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

Introduction

CAUTION:

DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine before welding (see Section 8).

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
General Locator ……………………………………………………………………………………………………………….xvi
Section 1 – Safety……………………………………………………………………1-1
Section 1 Contents …………………………………………………………………………………………………………. 1-3
Safety …………………………………………………………………………………………………………………………….. 1-4
Personal Protective Equipment …………………………………………………………………………………….. 1-4
Noise ………………………………………………………………………………………………………………………… 1-4
Electrical Contact ……………………………………………………………………………………………………….. 1-4
Overhead and Buried Utilities……………………………………………………………………………………….. 1-4
Contact with Electric Wires…………………………………………………………………………………………… 1-5
Contaminated Air………………………………………………………………………………………………………… 1-5
Machine Stability ………………………………………………………………………………………………………… 1-6
Moving and Rotating Parts …………………………………………………………………………………………… 1-7
High Pressure Air or Fluid ……………………………………………………………………………………………. 1-7
Before Operation ………………………………………………………………………………………………………… 1-7
During Operation ………………………………………………………………………………………………………… 1-8
Maintenance…………………………………………………………………………………………………………….. 1-10
Safety Locator ……………………………………………………………………………………………………………1-11
Section 2 – Operator’s Cab / Controls………………………………………2-1
Section 2 Contents …………………………………………………………………………………………………………. 2-3
Graphic Symbol Legend …………………………………………………………………………………………………. 2-4
Warning Decals………………………………………………………………………………………………………………. 2-8
Operators Controls and Indicators ………………………………………………………………………………… 2-10
Control Panels………………………………………………………………………………………………………….. 2-10
Right Hand Control Panel ……………………………………………………………………………………………….2-11
Instrument Panel and Circuit Breakers ………………………………………………………………………….. 2-12
Circuit Breakers………………………………………………………………………………………………………… 2-12
Light Switches ………………………………………………………………………………………………………….. 2-13
Instrument Panel ………………………………………………………………………………………………………. 2-13
System Pressure Guage Panel………………………………………………………………………………………. 2-14
Left Hand Control Panel………………………………………………………………………………………………… 2-16
Foot Control Pedals………………………………………………………………………………………………………. 2-22
Cab Foot Controls …………………………………………………………………………………………………….. 2-22
Thread Grease Switch……………………………………………………………………………………………….. 2-22
Pipe Safety Arm Override Switch ………………………………………………………………………………… 2-22
Air Conditioner……………………………………………………………………………………………………………… 2-23
T8 Series Split System Air Conditioning Manual ……………………………………………………………. 2-23
Section 3 – Main Frame / Crawlers……………………………………………3-1
Section 3 Contents …………………………………………………………………………………………………………. 3-3
Main Frame Repair – General …………………………………………………………………………………………… 3-5
Main Frame Repair……………………………………………………………………………………………………… 3-5
Leveling Jacks ……………………………………………………………………………………………………………….. 3-6
Leveling Jacks……………………………………………………………………………………………………………. 3-6
Leveling Jack Cylinders……………………………………………………………………………………………….. 3-7
Mast Elevating Cylinders ………………………………………………………………………………………………… 3-8
Mast Elevating Cylinders……………………………………………………………………………………………… 3-9
Remove…………………………………………………………………………………………………………………… 3-10
Repair……………………………………………………………………………………………………………………… 3-10
Replace …………………………………………………………………………………………………………………… 3-10
Crawler Assembly…………………………………………………………………………………………………………..3-11
Crawler Component Repair………………………………………………………………………………………… 3-12
Metric Bolt Torque Specifications………………………………………………………………………………….. 3-13
Track Maintenance………………………………………………………………………………………………………… 3-14
Before Operating the Machine ……………………………………………………………………………………. 3-14
General Maintenance ………………………………………………………………………………………………… 3-14
Track Tension Adjustment …………………………………………………………………………………………….. 3-15
Hydraulic Tensioner…………………………………………………………………………………………………… 3-16
Description ………………………………………………………………………………………………………………. 3-17
Nitrogen Tensioner ……………………………………………………………………………………………………. 3-18
Hydraulic Tensioner ……………………………………………………………………………………………………… 3-19
Repair……………………………………………………………………………………………………………………… 3-19
Nitrogen Tensioner Assembly ……………………………………………………………………………………….. 3-20
Nitrogen Tensioner – Fitting Instructions ……………………………………………………………………….. 3-21
Nitrogen Tensioner – Pressure Check ………………………………………………………………………….. 3-23
Nitrogen Tensioner – Pressure Release ……………………………………………………………………….. 3-23
Track Chain – Separate………………………………………………………………………………………………….. 3-24
Track Chain – Repair……………………………………………………………………………………………………… 3-25
Track Link – Repair & Replace…………………………………………………………………………………….. 3-25
Track Link – Description……………………………………………………………………………………………… 3-26
Track Shoes Installation………………………………………………………………………………………………… 3-27
Track Link Position ……………………………………………………………………………………………………. 3-27
Track Shoe – Mounting to Tracsk Chain ……………………………………………………………………….. 3-28
Track Shoe Bolt Torque (Direct Torque Method) …………………………………………………………….. 3-29
Track Shoe Bolt Torque (Torque Turn Method) ………………………………………………………………. 3-30
Track Chain and Shoe Installation …………………………………………………………………………………. 3-31
Track Chain with Shoes……………………………………………………………………………………………… 3-31
Track Chain & Shoe – Assembly & Installation ………………………………………………………………. 3-31
Final Drive ……………………………………………………………………………………………………………………. 3-33
Final Drive – General Description ………………………………………………………………………………… 3-33
Final Drive Unit Removal ………………………………………………………………………………………………. 3-34
Removal from Track Frame………………………………………………………………………………………… 3-34
Final Drive Unit Installation …………………………………………………………………………………………… 3-35
Installation into Track Frame ………………………………………………………………………………………. 3-35
Final Drive Maintenance………………………………………………………………………………………………… 3-36
Oil Check / Change …………………………………………………………………………………………………… 3-36
Final Drive Oil……………………………………………………………………………………………………………….. 3-37
Specifications …………………………………………………………………………………………………………… 3-37
Recommended Oil…………………………………………………………………………………………………….. 3-37
Final Drive Assembly…………………………………………………………………………………………………….. 3-38
Parking Brake – Description………………………………………………………………………………………… 3-39
Final Drive – Disconnect & Parking Brake ………………………………………………………………………. 3-40
Towing Procedure – Gear Drive Disconnect ………………………………………………………………….. 3-41
Parking Brake – Removal & Installation………………………………………………………………………… 3-41
Idler Unit Assembly ………………………………………………………………………………………………………. 3-42
Idler Unit – Assembly …………………………………………………………………………………………………. 3-44
Idler Unit Removal ………………………………………………………………………………………………………… 3-48
Idler Unit – Removal…………………………………………………………………………………………………… 3-48
Track and Support Rollers…………………………………………………………………………………………….. 3-50
General Description…………………………………………………………………………………………………… 3-50
Track Roller – Removal & Disassembly………………………………………………………………………… 3-52
Track and Support Roller – Assembly…………………………………………………………………………… 3-54
Track and Support Roller – Test and Install …………………………………………………………………… 3-55
Auxiliary Crane …………………………………………………………………………………………………………….. 3-57
Hydraulic Crane (Auxiliary Crane)……………………………………………………………………………….. 3-57
Load Lift Capacities…………………………………………………………………………………………………… 3-57
Maintenance…………………………………………………………………………………………………………….. 3-58
Section 4 – Engine / Drive Train / Compressor………………………….4-1
Section 4 Contents …………………………………………………………………………………………………………. 4-3
Power Group Locator ……………………………………………………………………………………………………… 4-6
Cummins Engine ……………………………………………………………………………………………………………. 4-7
Engine Fuel System ……………………………………………………………………………………………………. 4-8
Construction ………………………………………………………………………………………………………………. 4-9
Combo Fuel Filter Head & Pump Manifold……………………………………………………………………. 4-10
FS1006 Fuel Filter with Water Separator ……………………………………………………………………… 4-10
Fuel Manifold with Integrated FSO Valve ……………………………………………………………………….4-11
Fuel Connections ……………………………………………………………………………………………………….4-11
Pre Filters ………………………………………………………………………………………………………………… 4-12
Wiring with EFS Power Relay …………………………………………………………………………………….. 4-12
Pressure and Temperature Sensors…………………………………………………………………………….. 4-12
Operation…………………………………………………………………………………………………………………. 4-13
QST30 Electric Fuel Supply System ……………………………………………………………………………. 4-14
Oil Reserve Systems…………………………………………………………………………………………………. 4-16
Engine Oil Reserve System (Basic Circuit) …………………………………………………………………… 4-16
LED Monitor Readings ………………………………………………………………………………………………. 4-17
Adjustment of Running Oil Level …………………………………………………………………………………. 4-17
Oil Reserve Basic Circuit……………………………………………………………………………………………. 4-18
Oil Pressure Switch …………………………………………………………………………………………………… 4-18
Oil Reserve System…………………………………………………………………………………………………… 4-18
Troubleshooting………………………………………………………………………………………………………… 4-19
Maintenance…………………………………………………………………………………………………………….. 4-19
Engine and Compressor Air Cleaner ……………………………………………………………………………… 4-20
Engine and Compressor Air Cleaner Service………………………………………………………………… 4-21
Compressor Assembly………………………………………………………………………………………………….. 4-24
Flexible Drive Coupling…………………………………………………………………………………………………. 4-25
Flexible Drive Coupling Service ………………………………………………………………………………….. 4-25
Pump Drive…………………………………………………………………………………………………………………… 4-27
Pump Identification……………………………………………………………………………………………………. 4-27
Pump Drive Assembly – Removal and Replacement………………………………………………………. 4-28
Pump Drive Gearbox …………………………………………………………………………………………………….. 4-29
Pump Drive Gearbox Repair ………………………………………………………………………………………. 4-30
3″ Input Shaft Assembly …………………………………………………………………………………………….. 4-32
Hydraulic Pump ……………………………………………………………………………………………………………. 4-33
Hydraulic Pumps – Removal and Replacement……………………………………………………………… 4-33
Compressor Installation………………………………………………………………………………………………… 4-34
Compressor Drive Coupling ……………………………………………………………………………………….. 4-34
Compressor Installation……………………………………………………………………………………………… 4-36
Compressor Drive Coupling – Removal and Replacement………………………………………………. 4-38
Compressor Shaft Seal …………………………………………………………………………………………………. 4-40
Compressor Shaft Seal ……………………………………………………………………………………………… 4-40
Low Pressure Compressosr ………………………………………………………………………………………….. 4-43
Safety ……………………………………………………………………………………………………………………… 4-43
Description ………………………………………………………………………………………………………………. 4-46
Compressed Air Functions …………………………………………………………………………………………. 4-46
Compressor Oil Circuit …………………………………………………………………………………………………. 4-50
Diagram Legend……………………………………………………………………………………………………….. 4-50
Compressor Oil Circuit – COLD …………………………………………………………………………………… 4-51
Compressor Oil Circuit – HOT …………………………………………………………………………………….. 4-52
Compressor Condensation Table ………………………………………………………………………………….. 4-53
Compressor Functional Description………………………………………………………………………………. 4-69
Shutdown Mode ……………………………………………………………………………………………………….. 4-71
Compressor Operation………………………………………………………………………………………………….. 4-72
Operation…………………………………………………………………………………………………………………. 4-72
Compressor Maintenance……………………………………………………………………………………………… 4-75
General Maintenance ………………………………………………………………………………………………… 4-75
Discharge Check Valve ……………………………………………………………………………………………… 4-77
Compressor Receiver Tank Assembly………………………………………………………………………….. 4-78
Separator Elements…………………………………………………………………………………………………… 4-80
Separator Elements – Remove & Replace ……………………………………………………………………. 4-81
Scavenge Line………………………………………………………………………………………………………….. 4-82
Compressor Discharge Temperature Gauge, Switch and Sender ……………………………………. 4-83
Minimum Pressure Valve……………………………………………………………………………………………. 4-84
Minimum Pressure / Check Valve Maintenance…………………………………………………………….. 4-84
Thermal Bypass Valve……………………………………………………………………………………………….. 4-85
Thermal Bypass Valve Maintenance ……………………………………………………………………………. 4-86
Oil Stop Valve…………………………………………………………………………………………………………… 4-87
Compressor Fluid Filter ……………………………………………………………………………………………… 4-89
Changing Filter Elements …………………………………………………………………………………………… 4-90
Bearing Oil Filter……………………………………………………………………………………………………….. 4-91
Compressor Inlet Valve Control System……………………………………………………………………….. 4-92
Compressor Inlet Valve Control System……………………………………………………………………….. 4-93
Relieving Regulators …………………………………………………………………………………………………. 4-94
System Blowdown Valve ……………………………………………………………………………………………. 4-97
Running Blowdown Valve…………………………………………………………………………………………… 4-98
Running Blowdown Maintenance………………………………………………………………………………… 4-99
Moisture Separator Maintenance ………………………………………………………………………………. 4-100
Auxiliary Regulators ………………………………………………………………………………………………… 4-101
Auxiliary Regulator Maintenance……………………………………………………………………………….. 4-102
Troubleshooting………………………………………………………………………………………………………. 4-105
Aluminum Tube Air to Oil Cooler …………………………………………………………………………………. 4-107
Compressor Oil Cooler…………………………………………………………………………………………….. 4-107
Radiator Cooler…………………………………………………………………………………………………………….4-116
Radiator Hydraulic Oil Cooler Assembly ………………………………………………………………………4-116
Radiator / Oil Cooler Repair ……………………………………………………………………………………… 4-124
Section 5 – Dust Control System……………………………………………..5-1
Dust Control System ………………………………………………………………………………………………………. 5-4
Dust Control Systems………………………………………………………………………………………………….. 5-4
Water Injection ……………………………………………………………………………………………………………….. 5-5
Water Tanks……………………………………………………………………………………………………………….. 5-5
Water Tank Top up Soleniod Valve………………………………………………………………………………… 5-6
Water Injection Relief Valve………………………………………………………………………………………….. 5-8
Water Injection Control………………………………………………………………………………………………… 5-9
Water Injection Basic Circuit…………………………………………………………………………………………5-11
Water Pump………………………………………………………………………………………………………………….. 5-12
Pump Specifications………………………………………………………………………………………………….. 5-12
Servicing Instructions ………………………………………………………………………………………………… 5-12
Parts List …………………………………………………………………………………………………………………. 5-13
Replacing Piston Cup Seals……………………………………………………………………………………….. 5-14
Replacing Suction and Discharge Valves……………………………………………………………………… 5-15
Replacing Power End Bearings…………………………………………………………………………………… 5-16
Servicing the Wrist Pin Bearings …………………………………………………………………………………. 5-17
Fastener Torque Requirements…………………………………………………………………………………… 5-17
Recommended Lubricants …………………………………………………………………………………………. 5-18
Water Pump Motor Repair………………………………………………………………………………………….. 5-18
Water Injection Hydraulic Control Valve Repair……………………………………………………………… 5-18
Water Pump Drive Coupling……………………………………………………………………………………….. 5-18
Level and Flow Transducer ………………………………………………………………………………………… 5-18
High Pressure Cleaner ………………………………………………………………………………………………….. 5-19
High Pressure Wash down (Motor and Pump)………………………………………………………………. 5-19
Water Injection Valve…………………………………………………………………………………………………….. 5-25
Water Injection Ball valve assembly…………………………………………………………………………….. 5-25
Water Injection Ball valve …………………………………………………………………………………………… 5-25
Actuator – Installation Operation and Maintenance Manual …………………………………………….. 5-27
Actuator – Contents …………………………………………………………………………………………………… 5-28
Actuator – Air Connections………………………………………………………………………………………….. 5-29
Actuator – Installation…………………………………………………………………………………………………. 5-30
Actuator – Dis-assembly …………………………………………………………………………………………….. 5-31
Actuator – Removing Endcaps type ES ………………………………………………………………………… 5-32
Actuator – Removing Pistons/Spindle…………………………………………………………………………… 5-33
Actuator – Re-assembly guide band and shaft ………………………………………………………………. 5-33
Actuator – Reassembly Pistons …………………………………………………………………………………… 5-34
Actuator – Re-assembly Endcaps single acting actuators ……………………………………………….. 5-35
Actuator – Re-assembly of springclip and insert…………………………………………………………….. 5-36
Actuator – Parts List…………………………………………………………………………………………………… 5-37
Section 6 – Mast / Rotary Drive / Pipe Rack………………………………6-1
Section 6 Contents …………………………………………………………………………………………………………. 6-3
Mast Weldment……………………………………………………………………………………………………………….. 6-4
Mast Repair ……………………………………………………………………………………………………………….. 6-4
Mast Assembly……………………………………………………………………………………………………………….. 6-5
Mast Assembly …………………………………………………………………………………………………………… 6-5
Mast Pivot………………………………………………………………………………………………………………….. 6-6
Feed Cylinders ……………………………………………………………………………………………………………….. 6-7
Feed Cylinder – Removal……………………………………………………………………………………………… 6-9
Feed Cylinder Assembly………………………………………………………………………………………………6-11
Repair……………………………………………………………………………………………………………………… 6-12
Installation ……………………………………………………………………………………………………………….. 6-12
Hoist / Pulldown Cable Adjustment ……………………………………………………………………………….. 6-13
Hosit / Pulldown Cable Adjustment ……………………………………………………………………………… 6-14
Hoist / Pulldown Cable Replacement …………………………………………………………………………… 6-17
Rotary Drive Assembly………………………………………………………………………………………………….. 6-18
Rotary Head Guide Alignment…………………………………………………………………………………….. 6-19
Rotary Head – Drive System……………………………………………………………………………………….. 6-20
Rotary Drive – Removal from Mast ………………………………………………………………………………. 6-21
Rotary Drive – Installation …………………………………………………………………………………………… 6-21
Rotary Drive Gearbox……………………………………………………………………………………………………. 6-22
Rotary Drive Gearbox – Item Listing …………………………………………………………………………….. 6-23
Rotary Head Bull Shaft Bearing Nut…………………………………………………………………………….. 6-23
Rotary Drive Gearbox – Repair……………………………………………………………………………………. 6-24
Air Swivel…………………………………………………………………………………………………………………. 6-25
Winch Assembly …………………………………………………………………………………………………………… 6-26
Precautions on the use of Winches……………………………………………………………………………… 6-26
Wedge Socket ………………………………………………………………………………………………………….. 6-28
Grooved Drums………………………………………………………………………………………………………… 6-29
Plain (Smooth) Drums ……………………………………………………………………………………………….. 6-29
Drums – Multiple Layers …………………………………………………………………………………………….. 6-29
Winch Assembly Service ……………………………………………………………………………………………. 6-30
BG8A and BG8B Hydraulic Winch Service Manual………………………………………………………… 6-31
Deck Wrench ………………………………………………………………………………………………………………… 6-62
H.O.B.O. Wrench…………………………………………………………………………………………………………… 6-63
Breakout System – HOBO ………………………………………………………………………………………….. 6-64
Pipe Safety Arm………………………………………………………………………………………………………… 6-64
Pipe Positioner……………………………………………………………………………………………………………… 6-65
Carousel Pipe Rack ………………………………………………………………………………………………………. 6-66
Major Components……………………………………………………………………………………………………. 6-66
Rod Handling – Carousel Indexing ………………………………………………………………………………. 6-67
Carousel Pipe Rack Assembly ……………………………………………………………………………………. 6-68
General Information…………………………………………………………………………………………………… 6-69
Pipe Rack Bearings – Removal …………………………………………………………………………………… 6-69
Pipe Rack Componetns – Inspection ……………………………………………………………………………. 6-72
Pipe Rack – Assembly and Installation …………………………………………………………………………. 6-73
Pipe Rack Roller – Remove and Replace……………………………………………………………………… 6-74
Pipe Rack Roller – Disassembly and Assembly……………………………………………………………… 6-75
Section 7 – Hydraulic Systems…………………………………………………7-1
Section 7 Contents …………………………………………………………………………………………………………. 7-3
Hydraulic Symbols …………………………………………………………………………………………………………. 7-6
Pressure Setting Sequence …………………………………………………………………………………………….. 7-8
Pressure Setting Sequence………………………………………………………………………………………….. 7-8
Hydraulic Tank ……………………………………………………………………………………………………………… 7-10
Hydraulic Tank………………………………………………………………………………………………………….. 7-10
Return Hydraulic Filters……………………………………………………………………………………………….7-11
Main Return and Case Drain Filters ……………………………………………………………………………….. 7-12
Routine Maintenance ………………………………………………………………………………………………… 7-13
Changing Filter Elements …………………………………………………………………………………………… 7-13
Main Hydraulic Pumps ………………………………………………………………………………………………….. 7-14
Pump Identification……………………………………………………………………………………………………. 7-14
Right Track, Left Track / Rotation Pumps ………………………………………………………………………. 7-15
Hydraulic Piston Pumps – Removal and REplacement …………………………………………………… 7-15
AA4VG 180 Hydraulic Pump HD/D Control…………………………………………………………………… 7-16
Technical Data………………………………………………………………………………………………………….. 7-18
Port Locations ………………………………………………………………………………………………………….. 7-22
Setting Procedure……………………………………………………………………………………………………… 7-23
Charge Pressure, High Pressure, P.O.R. and Zero Position Settings……………………………….. 7-24
Set Charge Pressure – 450psi (31 bar) ………………………………………………………………………… 7-24
Set Crossover Relief (High Pressure) – 5500psi (380 bar)………………………………………………. 7-25
Set Pressure Override (P.O.R) – 5000psi (345 bar)………………………………………………………… 7-26
Set Mechanical Zero Position – HD Pump Control …………………………………………………………. 7-27
Set Hydraulic Zero Position – HD Pump Control ……………………………………………………………. 7-28
Removal and Inspection of Charge Pump…………………………………………………………………….. 7-29
Removal and Installation of Shaft Seal ………………………………………………………………………… 7-30
Routine Maintenance ………………………………………………………………………………………………… 7-31
Charge Filter…………………………………………………………………………………………………………………. 7-34
Routine Maintenance ………………………………………………………………………………………………… 7-34
Changing Filter Elements …………………………………………………………………………………………… 7-34
Main Pumps Circuit ………………………………………………………………………………………………………. 7-36
Main Pumps Circuit …………………………………………………………………………………………………… 7-36
Loop Filters ………………………………………………………………………………………………………………….. 7-38
Routine Maintenance ………………………………………………………………………………………………… 7-38
Changing Filter Elements …………………………………………………………………………………………… 7-41
Rotation Circuit…………………………………………………………………………………………………………….. 7-42
Rotation Circuit…………………………………………………………………………………………………………. 7-42
Rotary Drive Gearbox Motor………………………………………………………………………………………….. 7-44
Rotary Drive Gearbox Motor – Test and Repair ……………………………………………………………… 7-44
Shaft Seal Replacement…………………………………………………………………………………………….. 7-45
Trouvle Shooting ………………………………………………………………………………………………………. 7-47
Tram Circuit………………………………………………………………………………………………………………….. 7-49
Tram Circuit ……………………………………………………………………………………………………………… 7-49
Feed and Auxiliary Pump Circuit……………………………………………………………………………………. 7-51
Hydraulic Piston Pumps – Removal and Replacement……………………………………………………. 7-51
Feed and Auxiliary Functions Pump…………………………………………………………………………….. 7-54
Repair Instructions ……………………………………………………………………………………………………. 7-55
Pump Replacement – Start Up ……………………………………………………………………………………. 7-56
Hydraulic Systems………………………………………………………………………………………………………… 7-58
Auxiliary and Feed Circuits…………………………………………………………………………………………. 7-58
Main Control Valves………………………………………………………………………………………………………. 7-59
Valve Stand Assembly……………………………………………………………………………………………….. 7-59
MP18 Valve – Jack and Mast Raise Valve………………………………………………………………………… 7-60
MP22 Valve – Hoist and Pulldown Control………………………………………………………………………. 7-62
4WE6 – Aux. Functions and Mast Valves ………………………………………………………………………… 7-65
Repair Kits……………………………………………………………………………………………………………….. 7-67
Exploded View of 4WE6…………………………………………………………………………………………….. 7-68
Counterbalance Valves …………………………………………………………………………………………………. 7-69
Counterbalance Valve Adjustment ………………………………………………………………………………. 7-69
Pilot Control Manifold……………………………………………………………………………………………………. 7-70
Control Valve Assembly………………………………………………………………………………………………… 7-72
Auxiliary Pump Load Solenoid Valve……………………………………………………………………………. 7-72
Hydraulic Feed Circuit…………………………………………………………………………………………………… 7-78
Feed Valve Assembly ……………………………………………………………………………………………………. 7-83
Jack Control and Mast Elevating Circuit ………………………………………………………………………… 7-87
Jack Control and Mast Elevating Circuit……………………………………………………………………….. 7-88
Leveling Jack Cylinders………………………………………………………………………………………………… 7-89
Counterbalance Valve Test Procedure …………………………………………………………………………. 7-90
Mast Elevating Cylinders ………………………………………………………………………………………………. 7-91
Counterbalance Valve Test Procedure …………………………………………………………………………. 7-92
Auxiliary Functions Circuit ……………………………………………………………………………………………. 7-93
Auxiliary Functions Circuit ………………………………………………………………………………………….. 7-93
Hydraulic Operated Breakout Wrench……………………………………………………………………………. 7-95
Setting of HOBO Sequence Valves……………………………………………………………………………… 7-96
Cooler Fan Circuit……………………………………………………………………………………………………….. 7-102
Fan Motor Circuit…………………………………………………………………………………………………….. 7-102
Cooler Fan Motor ………………………………………………………………………………………………………… 7-105
Hydraulic Motor ………………………………………………………………………………………………………. 7-105
Hydraulic Thermostatic Valve………………………………………………………………………………………. 7-109
Hydraulic Cooler – Thermal Valve………………………………………………………………………………. 7-109
Central Lube…………………………………………………………………………………………………………………7-110
Hydraulic Circuit ……………………………………………………………………………………………………….7-111
Air Conditioner Compressor Drive Circuit ……………………………………………………………………..7-112
Air Conditioner Drive Motor…………………………………………………………………………………………..7-113
Design …………………………………………………………………………………………………………………….7-113
Operational Check…………………………………………………………………………………………………….7-113
Shaft Seal Replacement…………………………………………………………………………………………….7-114
Screw Tightening Torque……………………………………………………………………………………………7-114
Gear Backlash………………………………………………………………………………………………………….7-114
Specifications …………………………………………………………………………………………………………..7-114
Parts List …………………………………………………………………………………………………………………7-115
Water Injection / Foam Injection Circuit …………………………………………………………………………7-116
Water Injection / Foam Injection Valve …………………………………………………………………………7-117
Water Injection / Foam Injection Valve …………………………………………………………………………..7-119
Introduciton………………………………………………………………………………………………………………7-119
Valve Stack Assembly ……………………………………………………………………………………………… 7-120
Segment Alterations ………………………………………………………………………………………………… 7-121
Pulsar Solenoid Removal and Plug……………………………………………………………………………. 7-123
Recommended Test Stand ……………………………………………………………………………………….. 7-124
Final Stack Adjustment…………………………………………………………………………………………….. 7-127
Assembly Drawing – VBL Bypass Inlet Segment Parts List……………………………………………. 7-133
Assembly Drawing – VPL Work Segment Parts List ……………………………………………………… 7-135
Water Pump Motor………………………………………………………………………………………………………. 7-137
Water Pump Motor Repair Information……………………………………………………………………….. 7-137
Shaft Seal Repair ……………………………………………………………………………………………………. 7-138
Foam Injection Unit……………………………………………………………………………………………………… 7-141
Hydraulic Cylinder Repair……………………………………………………………………………………………. 7-142
General Information…………………………………………………………………………………………………. 7-143
H Head ………………………………………………………………………………………………………………….. 7-145
N Head ………………………………………………………………………………………………………………….. 7-146
Z Head…………………………………………………………………………………………………………………… 7-147
Z Head ( Two Piece)………………………………………………………………………………………………… 7-148
K Head ………………………………………………………………………………………………………………….. 7-149
M Head………………………………………………………………………………………………………………….. 7-150
Z Piston …………………………………………………………………………………………………………………. 7-151
Z Piston (Threaded) ………………………………………………………………………………………………… 7-152
H & K Piston …………………………………………………………………………………………………………… 7-153
M Piston ………………………………………………………………………………………………………………… 7-154
N Piston…………………………………………………………………………………………………………………. 7-157
Section 8 – Electrical Components…………………………………………..8-1
Section 8 Contents …………………………………………………………………………………………………………. 8-3
Electrical Locator……………………………………………………………………………………………………………. 8-4
Electrical Locator Parts List………………………………………………………………………………………….. 8-6
Jump Starting…………………………………………………………………………………………………………………. 8-7
Batteries ………………………………………………………………………………………………………………………… 8-9
Welding Precautions …………………………………………………………………………………………………….. 8-10
Vigilante Guide……………………………………………………………………………………………………………….8-11
Important Information ………………………………………………………………………………………………….8-11
PLC ………………………………………………………………………………………………………………………… 8-12
EEPROM…………………………………………………………………………………………………………………. 8-13
Output Card……………………………………………………………………………………………………………… 8-14
Touchscreen…………………………………………………………………………………………………………….. 8-15
Laser Depth System………………………………………………………………………………………………….. 8-16
Safety Instructions & Precautions ……………………………………………………………………………….. 8-17
Pipe in Hole Detection……………………………………………………………………………………………….. 8-18
Distance Meter …………………………………………………………………………………………………………. 8-18
Start Up and Shut Down…………………………………………………………………………………………….. 8-19
Hydraulic Function Enable …………………………………………………………………………………………. 8-19
Alarms …………………………………………………………………………………………………………………….. 8-19
Solenoid Control……………………………………………………………………………………………………….. 8-20
Auto Lube ………………………………………………………………………………………………………………… 8-23
Hammer Oiler System ……………………………………………………………………………………………….. 8-23
Gauges……………………………………………………………………………………………………………………. 8-24
Pressure Transducer …………………………………………………………………………………………………. 8-24
Level Transducer………………………………………………………………………………………………………. 8-24
Hammer Oil Level Transducer…………………………………………………………………………………….. 8-24
Temperature Transducer ……………………………………………………………………………………………. 8-25
Water Flow Transducer ……………………………………………………………………………………………… 8-27
Inclinometers ……………………………………………………………………………………………………………. 8-28
Head Speed Module………………………………………………………………………………………………….. 8-29
Level Switches …………………………………………………………………………………………………………. 8-30
Dust Suppression ……………………………………………………………………………………………………… 8-30
Turkey Spray ……………………………………………………………………………………………………………. 8-30
Water Suppression Tank – Top Up……………………………………………………………………………….. 8-30
Vigilante System Component Information ……………………………………………………………………… 8-31
Head Speed Module………………………………………………………………………………………………….. 8-31
Inclinometer……………………………………………………………………………………………………………… 8-33
Ladder Prox Switch …………………………………………………………………………………………………… 8-36
LDM 40 A Laser………………………………………………………………………………………………………… 8-37
Level Switches – Capacitive Level Switch (Hydraulic Oil Level)……………………………………….. 8-49
Radiator Level Switch………………………………………………………………………………………………… 8-53
Level Transducer – Electronic Level Sensor………………………………………………………………….. 8-57
Hammer Oil Level Transducer…………………………………………………………………………………….. 8-67
Pressure Transducer – Combined Pressure Sensor……………………………………………………….. 8-69
Temperature Transducer – Control Monitor for Temperature Sensors……………………………….. 8-78
Temperature Sensor………………………………………………………………………………………………….. 8-90
Water Flow Transducer – Flow Sensor Analog ………………………………………………………………. 8-91
Water Control Module………………………………………………………………………………………………. 8-105
Rod Counter Switch ………………………………………………………………………………………………… 8-134
Remote Fuel Level Display ………………………………………………………………………………………. 8-135
Section 9 – Lubrication and Preventive Maintenance………………..9-1
Section 9 Contents …………………………………………………………………………………………………………. 9-3
Central Lube System ………………………………………………………………………………………………………. 9-5
Hydraulic Control Schematic ………………………………………………………………………………………… 9-6
Auto Lube ………………………………………………………………………………………………………………….. 9-6
Central Lube Pump Module………………………………………………………………………………………… 9-10
Central Lube Pump …………………………………………………………………………………………………… 9-23
Hammer Oiler Tank Assembly ……………………………………………………………………………………….. 9-49
Hammer Oil Circuit ……………………………………………………………………………………………………….. 9-50
Hammer Oil System………………………………………………………………………………………………………. 9-51
Air Service Unit Components ……………………………………………………………………………………… 9-51
Filter Regulator…………………………………………………………………………………………………………. 9-52
Air Line Oiler…………………………………………………………………………………………………………….. 9-53
Fire Ball 425 Pump – Instructions ………………………………………………………………………………… 9-54
Pipe Thread Lubricator …………………………………………………………………………………………………. 9-71
Air Service Unit…………………………………………………………………………………………………………. 9-71
Filter Regulator…………………………………………………………………………………………………………. 9-72
Air Line Lubricator …………………………………………………………………………………………………….. 9-73
Pipe Thread Pump …………………………………………………………………………………………………….9-74  Locator………………………………………………………………………………………………………………… 9-82
Lubrication General………………………………………………………………………………………………………. 9-84
Equipment Lubrication……………………………………………………………………………………………….. 9-84
Care of Lubrication Points ………………………………………………………………………………………….. 9-84
Lubrication and Preventive Maintenance……………………………………………………………………….. 9-85
Safety ……………………………………………………………………………………………………………………… 9-85
Track Gear……………………………………………………………………………………………………………….. 9-85
Engine Maintenance………………………………………………………………………………………………….. 9-87
Air Cleaners……………………………………………………………………………………………………………… 9-88
Air Filter Elements …………………………………………………………………………………………………….. 9-88
Alternator Maintenance ……………………………………………………………………………………………… 9-88
Pump Drive and Drive Shaft Maintenance ……………………………………………………………………. 9-89
Compressor Maintenance ………………………………………………………………………………………….. 9-89
Cooler Packs ……………………………………………………………………………………………………………. 9-89
A-Frame and Pivot Point Maintenance…………………………………………………………………………. 9-91
Pull Down and Hoist Ropes and Sheaves Maintenance …………………………………………………. 9-91
Hydraulic System Maintenance…………………………………………………………………………………… 9-93
Hydraulic Maintenance………………………………………………………………………………………………. 9-93
Water Pump Maintenance………………………………………………………………………………………….. 9-93
Cab Maintenance ……………………………………………………………………………………………………… 9-93
Air Conditioner Maintenance ………………………………………………………………………………………. 9-95
Battery Maintenance …………………………………………………………………………………………………. 9-95
Lubrication System Maintenance ………………………………………………………………………………… 9-95
Fire Suppression Maintenance……………………………………………………………………………………. 9-95
Lubrication and Maintenance Chart 250hr ……………………………………………………………………… 9-97
Lubrication and Maintenance Chart 500hr ……………………………………………………………………. 9-107
Lubrication and Maintenance Chart 1000hr ……………………………………………………………………9-118
Lubrication and Maintenance Chart 2000hr ………………………………………………………………….. 9-129
Lubricant Specifications ……………………………………………………………………………………………… 9-141
Hydraulic System ……………………………………………………………………………………………………. 9-141
Hydraulic Tank Capacity…………………………………………………………………………………………… 9-141
Compressor Lubrication …………………………………………………………………………………………… 9-142
Compressor Lubricant Specifications…………………………………………………………………………. 9-142
Lubricating Grease ………………………………………………………………………………………………….. 9-143
Gear Lubricant………………………………………………………………………………………………………… 9-143
Scheduled Oil Sampling Analysis………………………………………………………………………………. 9-143
Torque Valves for Split Flange Connections…………………………………………………………………. 9-144

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