Cat Rotary Track Drill MD6240 SKF-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
DESCRIPTION:
Cat Rotary Track Drill MD6240 SKF-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
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
WARNING:
DO NOT use this machine for any other purpose than blasthole drilling. The Infinity Series rotary blasthole drill is designed for blasthole drilling purposes only. Any other use could result in personal injury and/or property damage and will void the warranty
CAUTION:
Each person performing service work must be satisfied that they have adequate knowledge and training to perform the required tasks. A thorough understanding of hydraulic and pneumatic systems as well as electrical and mechanical knowledge and experience is required
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 Rotary Track Drill MD6240 SKF-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
SKF-12_C83 Service Manual.pdf....................................................... 0
SKF-12_C83 Cover................................................................ 2
Introduction................................................................ 4
Safety Information...................................................... 4
Parts Ordering and Product Support...................................... 5
Table of Contents....................................................... 6
General Locator......................................................... 17
SKF-12_C83 Section 1............................................................ 20
Section 1 - Safety.......................................................... 20
Section 1 Contents...................................................... 22
Safety.................................................................. 23
Personal Protective Equipment....................................... 23
Noise............................................................... 23
Electrical Contact.................................................. 23
Overhead and Buried Utilities....................................... 23
Contact with Electric Wires......................................... 24
Contaminated Air.................................................... 24
Machine Stability................................................... 25
Moving and Rotating Parts........................................... 26
High Pressure Air or Fluid.......................................... 26
Before Operation.................................................... 26
During Operation.................................................... 27
Maintenance......................................................... 29
Safety Locator...................................................... 30
SKF-12_C83 Section 2............................................................ 32
Section 2 - Operator's Cab / Controls....................................... 32
Section 2 Contents...................................................... 34
Graphic Symbol Legend................................................... 35
Warning Decals.......................................................... 39
Operators Controls and Indicators....................................... 41
Control Panels...................................................... 41
Right Hand Control Panel................................................ 42
Instrument Panel and Circuit Breakers................................... 43
Circuit Breakers.................................................... 43
Light Switches...................................................... 44
Instrument Panel.................................................... 44
System Pressure Guage Panel............................................. 45
Left Hand Control Panel................................................. 47
Foot Control Pedals..................................................... 53
Cab Foot Controls................................................... 53
Thread Grease Switch................................................ 53
Pipe Safety Arm Override Switch..................................... 53
Air Conditioner......................................................... 54
T8 Series Split System Air Conditioning Manual...................... 54
SKF-12_C83 Section 3............................................................ 84
Section 3 - Main Frame / Crawlers........................................... 84
Section 3 Contents...................................................... 86
Main Frame Repair - General............................................. 88
Main Frame Repair................................................... 88
Leveling Jacks.......................................................... 89
Leveling Jacks...................................................... 89
Leveling Jack Cylinders............................................. 90
Mast Elevating Cylinders................................................ 91
Crawler Assembly........................................................ 92
Metric Bolt Torque Specifications....................................... 93
Track Maintenance....................................................... 94
Before Operating the Machine........................................ 94
General Maintenance................................................. 94
Track Tension Adjustment................................................ 95
Hydraulic Tensioner................................................. 96
Idler Unit.............................................................. 97
General Description................................................. 97
Removal and Disassembly............................................. 99
Assembly and Installation...........................................101
Track Tension Unit......................................................103
Installation........................................................104
Track Rollers...........................................................105
General Description.................................................105
Removal and Disassembly.............................................107
Track Roller - Assembly.............................................108
Track Roller - Test and Install.....................................109
Support Rollers.........................................................110
General Description.................................................110
Support Roller Assembly.............................................111
Removal and Disassembly.............................................112
Track Chain - Separate..................................................115
Track Chain - Repair....................................................116
Track Link - Repair & Replace.......................................116
Track Link - Description............................................117
Track Shoes Installation................................................118
Track Link Position.................................................118
Track Shoe - Mounting to Tracsk Chain...............................119
Track Shoe Bolt Torque (Direct Torque Method)...........................120
Track Shoe Bolt Torque (Torque Turn Method).............................121
Track Chain and Shoe Installation.......................................122
Track Chain with Shoes..............................................122
Track Chain & Shoe - Assembly & Installation........................122
Track and Support Rollers...............................................124
General Description.................................................124
Track Roller - Removal & Disassembly................................126
Track and Support Roller - Assembly.................................128
Track and Support Roller - Test and Install.........................129
Final Drive.............................................................131
Final Drive - General Description...................................131
Final Drive Unit Removal................................................132
Removal from Track Frame............................................132
Final Drive Unit Installation...........................................133
Installation into Track Frame.......................................133
Final Drive Maintenance.................................................134
Oil Check / Change..................................................134
Final Drive Oil.........................................................135
Specifications......................................................135
Recommended Oil.....................................................135
Final Drive Assembly....................................................137
Auxiliary Crane.........................................................196
Hydraulic Crane (Auxiliary Crane)...................................196
Load Lift Capacities................................................196
Maintenance.........................................................197
SKF-12_C83 Section 4............................................................198
Section 4 - Engine / Drive Train / Compressor...............................198
Section 4 Contents......................................................200
Power Group Locator.....................................................203
Cummins Engine..........................................................204
Engine Fuel System..................................................205
Construction........................................................206
Combo Fuel Filter Head & Pump Manifold..............................207
FS1006 Fuel Filter with Water Separator.............................207
Fuel Manifold with Integrated FSO Valve.............................208
Fuel Connections....................................................208
Pre Filters.........................................................209
Wiring with EFS Power Relay.........................................209
Pressure and Temperature Sensors....................................209
Operation...........................................................210
QST30 Electric Fuel Supply System...................................211
Oil Reserve Systems.................................................213
Engine Oil Reserve System (Basic Circuit)...........................213
LED Monitor Readings................................................214
Adjustment of Running Oil Level.....................................214
Oil Reserve Basic Circuit...........................................215
Oil Pressure Switch.................................................215
Oil Reserve System..................................................215
Troubleshooting.....................................................216
Maintenance.........................................................216
Engine and Compressor Air Cleaner.......................................217
Engine and Compressor Air Cleaner Service...........................218
Compressor Assembly.....................................................221
Flexible Drive Coupling.................................................222
Flexible Drive Coupling Service.....................................222
Pump Drive..............................................................224
Pump Drive Assembly - Removal and Replacement.......................224
Pump Drive Gearbox......................................................225
Pump Drive Gearbox - Repair.........................................225
Hydraulic Pumps.........................................................227
Hydraulic Pump Identification.......................................227
Hydraulic Pump Removal and Replacement..............................228
Compressor Service Procedures...........................................229
Compressor Installation.............................................229
Compressor Drive Coupling - Removal and Replacement.................230
Taper-Loc Bushing Installation......................................232
Compressor Shaft Seal...................................................233
High Pressure Compressosr...............................................236
Safety..............................................................236
Description.........................................................239
Compressed Air Functions............................................239
Compressor Oil Circuit..................................................243
Compressor Condensation Table...........................................246
Compressor Air Circuit..................................................247
Legend..............................................................248
Compressor Functional Description.......................................262
Compressor Operation....................................................264
Operation...........................................................264
Compressor Maintenance..................................................267
General Maintenance.................................................267
Interstage Tube.....................................................269
Discharge Check Valve...............................................270
Separator Elements..................................................271
Separator Elements - Remove & Replace...............................272
Scavenge Line.......................................................273
Compressor Discharge Temperature Gauge, Switch and Sender...........274
Minimum Pressure Valve..............................................275
Minimum Pressure / Check Valve Maintenance..........................275
Thermal Bypass Valve................................................276
Thermal Bypass Valve Maintenance....................................277
Oil Stop Valve......................................................278
Compressor Fluid Filter.............................................280
Changing Filter Elements............................................281
Inlet Valve.........................................................282
Relieving Regulators................................................284
System Blowdown Valve...............................................289
Running Blowdown Valve..............................................290
Running Blowdown Maintenance........................................291
Moisture Separator Maintenance......................................292
Auxiliary Regulators................................................293
Auxiliary Regulator Maintenance.....................................295
Troubleshooting.....................................................297
Compressor Oil Cooler Assembly..........................................300
Hydraulic Oil / Radiator Cooler Assembly................................301
Coolers Maintenance.....................................................302
Compressor Oil / Hydraulic Oil Cooler Service Manual....................303
Radiator Cooler Service Manual..........................................310
SKF-12_C83 Section 5............................................................317
Section 5 - Dust Control System.............................................317
Dust Control System.....................................................320
Dust Control Systems................................................320
Water Injection.........................................................321
Water Tanks.........................................................321
Water Tank Top up Soleniod Valve....................................322
Water Injection Relief Valve........................................324
Water Injection Control.............................................325
Water Injection Basic Circuit.......................................327
Water Pump..............................................................328
Pump Specifications.................................................328
Servicing Instructions..............................................328
Parts List..........................................................329
Replacing Piston Cup Seals..........................................330
Replacing Suction and Discharge Valves..............................331
Replacing Power End Bearings........................................332
Servicing the Wrist Pin Bearings....................................333
Fastener Torque Requirements........................................333
Recommended Lubricants..............................................334
Water Pump Motor Repair.............................................334
Water Injection Hydraulic Control Valve Repair......................334
Water Pump Drive Coupling...........................................334
Level and Flow Transducer...........................................334
SKF-12_C83 Section 6............................................................335
Section 6 - Mast / Rotary Drive / Pipe Rack.................................335
Section 6 Contents......................................................337
Mast Weldment...........................................................339
Mast Repair.........................................................339
Mast Assembly...........................................................340
Mast Assembly.......................................................340
Mast Pivot Caps.....................................................341
Mast Elevate Cylinders..............................................341
Angle Drilling......................................................342
Feed Cylinders..........................................................343
SKF 12 Feed System..................................................343
Feed Cylinder - Removal.............................................344
Feed Cylinder Assembly..............................................345
Feed CylinderRepair.................................................346
Feed Cylinder Installation..........................................346
Hoist / Pulldown Cable Assembly.........................................347
Hoist / Pulldown Cable Adjustment.......................................348
Auto Tensioning - Operating Principle...............................348
Auto Tensioning - Cable Removal, Adjustment and Installation........348
Rope Tensioning Circuit.............................................350
Rotary Drive Alignment..................................................353
Alignment Procedure.................................................353
Rotary Drive Assembly...................................................354
Rotary Drive - Removal from Mast....................................355
Rotary Drive - Installation.........................................355
Rotary Drive Gearbox....................................................356
Air Swivel (Dual Seal Style)........................................358
Air Swivel Service..................................................358
Rotary Drive Motor......................................................359
Repair..............................................................359
Rotary Drive Rebuild Manual.............................................360
Winch Assembly..........................................................400
Precautions on the use of Winches...................................400
Wedge Socket........................................................402
Grooved Drums.......................................................403
Plain (Smooth) Drums................................................403
Drums - Multiple Layers.............................................403
Winch Assembly Service..............................................404
BG8A and BG8B Hydraulic Winch Service Manual........................405
H.O.B.O. Wrench.........................................................436
Breakout System - HOBO..............................................437
Pipe Safety Arm.....................................................437
Deck Wrench.............................................................438
Pipe Positioner.........................................................439
Carousel Pipe Rack......................................................440
If Pipe Rack does not Rotate........................................440
Chain Drive - Adjust / Replace......................................440
Pipe Rack Bearings - Replace........................................441
Carousel Top Tube Bearing - Replace.................................442
Carousel Lower Bearing - Replace....................................444
Carousel Pivot Support Upper Bearing - Replace......................446
Carousel Pivot Support Lower Bearing - Replace......................448
Mid Point Carousel Pivot Support....................................449
Carousel Rotate Motor...............................................449
SKF-12_C83 Section 7............................................................451
Section 7 - Hydraulic Systems...............................................451
Hydraulic Symbols.......................................................455
Hydraulic Tank..........................................................457
Pressure Setting Sequence...............................................459
Pressure Setting Sequence...........................................459
Main Return and Case Drain Filter.......................................460
Routine Maintenance.................................................461
Changing Filter Elements............................................461
Main Hydraulic Pump.....................................................462
Hydraulic Pump Identification - SKF12...............................462
Hydraulic Piston Pumps Removal and Replacement......................463
Hydraulic Piston Pumps Adjustment...................................463
Right Track / Pulldown, Left Track / Rotation Pumps.....................464
Technical Data......................................................464
AA4VG EP Controller.................................................467
EP (24VDC) Control..................................................469
Main Pump Adjustments...............................................474
Hydraulic Centering.................................................475
Set Charge Pressure 450psi..........................................477
Set Pressure Override 5000psi.......................................477
Hydraulic Piston Pumps - Maintenance....................................479
Hydraulic Piston Pumps - Troubleshooting................................481
Charge Circuit..........................................................485
Double Gear Pump - Right Charge and Water Injection.................485
Routine Maintenance.................................................488
Changing Filter Elements............................................488
Loop Filters............................................................489
Loop Filters........................................................489
Routine Maintenance.................................................492
Changing Filter Elements............................................492
Diverter Valve..........................................................493
Operation...........................................................493
Diverter Valve......................................................493
Tram Circuit............................................................494
Hoist / Pulldown Circuit................................................496
Basic Pulldown Circuit..............................................496
Hoist / Pulldown Circuit............................................497
Rope Tensioning Circuit.................................................498
Rotation Circuit........................................................500
Rotation Circuit....................................................500
Rotary Drive Gearbox Motor..............................................502
Rotation Motor......................................................506
Fan and Auxiliary Pump Circuit..........................................516
Fan and Auxiliary Functions Pump....................................518
Hydraulic Pumps.........................................................519
Hydraulic Piston Pumps - Removal and Replacement....................519
Model A11VLO Hydraulic Piston Pumps - Repair........................519
Repair Instructions.................................................520
New or Rebuilt Hydraulic Pump - Start Up................................521
Start Up Procedure..................................................521
Auxiliary Functions / Fan Circuit.......................................523
Operation...........................................................524
Cooler Fan Circuit......................................................530
Cooler Fan Motor........................................................532
Jack and Mast Elevate Circuit...........................................536
4 Bank Valve........................................................536
Counterbalance Valve Adjustment.........................................538
Counterbalance Valve Adjustments....................................538
Mast Elevating Cylinders................................................539
Mast Elevating Cylinders Counterbalance Valves......................539
Leveling Jack Cylinders.................................................540
Jack Counterbalance Valves..........................................540
Auxiliary Functions / 6 Bank Valve......................................541
Auxiliary Funstions / 9 Bank Valve......................................543
Hydraulic Operated Breakout Wrench (HOBO)...............................544
Setting of Sequence Valves..........................................544
Carousel Rotate Motor...................................................545
Repair Information..................................................545
Pilot Control Manifold..................................................552
Hydraulic Gear Pump.....................................................567
Hydraulic Gear Pumps - Removal and Replacement......................567
Hydraulic Gear Pump - Repair........................................567
Hydraulic Gear Pumps - Shaft Seal Removal and Replacement...........568
Dust Collector / Water Injection Circuit................................570
Pressure Adjustment.................................................570
Water Injection / Foam Injection Valve..............................572
Water Injection / Foam Injection Valve..................................573
Introduciton........................................................573
Valve Stack Assembly................................................574
Segment Alterations.................................................575
Pulsar Solenoid Removal and Plug....................................577
Recommended Test Stand..............................................578
Final Stack Adjustment..............................................581
Assembly Drawing - VBL Bypass Inlet Segment Parts List..............587
Assembly Drawing - VPL Work Segment Parts List......................589
Air Conditioner Compressor Drive Circuit................................591
Hydraulic Cylinder Repair...............................................592
SKF-12_C83 Section 8............................................................607
Section 8 - Electrical Components...........................................607
Section 8 Contents......................................................609
Electrical Locator......................................................611
Jump Starting...........................................................613
Batteries...............................................................615
Welding Precautions.....................................................616
Vigilante Guide.........................................................617
Important Information...............................................617
PLC.................................................................618
EEPROM..............................................................619
Output Card.........................................................620
Touchscreen.........................................................621
Laser Depth System..................................................622
Safety Instructions & Precautions...................................623
Pipe in Hole Detection..............................................624
Distance Meter......................................................624
Start Up and Shut Down..............................................625
Hydraulic Function Enable...........................................625
Alarms..............................................................625
Solenoid Control....................................................626
Auto Lube...........................................................629
Hammer Oiler System.................................................629
Gauges..............................................................630
Pressure Transducer.................................................630
Level Transducer....................................................630
Hammer Oil Level Transducer.........................................630
Temperature Transducer..............................................631
Water Flow Transducer...............................................633
Inclinometers.......................................................634
Head Speed Module...................................................635
Level Switches......................................................636
Dust Suppression....................................................636
Turkey Spray........................................................636
Water Suppression Tank - Top Up.....................................636
CAED Electrical Guide...............................................637
Vigilante System Component Information..................................661
Head Speed Module...................................................661
Inclinometer........................................................663
Ladder Prox Switch..................................................666
LDM 40 A Laser......................................................667
Level Switches - Capacitive Level Switch (Hydraulic Oil Level)......679
Radiator Level Switch...............................................683
Level Transducer - Electronic Level Sensor..........................687
Hammer Oil Level Transducer.........................................697
Pressure Transducer - Combined Pressure Sensor......................699
Temperature Transducer - Control Monitor for Temperature Sensors....708
Temperature Sensor..................................................720
Water Flow Transducer - Flow Sensor Analog..........................721
Water Control Module................................................735
Rod Counter and Distance Meter Prox Switch..........................764
Remote Fuel Level Display...........................................765
SKF-12_C83 Section 9............................................................767
Section 9 - Lubrication and Preventive Maintenance..........................767
Section 9 Contents......................................................769
Central Lube System.....................................................771
Hydraulic Control Schematic.........................................772
Auto Lube...........................................................772
Central Lube Pump Module............................................776
Central Lube Pump...................................................789
Hammer Oiler Tank Assembly..............................................815
Hammer Oil Circuit......................................................816
Hammer Oil System.......................................................817
Air Service Unit Components.........................................817
Filter Regulator....................................................818
Air Line Oiler......................................................819
Fire Ball 425 Pump - Instructions...................................820
Pipe Thread Lubricator..................................................837
Air Service Unit....................................................837
Filter Regulator....................................................838
Air Line Lubricator.................................................839
Pipe Thread Pump....................................................840
Filter Locator..........................................................848
Lubrication General.....................................................850
Equipment Lubrication...............................................850
Care of Lubrication Points..........................................850
Lubrication and Preventive Maintenance..................................851
Safety..............................................................851
Isolation - Battery Switch..........................................852
Track Check and Lubrication.........................................853
Engine Maintenance..................................................854
Air Cleaners........................................................855
Air Filter Elements.................................................855
Alternator Maintenance..............................................855
Compressor Checks and Servicing.....................................856
Air Conditioner Checks and Servicing................................857
Drive Shaft Checks and Maintenance..................................857
Cooler Checks and Servicing.........................................858
Hydraulic Checks and Servicing......................................859
A-Frame and Mast Pivot Point checks and Maintenance.................860
Rotary Head Check and Service Points................................861
Pull Down / Hoist Sheaves and Ropes Checks and Servicing............862
Cabin Checks and Service Points.....................................863
Fire Suppression (Optional) Checks and Servicing....................863
Battery Checks and Servicing........................................864
Bean Pump Checks and Maintenance....................................864
Lubrication System Checks and Servicing.............................865
250hr Lubrication and Maintenance.......................................866
500hr Lubrication and Maintenance.......................................879
1000hr Lubrication and Maintenance......................................894
2000hr Lubrication and Maintenance......................................909
CAT ROTARY TRACK DRILL MD6240 SKF-12 TEREX INFINITY BLASTHOLE DRILL SERVICE MANUAL – PDF DOWNLOAD:
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Cat Rotary Track Drill MD6240 SKF-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOADCat Rotary Track Drill MD6240 SKF-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
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