CAT Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1M68M11 – PDF DOWNLOAD

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CAT Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1M68M11 – PDF DOWNLOAD

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CAT Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1M68M11 – PDF DOWNLOAD

Language : English
Pages :984
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1M68M11 – 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

There are many personal hazards and dangers associated with working on and around a drill rig. If the safety instructions outlined in this section are adhered to, risk of injury or harm to yourself and others will be significantly reduced. In this section and those that follow, the word:

• DANGER means that severe injury or death will result from failure to follow instruction.
• WARNING means that severe injury or death can result from failure to follow instruction.
• CAUTION means that minor injury or property damage can result from failure to follow instruction.
• NOTE means that special attention should be given to the instruction.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1M68M09 – PDF DOWNLOAD

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
General Locator 1-12
Notes 1-14
Section 2 – Operator’s Cab / Controls 2-1
Section 2 Contents 2-3
Graphic Symbol Legend 2-5
Warning Decals 2-10
Operators Controls and Indicators 2-12
Right Hand Control Panel 2-13
Control Panels 2-13
Instrument Panel and Circuit Breakers 2-14
Instrument Panel 2-15
Circuit Breakers 2-15
Light Switches 2-15
System Pressure Gauge Panel 2-16
Left Hand Control Panel 2-18
Foot Control Pedals 2-24
Cab Foot Controls 2-24
Thread Grease Switch 2-24
Pipe Safety Arm Override Switch 2-24
Air Conditioner 2-25
T8 Series Split System Air Conditioning Manual Contents 2-25
Section 1 0 Technical Data and Control Settings 2-26
Section 2 0 Installation and Commissioning 2-28
Section 3 0 Routine Maintenance Procedures 2-32
Section 4 0 Fault Diagnosis 2-33
Section 5 0 Basic Spare Parts Listing 2-42
Section 6 0 Reference Drawings 2-44
Zexel DK-32 Compressor 2-48
Performance Curve 2-49
Notes 2-50
BI620407
Int-6 SKF Introduction
Contents
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
Levelling Jacks 3-6
Levelling Jacks 3-6
Levelling Jack Cylinders 3-7
Mast Elevating Cylinders 3-8
Crawler Assembly 3-9
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
Idler Unit 3-14
General Description 3-14
Removal and Disassembly 3-16
Assembly and Installation 3-18
Track Tension Unit 3-20
Installation 3-21
Track Rollers 3-22
General Description 3-22
Removal and Disassembly 3-24
Track Roller – Assembly 3-25
Track Roller – Test and Install 3-26
Support Rollers 3-27
General Description 3-27
Support Roller Assembly 3-28
Removal and Disassembly 3-29
Track Chain – Separate 3-32
Track Chain Separate 3-32
Track Chain – Repair 3-33
Track Link – Description 3-33
Track Link – Repair and Replace 3-33
Track Shoes Installation 3-35
Track Link Position 3-35
Track Shoe – Mounting to Tracks Chain 3-35
Track Shoe Bolt Torque (Direct Torque Method) 3-36
Track Shoe Bolt Torque (Torque Turn Method) 3-37
Track Chain and Shoe Installation 3-38
Track Chain with Shoes 3-38
Track Chain and Shoe – Assembly and Installation 3-38
Track and Support Rollers 3-40
General Description 3-40
Track Roller – Removal and Disassembly 3-41
BI620407
SKF Introduction Int-7
Contents
Support Roller – Assembly and Disassembly 3-41
Track and Support Roller – Assembly 3-42
Track and Support Roller – Test and Install 3-43
Final Drive 3-46
Final Drive – General Description 3-46
Final Drive Unit Removal 3-47
Removal from Track Frame 3-47
Final Drive Unit Installation 3-48
Installation into Track Frame 3-48
Final Drive Maintenance 3-49
Oil Check / Change 3-49
Final Drive Oil 3-50
Specifications 3-50
Recommended Oils 3-50
Final Drive Assembly 3-52
Parking Brake – Description 3-54
Parking Brake – Removal and Installations 3-55
Towing Procedures – Gear Drive Disconnect 3-55
Repair Manual 3-56
A – General Instructions 3-57
B – Safety Instructions 3-62
C – General Specifications 3-66
D – Disassembly and Assembly Operation 3-74
E – Troubleshooting 3-108
F – Special Tools 3-109
Auxiliary Crane 3-110
Hydraulic Crane (Auxiliary Crane) 3-110
Maintenance 3-111
Checking of Worm Gear 3-111
Notes 3-112
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
Electric Fuel Supply Pumps 4-9
Combo Fuel Filter Head and 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
BI620407
Int-8 SKF Introduction
Contents
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
Wiring Diagram – 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 Drive Assembly – Removal and Replacement 4-27
Pump Drive Gearbox 4-28
Pump Drive Gearbox – Repair 4-28
Hydraulic Pumps 4-30
Hydraulic Pump Identification 4-30
Hydraulic Pump – Removal and Replacement 4-31
Compressor Service Procedures 4-32
Compressor Drive Coupling 4-32
Compressor Drive Coupling – Removal and Replacement 4-32
Taper-Loc Bushing Installation – Model ACT5 SN F2 V1 3535 4-34
Before Installation and Start-up of New or Rebuilt Compressor 4-35
Compressor Unit – Installation 4-35
Compressor Shaft Seal 4-36
High Pressure Compressosr 4-39
Safety 4-39
Description 4-42
Compressed Air Functions 4-42
Compressor Oil Circuit 4-46
Compressor Condensation Table 4-49
Compressor Air Circuit 4-50
Compressor Air Circuits – 1475cfm @ 500psi 4-50
Compressor Air Circuit Diagram Legend 4-51
Compressor Functional Description 4-65
Compressor Operation 4-67
Operation 4-67
Compressor Maintenance 4-70
General Maintenance 4-70
Interstage Tube 4-72
Discharge Check Valve 4-73
Separator / Receiver Tank 4-74
BI620407
SKF Introduction Int-9
Contents
Scavenge Line 4-76
Compressor Discharge Temperature Gauge, Switch and Sender 4-77
Minimum Pressure / Check Valve 4-78
Minimum Pressure / Check Valve Maintenance 4-78
Thermal Bypass Valve 4-79
Thermal Bypass Valve Maintenance 4-80
Compressor Fluid Filter 4-81
Changing Filter Elements 4-81
Fluid Stop Valve 4-83
Inlet Valve 4-85
Relieving Regulators 4-87
Reducing Regulators 4-90
Reducing Regulators Maintenance 4-90
System Blowdown Valve 4-92
Running Blowdown Valve 4-93
Running Blowdown Maintenance 4-94
Moisture Separator Maintenance 4-95
Auxiliary Regulators 4-96
Auxiliary Regulator Maintenance 4-98
Troubleshooting 4-100
Compressor Oil Cooler Assembly 4-103
Compressor Oil Cooler 4-103
Hydraulic Oil / Radiator Cooler Assembly 4-104
Hydraulic Oil / Radiator Cooler Assembly 4-104
Coolers Maintenance 4-105
Compressor Oil / Hydraulic Oil Cooler Service Manual 4-106
Radiator Cooler Service Manual 4-111
Notes 4-117
Section 5 – Dust Control System 5-1
Section 5 Contents 5-3
Dust Control System 5-5
Dust Control Systems 5-5
Water Injection 5-6
Water Tanks 5-6
Water Injection Relief Valve 5-7
Water Injection Control 5-8
Water Injection Basic Circuit 5-10
Water Pump 5-11
Pump Specifications 5-11
Servicing Instructions 5-11
Parts List 5-12
Replacing Piston Cup Seals 5-13
Replacing Suction and Discharge Valves 5-14
Replacing Power End Bearings 5-15
Servicing the Wrist Pin Bearings 5-16
BI620407
Int-10 SKF Introduction
Contents
Fastener Torque Requirements 5-16
Recommended Lubricants 5-17
Water Pump Motor Repair 5-17
Water Injection Hydraulic Control Valve Repair 5-17
Water Pump Drive Coupling 5-17
Level and Flow Transducer 5-17
Foam Injection System 5-18
Foam Injection System Manual 5-18
Routine Maintenance 5-21
Maintenance Schedule 5-25
Fault Finding 5-28
Notes 5-32
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Mast Assembly 6-6
Mast Assembly 6-6
Mast Pivot Caps 6-7
Mast Elevate Cylinders 6-7
Angle Drilling 6-8
Feed Cylinders 6-9
SKF Feed System 6-9
Feed Cylinder – Removal 6-10
Feed Cylinder Assembly 6-11
Feed Cylinder Repair 6-12
Feed Cylinder Installation 6-12
Hoist / Pulldown Cable Assembly 6-13
Hoist / Pulldown Cable Adjustment 6-14
Auto Tensioning – Operating Principle 6-14
Auto Tensioning – Cable Removal, Adjustment and Installation 6-14
Rope Tensioning Circuit 6-16
Wire Rope 6-18
Sheave Rollers 6-18
Rotary Head Guide Alignment 6-19
Alignment Procedure 6-19
Rotary Drive Assembly 6-20
Rotary Drive – Removal from Mast 6-21
Rotary Drive – Installation 6-21
Rotary Drive Gearbox 6-22
Air Swivel (Single Seal Style) 6-24
Air Swivel Service 6-24
Rotary Drive Motor – Repair 6-25
Rotary Drive Rebuild Manual 6-26
BI620407
SKF Introduction Int-11
Contents
Winch Assembly 6-66
Precautions On The Use Of Winches 6-66
Wire Rope 6-66
Wedge Socket 6-68
Grooved Drums 6-69
Plain (Smooth) Drums 6-69
Drums – Multiple Layers 6-69
Winch Assembly Service 6-70
BG8A and BG8B Hydraulic Winch Service Manual 6-71
H O B O Wrench 6-102
Tong Dies 6-103
Deck Wrench 6-104
Pipe Positioner 6-105
Carousel Pipe Rack 6-106
If Pipe Rack does not Rotate 6-106
Chain Drive – Adjust / Replace 6-106
Pipe Rack Bearings – Replace 6-107
Carousel Top Tube Bearing – Replace 6-108
Carousel Lower Bearing – Replace 6-110
Carousel Pivot Support Upper Bearing – Replace 6-112
Carousel Pivot Support Lower Bearing – Replace 6-114
Mid Point Carousel Pivot Support 6-115
Carousel Rotate Motor 6-115
Notes 6-116
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-5
Hydraulic Tank 7-7
Pressure Setting Sequence 7-9
Pressure Setting Sequence 7-9
Hydraulic System 7-9
Main Return and Case Drain Filter 7-10
Routine Maintenance 7-11
Changing Filter Elements 7-11
Main Hydraulic Pumps 7-12
Hydraulic Pump Identification – SKF12 7-12
Hydraulic Piston Pumps Removal and Replacement 7-13
Hydraulic Piston Pumps – Operation, Specifications, Adjustment and Repair 7-13
Right Track / Pulldown, Left Track / Rotation Pumps 7-14
Main Pumps 7-14
AA4VG125 Hydraulic pump EP2 Control 7-14
AA4VG EP Controller 7-16
Technical Data 7-17
EP (24V DC) Control 7-19
Schematic Drawing – Standard Model 7-19
BI620407
Int-12 SKF Introduction
Contents
Port Locations 7-22
Connections 7-22
Main Pump Adjustments 7-23
Change Pressure, High Pressure, P O R and Zero Positions Setting 7-24
Set Charge Pressure – 450psi (31bar) 7-25
Set Pressure Override – 5500psi (380bar) 7-25
Set Pressure Override (P O R ) – 5000psi (345bar) 7-26
Mechanical Zero Position 7-27
Hydraulic Centreing 7-28
Removable and Inspection of Charge Pump 7-29
Removal and Installation of Shaft Steel 7-30
Routine Maintenance 7-31
Hydraulic Piston Pumps – Maintenance 7-34
Hydraulic Piston Pumps – Troubleshooting 7-36
Charge Circuit 7-40
Double Gear Pump – Right Charge and Water Injection 7-40
Routine Maintenance 7-43
Changing Filter Elements 7-43
Loop Filters 7-44
Loop Filters 7-44
Routine Maintenance 7-47
Changing Filter Elements 7-47
Diverter Valve 7-48
Operation 7-48
Diverter Valve 7-48
Tram Circuit 7-50
Hoist / Pulldown Circuit 7-52
Basic Pulldown Circuit 7-52
Hoist / Pulldown Circuit 7-53
Rope Tensioning Circuit 7-54
Auto Tensioning – Operating Principle 7-54
Rotation Circuit 7-56
Rotation Circuit 7-56
Rotary Drive Gearbox Motor 7-58
Rotation Motor 7-62
Fan and Auxiliary Pump Circuit 7-72
Fan and Auxiliary Functions Pump 7-74
Hydraulic Pumps 7-75
Hydraulic Piston Pumps – Removal and Replacement 7-75
Model A11VLO Hydraulic Piston Pumps – Repair 7-75
Repair Instructions 7-76
New or Rebuilt Hydraulic Pump – Start-up 7-77
Start-up Procedure 7-77
Auxiliary Functions / Fan Circuit 7-79
Operation 7-80
Auxiliary Priority Function 7-85
BI620407
SKF Introduction Int-13
Contents
Cooler Fan Circuit 7-86
Cooler Fan Motor 7-88
Hydraulic Motor F12 Series 7-91
Jack and Mast Elevate Circuit 7-92
4 Bank Valve 7-92
Counterbalance Valve Adjustment 7-94
Counterbalance Valve Adjustments 7-94
Mast Elevating Cylinders 7-95
Mast Elevating Cylinders Counterbalance Valves 7-95
Levelling Jack Cylinders 7-96
Jack Counterbalance Valves 7-96
Auxiliary Functions / 6 Bank Valve 7-97
Auxiliary Functions / 9 Bank Valve 7-99
Hydraulic Operated Breakout Wrench (HOBO) 7-100
Setting of Sequence Valves 7-100
Mast Raise / Jacks Valve and Water Foam Valve 7-101
Carousel Rotate Motor 7-106
Pilot Control Manifold 7-113
Electro Proportional Valves 7-123
Proportional Valve Set-up 7-124
OEM Electro Proportional Mast Raise / Jacks Valve 7-124
Proportional Pulldown 7-125
OEM Controllers / EP levers 7-126
Auto Pulldown Card 7-127
Reduced Pulldown Potentiometer ‘Pot’ 7-128
Hydraulic Gear Pumps 7-129
Hydraulic Gear Pumps – Removal and Replacement 7-129
Hydraulic Gear Pump – Repair 7-129
Hydraulic Gear Pumps – Shaft Seal Removal and Replacement 7-130
Dust Collector / Water Injection Circuit 7-132
Water Injection / Foam Injection Valve Circuit 7-133
Air Conditioner Compressor Drive Circuit 7-134
Hydraulic Cylinder Repair 7-136
General Information 7-137
H Head 7-139
N Head 7-140
Z Head 7-141
K Head 7-143
M Head 7-144
Z Piston 7-145
H and K Piston 7-146
M piston 7-147
N Piston 7-150
Notes 7-151
BI620407
Int-14 SKF Introduction
Contents
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-5
Jump Starting 8-7
Batteries 8-9
Welding Precautions 8-10
Vigilante Guide 8-11
Important Information 8-11
PLC 8-12
Touchscreen 8-15
Laser Depth System 8-16
Distance Meter 8-19
Start Up and Shut Down 8-19
Hydraulic Function Enable 8-19
Alarms 8-20
Solenoid Control 8-21
Auto Lube 8-24
Hammer Oiler System 8-24
Gauges 8-25
Head Speed 8-27
Level Switches 8-27
Dust Suppression 8-28
N B: For further information on specific electronic components, please refer to
Electronic Components Section on Service Manual CD
Acknowledgements 8-29
Disclaimers 8-29
Notes 8-30
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 System Circuit 9-8
Central Lube Pump Module 9-10
Central Lube Pump 9-23
SL-1 Injectors 9-47
SL-1 Injectors Assembly 9-47
SL-1 Injectors Specifications 9-47
Hammer Oiler Tank Assembly 9-49
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
BI620407
SKF Introduction Int-15
Contents
Pipe Thread Lubricator 9-71
Air Service Unit 9-71
Filter Regulator 9-72
Air Line Lubricator 9-73
Pipe Thread Pump 9-74
Filter Locator 9-82
Filter Location Assembly 9-83
Lubrication General 9-84
Equipment Lubrication 9-84
Care of Lubrication Points 9-84
Lubrication and Preventive Maintenance 9-85
Safety 9-85
Isolation – Battery Switch 9-86
Track – Check and Lubrication 9-87
Engine Maintenance 9-88
Air Cleaners 9-89
Air Filter Elements 9-89
Alternator Maintenance 9-89
Compressor – Checks and Servicing 9-90
Air Conditioner – Checks and Servicing 9-91
Drive Shaft – Checks and Maintenance 9-91
Cooler – Checks and Servicing 9-92
Hydraulic – Checks and Servicing 9-93
A-frame and Mast Pivot Point – Checks and Maintenance 9-94
Rotary Head – Checks and Service Points 9-95
Pulldown / Hoist Sheaves and Ropes – Checks and Servicing 9-96
Cabin – Checks and Service Points 9-97
Fire Suppression (Optional) – Checks and Servicing 9-97
Battery – Checks and Servicing 9-98
Bean Pump – Checks and Maintenance 9-98
Lubrication System – Checks and Servicing 9-99
250hr Lubrication and Maintenance 9-100
500hr Lubrication and Maintenance 9-115
1000hr Lubrication and Maintenance 9-131
2000hr Lubrication and Maintenance 9-147

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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