Terex SKSS-15 Series Infinity Blasthole Drill Index:

Introduction
Parts Ordering & Product Support ………………………………………………………………………….. i
Safety Information …………………………………………………………………………………………………. ii
Product Description ……………………………………………………………………………………………… iii
Manual Contents…………………………………………………………………………………………………… iii
Table of Contents………………………………………………………………………………………………….. iv
General Locators ………………………………………………………………………………………………… xvi
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
BeforeOperation…………………………………………………………………………………………………………….1-5
During Operation………………………………………………………………………………………………………… 1-6
Maintenance ………………………………………………………………………………………………………………. 1-8
Safety Locators…………………………………………………………………………………………………… 1-9
Section 2
Operator’s Cab/ Controls ……………………………………………………… 2-1
Operator’s Controls and Indicators ……………………………………………………………………… 2-2
Control Panels …………………………………………………………………………………………………………… 2-2
Right Hand Control Panel ……………………………………………………………………………………. 2-3
Instrument Panel and Circuit Breakers ………………………………………………………………… 2-4
Circuit Breakers …………………………………………………………………………………………………………. 2-4
Light Switches……………………………………………………………………………………………………………. 2-5
Instrument Panel ………………………………………………………………………………………………………… 2-5
System Pressure Guage Panel …………………………………………………………………………….. 2-6
Left Hand Control Panel ………………………………………………………………………………………. 2-8
Foot Control Pedals ………………………………………………………………………………………….. 2-14
Thread Grease Switch ………………………………………………………………………………………….. 14
Pipe Safety Arm Override Switch ………………………………………………………………………….. 14
Foot Control Pedals …………………………………………………………………………………………….. 14
Air Conditioner …………………………………………………………………………………………………….. 15
Contents ………………………………………………………………………………………………………………… 2-17
Introduction………………………………………………………………………………………………………………. 2-19
Unit Specification………………………………………………………………………………………………………. 2-20
Technical Data and Control Settings ……………………………………………………………………………. 2-23
Installation and Commissioning ………………………………………………………………………………….. 2-25
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SKSS Introduction v
Table of Contents
Operating Instructions ……………………………………………………………………………………………….. 2-32
Routine Maintenance Proceedures ……………………………………………………………………………… 2-34
Fault Diagnosis ………………………………………………………………………………………………………… 2-38
Warranty………………………………………………………………………………………………………………….. 2-48
Basic Spare Parts Listing…………………………………………………………………………………………… 2-49
Reference Drawings …………………………………………………………………………………………………. 2-51
Section 3
Main Frame – Crawlers ………………………………………………………….. 3-1
Main Frame Repair …………………………………………………………………………………………….. .3-2
Leveling Jacks ……………………………………………………………………………………………………. 3-3
Leveling Jack Cylinders …………………………………………………………………………………………… 3-4
Remove ……………………………………………………………………………………………………………………. 3-4
Repair ………………………………………………………………………………………………………………………. 3-4
Replace…………………………………………………………………………………………………………………….. 3-4
Mast Elevating Cylinders …………………………………………………………………………………….. 3-5
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 Machine: …………………………………………………………………………………………. 3-11
GeneralMaintenance …………………………………………………………………………………………………. 3-11
Track Tension Adjustment …………………………………………………………………………………. 3-12
Hydraulic Tensioner …………………………………………………………………………………………………… 3-13
Correct Track Tension ……………………………………………………………………………………………….. 3-13
Description………………………………………………………………………………………………………………. 3-14
Nitrogen Tensioner ……………………………………………………………………………………………………. 3-15
Hydraulic Tensioner ………………………………………………………………………………………….. 3-16
Repair …………………………………………………………………………………………………………………….. 3-16
Nitrogen Tensioner Assembly ……………………………………………………………………………. 3-17
Track Tension Adjustment …………………………………………………………………………………. 3-18
Nitrogen Tensioner – Filling Instructions………………………………………………………………………… 3-18
Nitrogen Tensioner – Pressure Check ………………………………………………………………………….. 3-20
Nitrogen Tensioner – Pressure Release ……………………………………………………………………….. 3-20
Track Chain – Separate ………………………………………………………………………………………. 3-22
Track Chain Repair ……………………………………………………………………………………………. 3-24
Track Link – Repair & Replace ……………………………………………………………………………………. 3-24
Track Link – Description …………………………………………………………………………………………….. 3-25
Track Shoes Installation…………………………………………………………………………………….. 3-26
Track Link Position ……………………………………………………………………………………………………. 3-26
Track Shoe – Mounting to Track Chain …………………………………………………………………………. 3-26
Track Shoe – Mounting to Track Chain …………………………………………………………………………. 3-27

Torque Turn Method…………………………………………………………………………………………………… 3-27
Track Shoe – Retightening………………………………………………………………………………………….. 3-27
Track Shoe Bolt Torque (Direct Torque Method) …………………………………………………. 3-28
Track Shoe Bolt Torque (Torque Turn Method) …………………………………………………… 3-29
Track Chain and Shoe Installation ……………………………………………………………………… 3-30
Track Chain with Shoes …………………………………………………………………………………………….. 3-30
Track Chain & Shoe – Assembly & Installation ………………………………………………………………. 3-30
Final Drive…………………………………………………………………………………………………………. 3-32
Final Drive – General Description ………………………………………………………………………………… 3-32
Final Drive Unit Removal……………………………………………………………………………………. 3-33
Removal from Track Frame ……………………………………………………………………………………….. 3-33
Installation into Track Frame ………………………………………………………………………………………. 3-34
Final Drive Maintenance…………………………………………………………………………………….. 3-35
Oil Check / Change…………………………………………………………………………………………………… 3-35
Final Drive Oil ……………………………………………………………………………………………………. 3-36
Specifications …………………………………………………………………………………………………………… 3-36
Recommended Oil ……………………………………………………………………………………………………. 3-36
Final Drive Assembly …………………………………………………………………………………………. 3-37
Parking Brake – Description ……………………………………………………………………………………….. 3-38
Final Drive Disconnect ………………………………………………………………………………………. 3-39
Final Drive – Disconnect & Parking Brake…………………………………………………………… 3-40
Towing Procedure – Gear Drive Disconnect ………………………………………………………………….. 3-40
Parking Brake – Removal & Installation ………………………………………………………………………… 3-40
IdlerAssembly …………………………………………………………………………………………………… 3-41
Idler Unit Removal …………………………………………………………………………………………….. 3-43
Idler Unit – Assembly………………………………………………………………………………………….. 3-45
Track and Support Rollers…………………………………………………………………………………. 3-49
General Description ………………………………………………………………………………………………….. 3-49
Track Roller – Removal & Disassembly ……………………………………………………………………….. 3-51
Support Roller – Removal & Disassembly ……………………………………………………………………. 3-52
Track and Support Roller – Assembly…………………………………………………………………………… 3-53
Track and Support Roller – Test and Install……………………………………………………………………. 3-54
Auxiliary Crane………………………………………………………………………………………………….. 3-56
Palfinger Hydraulic Crane Operators Manual ………………………………………………………….. 3-57
Contents………………………………………………………………………………………………………………….. 3-58
Before Operation of Crane …………………………………………………………………………………………. 3-64
Start Operation of Crane ……………………………………………………………………………………………. 3-65
Section 4
Engine / Drive Train / Compressor ………………………………………… 4-1
Power Group Locator ………………………………………………………………………………………….. 4-2
Engine………………………………………………………………………………………………………………… 4-3
Engine Fuel System……………………………………………………………………………………………………. 4-4
Engine Oil Reserve System Circuit …………………………………………………………………………….. 4-12
Engine Oil Reserve System……………………………………………………………………………………….. 4-12
Oil Reserve Systems ………………………………………………………………………………………………… 4-14
LED Monitor Readings ………………………………………………………………………………………………. 4-15
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Signals ……………………………………………………………………………………………………………………. 4-15
Adjustment of Running Oil Level …………………………………………………………………………………. 4-15
Servicing …………………………………………………………………………………………………………………. 4-16
Troubleshooting………………………………………………………………………………………………………… 4-16
Oil Reserves Systems – Maintenance………………………………………………………………………….. 4-17
Engine and Compressor Air Cleaners ………………………………………………………………… 4-18
Engine and Compressor Air Cleaner Service ………………………………………………………….. 4-19
Inspection and General Service ………………………………………………………………………………….. 4-19
Engine and Compressor Air Cleaner Service ……………………………………………………………….. 4-21
Safety Element Service……………………………………………………………………………………………… 4-21
Flexible Drive Coupling Service …………………………………………………………………………. 4-22
Adaptor Flanges ……………………………………………………………………………………………………….. 4-22
Centering Flanges…………………………………………………………………………………………………….. 4-22
Rubber Element ……………………………………………………………………………………………………….. 4-22
Tube Assembly…………………………………………………………………………………………………………. 4-22
Mounting Screws andAdhesive ………………………………………………………………………………….. 4-23
Pump Drive Assembly – Removal and Replacement ……………………………………………………… 4-25
Pump Drive……………………………………………………………………………………………………….. 4-25
Pump Identification ……………………………………………………………………………………………………. 4-26
Pump Drive Gearbox …………………………………………………………………………………………. 4-27
Pump Drive Gearbox – Repair …………………………………………………………………………………….. 4-28
3″ Input Shaft Assembly …………………………………………………………………………………………….. 4-30
Hydraulic Piston Pumps ……………………………………………………………………………………. 4-31
Hydraulic Piston Pumps – Removal and Replacement …………………………………………………… 4-31
Hydraulic Piston Pumps – Repair ………………………………………………………………………………. 4-31
Tram and Rotation Pumps …………………………………………………………………………………. 4-32
Hydraulic Piston Pumps ……………………………………………………………………………………. 4-69
Hydraulic Piston Pumps – Removal and Replacement …………………………………………………… 4-69
Hydraulic Piston Pumps – Repair ………………………………………………………………………………. 4-69
Feed and Auxiliary Pump …………………………………………………………………………………… 4-70
Hydraulic Gear Pumps …………………………………………………………………………………….. 4-101
Hydraulic Gear Pumps – Removal and Replacement …………………………………………………….4-101
Hydraulic Gear Pumps – Repair ………………………………………………………………………………..4-101
Compressor Installation…………………………………………………………………………………… 4-115
Compressor Replacement and Drive Coupling Maintenance………………………………….. 4-116
Disassembly …………………………………………………………………………………………………………… 4-116
Before Installation of New or Rebuilt Compressor: ……………………………………………………….. 4-117
Reassembly ……………………………………………………………………………………………………………. 4-118
Before Start-Up of New or Rebuilt Compressor: …………………………………………………………… 4-118
Drill Compressor ……………………………………………………………………………………………… 4-119
High Pressure Compressor……………………………………………………………………………… 4-120
Section 1 Safety ……………………………………………………………………………………………………..4-120
General …………………………………………………………………………………………………………………..4-120
Pressure Release …………………………………………………………………………………………………….4-120
Fire and Explosion…………………………………………………………………………………………………….4-121
Moving Parts ……………………………………………………………………………………………………………4-121
Toxic and Irritating Substances …………………………………………………………………………………..4-121
Electrical Shock ……………………………………………………………………………………………………….4-122

Lifting………………………………………………………………………………………………………………………4-122
Section 2 Description……………………………………………………………………………………………..4-123
Introduction………………………………………………………………………………………………………………4-123
Compressed Air Functions ………………………………………………………………………………………..4-123
Sullair Compressor Unit …………………………………………………………………………………………….4-124
Compressor Discharge System…………………………………………………………………………………4-125
Compressor Cooling and Lubrication System………………………………………………………………4-126
Compressor Fluid Circuit …………………………………………………………………………………. 4-127
Compressor Condensation Table…………………………………………………………………….. 4-130
Compressor Air Circuit 1475cfm @ 500psi ……………………………………………………….. 4-131
Compressor Description………………………………………………………………………………….. 4-143
Air Inlet System………………………………………………………………………………………………………..4-143
Instrument Group ……………………………………………………………………………………………………..4-145
Protection System…………………………………………………………………………………………………….4-145
Compressor Operation ……………………………………………………………………………………. 4-146
Section 3 Operation ……………………………………………………………………………………………….4-146
General …………………………………………………………………………………………………………………..4-146
Purpose Of Controls …………………………………………………………………………………………………4-146
Initial Start-up Procedure ……………………………………………………………………………………………4-148
Subsequent Start-up Procedure………………………………………………………………………………….4-149
Shutdown Procedure ………………………………………………………………………………………………..4-149
General Operating Instructions …………………………………………………………………………………..4-149
Compressor Maintenance ……………………………………………………………………………….. 4-150
Section 4 General Maintenance ……………………………………………………………………………..4-150
General …………………………………………………………………………………………………………………..4-150
Daily Operation ………………………………………………………………………………………………………..4-150
Maintenance After Initial 50 Hours Of Operation…………………………………………………………….4-151
Maintenance Every 250 Hours ……………………………………………………………………………………4-151
Maintenance Every 500 Hours ……………………………………………………………………………………4-151
Maintenance Every 1000 Hours ………………………………………………………………………………….4-151
Main Drive Shaft Seal Replacement ……………………………………………………………………………4-152
Interstage Tube ………………………………………………………………………………………………………..4-155
Discharge Check Valve ……………………………………………………………………………………………..4-156
Separator/Receiver Tank……………………………………………………………………………………………4-157
Minimum Pressure / Check Valve ……………………………………………………………………………….4-159
Scavenge Line …………………………………………………………………………………………………………4-160
Scavenge Line Sight Glass ………………………………………………………………………………………..4-160
Scavenge Line Oriface………………………………………………………………………………………………4-160
Compressor Discharge Temperature Switches, Senders and Gauges…………………………….4-161
Thermal/Bypass Valve ………………………………………………………………………………………………4-162
Fluid Stop Valve ………………………………………………………………………………………………………..4-164
Compressor Fluid Filter …………………………………………………………………………………………….4-166
Inlet Valve ………………………………………………………………………………………………………………..4-168
Compressor Regulation………………………………………………………………………………………….4-170
Relieving Regulators …………………………………………………………………………………………………4-170
Reducing Regulators ………………………………………………………………………………………………..4-173
System Blowdown Valve ……………………………………………………………………………………………4-175
Running Blowdown Valve …………………………………………………………………………………………..4-176
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Moisture Separator Maintenance…………………………………………………………………………………4-178
Auxiliary Regulator…………………………………………………………………………………………………….4-179
Troubleshooting………………………………………………………………………………………………………..4-181
Compressor Oil Cooler Assembly…………………………………………………………………….. 4-185
Compressor oil cooler ……………………………………………………………………………………………….4-185
Radiator/Hydraulic Oil Cooler Assembly …………………………………………………………… 4-186
Radiator/Oil Cooler Repair ……………………………………………………………………………….. 4-187
High Pressure Compressor Fluid Cooler ………………………………………………………….. 4-189
Radiator Cooler ……………………………………………………………………………………………….. 4-197
Section 5
Dust Control Systems…………………………………………………………… 5-1
Water Injection…………………………………………………………………………………………………….. 5-3
Water Injection Control ………………………………………………………………………………………………… 5-4
Basic Water Injection System – SKSS-15 ………………………………………………………………………. 5-6
Water Pump ………………………………………………………………………………………………………… 5-7
Recommended Lubricants ……………………………………………………………………………………………… 9
Water Pump Motor Repair ……………………………………………………………………………………………….9
Water Pump Motor ……………………………………………………………………………………………….. 10
Foam Injection System…………………………………………………………………………………………. 18
Foam Injection Pump …………………………………………………………………………………………… 20
Section 6
Mast / Rotary Drive / Pipe Rack………………………………………………. 6-1
Mast Weldment ……………………………………………………………………………………………………. 6-2
Mast Repair ……………………………………………………………………………………………………………….. 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
Hoist/Pulldown Cable Replacement …………………………………………………………………… 6-14
Rotary Head Guide Alignment ……………………………………………………………………………. 6-16
Rotary Drive Assembly………………………………………………………………………………………. 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…………………………………………………………………………………… 6-21
Rotary Drive Gearbox – Repair ……………………………………………………………………………………. 6-22
Main Shaft Bearing Preload………………………………………………………………………………………… 6-22
Air Swivel…………………………………………………………………………………………………………………. 6-23

Set Max. Pulldown Relief Valve (V15) …………………………………………………………………………… 7-59
Feed Control Valve ……………………………………………………………………………………………………. 7-61
Holdback Control………………………………………………………………………………………………. 7-67
Feed Valve Assembly ………………………………………………………………………………………… 7-68
Jack Control and Mast Elevating Circuit …………………………………………………………….. 7-69
Pressure Adjustment…………………………………………………………………………………………………. 7-70
Leveling Jack Cylinders…………………………………………………………………………………….. 7-71
Counterbalance Valve Test Procedure …………………………………………………………………………. 7-72
Mast Elevating Cylinders …………………………………………………………………………………… 7-73
Counterbalance Valve Test Procedure …………………………………………………………………………. 7-74
Auxiliary Functions Circuit ………………………………………………………………………………… 7-75
Hydraulic Operated Breakout Wrench ……………………………………………………………….. 7-77
Setting of HOBO Sequence Valves……………………………………………………………………………… 7-78
Pipe Positioner Sequence Valves ………………………………………………………………………. 7-79
Setting of Pipe Positioner Sequence Valves …………………………………………………………………. 7-79
Pipe Safety Arm Sequence Valves ……………………………………………………………………… 7-80
Setting of Pipe Safety Arm Sequence Valves ………………………………………………………………… 7-80
Cooler Fan Circuit ……………………………………………………………………………………………… 7-81
Fan Motor Circuit ………………………………………………………………………………………………………. 7-81
Adjustment ………………………………………………………………………………………………………………. 7-81
Cooler Fan Motor ………………………………………………………………………………………………. 7-84
Hydraulic Thermostatic Valve…………………………………………………………………………….. 7-88
Central Lube……………………………………………………………………………………………………… 7-89
Hydraulic Circuit ……………………………………………………………………………………………………….. 7-90
Air Conditioner Compressor Drive Circuit ………………………………………………………….. 7-91
Air Conditioner Drive Motor ……………………………………………………………………………….. 7-92
Water Injection Circuit ……………………………………………………………………………………….. 7-96
Water Injection valve …………………………………………………………………………………………………. 7-97
Toc-2 Controller ………………………………………………………………………………………………………… 7-99
Water Injection Valve …………………………………………………………………………………………. 7-99
Hydraulic Cylinders Repair………………………………………………………………………………. 7-116
Hydraulic Cylinders List…………………………………………………………………………………………….. 7-116
Section 8
Vigilante Guide and Electrical Components ……………………………. 8-1
Electrical Locator ………………………………………………………………………………………………… 8-2
Batteries……………………………………………………………………………………………………………… 8-5
Jump Starting……………………………………………………………………………………………………… 8-6
Welding Precautions …………………………………………………………………………………………… 8-8
Vigilante Guide ……………………………………………………………………………………………………. 8-9
Contents……………………………………………………………………………………………………………………. 8-9
Important Information ………………………………………………………………………………………………… 8-10
PLC…………………………………………………………………………………………………………………………. 8-11
Eeprom …………………………………………………………………………………………………………………… 8-12
Output Card …………………………………………………………………………………………………………….. 8-13
Touchscreen ……………………………………………………………………………………………………………. 8-14
Laser Depth System…………………………………………………………………………………………………. 8-15
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Pipe in Hole Detection ……………………………………………………………………………………………….. 8-17
Tram Protection ……………………………………………………………………………………………………….. 8-17
Mast and Jack Lowering Protection …………………………………………………………………………….. 8-17
Pipe Rack Swing Interlock …………………………………………………………………………………………. 8-17
Distance Meter …………………………………………………………………………………………………………. 8-17
Start Up and Shut Down…………………………………………………………………………………………….. 8-18
Hydraulic Function Enable …………………………………………………………………………………………. 8-18
Drill Tram Enable Function…………………………………………………………………………………………. 8-18
Alarms…………………………………………………………………………………………………………………….. 8-18
Solenoid Control ……………………………………………………………………………………………………….. 8-19
Auto Lube ………………………………………………………………………………………………………………… 8-22
Hammer Oiler System………………………………………………………………………………………………. 8-22
Gauges …………………………………………………………………………………………………………………… 8-23
Pressure Transducer ………………………………………………………………………………………………… 8-23
Level Transducer ……………………………………………………………………………………………………… 8-23
Temperature Transducer ……………………………………………………………………………………………. 8-24
Water Flow Transducer ……………………………………………………………………………………………… 8-24
Inclinometers……………………………………………………………………………………………………………. 8-25
Head SpeedModule ………………………………………………………………………………………………….. 8-26
Level Switches …………………………………………………………………………………………………………. 8-27
Dust Suppression …………………………………………………………………………………………………….. 8-27
Turkey Spray ……………………………………………………………………………………………………………. 8-27
Water Suppression Tank Top Up …………………………………………………………………………………. 8-27
Vigilante System Component Information ………………………………………………………….. 8-28
Contents………………………………………………………………………………………………………………….. 8-28
Head Speed Module ………………………………………………………………………………………….. 8-29
Inclinometer ………………………………………………………………………………………………………. 8-31
Ladder Prox Switch …………………………………………………………………………………………… 8-34
Laser ………………………………………………………………………………………………………………… 8-35
Level Switches………………………………………………………………………………………………….. 8-47
Radiator Level Switch ……………………………………………………………………………………….. 8-51
Level Transducers …………………………………………………………………………………………….. 8-55
Pressure Transducers……………………………………………………………………………………….. 8-65
Temperature Transducer……………………………………………………………………………………. 8-74
Water Flow Transducer ……………………………………………………………………………………… 8-83
Water Control Module………………………………………………………………………………………… 8-97
Rod Counter Prox Switch ………………………………………………………………………………… 8-104
Remote Fuel Level Display ………………………………………………………………………………. 8-105
Section 9
Lubrication and Preventive Maintenance……………………………….. 9-1
Central Lube System…………………………………………………………………………………………… 9-2
Hydraulic Control Schematic………………………………………………………………………………………… 9-3
Auto Lube ………………………………………………………………………………………………………………….. 9-3
Central Lube System Circuit Drawing ………………………………………………………………….. 9-5
Central Lube Tank Assembly……………………………………………………………………………….. 9-6
Central Lube System…………………………………………………………………………………………… 9-7