Cat Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1S68A05 – PDF DOWNLOAD

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Cat Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1S68A05 – PDF DOWNLOAD

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Cat Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1S68A05 – PDF DOWNLOAD

Language : English
Pages : 793
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Cat Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1S68A05 – PDF DOWNLOAD

Safety Information:

• This manual is furnished with your Infinity Series rotary blasthole drill to aid you in performing
  the necessary service work to maintain your drill in good operating condition.
• This manual contains repair and adjustment information for all major operating systems on the
  machine. In some cases such as hydraulic pumps and motors it is better to replace the unit with a
  new or rebuilt unit than to perform major repairs. Should further information be desired or should
  particular problems arise which are not covered sufficiently in this manual, the matter should be
  referred to manufacturer.
• The descriptions and specifications contained in this manual were in effect at the time of printing.
  The right is reserved to make changes at any time without notice and without obligation.
• 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 recognised 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 Bucyrus Terex SKF-12 Infinity Blasthole Drill Service Manual SN 1S68A05 – PDF DOWNLOAD

Section 1 – Safety 1-1
Section 1 Contents 1-3
Safety 1-5
Personal Protective Equipment 1-5
Noise 1-5
Electrical Contact 1-5
Overhead and Buried Utilities 1-5
Contact with Electric Wires 1-6
Contaminated Air 1-6
Machine Stability 1-7
Moving and Rotating Parts 1-8
High Pressure Air or Fluid 1-8
Before Operation 1-8
During Operation 1-9
Maintenance 1-11
Safety Locator 1-12
Notes 1-14
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
Operators Control Panels 2-10
System Pressure Gauge Panel 2-13
Switch Panel 2-14
Switches / Diagnosis Control Panel 2-17
Cab Heater 2-18
Cab Heater Fault Isolation 2-18
Air Conditioner 2-19
TDR7BX1 Packaged Unit Manual 2-19
Section 1 0 – Introduction 2-21
Section 2 0 – Unit Specification and Settings 2-22
Section 3 0 – Technical Data and Control Settings 2-27
Section 4 0 – Installation and Commissioning 2-29
Section 5 0 – Operating Instructions 2-41
Section 6 0 – Routine Maintenance Procedures 2-43
Section 7 0 – Fault Diagnosis 2-49
Section 8 0 Warranty 2-60
Electrical Schematic 2-61
Notes 2-63
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
BI620406
Int-6 SKF Introduction
Contents
Weld Inspection Schedule 3-6
Main Frame 3-6
Levelling Jacks 3-7
Levelling Jacks 3-8
Levelling Jack Cylinders 3-8
Lubricating Jack Casings 3-8
Mast Elevating Cylinders 3-9
Mast Elevating Cylinders 3-9
Crawler Assembly 3-10
Crawler Assembly 3-10
Crawler Component Repair 3-10
Metric Bolt Torque Specifications 3-11
Track Maintenance 3-12
Before Operating the Machine 3-12
General Maintenance 3-12
Track Tension Adjustment 3-13
Track Chain 3-15
Separate Track Chain Assembly 3-15
Track Link – Repair and Replace 3-16
Track Shoes 3-18
Track Link Position 3-18
Track Shoe – Mounting to Tracks Chain 3-18
Track Shoe Bolt Torque (Direct Torque Method) 3-20
Bolt Torque KN111 3-20
Track Shoe Bolt Torque (Torque Turn Method) 3-21
Bolt Torque KN111 3-21
Track Chain and Shoe Installation 3-22
Track Chain with Shoes 3-22
Track Chain and Shoe – Assembly and Installation 3-22
Final Drive 3-24
General Description 3-24
Removal from Track Frame 3-25
Installation into Track Frame 3-26
Oil Check Charge 3-27
Final Drive Oil 3-28
Specifications 3-28
Recommended Oils 3-28
Final Drive Assembly 3-30
Final Drive Assembly 3-30
Parking Brake – Description 3-32
Parking Brake – Removal and Installations 3-33
Towing Procedures – Gear Drive Disconnect 3-33
Repair Manual Final Drive Model F100 3-34
A – General Instructions 3-34
B – Safety Instructions 3-39
C – General Specifications 3-43
BI620406
SKF Introduction Int-7
Contents
D – Disassembly and Assembly Operation 3-52
E – Troubleshooting 3-86
F – Special Tools 3-87
Idler Unit 3-88
General Description 3-88
Removal and Disassembly 3-90
Assembly and Installation 3-92
Track Tension Unit 3-94
Installation 3-95
Track Rollers 3-96
General Description 3-96
Track Roller Assembly 3-97
Auxiliary Crane 3-98
Palfinger Hydraulic Crane PC1300 Operators Manual 3-98
Possible Dangers 3-99
During Operation of the Crane 3-100
Visual Inspections 3-102
Survey of the Crane 3-103
During Operation of the Crane 3-105
Safety Devices 3-108
Optional Features 3-111
Maintenance 3-112
Cleaning the Crane 3-118
PC1300 Specifications 3-118
Remote Winch Pendant 3-123
Notes 3-124
Section 4 – Engine / Drive Train / Compressor 4-1
Section 4 Contents 4-3
Engine and Drive Train Service Procedures 4-5
Service Procedures Outlined on the Section Include 4-5
Power Train 4-5
Engine Service Procedures 4-5
Caterpillar 3412E Engine 4-6
Engine and Compressor Air Cleaner 4-7
Engine and Compressor Air Cleaner 4-8
Engine and Compressor Air Cleaner Service 4-8
Flexible Drive Coupling 4-11
Flexible Drive Coupling Service 4-11
Pump Drive 4-13
Pump Drive Assembly – Removal and Replacement 4-13
Pump Drive Gearbox 4-14
Pump Drive Gearbox – Repair 4-14
Hydraulic Pumps 4-16
Hydraulic Pump Identification 4-16
Hydraulic Pump Removal and Replacement 4-17
BI620406
Int-8 SKF Introduction
Contents
Compressor Service Procedures 4-18
Compressor Drive Coupling 4-18
Compressor Drive Coupling – Removal and Replacement 4-18
Mounting Instructions for ARCUSFLEX™ Flywheel Couplings 4-19
Taper-Loc Bushing Installation 4-20
Tightening Torques for ARCUSFLEX™ Flywheel Coupling 4-20
Before Installation and Start-up of New or Rebuilt Compressor 4-21
Compressor Unit Installation 4-21
Compressor Shaft Seal 4-22
High Pressure Compressor 4-25
Safety 4-25
Description 4-28
Compressed Air Functions 4-28
Compressor Oil Circuit 4-32
Compressor Oil Circuit 4-32
Compressor Oil Circuit – 1150cfm @ 350psi 4-32
Compressor Condensation Table 4-34
Compressor Functional Description 4-35
Compressor Operation 4-38
Operation 4-38
Compressor Air Circuit – 1150cfm @ 350psi 4-41
Initial Start-up Procedure 4-42
Compressor Maintenance 4-44
General Maintenance 4-44
Interstage Tube 4-46
Discharge Check Valve 4-47
Separator / Receiver Elements 4-48
Scavenge Line 4-50
Compressor Discharge Temperature Gauge, Switch and Sender 4-51
Minimum Pressure / Check Valve 4-52
Minimum Pressure / Check Valve Maintenance 4-52
Thermal Bypass Valve 4-53
Thermal Bypass Valve Maintenance 4-54
Compressor Fluid Filter 4-55
Changing Filter Elements 4-55
Fluid Stop Valve 4-57
Inlet Valve 4-59
Relieving Regulators 4-61
Reducing Regulators 4-63
Reducing Regulator Maintenance 4-64
System Blowdown Valve 4-66
Running Blowdown Valve 4-67
Running Blowdown Maintenance 4-68
Moisture Separator Maintenance 4-69
Troubleshooting 4-70
BI620406
SKF Introduction Int-9
Contents
Fan / Oil Cooler Piping 4-72
Fan / Oil Cooler Piping 4-72
Fan and Motor Installation 4-73
Compressor Oil / Hydraulic Oil Cooler Service Manual 4-74
Standard Parts – High Pressure Oil Coolers 4-74
Repair Instruction – External Cleaning and Tube Removal 4-75
Repair Instruction – Seal Removal, Heater Plate Preparation and Seal Installation 4-76
Repair Instruction – Tube Installation, Final Assembly and Testing 4-77
Repair Instruction – Special Header Plate Repair 4-78
Radiator / Oil Cooler Repair 4-79
Radiator Cooler Service Manual 4-80
Typical Radiator Core – Standard Parts 4-80
Cleaning 4-81
Tube Removal 4-81
Seal Installation 4-82
Tube Installation 4-83
Notes 4-85
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
Pressure Adjustment 5-6
Water injection Circuit 5-7
Basic Water Injection System 5-8
Water Pump 5-9
Pump Specifications 5-9
Servicing Instructions 5-9
Water Injection Pump and Parts List 5-10
Replacing Piston Cup Seals 5-11
Replacing Suction and Discharge Valves 5-12
Replacing Power End Bearings 5-13
Servicing the Wrist Pin Bearings 5-14
Fastener Torque Requirements 5-14
Recommended Lubricants 5-15
Water Pump Motor Repair 5-15
Water Injection Hydraulic Control Valve Repair 5-15
Water Pump Drive Coupling 5-15
Level and Flow Transducer 5-15
Water Pump Motor 5-16
Char-Lynn® Hydraulic Motor Manual – ‘H’ Series 5-16
Tools Required for Disassembly and Reassembly 5-17
Shaft Seal Repair 5-18
Notes 5-21
BI620406
Int-10 SKF Introduction
Contents
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Weld Inspection Schedule 6-6
Inspection Mast 6-6
Mast Assembly 6-7
Mast Assembly 12m 6-7
Mast Pivot Caps 6-8
Mast Elevate Cylinders 6-8
Angle Drilling 6-9
Feed Cylinders 6-10
SKF 12 Feed System 6-10
Feed Cylinder – Removal 6-11
SKF-12 Feed Cylinder 6-12
Repair 6-13
Installation 6-13
Hoist / Pulldown Cable 6-14
Auto Tensioning – Operating Principle 6-15
Auto Tensioning – Cable Removal, Adjustment and Installation 6-15
Rope Tensioning Circuit 6-17
Wire Rope 6-19
Sleave Rollers 6-19
Rotary Head Guide Alignment 6-20
Alignment Procedure 6-20
Rotary Drive Assembly 6-21
Rotary Drive Assembly 6-21
Rotary Drive – Removal from Mast 6-22
Rotary Drive – Installation 6-22
Rotary Drive Gearbox 6-23
Single Motor Rotary Drive Gearbox 6-23
Air Swivel (Dual Seal Style) 6-25
Service 6-25
Rotary Drive Motor – Repair 6-26
Top Mast Drive Transmission TM2132-4 Manual 6-27
Preface 6-28
General Working Instructions 6-29
Work Safety 6-30
Symbol Explanation 6-30
Conversion Table 6-31
Torque Limit Table Grade 5 UNC 6-32
Torque Limit Table Grade 5 UNF 6-33
Torque Limit Table Grade 8 UNC 6-34
Torque Limit Table Grade 8 UNF 6-35
Inscription of the Model Identification Plate 6-36
BI620406
SKF Introduction Int-11
Contents
Disassembly Transmission 6-37
Assembly Transmission 6-44
Rotary Drive Motor 6-62
Rotary Drive Motor 6-62
Winch Assembly 6-63
Precautions on the use of Winches 6-63
Wire Rope 6-63
Wedge Socket 6-65
Grooved Drums 6-65
Plain (Smooth) Drums 6-66
Drums – Multiple Layers 6-66
Winch Assembly Service 6-67
BG8A and BG8B Hydraulic Winch Manual 6-68
Forward 6-69
Explanation of Model Number 6-69
Theory of Operation 6-70
Winch Installation 6-72
Wire Rope Installation 6-73
Preventative Maintenance 6-74
071 Motor 6-75
Troubleshooting 6-76
Disassembly of Winch 6-80
Planetary Carrier Service 6-82
Motor Support Brake Cylinder Service 6-84
Brake Clutch Service 6-88
Winch Assembly 6-90
Brake Valve Service 6-92
Reversing Direction of Drum Rotation 6-94
Recommended Fastener Torque 6-95
Metric Conversion Table 6-96
H O B O Wrench 6-97
Tong Dies 6-98
Deck Wrench 6-99
Pipe Positioner 6-100
Pipe Positioner 6-100
Carousel Pipe Rack 6-101
If Pipe Rack Does Not Rotate 6-101
Chain Drive – Adjust / Replace 6-101
Pipe Rack Bearings – Replace 6-102
Carousel Top Tube Bearing – Replace 6-103
Carousel Lower Bearing – Replace 6-105
Carousel Pivot Support Upper Bearing – Replace 6-107
Carousel Pivot Support Lower Bearing – Replace 6-109
Mid Point Carousel Pivot Support 6-110
Carousel Rotate Motor 6-110
Notes 6-111
BI620406
Int-12 SKF Introduction
Contents
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-7
Hydraulic Tank 7-9
Hydraulic Tank 7-10
Hydraulic System 7-10
Pressure Setting Sequence 7-11
Pressure Setting Sequence 7-11
Hydraulic System 7-11
Main Return and Case Drain Filter 7-12
Routine Maintenance 7-13
Changing Filter Elements 7-13
Main Hydraulic Pumps 7-14
Hydraulic Pump Identification 7-14
Right Track / Pulldown, Left Track / Rotation Pumps 7-15
Hydraulic Piston Pumps – Removal and Replacement 7-15
Main Pumps 7-16
AA4VG 125 Hydraulic Pump EP2 Control 7-16
AA4VG EP Controller 7-18
Technical Data 7-19
EP (24V DC) Control 7-21
Schematic Drawing – Standard Model 7-21
Technical Data 7-22
Port Locations 7-24
Connections 7-24
Main Pump Adjustments 7-25
Set Charge Pressure 450psi (31bar) 7-27
Set Pressure Override 5000psi (38bar) 7-27
Set Pressure Override (P O R) – 5000psi (345bar) 7-28
Mechanical Zero Position 7-29
Hydraulic Piston Pumps – Maintenance 7-30
Hydraulic Centreing 7-30
Removal and Inspection of Charge Pump 7-31
Hydraulic Piston Pumps – Troubleshooting 7-32
Removal and Installation of Shaft Seal 7-32
Routine Maintenance 7-33
Charge Circuit 7-38
Double Gear Pump – Right Charge and Water Injection 7-38
Charge Circuit Schematic 7-39
Routine Maintenance 7-41
Changing Filter Elements 7-41
Loop Filters 7-42
Loop Filters 7-42
Routine Maintenance 7-45
Changing Filter Elements 7-45
BI620406
SKF Introduction Int-13
Contents
Diverter Valve 7-46
Diverter Valve 7-46
Operation 7-46
Diverter Valve 7-46
Hydraulic Feed and Rotation Circuit 7-47
Basic Left Track / Rotation Pump Circuit 7-47
Basic Left Track / Rotation Pump 7-47
Rotation Circuit 7-48
Basic Right Track / Pulldown and Hoist Circuit 7-49
Basic Right Track / Pulldown and Hoist 7-49
Hoist / Pulldown Circuit 7-50
Drill / Tram Control Circuit 7-51
Operation 7-51
Rope Tensioning Circuit 7-54
Auto Tensioning – Operating Principle 7-54
Rotary Drive Gearbox Motor 7-55
Variable Displacement Motor AA6VM 7-55
Rotation Motor 7-59
Fan and Auxiliary Pump Circuit 7-89
Hydraulic Pump Identification 7-89
Fan and Auxiliary Functions Pump 7-71
Hydraulic Pumps 7-72
Hydraulic Piston Pumps – Removal and Replacement 7-72
Model A11VLO Hydraulic Piston Pumps – Repair 7-72
Repair Instructions 7-73
New or Rebuilt Hydraulic Pump – Start-up 7-74
Start-up Procedure 7-74
Auxiliary Functions / Fan Circuit 7-76
Operation 7-77
Auxiliary Functions / Fan Circuit 7-79
Auxiliary Fan Circuit 7-81
Auxiliary Priority Function 7-82
Cooler Fan Circuit 7-83
Cooler Fan Circuit 7-83
Cooler Fan Motor 7-85
Hydraulic Motor F12 Series Service Manual 7-85
Specification and Tools 7-86
Hydraulic Motor F12 Series 7-88
Jack and Mast Elevate Circuit 7-89
4 Bank Valve 7-89
Counterbalance Valve Adjustment 7-91
Counterbalance Valve Adjustments 7-91
Mast Elevating Cylinders 7-92
Mast Elevating Cylinders Counterbalance Valves 7-92
Levelling Jack Cylinders 7-93
Jack Counterbalance Valves 7-93
BI620406
Int-14 SKF Introduction
Contents
Auxiliary Functions / 6 Bank Valve 7-94
Auxiliary Functions / 9 Bank Valve 7-95
Hydraulic Operated Breakout Wrench (HOBO) 7-96
Setting of Sequence Valves 7-96
Carousel Rotate Motor 7-97
2000 Series Disc Valve Geroler Motor Repair Information 7-97
Disassembly 7-99
Reassembly 7-101
Pilot Control Manifold 7-104
Hydraulic Gear Pumps 7-118
Hydraulic Gear Pumps – Removal and Replacement 7-118
Hydraulic Gear Pump – Repair 7-118
Hydraulic Gear Pumps – Shaft Seal Removal and Replacement 7-119
Tool List 7-120
Dust Collector / Water Injection Circuit 7-121
Pressure Adjustment 7-121
Dust Collector / Water Injection Circuit 7-122
Hydraulic Cylinder Repair 7-123
General Information 7-124
H Head 7-126
N Head 7-127
Z Head 7-128
Z Head (Two Piece) 7-129
K Head 7-130
M Head 7-131
Z Piston 7-132
H and K Piston 7-133
M piston 7-134
N Piston 7-137
Notes 7-138
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-5
Electrical Locator 8-5
Jump Starting 8-7
Batteries 8-9
Electrical Components 8-10
Electrical Circuits 8-10
Transducers 8-10
Joystick Adjustments 8-12
Welding Precautions 8-14
Vigilante Guide 8-15
Important Information 8-15
PLC 8-16
Touchscreen 8-19
BI620406
SKF Introduction Int-15
Contents
Laser Depth System 8-20
Start Up and Shut Down 8-22
Alarms 8-23
Solenoid Control 8-24
Auto Lube 8-26
Hammer Oil System 8-26
Gauges 8-27
Dust Suppression 8-27
Important Information 8-28
Disclaimers 8-28
Vigilante System Component Information 8-29
Ladder Prox Switch 8-29
Jacks Prox Switch 8-29
LDM 40 A Laser 8-30
General 8-30
Safety Instructions 8-31
Performance Data 8-32
Working Principle 8-33
Setup 8-33
Interface Cable Wire Assignment 8-34
Limiting Values for Voltages 8-35
Starting Up 8-35
Parameters 8-36
Functions 8-39
Service, Maintenance, Warranty 8-41
Radiator Level Switch 8-42
Hammer Oil Level Transducer 8-46
Pressure Transducers – Combined Pressure Sensor 8-48
Access Light Timer 8-57
Rod Counter Prox Switch 8-58
Cat 3412E Flash Codes 8-59
Cat 3412E Electrical System 8-61
Cat 3412E Sensor Layout 8-62
Cat 3412E Sensor Schematic 8-66
Notes 8-6
Section 9 – Lubrication and Preventive Maintenance 9-1
Section 9 Contents 9-3
Central Lube System 9-5
Description 9-5
Auto Lube 9-5
Auto Lube Lincoln Pneumatic Pump Owners Manual 9-6
SL-1 Injectors 9-15
SL-1 Injectors Assembly 9-15
SL-1 Injectors Specifications 9-15
SL-1 Injectors Operations 9-16
BI620406
Int-16 SKF Introduction
Contents
Filter / Regulator / Lubricator 9-17
Filter Maintenance and Repair 9-18
Lubrication Maintenance and Repair 9-20
Air Service Units 9-21
Filter Regulator 9-21
Air Oil Oiler 9-22
Pipe Thread Lubricator 9-23
Air Service Unit 9-23
Air Operated Pipe Thread Pump 9-24
Hammer Oil System 9-32
Hammer Oiler Tank Assembly 9-32
Hammer Oil Circuit 9-33
Air Service Unit Components 9-34
Filter Regulator 9-35
Air Line Oiler 9-36
10:1 Hammer Oil Pump Manual 9-37
Symbols 9-38
Installation 9-40
Operation 9-43
Air Motor and Throat Service 9-45
Displacement Pump Service 9-49
Dimensions 9-50
Technical Data 9-50
Performance Data 9-51
Lubrication General 9-52
Equipment Lubrication 9-52
Care of Lubrication Points 9-52
Lubrication and Preventive Maintenance 9-53
Safety 9-53
Isolation – Battery Switch 9-54
Track – Check and Lubrication 9-55
Engine Maintenance 9-56
Air Cleaners 9-57
Air Filter Elements 9-57
Alternator Maintenance 9-57
Compressor – Checks and Servicing 9-58
Air Conditioner – Checks and Servicing 9-59
Drive Shaft – Checks and Maintenance 9-59
Cooler – Checks and Servicing 9-60
Hydraulic – Checks and Servicing 9-61
A-frame and Mast Pivot Point – Checks and Maintenance 9-62
Rotary Head – Checks and Service Points 9-63
Pulldown / Hoist Sheaves and Ropes – Checks and Servicing 9-64
Cabin – Checks and Service Points 9-65
Fire Suppression (Optional) – Checks and Servicing 9-65
Battery – Checks and Servicing 9-66
BI620406
SKF Introduction Int-17
Contents
Bean Pump – Checks and Maintenance 9-66
Lubrication System – Checks and Servicing 9-67
Weld Inspection Schedule 9-68
Weld Inspection Schedule SK Series 9-68
250hr Lubrication and Maintenance 9-69
500hr Lubrication and Maintenance 9-84
1000hr Lubrication and Maintenance 9-100
2000hr Lubrication and Maintenance 9-116
Lubricant Specifications 9-134
Equipment Lubrication 9-134
Care of Lubrication Points 9-134
Compressor Lubrication Procedure 9-134
Winch Assembly Lubrication (Braden BG-8H) 9-134
Compressor 9-135
Lubricating Grease 9-135
Gear Lubricant 9-135
Hydraulic System 9-136
Hydraulic Tank Capacity 9-136
Hydraulic System Maintenance 9-137
Cooling System Maintenance 9-137
Cooling System Freeze Protection 9-138
Air Cleaner 9-138
Air Filter Elements 9-138
Electrical System 9-138
Schedule Oil Sampling Analysis 9-139
Torque Values for Split Flange Connections 9-140
Procedure No 1-87 Revision A 9-140
Torque Values for Split Flange Connections 9-141
Notes 9-143

Customer Support: [email protected]

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