Turn Method).....................................125
		Track Chain and Shoe Installation...............................................126
			Track Chain with Shoes......................................................126
			Track Chain & Shoe - Assembly & Installation................................126
		Final Drive.....................................................................128
			Final Drive - General Description...........................................128
		Final Drive Unit ...............................................................129
			Removal from Track Frame....................................................129
			Installation into Track Frame...............................................130
		Final Drive Maintenance.........................................................131
			Oil Check / Change..........................................................131
		Final Drive Oil.................................................................132
			Specifications..............................................................132
			Recommended Oil.............................................................132
		Final Drive Assembly............................................................133
			Parking Brake - Description.................................................134
		Final Drive Disconnect..........................................................135
		Final Drive - Disconnect & Parking Brake........................................136
			Towing Procedure - Gear Drive Disconnect....................................136
			Parking Brake - Removal & Installation......................................136
		Idler Assembly..................................................................137
		Idler Unit Removal..............................................................139
		Track and Support Rollers.......................................................145
			General Description.........................................................145
			Track Roller Assembly.......................................................146
			Track Roller - Removal & Disassembly........................................147
			Support Roller - Removal & Disassembly......................................148
			Track and Support Roller - Assembly.........................................149
			Track and Support Roller - Test and Install.................................150
		Auxiliary Crane.................................................................152
			Maintenance.................................................................153
		Fuel Tank Fill Assembly.........................................................154
			Hydrau-flow Fuel Fill.......................................................154
	Section 4 - Engine/Drive Train/Compressor...........................................157
		Power Group Locator.............................................................158
		Engine..........................................................................159
			Engine Oil Pressure Switches................................................159
			Engine Service Procedures...................................................159
			Engine Fuel System..........................................................160
			Oil Reserve Systems.........................................................168
			Engine Oil Reserve System (Basic Circuit)...................................168
			LED Monitor Readings........................................................169
			Adjustment of Running Oil Level.............................................169
			Wiring Diagram - Oil Reserve Basic Circuit..................................170
			Oil Pressure Switch.........................................................170
			Oil Reserve System Servicing................................................170
			Troubleshooting.............................................................171
			Maintenance.................................................................171
		Engine and Compressor Air Cleaners..............................................172
			Engine and Compressor Air Cleaner Service...................................173
		Flexible Drive Coupling.........................................................176
			Flexible Drive Coupling Service.............................................176
			Removal.....................................................................177
			Installation................................................................177
			Mounting Screws and Adhesive................................................177
		Pump Drive......................................................................179
			Pump Identification.........................................................179
			Pump Drive Assembly - Removal and Replacement...............................180
		Pump Drive Gearbox..............................................................181
			Pump Drive Gearbox - Repair.................................................182
			3” Input Shaft Assembly.....................................................184
		Hydraulic Pumps.................................................................185
			Hydraulic Pumps - Removal and Replacement...................................185
		Compressor Installation.........................................................186
			Compressor Drive Coupling - Removal and Replacement.........................187
		Drill Compressor................................................................191
			Drill CompressorModel 20/121475cfm @ 500psi.................................191
		High Pressure Compressor........................................................192
			Section 1 Safety............................................................192
			Description.................................................................195
			Compressed Air Functions....................................................195
		Compressor Fluid Circuit........................................................199
		Compressor Condensation Table...................................................202
		Compressor Air Circuit 1475cfm @ 500psi.........................................203
		Compressor Air Circuit..........................................................204
		Compressor Functional Description...............................................217
			Capacity Control System With Poppet Valve, Functional Description...........218
			Start Mode..................................................................218
			Normal Operation............................................................218
			Modulating mode.............................................................218
			Unload mode.................................................................218
			Shutdown Mode...............................................................219
		Compressor Operation............................................................220
			General.....................................................................220
			Purpose Of Controls.........................................................220
			Initial Start-up Procedure..................................................222
			Regulator Set Up............................................................222
			Subsequent Start-up Procedure...............................................223
			Shutdown Procedure..........................................................223
			General Operating Instructions..............................................223
		Compressor Maintenance..........................................................224
			General.....................................................................224
			Daily Operation.............................................................224
			Maintenance After Initial 50 Hours Of Operation.............................224
			Maintenance Every 250 Hours.................................................225
			Maintenance Every 500 Hours.................................................225
			Maintenance Every 1000 Hours................................................225
			Main Drive Shaft Seal Replacement...........................................226
			Disassembly Shaft Seal assembly.............................................226
			Inspection and Preparation For Seal Assembly................................227
			Installation Of The Seal Seat...............................................227
			Installation Of The Seal Assembly...........................................227
			Installation Of The Seat Retainer...........................................228
			Installation of Dust Shield, Gasket and V-Rings.............................228
			Interstage Tube.............................................................229
			Discharge Check Valve.......................................................230
			Separator/Receiver Tank.....................................................231
			Minimum Pressure / Check valve..............................................233
			Scavenge Line...............................................................234
			Compressor Discharge Temperature Switches,Senders and Gauges................235
			Thermal/Bypass Valve........................................................236
			Fluid Stop Valve............................................................238
			Compressor Fluid Filter.....................................................240
			Inlet Valve.................................................................242
			Compressor Regulation.......................................................244
			Relieving Regulators........................................................244
			Reducing Regulators.........................................................247
			System Blowdown Valve.......................................................249
			Running Blowdown Valve......................................................250
			Moisture Separator Maintenance..............................................252
			Auxiliary Regulator.........................................................253
			Troubleshooting.............................................................257
			Spare Parts List............................................................260
		Compressor Oil Cooler Assembly..................................................261
			Compressor oil cooler.......................................................261
		Radiator/Hydraulic Oil Cooler Assembly..........................................262
		Radiator/Oil Cooler Repair......................................................263
		High Pressure Compressor Fluid Cooler...........................................265
		Radiator Cooler.................................................................273
	Section 5 - Dust Control Systems....................................................281
		Water Injection.................................................................283
			Water Tanks.................................................................283
			Water Tank Top up Solenoid Valve............................................284
			Water Injection Pump........................................................286
			Water Injection Relief Valve................................................286
			Water Injection Control.....................................................287
			Water Injection System Circuit..............................................289
			Water Pump..................................................................290
				Pump Specifications.....................................................290
				Servicing Instructions..................................................290
				Parts List..............................................................291
				Recommended Lubricants..................................................296
				Water Pump Drive Coupling...............................................296
			Water Injection Valve.......................................................297
				Water Injection Ball valve assembly.....................................297
				Actuator................................................................299
			High Pressure Cleaner.......................................................311
				High Pressure Wash-down (Motor and Pump)................................311
				Foam Injection..........................................................317
	Section 6 - Mast/Rotary Drive/Pipe Rack.............................................319
		Mast Weldment...................................................................320
			Mast Repair.................................................................320
		Mast Assembly...................................................................321
			Mast Pivot..................................................................322
		Feed Cylinders..................................................................323
			Feed Cylinder - Removal.....................................................325
		Feed Cylinder Assembly..........................................................327
		Feed Cylinder...................................................................328
			Repair......................................................................328
			Installation................................................................328
		Hoist/Pulldown Cable Adjustment.................................................329
		Hoist/Pulldown Cable Replacement................................................332
		Rotary Drive Assembly...........................................................334
			Rotary Head Guide Alignment.................................................335
			Rotary Head - Drive System..................................................336
			Rotary Drive - Removal from Mast............................................337
		Rotary Drive Gearbox............................................................338
			Rotary Drive Gearbox - Item Listing.........................................339
			Rotary Head Bull Shaft Bearing Nut..........................................339
			Rotary Drive Gearbox - Repair...............................................340
			Air Swivel..................................................................341
		Winch Assembly..................................................................342
			Precautions on the Use of Winches...........................................342
			Wire Rope...................................................................342
			Wedge Sockets...............................................................344
			Grooved Drums...............................................................345
			Plain (Smooth) Drums........................................................345
			Drums - Multiple Layers.....................................................345
			Winch Assembly Service......................................................346
			Hydraulic Winch.............................................................347
		Deck Wrench.....................................................................378
		H.O.B.O. Wrench.................................................................379
		Pipe Safety Arm.................................................................380
		Pipe Positioner.................................................................381
		Carousel Pipe Rack..............................................................382
			Major Components............................................................382
			Rod Handling - Carousal Indexing............................................383
			General Information.........................................................385
			Pipe Rack Bearings - Removal................................................385
			Pipe Rack Components - Inspection...........................................388
			Pipe Rack - Assembly and Installation.......................................389
			Pipe Rack Roller - Remove and Replace.......................................390
			Pipe Rack Roller -Disassembly and Assembly..................................391
	Section 7 - Hydraulic Systems.......................................................393
		Hydraulic Symbols...............................................................394
		Pressure Setting Sequence.......................................................396
		Hydraulic Tank..................................................................398
			Return hydraulic filters....................................................399
		Main Return and Case Drain Filter...............................................400
			Routine Maintenance.........................................................401
			Changing Filter Elements....................................................401
		Main Hydraulic Pumps............................................................402
			Pump Identification.........................................................402
		Right Track, Left Track/Rotation Pumps..........................................403
			Hydraulic Piston Pumps - Removal and Replacement............................403
			Hydraulic Piston Pumps - Operation, Specifications,Adjustment and Repair....403
			AA4VG 180 Hydraulic Pump HD/D Control.......................................404
			Technical Data..............................................................406
			Port Locations..............................................................410
			Setting Procedure...........................................................411
			Charge Pressure, High Pressure,P.O.R. and Zero Position settings............412
			Set Charge Pressure.........................................................412
			Set Crossover Relief (High Pressure)........................................413
			Set Pressure Override (P.O.R.)..............................................414
			Set Mechanical Zero Position - HD Pump Control..............................415
			Set Hydraulic Zero Position - HD Pump Control...............................416
			Removal and Inspection of Charge Pump.......................................417
			Removal and Installation of Shaft Seal......................................418
			Routine Maintenance.........................................................419
			Maintenance.................................................................420
		Charge Filter...................................................................422
			Routine Maintenance.........................................................422
			Changing Filter Elements....................................................422
		Tram/Rotation Pump Circuit......................................................424
			Rotation Circuit............................................................426
			Rotary Torque Control (Pump Controller Method)..............................427
			Rotary Torque ControlCircuit C80............................................428
			Rotation/Tram Motor Circuit.................................................429
		Loop Filters....................................................................430
			Routine Maintenance.........................................................430
			Changing Filter Elements....................................................433
		Rotary Drive Gearbox Motor......................................................434
			Rotary Drive Gearbox Motor - Test and Repair................................434
			Case leakage Bypass test....................................................434
			Shaft Seal Replacement......................................................435
			Rotary Drive Gearbox Motor Assembly.........................................436
			Trouble Shooting............................................................437
		Feed and Auxiliary Pump Circuit.................................................439
			Hydraulic Piston Pumps - Removal and Replacement............................439
			Hydraulic Piston Pumps - Operation,Specifications, Adjustment and Repair....439
			AA11VLO- Pump...............................................................440
			Feed & Auxiliary Functions Pump.............................................442
			Repair InstructionsShaft Seal Change........................................443
			Pump Replacement - Start Up.................................................444
			Auxiliary and Feed Circuits.................................................445
		Main Control Valves.............................................................446
			Valve Stand Assembly........................................................446
		MP18 Valve - Jack and Mast Raise Valve..........................................447
		MP22 Valve - Hoist and Pulldown Control.........................................449
		4WE6 - Aux. Functions and Mast Valves...........................................452
		Counterbalance Valves...........................................................456
			Counterbalance Valve Adjustments............................................456
		Pilot Control Manifold..........................................................457
			Pilot Control Manifold Schematic............................................458
		Control Valve Assembly..........................................................459
			Auxiliary Pump Load Solenoid Valve..........................................459
			Shuttle Valve - V04.........................................................459
			Auxiliary Pump Load Sense Relief............................................459
			Jacks/Mast raise Load Sense relief..........................................460
			Drill/Tram Interlock Solenoid Valve.........................................460
			Drill/Tram Solenoid Valve...................................................461
			Auto Pulldown Solenoid Valve................................................461
			Pilot Operated Directional Valve (RotationTorque Control On/Off)............461
			Set-up Interlock Solenoid Valve.............................................461
			Auto Pulldown Pressure Reducing Valve.......................................462
			Shuttle Valve - V13.........................................................462
			Surge Protection Relief Valve...............................................462
			Maximum Pulldown Pressure Relief............................................463
			2nd Maximum Pulldown Relief Valve...........................................463
			Reduced Pulldown Relief Valve...............................................463
			Reduced Pulldown Solenoid Valve.............................................463
			Shuttle Valve - V19.........................................................464
			Orifice.....................................................................464
			Maximum Rotation Pressure Relief............................................464
			Surge Protection Pressure Reducing/Relieving Valve..........................464
		Feed Valve Assembly.............................................................465
			Hoist/Pulldown Control Valve 410665 MP22....................................465
			Set Max. Pulldown Relief Valve (V15)........................................465
			Feed Control Valve..........................................................467
		Hydraulic Feed Circuit..........................................................468
			Procedure for adjustment: Valve “A”.........................................469
			Hydraulic Feed Circuit Schematic............................................470
			Procedure for adjusting Valve “F”:..........................................471
		Holdback Control................................................................473
		Jack Control and Mast Elevating Circuit.........................................474
		Leveling Jack Cylinders.........................................................476
			Counterbalance Valve Test Procedure.........................................477
		Auxiliary Functions Circuit.....................................................480
		Hydraulic Operated Breakout Wrench..............................................482
			Setting of HOBO Sequence Valves.............................................483
		Pipe Positioner Sequence Valves.................................................484
			Setting of Pipe Positioner Sequence Valves..................................484
		Pipe Safety Arm Sequence Valves.................................................485
			Pipe Safety Arm.............................................................485
			Setting of Pipe Safety Arm Sequence Valves..................................485
		Hydraulic Gear Pumps............................................................486
			Hydraulic Gear Pumps - Removal and Replacement..............................486
			Hydraulic Gear Pumps - Repairs, Operation,Specifications and Adjustment.....486
			Hydraulic Gear Pumps - Shaft Seal Removal and Replacement...................487
			Remove Shaft Seal...........................................................487
			Replace Shaft Seal..........................................................488
		Cooler Fan Circuit..............................................................489
			Fan Motor Circuit...........................................................489
			Adjustment..................................................................489
			Cooler Fan Circuit - Schematic..............................................490
			Cooler Fan Circuit - Basic Circuit..........................................491
		Cooler Fan Motor................................................................492
			Hydraulic Motor.............................................................492
		Hydraulic Thermostatic Valve....................................................496
			Hydraulic cooler - Thermal valve............................................496
		Central Lube....................................................................497
			Auto Lube...................................................................497
			Hydraulic Circuit...........................................................498
		Air Conditioner Compressor Drive Circuit........................................499
		Air Conditioner Drive Motor.....................................................500
			Specifications..............................................................500
		Water Injection Circuit.........................................................504
			Water Injection Pump........................................................504
			Water Injection valve.......................................................505
			Water InjectionElectrical Circuit...........................................506
		Water Injection Valve...........................................................507
		Water Pump Motor................................................................524
			Shaft Seal Repair...........................................................525
		Hydraulic Cylinder Repair.......................................................528
			Hydraulic Cylinders Identification..........................................528
		Hydraulic Cylinder Repair.......................................................529
			General Information.........................................................529
	Section 8 - Vigilante Guide and Electrical Components...............................545
		Electrical Locator..............................................................546
		Batteries.......................................................................549
		Jump Starting...................................................................550
		Welding Precautions.............................................................552
		Vigilante Guide.................................................................553
			CONTENTS....................................................................553
			IMPORTANT Information.......................................................554
			PLC.........................................................................555
			EEPROM......................................................................556
			Output Card.................................................................557
			Touchscreen.................................................................558
			Laser Depth System..........................................................559
			Safety Instructions & Precautions...........................................560
			Pipe in Hole Detection......................................................561
			Distance Meter..............................................................561
			Start Up and Shut Down......................................................562
			Hydraulic Function Enable...................................................562
			Alarms......................................................................562
			Solenoid Control............................................................563
			Auto Lube...................................................................566
			Hammer Oiler System.........................................................566
			Gauges......................................................................567
			Pressure Transducer.........................................................567
			Level Transducer............................................................567
			Hammer Oil Level Transducer.................................................567
			Temperature Transducer......................................................568
			Water Flow Transducer.......................................................570
			Inclinometers...............................................................571
			Head Speed Module...........................................................572
			Level Switches..............................................................573
			Dust Suppression............................................................573
			Turkey Spray................................................................573
			Water Suppression Tank - Top Up.............................................573
		Vigilante System Component Information..........................................574
			CONTENTS....................................................................574
		Head Speed Module...............................................................575
		Inclinometer....................................................................577
		Ladder Prox Switch..............................................................580
		Laser...........................................................................581
		Level Switches..................................................................593
		Radiator Level Switch...........................................................597
		Level Transducers...............................................................601
		Hammer Oil Level Transducer.....................................................611
		Pressure Transducers............................................................613
		Temperature Transducer..........................................................622
		Temperature Sensor..............................................................634
		Water Flow Transducer...........................................................635
		Water Control Module............................................................649
		Rod Counter Prox Switch.........................................................656
		Remote Fuel Level Display.......................................................657
	Section 9 - Lubrication and Preventative Maintenance................................659
		Central Lube System.............................................................660
			Hydraulic Control Schematic.................................................661
			Auto Lube...................................................................661
		Central Lube System Circuit Drawing.............................................663
		Central Lube Tank Assembly......................................................664
		Central Lube System Technical Data..............................................665
			Central Lube Pump Module....................................................666
			Vent Valve..................................................................702
			SL-1 Injector Assembly......................................................704
		Hammer Oiler Tank Assembly......................................................706
		Hammer Oil Circuit..............................................................707
			Auto Mode...................................................................707
			Manual Mode.................................................................707
			Air Service Unit Components.................................................708
			Filter Regulator............................................................709
			Air Line Oiler..............................................................710
		Hammer Oil System...............................................................711
			Hammer Oil System - Pump....................................................711
		Pipe Thread Lubricator..........................................................728
			Filter Regulator............................................................729
			Air Line Lubricator.........................................................730
			Pipe Thread Pump............................................................731
		Filter Locator..................................................................739
			Filter Location Assembly....................................................740
		Lubrication And Maintenance.....................................................741
			Safety......................................................................741
			Track Gear..................................................................741
			Engine Maintenance..........................................................742
			Air Cleaners................................................................743
			Air Filter Elements.........................................................743
			Pump Drive And Drive Shaft Maintenance......................................744
			Compressor Maintenance......................................................744
			A-Frame And Pivot Point Maintenance.........................................745
			Pull Down And Hoist Ropes AndSheaves Maintenance............................746
			Rotary Head Maintenance.....................................................746
			Hydraulic System Maintenance................................................747
			Hydraulic Maintenance.......................................................747
			Water Pump Maintenance......................................................748
			Cab Maintenance.............................................................748
			Air Conditioner Maintenance.................................................748
			Battery Maintenance.........................................................749
			Lubrication System Maintenance..............................................749
			Fire Suppression Maintenance................................................749
			Equipment Lubrication.......................................................750
		Lubrication & Maintenance Chart - 250hr.........................................751
		Lubrication & Maintenance Chart - 500hr.........................................761
		Lubrication & Maintenance Chart - 1000hr........................................772
		Lubrication & Maintenance Chart - 2000hr........................................783
		NOTES...........................................................................795
		Lubricant Specifications........................................................796
			Hydraulic System............................................................796
			Hydraulic Tank Capacity.....................................................796
			Compressor Lubrication......................................................797
			Compressor Lubricant Specifications.........................................797
			Lubricating Grease..........................................................798
			Gear Lubricant..............................................................798
			Scheduled Oil Sampling Analysis.............................................798
		Torque Values for Split Flange Connections......................................799
		Torque Values for Hydraulic Tubes & Fittings....................................800
		Torque Values for Standard Fasteners............................................801

CAT ROTARY TRACK DRILL MD6420 SKSS-12 SERIES TEREX INFINITY BLASTHOLE DRILL OPERATOR & MAINTENANCE MANUAL – PDF DOWNLOAD:

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S.M