Cat Rotary Track Drill MD6420 SKSS-16 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
DESCRIPTION:
Cat Rotary Track Drill MD6420 SKSS-16 Terex Infinity Blasthole Drill Service 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
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.
TABLE OF CONTENTS:
Cat Rotary Track Drill MD6420 SKSS-16 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
SKSS A07 Service Manual.pdf...................................................... 0
Introduction................................................................. 3
Safety Information....................................................... 3
Parts Ordering and Product Support....................................... 4
Table of Contents........................................................ 5
General Locator.......................................................... 17
Section 1 - Safety........................................................... 20
Section 1 Contents....................................................... 22
Safety................................................................... 23
Personal Protective Equipment........................................ 23
Noise................................................................ 23
Electrical Contact................................................... 23
Overhead and Buried Utilities........................................ 23
Contact with Electric Wires.......................................... 24
Contaminated Air..................................................... 24
Machine Stability.................................................... 25
Moving and Rotating Parts............................................ 26
High Pressure Air or Fluid........................................... 26
Before Operation..................................................... 26
During Operation..................................................... 27
Maintenance.......................................................... 29
Safety Locator....................................................... 30
Section 2 - Operator's Cab / Controls........................................ 32
Section 2 Contents....................................................... 34
Graphic Symbol Legend.................................................... 35
Warning Decals........................................................... 39
Operators Controls and Indicators........................................ 41
Control Panels....................................................... 41
Right Hand Control Panel................................................. 42
Instrument Panel and Circuit Breakers.................................... 43
Circuit Breakers..................................................... 43
Light Switches....................................................... 44
Instrument Panel..................................................... 44
System Pressure Guage Panel.............................................. 45
Left Hand Control Panel.................................................. 47
Foot Control Pedals...................................................... 53
Cab Foot Controls.................................................... 53
Thread Grease Switch................................................. 53
Pipe Safety Arm Override Switch...................................... 53
Air Conditioner.......................................................... 54
T8 Series Split System Air Conditioning Manual....................... 54
Section 3 - Main Frame / Crawlers............................................ 84
Section 3 Contents....................................................... 86
Main Frame Repair - General.............................................. 88
Main Frame Repair.................................................... 88
Leveling Jacks........................................................... 89
Leveling Jacks....................................................... 89
Leveling Jack Cylinders.............................................. 90
Mast Elevating Cylinders................................................. 91
Mast Elevating Cylinders............................................. 92
Remove............................................................... 93
Repair............................................................... 93
Replace.............................................................. 93
Crawler Assembly......................................................... 94
Crawler Component Repair............................................. 95
Metric Bolt Torque Specifications........................................ 96
Track Maintenance........................................................ 97
Before Operating the Machine......................................... 97
General Maintenance.................................................. 97
Track Tension Adjustment................................................. 98
Hydraulic Tensioner.................................................. 99
Description..........................................................100
Nitrogen Tensioner...................................................101
Hydraulic Tensioner......................................................102
Repair...............................................................102
Nitrogen Tensioner Assembly..............................................103
Nitrogen Tensioner - Fitting Instructions................................104
Nitrogen Tensioner - Pressure Check..................................106
Nitrogen Tensioner - Pressure Release................................106
Track Chain - Separate...................................................107
Track Chain - Repair.....................................................108
Track Link - Repair & Replace........................................108
Track Link - Description.............................................109
Track Shoes Installation.................................................110
Track Link Position..................................................110
Track Shoe - Mounting to Tracsk Chain................................111
Track Shoe Bolt Torque (Direct Torque Method)............................112
Track Shoe Bolt Torque (Torque Turn Method)..............................113
Track Chain and Shoe Installation........................................114
Track Chain with Shoes...............................................114
Track Chain & Shoe - Assembly & Installation.........................114
Final Drive..............................................................116
Removal from Track Frame.............................................116
Final Drive Assembly.................................................117
Final Drive Service..................................................119
Final Drive Installation.............................................141
Idler Unit Assembly......................................................142
Idler Unit - Assembly................................................144
Idler Unit Removal.......................................................148
Idler Unit - Removal.................................................148
Track and Support Rollers................................................150
General Description..................................................150
Track Roller - Removal & Disassembly.................................152
Track and Support Roller - Assembly..................................154
Track and Support Roller - Test and Install..........................155
Auxiliary Crane..........................................................157
Hydraulic Crane (Auxiliary Crane)....................................157
Load Lift Capacities.................................................157
Maintenance..........................................................158
Section 4 - Engine / Drive Train / Compressor................................160
Section 4 Contents.......................................................162
Power Group Locator......................................................165
Cummins Engine...........................................................166
Engine Fuel System...................................................167
Construction.........................................................168
Combo Fuel Filter Head & Pump Manifold...............................169
FS1006 Fuel Filter with Water Separator..............................169
Fuel Manifold with Integrated FSO Valve..............................170
Fuel Connections.....................................................170
Pre Filters..........................................................171
Wiring with EFS Power Relay..........................................171
Pressure and Temperature Sensors.....................................171
Operation............................................................172
QST30 Electric Fuel Supply System....................................173
Oil Reserve Systems..................................................175
Engine Oil Reserve System (Basic Circuit)............................175
LED Monitor Readings.................................................176
Adjustment of Running Oil Level......................................176
Oil Reserve Basic Circuit............................................177
Oil Pressure Switch..................................................177
Oil Reserve System...................................................177
Troubleshooting......................................................178
Maintenance..........................................................178
Engine and Compressor Air Cleaner........................................179
Engine and Compressor Air Cleaner Service............................180
Compressor Assembly......................................................183
Flexible Drive Coupling..................................................184
Flexible Drive Coupling Service......................................184
Pump Drive...............................................................186
Pump Identification..................................................186
Pump Drive Assembly - Removal and Replacement........................187
Pump Drive Gearbox.......................................................188
Pump Drive Gearbox Repair............................................189
3" Input Shaft Assembly..............................................191
Hydraulic Pump...........................................................192
Hydraulic Pumps - Removal and Replacement............................192
Compressor Installation..................................................193
Compressor Drive Coupling............................................193
Compressor Drive Coupling - Removal and Replacement..................197
Compressor Shaft Seal....................................................199
Compressor Shaft Seal................................................199
High Pressure Compressosr................................................202
Safety...............................................................202
Description..........................................................205
Compressed Air Functions.............................................205
Compressor Oil Circuit...................................................209
Diagram Legend.......................................................209
Compressor Oil Circuit - COLD........................................210
Compressor Oil Circuit - HOT.........................................211
Compressor Condensation Table............................................212
Compressor Air Circuit...................................................213
Compressor Air Circuits - 1475cfm @ 500psi...........................213
Compressor Functional Description........................................228
Compressor Operation.....................................................231
Operation............................................................231
Compressor Maintenance...................................................234
General Maintenance..................................................234
Interstage Tube......................................................236
Discharge Check Valve................................................237
Separator/Receiver Tank..............................................238
Scavenge Line........................................................240
Compressor Discharge Temperature Gauge, Switch and Sender............241
Minimum Pressure Valve...............................................242
Minimum Pressure / Check Valve Maintenance...........................242
Thermal Bypass Valve.................................................243
Thermal Bypass Valve Maintenance.....................................244
Oil Stop Valve.......................................................245
Compressor Fluid Filter..............................................247
Changing Filter Elements.............................................248
Inlet Valve..........................................................249
Relieving Regulators.................................................251
Reducing Regulators..................................................254
System Blowdown Valve................................................256
Running Blowdown Valve...............................................257
Running Blowdown Maintenance.........................................258
Moisture Separator Maintenance.......................................259
System Air Dryer.....................................................260
Airodyn Compressed Air Drain Trap Installation.......................261
Airodyn Compressed Air Drain Trap Operation..........................261
Airodyn Compressed Air Drain Trap Maintenance........................262
Auxiliary Regulators.................................................263
Auxiliary Regulator Maintenance......................................265
Troubleshooting......................................................267
Cooler Locator...........................................................270
Compressor Oil Cooler Assembly...........................................271
Hydraulic Oil / Radiator Cooler Assembly.................................272
Coolers Maintenance......................................................273
Compressor Oil / Hydraulic Oil Cooler Service Manual.....................274
Radiator Cooler Service Manual...........................................281
Section 5 - Dust Control System..............................................288
Dust Control System......................................................291
Dust Control Systems.................................................291
Water Injection..........................................................292
Water Tanks..........................................................292
Water Tank Top up Soleniod Valve.....................................293
Water Injection Relief Valve.........................................295
Water Injection Control..............................................296
Water Injection Basic Circuit........................................298
Water Pump...............................................................299
Pump Specifications..................................................299
Servicing Instructions...............................................299
Parts List...........................................................300
Replacing Piston Cup Seals...........................................301
Replacing Suction and Discharge Valves...............................302
Replacing Power End Bearings.........................................303
Servicing the Wrist Pin Bearings.....................................304
Fastener Torque Requirements.........................................304
Recommended Lubricants...............................................305
Water Pump Motor Repair..............................................305
Water Injection Hydraulic Control Valve Repair.......................305
Water Pump Drive Coupling............................................305
Level and Flow Transducer............................................305
High Pressure Cleaner....................................................306
High Pressure Wash down (Motor and Pump).............................306
Water Injection Valve....................................................312
Water Injection Ball valve assembly..................................312
Water Injection Ball valve...........................................312
Actuator - Installation Operation and Maintenance Manual.............314
Actuator - Contents..................................................315
Actuator - Air Connections...........................................316
Actuator - Installation..............................................317
Actuator - Dis-assembly..............................................318
Actuator - Removing Endcaps type ES..................................319
Actuator - Removing Pistons/Spindle..................................320
Actuator - Re-assembly guide band and shaft..........................320
Actuator - Reassembly Pistons........................................321
Actuator - Re-assembly Endcaps single acting actuators...............322
Actuator - Re-assembly of springclip and insert......................323
Actuator - Parts List................................................324
Section 6 - Mast / Rotary Drive / Pipe Rack..................................326
Section 6 Contents.......................................................328
Mast Weldment............................................................329
Mast Repair..........................................................329
Mast Assembly............................................................330
Mast Assembly........................................................330
Mast Pivot...........................................................331
Feed Cylinders...........................................................332
Feed Cylinder - Removal..............................................334
Feed Cylinder Assembly...............................................336
Repair...............................................................337
Installation.........................................................337
Hoist / Pulldown Cable Adjustment........................................338
Hosit / Pulldown Cable Adjustment....................................339
Hoist / Pulldown Cable Replacement...................................342
Rotary Drive Assembly....................................................343
Rotary Head Guide Alignment..........................................344
Rotary Head - Drive System...........................................345
Rotary Drive - Removal from Mast.....................................346
Rotary Drive - Installation..........................................346
Rotary Drive Gearbox.....................................................347
Rotary Drive Gearbox - Item Listing..................................348
Rotary Head Bull Shaft Bearing Nut...................................348
Rotary Drive Gearbox - Repair........................................349
Air Swivel...........................................................350
Winch Assembly...........................................................351
Precautions on the use of Winches....................................351
Wedge Socket.........................................................353
Grooved Drums........................................................354
Plain (Smooth) Drums.................................................354
Drums - Multiple Layers..............................................354
Winch Assembly Service...............................................355
BG8A and BG8B Hydraulic Winch Service Manual.........................356
Deck Wrench..............................................................387
H.O.B.O. Wrench..........................................................388
Breakout System - HOBO...............................................389
Pipe Safety Arm......................................................389
Pipe Positioner..........................................................390
Carousel Pipe Rack.......................................................391
Major Components.....................................................391
Rod Handling - Carousel Indexing.....................................392
Carousel Pipe Rack Assembly..........................................393
General Information..................................................394
Pipe Rack Bearings - Removal.........................................394
Pipe Rack Componetns - Inspection....................................397
Pipe Rack - Assembly and Installation................................398
Pipe Rack Roller - Remove and Replace................................399
Pipe Rack Roller - Disassembly and Assembly..........................400
Section 7 - Hydraulic Systems................................................402
Section 7 Contents.......................................................404
Hydraulic Symbols........................................................407
Pressure Setting Sequence................................................409
Pressure Setting Sequence............................................409
Hydraulic Tank...........................................................411
Hydraulic Tank.......................................................411
Return Hydraulic Filters.............................................412
Main Return and Case Drain Filters.......................................413
Routine Maintenance..................................................414
Changing Filter Elements.............................................414
Main Hydraulic Pumps.....................................................415
Pump Identification..................................................415
Right Track, Left Track / Rotation Pumps.................................416
Hydraulic Piston Pumps - Removal and REplacement.....................416
AA4VG 180 Hydraulic Pump HD/D Control................................417
Technical Data.......................................................419
Port Locations.......................................................423
Setting Procedure....................................................424
Charge Pressure, High Pressure, P.O.R. and Zero Position Settings....425
Set Charge Pressure - 450psi (31 bar)................................425
Set Crossover Relief (High Pressure) - 5500psi (380 bar).............426
Set Pressure Override (P.O.R) - 5000psi (345 bar)....................427
Set Mechanical Zero Position - HD Pump Control.......................428
Set Hydraulic Zero Position - HD Pump Control........................429
Removal and Inspection of Charge Pump................................430
Removal and Installation of Shaft Seal...............................431
Routine Maintenance..................................................432
Charge Filter............................................................435
Routine Maintenance..................................................435
Changing Filter Elements.............................................435
Main Pumps Circuit.......................................................437
Main Pumps Circuit...................................................437
Rotation/Tram Motor Circuit..........................................438
Loop Filters.............................................................439
Routine Maintenance..................................................439
Changing Filter Elements.............................................442
Rotation Circuit.........................................................443
Rotation Circuit.....................................................443
Rotary Drive Gearbox Motor...............................................445
Rotary Drive Gearbox Motor - Test and Repair.........................445
Shaft Seal Replacement...............................................446
Trouvle Shooting.....................................................448
Tram Circuit.............................................................450
Tram Circuit.........................................................450
Feed and Auxiliary Pump Circuit..........................................452
Hydraulic Piston Pumps - Removal and Replacement.....................452
Feed and Auxiliary Functions Pump....................................455
Repair Instructions..................................................456
Pump Replacement - Start Up..........................................457
Hydraulic Systems........................................................459
Auxiliary and Feed Circuits..........................................459
Main Control Valves......................................................460
Valve Stand Assembly.................................................460
Pilot Control Manifold...................................................461
Control Valve Assembly...................................................463
Auxiliary Pump Load Solenoid Valve...................................463
Hydraulic Feed Circuit...................................................469
MP22 Valve - Hoist and Pulldown Control..................................471
Feed Valve Assembly......................................................474
Holdback Control.........................................................477
Jack Control and Mast Elevating Circuit..................................478
Jack Control and Mast Elevating Circuit..............................479
MP18 Valve - Jack and Mast Raise Valve...................................480
Counterbalance Valves....................................................482
Counterbalance Valve Adjustment......................................482
Leveling Jack Cylinders..................................................483
Counterbalance Valve Test Procedure..................................484
Mast Elevating Cylinders.................................................485
Counterbalance Valve Test Procedure..................................486
Auxiliary Functions Circuit..............................................487
Auxiliary Functions Circuit..........................................487
4WE6 - Aux. Functions and Mast Valves....................................489
Repair Kits..........................................................491
Exploded View of 4WE6................................................492
Hydraulic Operated Breakout Wrench.......................................493
Setting of HOBO Sequence Valves......................................494
Hydraulic Systems........................................................495
Pipe Safety Arm......................................................496
Hydraulic Gear Pumps - Removal and Relpacement.......................497
Hydraulic Gear Pumps - Repair........................................497
Hydraulic Gear Pumps - Shaft Seal Removal and Replacement............498
Cooler Fan Circuit.......................................................500
Fan Motor Circuit....................................................500
Cooler Fan Motor.........................................................503
Hydraulic Motor......................................................503
Hydraulic Thermostatic Valve.............................................507
Hydraulic Cooler - Thermal Valve.....................................507
Central Lube.............................................................508
Hydraulic Circuit....................................................509
Air Conditioner Compressor Drive Circuit.................................510
Air Conditioner Drive Motor..............................................511
Design...............................................................511
Operational Check....................................................511
Shaft Seal Replacement...............................................512
Screw Tightening Torque..............................................512
Gear Backlash........................................................512
Specifications.......................................................512
Parts List...........................................................513
Water Injection / Foam Injection Circuit.................................514
Water Injection / Foam Injection Valve...............................515
Water Injection / Foam Injection Valve...................................517
Introduciton.........................................................517
Valve Stack Assembly.................................................518
Segment Alterations..................................................519
Pulsar Solenoid Removal and Plug.....................................521
Recommended Test Stand...............................................522
Final Stack Adjustment...............................................525
Assembly Drawing - VBL Bypass Inlet Segment Parts List...............531
Assembly Drawing - VPL Work Segment Parts List.......................533
Water Pump Motor.........................................................535
Water Pump Motor Repair Information..................................535
Shaft Seal Repair....................................................536
Foam Injection Unit......................................................539
Hydraulic Cylinder Repair................................................540
General Information..................................................541
H Head...............................................................543
N Head...............................................................544
Z Head...............................................................545
Z Head ( Two Piece)..................................................546
K Head...............................................................547
M Head...............................................................548
Z Piston.............................................................549
Z Piston (Threaded)..................................................550
H & K Piston.........................................................551
M Piston.............................................................552
N Piston.............................................................555
Section 8 - Electrical Components............................................556
Section 8 Contents.......................................................558
Electrical Locator.......................................................559
Electrical Locator Parts List........................................561
Jump Starting............................................................562
Batteries................................................................564
Welding Precautions......................................................565
Vigilante Guide..........................................................566
Important Information................................................566
PLC..................................................................567
EEPROM...............................................................568
Output Card..........................................................569
Touchscreen..........................................................570
Laser Depth System...................................................571
Safety Instructions & Precautions....................................572
Pipe in Hole Detection...............................................573
Distance Meter.......................................................573
Start Up and Shut Down...............................................574
Hydraulic Function Enable............................................574
Alarms...............................................................574
Solenoid Control.....................................................575
Auto Lube............................................................578
Hammer Oiler System..................................................578
Gauges...............................................................579
Pressure Transducer..................................................579
Level Transducer.....................................................579
Hammer Oil Level Transducer..........................................579
Temperature Transducer...............................................580
Water Flow Transducer................................................582
Inclinometers........................................................583
Head Speed Module....................................................584
Level Switches.......................................................585
Dust Suppression.....................................................585
Turkey Spray.........................................................585
Water Suppression Tank - Top Up......................................585
Vigilante System Component Information...................................586
Head Speed Module....................................................586
Rotary Head Speed Flowmeter..........................................588
Inclinometer.........................................................592
Ladder Prox Switch...................................................595
LDM 40 A Laser.......................................................596
Level Switches - Capacitive Level Switch (Hydraulic Oil Level).......608
Radiator Level Switch................................................612
Level Transducer - Electronic Level Sensor...........................616
Hammer Oil Level Transducer..........................................626
Pressure Transducer - Combined Pressure Sensor.......................628
Temperature Transducer - Control Monitor for Temperature Sensors.....637
Temperature Sensor...................................................649
Water Flow Transducer - Flow Sensor Analog...........................650
Water Control Module.................................................664
Rod Counter Switch...................................................693
Remote Fuel Level Display............................................694
Section 9 - Lubrication and Preventive Maintenance...........................696
Section 9 Contents.......................................................698
Central Lube System......................................................700
Hydraulic Control Schematic..........................................701
Auto Lube............................................................701
Central Lube Pump Module.............................................705
Central Lube Pump....................................................718
Hammer Oiler Tank Assembly...............................................744
Hammer Oil Circuit.......................................................745
Hammer Oil System........................................................746
Air Service Unit Components..........................................746
Filter Regulator.....................................................747
Air Line Oiler.......................................................748
Fire Ball 425 Pump - Instructions....................................749
Pipe Thread Lubricator...................................................766
Air Service Unit.....................................................766
Filter Regulator.....................................................767
Air Line Lubricator..................................................768
Pipe Thread Pump.....................................................769
Filter Locator...........................................................777
Lubrication General......................................................779
Equipment Lubrication................................................779
Care of Lubrication Points...........................................779
Torque Valves for Split Flange Connections...............................780
Lubrication and Preventive Maintenance...................................783
Safety...............................................................783
Track Gear...........................................................783
Engine Maintenance...................................................785
Air Cleaners.........................................................786
Air Filter Elements..................................................786
Alternator Maintenance...............................................786
Pump Drive and Drive Shaft Maintenance...............................787
Compressor Maintenance...............................................787
Cooler Packs.........................................................787
A-Frame and Pivot Point Maintenance..................................789
Pull Down and Hoist Ropes and Sheaves Maintenance....................789
Hydraulic System Maintenance.........................................791
Hydraulic Maintenance................................................791
Water Pump Maintenance...............................................791
Cab Maintenance......................................................791
Air Conditioner Maintenance..........................................793
Battery Maintenance..................................................793
Lubrication System Maintenance.......................................793
Fire Suppression Maintenance.........................................793
Lubrication and Maintenance Chart 250hr..................................795
Lubrication and Maintenance Chart 500hr..................................805
Lubrication and Maintenance Chart 1000hr.................................816
Lubrication and Maintenance Chart 2000hr.................................827
Lubricant Specifications.................................................839
Hydraulic System.....................................................839
Hydraulic Tank Capacity..............................................839
Compressor Lubrication...............................................840
Compressor Lubricant Specifications..................................840
Lubricating Grease...................................................841
Gear Lubricant.......................................................841
Scheduled Oil Sampling Analysis......................................841
CAT ROTARY TRACK DRILL MD6420 SKSS-16 TEREX INFINITY BLASTHOLE DRILL SERVICE MANUAL – PDF DOWNLOAD:
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Cat Rotary Track Drill MD6420 SKSS-16 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOADCat Rotary Track Drill MD6420 SKSS-16 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
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