Cat Rotary Track Drill SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

Description

Cat Rotary Track Drill SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Rotary Track Drill SKSS-12 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 SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

Introduction…………………………………………………………………………. Int-2
Safety Information ………………………………………………………………………………………………………… Int-2
Parts Ordering and Product Support……………………………………………………………………………… Int-3
Table of Contents……………………………………………………………………………………………………………….iv
Section 1 – Safety……………………………………………………………………1-1
Personal Protective Equipment …………………………………………………………………………………….. 1-2
Noise ………………………………………………………………………………………………………………………… 1-2
Electrical Contact ……………………………………………………………………………………………………….. 1-2
Overhead and Buried Utilities……………………………………………………………………………………….. 1-2
Contact with Electric Wires…………………………………………………………………………………………… 1-3
Contaminated Air………………………………………………………………………………………………………… 1-3
Machine Stability ………………………………………………………………………………………………………… 1-4
Moving and Rotating Parts …………………………………………………………………………………………… 1-5
High Pressure Air or Fluid ……………………………………………………………………………………………. 1-5
Before Operation ………………………………………………………………………………………………………… 1-5
During Operation ………………………………………………………………………………………………………… 1-6
Maintenance………………………………………………………………………………………………………………. 1-8
Safety Locator ……………………………………………………………………………………………………………. 1-9
Section 2 – Operator’s Cab / Controls……………………………………….2-1
Graphic Symbol Legend …………………………………………………………………………………………………. 2-2
Warning Decals………………………………………………………………………………………………………………. 2-6
Operators Controls and Indicators ………………………………………………………………………………….. 2-8
Control Panels……………………………………………………………………………………………………………. 2-8
Right Hand Control Panel ……………………………………………………………………………………………….. 2-9
Instrument Panel and Circuit Breakers ………………………………………………………………………….. 2-10
Circuit Breakers………………………………………………………………………………………………………… 2-10
Light Switches ……………………………………………………………………………………………………………2-11
Instrument Panel ………………………………………………………………………………………………………..2-11
System Pressure Guage Panel………………………………………………………………………………………. 2-12
Left Hand Control Panel………………………………………………………………………………………………… 2-14
Air Conditioner……………………………………………………………………………………………………………… 2-20
T8 Series Split System Air Conditioning Manual ……………………………………………………………. 2-20
Section 3 – Main Frame / Crawlers……………………………………………3-1
Main Frame Repair – General …………………………………………………………………………………………… 3-2
Main Frame Repair……………………………………………………………………………………………………… 3-2
Leveling Jacks ……………………………………………………………………………………………………………….. 3-3
Leveling Jacks……………………………………………………………………………………………………………. 3-3
Leveling Jack Cylinders……………………………………………………………………………………………….. 3-4
Mast Elevating Cylinders ………………………………………………………………………………………………… 3-5
Mast Elevating Cylinders……………………………………………………………………………………………… 3-6
Remove…………………………………………………………………………………………………………………….. 3-7
Repair……………………………………………………………………………………………………………………….. 3-7
Replace …………………………………………………………………………………………………………………….. 3-7
Crawler Assembly…………………………………………………………………………………………………………… 3-8
Crawler Component Repair………………………………………………………………………………………….. 3-9
Metric Bolt Torque Specifications………………………………………………………………………………….. 3-10
Track Maintenance………………………………………………………………………………………………………….3-11
Before Operating the Machine ……………………………………………………………………………………..3-11
General Maintenance ………………………………………………………………………………………………….3-11
Track Tension Adjustment …………………………………………………………………………………………….. 3-12
Hydraulic Tensioner…………………………………………………………………………………………………… 3-13
Description ………………………………………………………………………………………………………………. 3-14
Nitrogen Tensioner ……………………………………………………………………………………………………. 3-15
Hydraulic Tensioner ……………………………………………………………………………………………………… 3-16
Repair……………………………………………………………………………………………………………………… 3-16
Nitrogen Tensioner Assembly ……………………………………………………………………………………….. 3-17
Nitrogen Tensioner – Fitting Instructions ……………………………………………………………………….. 3-18
Nitrogen Tensioner – Pressure Check ………………………………………………………………………….. 3-20
Nitrogen Tensioner – Pressure Release ……………………………………………………………………….. 3-20
Track Chain – Separate………………………………………………………………………………………………….. 3-21
Track Chain – Repair……………………………………………………………………………………………………… 3-22
Track Link – Repair & Replace…………………………………………………………………………………….. 3-22
Track Link – Description……………………………………………………………………………………………… 3-23
Track Shoes Installation………………………………………………………………………………………………… 3-24
Track Link Position ……………………………………………………………………………………………………. 3-24
Track Shoe – Mounting to Tracsk Chain ……………………………………………………………………….. 3-25
Track Shoe Bolt Torque (Direct Torque Method) …………………………………………………………….. 3-26
Track Shoe Bolt Torque (Torque Turn Method) ………………………………………………………………. 3-27
Track Chain and Shoe Installation …………………………………………………………………………………. 3-28
Track Chain with Shoes……………………………………………………………………………………………… 3-28
Track Chain & Shoe – Assembly & Installation ………………………………………………………………. 3-28
Final Drive ……………………………………………………………………………………………………………………. 3-30
Final Drive – General Description ………………………………………………………………………………… 3-30
Final Drive Unit Removal ………………………………………………………………………………………………. 3-31
Removal from Track Frame………………………………………………………………………………………… 3-31
Final Drive Unit Installation …………………………………………………………………………………………… 3-32
Installation into Track Frame ………………………………………………………………………………………. 3-32
Final Drive Maintenance………………………………………………………………………………………………… 3-33
Oil Check / Change …………………………………………………………………………………………………… 3-33
Final Drive Oil……………………………………………………………………………………………………………….. 3-34
Specifications …………………………………………………………………………………………………………… 3-34
Recommended Oil…………………………………………………………………………………………………….. 3-34
Final Drive Assembly…………………………………………………………………………………………………….. 3-35
Parking Brake – Description………………………………………………………………………………………… 3-36
Final Drive – Disconnect & Parking Brake ………………………………………………………………………. 3-37
Towing Procedure – Gear Drive Disconnect ………………………………………………………………….. 3-38
Parking Brake – Removal & Installation………………………………………………………………………… 3-38
Idler Unit Assembly ………………………………………………………………………………………………………. 3-39
Idler Unit – Assembly …………………………………………………………………………………………………. 3-41
Idler Unit Removal ………………………………………………………………………………………………………… 3-45
Idler Unit – Removal…………………………………………………………………………………………………… 3-45
Track and Support Rollers…………………………………………………………………………………………….. 3-47
General Description…………………………………………………………………………………………………… 3-47
Track Roller – Removal & Disassembly………………………………………………………………………… 3-49
Track and Support Roller – Assembly…………………………………………………………………………… 3-51
Track and Support Roller – Test and Install …………………………………………………………………… 3-52
Auxiliary Crane …………………………………………………………………………………………………………….. 3-54
Hydraulic Crane (Auxiliary Crane)……………………………………………………………………………….. 3-54
Load Lift Capacities…………………………………………………………………………………………………… 3-54
Maintenance…………………………………………………………………………………………………………….. 3-55
Section 4 – Engine / Drive Train / Compressor………………………….4-1
Power Group Locator ……………………………………………………………………………………………………… 4-2
Cummins Engine ……………………………………………………………………………………………………………. 4-3
Engine Fuel System ……………………………………………………………………………………………………. 4-4
Construction ………………………………………………………………………………………………………………. 4-5
Combo Fuel Filter Head & Pump Manifold……………………………………………………………………… 4-6
FS1006 Fuel Filter with Water Separator ……………………………………………………………………….. 4-6
Fuel Manifold with Integrated FSO Valve ……………………………………………………………………….. 4-7
Fuel Connections ……………………………………………………………………………………………………….. 4-7
Pre Filters ………………………………………………………………………………………………………………….. 4-8
Wiring with EFS Power Relay ………………………………………………………………………………………. 4-8
Pressure and Temperature Sensors………………………………………………………………………………. 4-8
Operation…………………………………………………………………………………………………………………… 4-9
QST30 Electric Fuel Supply System ……………………………………………………………………………. 4-10
Oil Reserve Systems…………………………………………………………………………………………………. 4-12
Engine Oil Reserve System (Basic Circuit) …………………………………………………………………… 4-12
LED Monitor Readings ………………………………………………………………………………………………. 4-13
Adjustment of Running Oil Level …………………………………………………………………………………. 4-13
Oil Reserve Basic Circuit……………………………………………………………………………………………. 4-14
Oil Pressure Switch …………………………………………………………………………………………………… 4-14
Oil Reserve System…………………………………………………………………………………………………… 4-14
Troubleshooting………………………………………………………………………………………………………… 4-15
Maintenance…………………………………………………………………………………………………………….. 4-15
Engine and Compressor Air Cleaner ……………………………………………………………………………… 4-16
Engine and Compressor Air Cleaner Service………………………………………………………………… 4-17
Compressor Assembly………………………………………………………………………………………………….. 4-20
Flexible Drive Coupling…………………………………………………………………………………………………. 4-21
Flexible Drive Coupling Service ………………………………………………………………………………….. 4-21
Pump Drive…………………………………………………………………………………………………………………… 4-23
Pump Identification……………………………………………………………………………………………………. 4-23
Pump Drive Assembly – Removal and Replacement………………………………………………………. 4-24
Pump Drive Gearbox …………………………………………………………………………………………………….. 4-25
Pump Drive Gearbox Repair ………………………………………………………………………………………. 4-26
3″ Input Shaft Assembly …………………………………………………………………………………………….. 4-28
Hydraulic Pump ……………………………………………………………………………………………………………. 4-29
Hydraulic Pumps – Removal and Replacement……………………………………………………………… 4-29
Compressor Installation………………………………………………………………………………………………… 4-30
Compressor Drive Coupling ……………………………………………………………………………………….. 4-30
Compressor Installation……………………………………………………………………………………………… 4-32
Compressor Drive Coupling – Removal and Replacement………………………………………………. 4-34
Compressor Shaft Seal …………………………………………………………………………………………………. 4-35
Compressor Shaft Seal ……………………………………………………………………………………………… 4-35
Low Pressure Compressosr ………………………………………………………………………………………….. 4-38
Safety ……………………………………………………………………………………………………………………… 4-38
Description ………………………………………………………………………………………………………………. 4-41
Compressed Air Functions …………………………………………………………………………………………. 4-41
Compressor Oil Circuit …………………………………………………………………………………………………. 4-45
Diagram Legend……………………………………………………………………………………………………….. 4-45
Compressor Oil Circuit – COLD …………………………………………………………………………………… 4-46
Compressor Oil Circuit – HOT …………………………………………………………………………………….. 4-47
Compressor Oil Circuit – Shut Down ……………………………………………………………………………. 4-48
Compressor Condensation Table ………………………………………………………………………………….. 4-49
Compressor Air Circuits – 2400cfm @ 100psi …………………………………………………………………. 4-50
Diagram Legend……………………………………………………………………………………………………….. 4-52
Shutdown ………………………………………………………………………………………………………………… 4-53
Start Up …………………………………………………………………………………………………………………… 4-54
Run Loaded……………………………………………………………………………………………………………… 4-55
Drilling Air On …………………………………………………………………………………………………………… 4-56
Compressor Functional Description………………………………………………………………………………. 4-57
Compressor Operation………………………………………………………………………………………………….. 4-59
Operation…………………………………………………………………………………………………………………. 4-59
Compressor Maintenance……………………………………………………………………………………………… 4-62
General Maintenance ………………………………………………………………………………………………… 4-62
Discharge Check Valve ……………………………………………………………………………………………… 4-64
Compressor Receiver Tank Assembly………………………………………………………………………….. 4-65
Separator Elements…………………………………………………………………………………………………… 4-67
Separator Elements – Remove & Replace ……………………………………………………………………. 4-68
Scavenge Line………………………………………………………………………………………………………….. 4-69
Compressor Discharge Temperature Gauge, Switch and Sender ……………………………………. 4-70
Minimum Pressure Valve……………………………………………………………………………………………. 4-71
Minimum Pressure / Check Valve Maintenance…………………………………………………………….. 4-71
Thermal Bypass Valve……………………………………………………………………………………………….. 4-72
Thermal Bypass Valve Maintenance ……………………………………………………………………………. 4-73
Oil Stop Valve…………………………………………………………………………………………………………… 4-74
Compressor Fluid Filter ……………………………………………………………………………………………… 4-76
Changing Filter Elements …………………………………………………………………………………………… 4-77
Bearing Oil Filter……………………………………………………………………………………………………….. 4-78
Compressor Inlet Valve Control System……………………………………………………………………….. 4-79
Compressor Inlet Valve Control System……………………………………………………………………….. 4-80
Relieving Regulators …………………………………………………………………………………………………. 4-81
System Blowdown Valve ……………………………………………………………………………………………. 4-84
Running Blowdown Valve…………………………………………………………………………………………… 4-85
Running Blowdown Maintenance………………………………………………………………………………… 4-86
Moisture Separator Maintenance ………………………………………………………………………………… 4-87
Auxiliary Regulators ………………………………………………………………………………………………….. 4-88
Auxiliary Regulator Maintenance…………………………………………………………………………………. 4-89
Troubleshooting………………………………………………………………………………………………………… 4-92
Aluminum Tube Air to Oil Cooler …………………………………………………………………………………… 4-94
Compressor Oil Cooler………………………………………………………………………………………………. 4-94
Radiator Cooler…………………………………………………………………………………………………………… 4-102
Radiator Hydraulic Oil Cooler Assembly …………………………………………………………………….. 4-102
Radiator / Oil Cooler Repair ……………………………………………………………………………………….4-110
Section 5 – Dust Control System………………………………………………5-1
Dust Control System ………………………………………………………………………………………………………. 5-2
Dust Control Systems………………………………………………………………………………………………….. 5-2
Water Injection ……………………………………………………………………………………………………………….. 5-3
Water Tanks……………………………………………………………………………………………………………….. 5-3
Water Tank Top up Soleniod Valve………………………………………………………………………………… 5-4
Water Injection Relief Valve………………………………………………………………………………………….. 5-6
Water Injection Control ………………………………………………………………………………………………… 5-7
Water Injection Basic Circuit…………………………………………………………………………………………. 5-9
Water Pump………………………………………………………………………………………………………………….. 5-10
Pump Specifications………………………………………………………………………………………………….. 5-10
Servicing Instructions ………………………………………………………………………………………………… 5-10
Parts List …………………………………………………………………………………………………………………..5-11
Replacing Piston Cup Seals……………………………………………………………………………………….. 5-12
Replacing Suction and Discharge Valves……………………………………………………………………… 5-13
Replacing Power End Bearings…………………………………………………………………………………… 5-14
Servicing the Wrist Pin Bearings …………………………………………………………………………………. 5-15
Fastener Torque Requirements…………………………………………………………………………………… 5-15
Recommended Lubricants …………………………………………………………………………………………. 5-16
Water Pump Motor Repair………………………………………………………………………………………….. 5-16
Water Injection Hydraulic Control Valve Repair……………………………………………………………… 5-16
Water Pump Drive Coupling……………………………………………………………………………………….. 5-16
Level and Flow Transducer ………………………………………………………………………………………… 5-16
Section 6 – Mast / Rotary Drive / Pipe Rack………………………………6-1
Mast Weldment……………………………………………………………………………………………………………….. 6-2
Mast Repair ……………………………………………………………………………………………………………….. 6-2
Mast Assembly……………………………………………………………………………………………………………….. 6-3
Mast Assembly …………………………………………………………………………………………………………… 6-3
Mast Pivot………………………………………………………………………………………………………………….. 6-4
Feed Cylinders ……………………………………………………………………………………………………………….. 6-5
Feed Cylinder – Removal……………………………………………………………………………………………… 6-7
Feed Cylinder Assembly………………………………………………………………………………………………. 6-9
Repair……………………………………………………………………………………………………………………… 6-10
Installation ……………………………………………………………………………………………………………….. 6-10
Hoist / Pulldown Cable Adjustment …………………………………………………………………………………6-11
Hosit / Pulldown Cable Adjustment ……………………………………………………………………………… 6-12
Hoist / Pulldown Cable Replacement …………………………………………………………………………… 6-15
Rotary Drive Assembly………………………………………………………………………………………………….. 6-16
Rotary Head Guide Alignment…………………………………………………………………………………….. 6-17
Rotary Head – Drive System……………………………………………………………………………………….. 6-18
Rotary Drive – Removal from Mast ………………………………………………………………………………. 6-19
Rotary Drive – Installation …………………………………………………………………………………………… 6-19
Rotary Drive Gearbox……………………………………………………………………………………………………. 6-20
Rotary Drive Gearbox – Item Listing …………………………………………………………………………….. 6-21
Rotary Head Bull Shaft Bearing Nut…………………………………………………………………………….. 6-21
Rotary Drive Gearbox – Repair……………………………………………………………………………………. 6-22
Air Swivel…………………………………………………………………………………………………………………. 6-23
Winch Assembly …………………………………………………………………………………………………………… 6-24
Precautions on the use of Winches……………………………………………………………………………… 6-24
Wedge Socket ………………………………………………………………………………………………………….. 6-26
Grooved Drums………………………………………………………………………………………………………… 6-27
Plain (Smooth) Drums ……………………………………………………………………………………………….. 6-27
Drums – Multiple Layers …………………………………………………………………………………………….. 6-27
Winch Assembly Service ……………………………………………………………………………………………. 6-28
BG8A and BG8B Hydraulic Winch Service Manual………………………………………………………… 6-29
Deck Wrench ………………………………………………………………………………………………………………… 6-60
H.O.B.O. Wrench…………………………………………………………………………………………………………… 6-61
Breakout System – HOBO ………………………………………………………………………………………….. 6-62
Pipe Safety Arm………………………………………………………………………………………………………… 6-62
Pipe Positioner……………………………………………………………………………………………………………… 6-63
Carousel Pipe Rack ………………………………………………………………………………………………………. 6-64
Major Components……………………………………………………………………………………………………. 6-64
Rod Handling – Carousel Indexing ………………………………………………………………………………. 6-65
Carousel Pipe Rack Assembly ……………………………………………………………………………………. 6-66
General Information…………………………………………………………………………………………………… 6-67
Pipe Rack Bearings – Removal …………………………………………………………………………………… 6-67
Pipe Rack Componetns – Inspection ……………………………………………………………………………. 6-70
Pipe Rack – Assembly and Installation …………………………………………………………………………. 6-71
Pipe Rack Roller – Remove and Replace……………………………………………………………………… 6-72
Pipe Rack Roller – Disassembly and Assembly……………………………………………………………… 6-73
Section 7 – Hydraulic Systems…………………………………………………7-1
Hydraulic Symbols …………………………………………………………………………………………………………. 7-2
Pressure Setting Sequence …………………………………………………………………………………………….. 7-4
Pressure Setting Sequence………………………………………………………………………………………….. 7-4
Hydraulic Tank ……………………………………………………………………………………………………………….. 7-6
Hydraulic Tank……………………………………………………………………………………………………………. 7-6
Return Hydraulic Filters……………………………………………………………………………………………….. 7-7
Main Return and Case Drain Filters …………………………………………………………………………………. 7-8
Routine Maintenance ………………………………………………………………………………………………….. 7-9
Changing Filter Elements …………………………………………………………………………………………….. 7-9
Main Hydraulic Pumps ………………………………………………………………………………………………….. 7-10
Pump Identification……………………………………………………………………………………………………. 7-10
Right Track, Left Track / Rotation Pumps ………………………………………………………………………..7-11
Hydraulic Piston Pumps – Removal and REplacement …………………………………………………….7-11
AA4VG 180 Hydraulic Pump HD/D Control…………………………………………………………………… 7-12
Technical Data………………………………………………………………………………………………………….. 7-14
Port Locations ………………………………………………………………………………………………………….. 7-18
Setting Procedure……………………………………………………………………………………………………… 7-19
Charge Pressure, High Pressure, P.O.R. and Zero Position Settings……………………………….. 7-20
Set Charge Pressure – 450psi (31 bar) ………………………………………………………………………… 7-20
Set Crossover Relief (High Pressure) – 5500psi (380 bar)………………………………………………. 7-21
Set Pressure Override (P.O.R) – 5000psi (345 bar)………………………………………………………… 7-22
Set Mechanical Zero Position – HD Pump Control …………………………………………………………. 7-23
Set Hydraulic Zero Position – HD Pump Control ……………………………………………………………. 7-24
Removal and Inspection of Charge Pump…………………………………………………………………….. 7-25
Removal and Installation of Shaft Seal ………………………………………………………………………… 7-26
Routine Maintenance ………………………………………………………………………………………………… 7-27
Charge Circuit ………………………………………………………………………………………………………………. 7-30
Charge Filter…………………………………………………………………………………………………………………. 7-32
Routine Maintenance ………………………………………………………………………………………………… 7-32
Changing Filter Elements …………………………………………………………………………………………… 7-32
Main Pumps Circuit ………………………………………………………………………………………………………. 7-34
Main Pumps Circuit …………………………………………………………………………………………………… 7-34
Loop Filters ………………………………………………………………………………………………………………….. 7-35
Routine Maintenance ………………………………………………………………………………………………… 7-35
Changing Filter Elements …………………………………………………………………………………………… 7-38
Rotation Circuit…………………………………………………………………………………………………………….. 7-39
Rotation Circuit…………………………………………………………………………………………………………. 7-39
Rotary Drive Gearbox Motor………………………………………………………………………………………….. 7-40
Rotary Drive Gearbox Motor – Test and Repair ……………………………………………………………… 7-40
Shaft Seal Replacement…………………………………………………………………………………………….. 7-41
Trouvle Shooting ………………………………………………………………………………………………………. 7-43
Tram Circuit………………………………………………………………………………………………………………….. 7-45
Tram Circuit ……………………………………………………………………………………………………………… 7-45
Feed and Auxiliary Pump Circuit……………………………………………………………………………………. 7-47
Hydraulic Piston Pumps – Removal and Replacement……………………………………………………. 7-47
Feed and Auxiliary Functions Pump…………………………………………………………………………….. 7-50
Repair Instructions ……………………………………………………………………………………………………. 7-51
Pump Replacement – Start Up ……………………………………………………………………………………. 7-52
Hydraulic Systems………………………………………………………………………………………………………… 7-54
Auxiliary and Feed Circuits…………………………………………………………………………………………. 7-54
Main Control Valves………………………………………………………………………………………………………. 7-55
Valve Stand Assembly……………………………………………………………………………………………….. 7-55
MP18 Valve – Jack and Mast Raise Valve………………………………………………………………………… 7-56
MP22 Valve – Hoist and Pulldown Control………………………………………………………………………. 7-58
4WE6 – Aux. Functions and Mast Valves ………………………………………………………………………… 7-61
Repair Kits……………………………………………………………………………………………………………….. 7-63
Exploded View of 4WE6…………………………………………………………………………………………….. 7-64
Counterbalance Valves …………………………………………………………………………………………………. 7-65
Counterbalance Valve Adjustment ………………………………………………………………………………. 7-65
Pilot Control Manifold……………………………………………………………………………………………………. 7-66
Control Valve Assembly………………………………………………………………………………………………… 7-68
Auxiliary Pump Load Solenoid Valve……………………………………………………………………………. 7-68
Hydraulic Feed Circuit…………………………………………………………………………………………………… 7-74
Feed Valve Assembly ……………………………………………………………………………………………………. 7-79
Jack Control and Mast Elevating Circuit ………………………………………………………………………… 7-82
Jack Control and Mast Elevating Circuit……………………………………………………………………….. 7-83
Leveling Jack Cylinders………………………………………………………………………………………………… 7-84
Counterbalance Valve Test Procedure …………………………………………………………………………. 7-85
Mast Elevating Cylinders ………………………………………………………………………………………………. 7-86
Counterbalance Valve Test Procedure …………………………………………………………………………. 7-87
Auxiliary Functions Circuit ……………………………………………………………………………………………. 7-88
Auxiliary Functions Circuit ………………………………………………………………………………………….. 7-88
Hydraulic Operated Breakout Wrench……………………………………………………………………………. 7-90
Setting of HOBO Sequence Valves……………………………………………………………………………… 7-91
Cooler Fan Circuit…………………………………………………………………………………………………………. 7-92
Fan Motor Circuit………………………………………………………………………………………………………. 7-92
Cooler Fan Motor ………………………………………………………………………………………………………….. 7-95
Hydraulic Motor ………………………………………………………………………………………………………… 7-95
Hydraulic Thermostatic Valve………………………………………………………………………………………… 7-99
Hydraulic Cooler – Thermal Valve………………………………………………………………………………… 7-99
Central Lube……………………………………………………………………………………………………………….. 7-100
Hydraulic Circuit ……………………………………………………………………………………………………… 7-101
Air Conditioner Compressor Drive Circuit ……………………………………………………………………. 7-102
Air Conditioner Drive Motor…………………………………………………………………………………………. 7-103
Design …………………………………………………………………………………………………………………… 7-103
Operational Check…………………………………………………………………………………………………… 7-103
Shaft Seal Replacement…………………………………………………………………………………………… 7-104
Screw Tightening Torque………………………………………………………………………………………….. 7-104
Gear Backlash………………………………………………………………………………………………………… 7-104
Specifications …………………………………………………………………………………………………………. 7-104
Parts List ……………………………………………………………………………………………………………….. 7-105
Water Injection Circuit…………………………………………………………………………………………………. 7-106
Water Injection Valve……………………………………………………………………………………………….. 7-107
Water Injection Valve…………………………………………………………………………………………………… 7-109
Introduciton…………………………………………………………………………………………………………….. 7-109
Valve Stack Assembly ……………………………………………………………………………………………….7-110
Segment Alterations ………………………………………………………………………………………………….7-111
Pulsar Solenoid Removal and Plug……………………………………………………………………………..7-113
Recommended Test Stand …………………………………………………………………………………………7-114
Final Stack Adjustment………………………………………………………………………………………………7-117
Assembly Drawing – VBL Bypass Inlet Segment Parts List……………………………………………. 7-123
Assembly Drawing – VPL Work Segment Parts List ……………………………………………………… 7-125
Water Pump Motor………………………………………………………………………………………………………. 7-127
Water Pump Motor Repair Information……………………………………………………………………….. 7-127
Shaft Seal Repair ……………………………………………………………………………………………………. 7-128
Foam Injection Unit……………………………………………………………………………………………………… 7-131
Hydraulic Cylinder Repair……………………………………………………………………………………………. 7-132
General Information…………………………………………………………………………………………………. 7-133
H Head ………………………………………………………………………………………………………………….. 7-135
N Head ………………………………………………………………………………………………………………….. 7-136
Z Head…………………………………………………………………………………………………………………… 7-137
Z Head ( Two Piece)………………………………………………………………………………………………… 7-138
K Head ………………………………………………………………………………………………………………….. 7-139
M Head………………………………………………………………………………………………………………….. 7-140
Z Piston …………………………………………………………………………………………………………………. 7-141
Z Piston (Threaded) ………………………………………………………………………………………………… 7-142
H & K Piston …………………………………………………………………………………………………………… 7-143
M Piston ………………………………………………………………………………………………………………… 7-144
N Piston…………………………………………………………………………………………………………………. 7-147
Section 8 – Electrical Components…………………………………………..8-1
Electrical Locator……………………………………………………………………………………………………………. 8-2
Electrical Locator Parts List………………………………………………………………………………………….. 8-4
Jump Starting…………………………………………………………………………………………………………………. 8-5
Batteries ………………………………………………………………………………………………………………………… 8-7
Welding Precautions ………………………………………………………………………………………………………. 8-8
Vigilante Guide……………………………………………………………………………………………………………….. 8-9
Important Information ………………………………………………………………………………………………….. 8-9
PLC ………………………………………………………………………………………………………………………… 8-10
EEPROM…………………………………………………………………………………………………………………..8-11
Output Card……………………………………………………………………………………………………………… 8-12
Touchscreen…………………………………………………………………………………………………………….. 8-13
Laser Depth System………………………………………………………………………………………………….. 8-14
Safety Instructions & Precautions ……………………………………………………………………………….. 8-15
Pipe in Hole Detection……………………………………………………………………………………………….. 8-16
Distance Meter …………………………………………………………………………………………………………. 8-16
Start Up and Shut Down…………………………………………………………………………………………….. 8-17
Hydraulic Function Enable …………………………………………………………………………………………. 8-17
Alarms …………………………………………………………………………………………………………………….. 8-17
Solenoid Control……………………………………………………………………………………………………….. 8-18
Auto Lube ………………………………………………………………………………………………………………… 8-21
Hammer Oiler System ……………………………………………………………………………………………….. 8-21
Gauges……………………………………………………………………………………………………………………. 8-22
Pressure Transducer …………………………………………………………………………………………………. 8-22
Level Transducer………………………………………………………………………………………………………. 8-22
Hammer Oil Level Transducer…………………………………………………………………………………….. 8-22
Temperature Transducer ……………………………………………………………………………………………. 8-23
Water Flow Transducer ……………………………………………………………………………………………… 8-25
Inclinometers ……………………………………………………………………………………………………………. 8-26
Head Speed Module………………………………………………………………………………………………….. 8-27
Level Switches …………………………………………………………………………………………………………. 8-28
Dust Suppression ……………………………………………………………………………………………………… 8-28
Turkey Spray ……………………………………………………………………………………………………………. 8-28
Water Suppression Tank – Top Up……………………………………………………………………………….. 8-28
Vigilante System Component Information ……………………………………………………………………… 8-29
Head Speed Module………………………………………………………………………………………………….. 8-29
Inclinometer……………………………………………………………………………………………………………… 8-31
Ladder Prox Switch …………………………………………………………………………………………………… 8-34
LDM 40 A Laser………………………………………………………………………………………………………… 8-35
Level Switches – Capacitive Level Switch (Hydraulic Oil Level)……………………………………….. 8-47
Radiator Level Switch………………………………………………………………………………………………… 8-51
Level Transducer – Electronic Level Sensor………………………………………………………………….. 8-55
Hammer Oil Level Transducer…………………………………………………………………………………….. 8-65
Pressure Transducer – Combined Pressure Sensor……………………………………………………….. 8-67
Temperature Transducer – Control Monitor for Temperature Sensors……………………………….. 8-76
Temperature Sensor………………………………………………………………………………………………….. 8-88
Water Flow Transducer – Flow Sensor Analog ………………………………………………………………. 8-89
Water Control Module………………………………………………………………………………………………. 8-103
Rod Counter Switch ………………………………………………………………………………………………… 8-132
Remote Fuel Level Display ………………………………………………………………………………………. 8-133
Section 9 – Lubrication and Preventive Maintenance………………..9-1
Central Lube System ………………………………………………………………………………………………………. 9-2
Hydraulic Control Schematic ………………………………………………………………………………………… 9-3
Auto Lube ………………………………………………………………………………………………………………….. 9-3
Central Lube Pump Module………………………………………………………………………………………….. 9-7
Central Lube Pump …………………………………………………………………………………………………… 9-20
Bit Oiler Tank Assembly………………………………………………………………………………………………… 9-46
Bit Oil Circuit………………………………………………………………………………………………………………… 9-47
Bit Oil System ………………………………………………………………………………………………………………. 9-48
Air Service Unit Components ……………………………………………………………………………………… 9-48
Filter Regulator…………………………………………………………………………………………………………. 9-49
Air Line Oiler…………………………………………………………………………………………………………….. 9-50
Fire Ball 425 Pump – Instructions ………………………………………………………………………………… 9-51
Pipe Thread Lubricator …………………………………………………………………………………………………. 9-68
Air Service Unit…………………………………………………………………………………………………………. 9-68
Filter Regulator…………………………………………………………………………………………………………. 9-69
Air Line Lubricator …………………………………………………………………………………………………….. 9-70
Pipe Thread Pump ……………………………………………………………………………………………………. 9-71
Filter Locator………………………………………………………………………………………………………………… 9-79
Lubrication General………………………………………………………………………………………………………. 9-81
Equipment Lubrication……………………………………………………………………………………………….. 9-81
Care of Lubrication Points ………………………………………………………………………………………….. 9-81
Lubrication and Preventive Maintenance……………………………………………………………………….. 9-82
Safety ……………………………………………………………………………………………………………………… 9-82
Track Gear……………………………………………………………………………………………………………….. 9-82
Engine Maintenance………………………………………………………………………………………………….. 9-84
Air Cleaners……………………………………………………………………………………………………………… 9-85
Air Filter Elements …………………………………………………………………………………………………….. 9-85
Alternator Maintenance ……………………………………………………………………………………………… 9-85
Pump Drive and Drive Shaft Maintenance ……………………………………………………………………. 9-86
Compressor Maintenance ………………………………………………………………………………………….. 9-86
Cooler Packs ……………………………………………………………………………………………………………. 9-86
A-Frame and Pivot Point Maintenance…………………………………………………………………………. 9-88
Pull Down and Hoist Ropes and Sheaves Maintenance …………………………………………………. 9-88
Hydraulic System Maintenance…………………………………………………………………………………… 9-90
Hydraulic Maintenance………………………………………………………………………………………………. 9-90
Water Pump Maintenance………………………………………………………………………………………….. 9-90
Cab Maintenance ……………………………………………………………………………………………………… 9-90
Air Conditioner Maintenance ………………………………………………………………………………………. 9-92
Battery Maintenance …………………………………………………………………………………………………. 9-92
Lubrication System Maintenance ………………………………………………………………………………… 9-92
Fire Suppression Maintenance……………………………………………………………………………………. 9-92
Lubrication and Maintenance Chart 250hr ……………………………………………………………………… 9-94
Lubrication and Maintenance Chart 500hr ……………………………………………………………………. 9-104
Lubrication and Maintenance Chart 1000hr ……………………………………………………………………9-115
Lubrication and Maintenance Chart 2000hr ………………………………………………………………….. 9-126
Lubricant Specifications ……………………………………………………………………………………………… 9-138
Hydraulic System ……………………………………………………………………………………………………. 9-138
Hydraulic Tank Capacity…………………………………………………………………………………………… 9-138
Compressor Lubrication …………………………………………………………………………………………… 9-139
Compressor Lubricant Specifications…………………………………………………………………………. 9-139
Lubricating Grease ………………………………………………………………………………………………….. 9-140
Gear Lubricant………………………………………………………………………………………………………… 9-140
Scheduled Oil Sampling Analysis………………………………………………………………………………. 9-140
Torque Valves for Split Flange Connections…………………………………………………………………. 9-141

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