Cat Rotary Track Drill MD6240 SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
DESCRIPTION:
Cat Rotary Track Drill MD6240 SKSS-12 Terex Infinity Blasthole Drill Service Manual – 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
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 SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
SKSS-12_F08 Service Manual.pdf................................................... 0
Introduction................................................................. 3
Safety Information....................................................... 3
Parts Ordering and Product Support....................................... 4
Table of Contents........................................................ 5
Section 1 - Safety........................................................... 16
Personal Protective Equipment............................................ 17
Noise.................................................................... 17
Electrical Contact....................................................... 17
Overhead and Buried Utilities............................................ 17
Contact with Electric Wires.............................................. 18
Contaminated Air......................................................... 18
Machine Stability........................................................ 19
Moving and Rotating Parts................................................ 20
High Pressure Air or Fluid............................................... 20
Before Operation......................................................... 20
During Operation......................................................... 21
Maintenance.............................................................. 23
Safety Locator........................................................... 24
Section 2 - Operator's Cab / Controls........................................ 26
Graphic Symbol Legend.................................................... 27
Warning Decals........................................................... 31
Operators Controls and Indicators........................................ 33
Control Panels....................................................... 33
Right Hand Control Panel................................................. 34
Instrument Panel and Circuit Breakers.................................... 35
Circuit Breakers..................................................... 35
Light Switches....................................................... 36
Instrument Panel..................................................... 36
System Pressure Guage Panel.............................................. 37
Left Hand Control Panel.................................................. 39
Air Conditioner.......................................................... 45
T8 Series Split System Air Conditioning Manual....................... 45
Section 3 - Main Frame / Crawlers............................................ 76
Main Frame Repair - General.............................................. 77
Main Frame Repair.................................................... 77
Leveling Jacks........................................................... 78
Leveling Jacks....................................................... 78
Leveling Jack Cylinders.............................................. 79
Mast Elevating Cylinders................................................. 80
Mast Elevating Cylinders............................................. 81
Remove............................................................... 82
Repair............................................................... 82
Replace.............................................................. 82
Crawler Assembly......................................................... 83
Crawler Component Repair............................................. 84
Metric Bolt Torque Specifications........................................ 85
Track Maintenance........................................................ 86
Before Operating the Machine......................................... 86
General Maintenance.................................................. 86
Track Tension Adjustment................................................. 87
Hydraulic Tensioner.................................................. 88
Description.......................................................... 89
Nitrogen Tensioner................................................... 90
Hydraulic Tensioner...................................................... 91
Repair............................................................... 91
Nitrogen Tensioner Assembly.............................................. 92
Nitrogen Tensioner - Fitting Instructions................................ 93
Nitrogen Tensioner - Pressure Check.................................. 95
Nitrogen Tensioner - Pressure Release................................ 95
Track Chain - Separate................................................... 96
Track Chain - Repair..................................................... 97
Track Link - Repair & Replace........................................ 97
Track Link - Description............................................. 98
Track Shoes Installation................................................. 99
Track Link Position.................................................. 99
Track Shoe - Mounting to Tracsk Chain................................100
Track Shoe Bolt Torque (Direct Torque Method)............................101
Track Shoe Bolt Torque (Torque Turn Method)..............................102
Track Chain and Shoe Installation........................................103
Track Chain with Shoes...............................................103
Track Chain & Shoe - Assembly & Installation.........................103
Final Drive..............................................................105
Final Drive - General Description....................................105
Final Drive Unit Removal.................................................106
Removal from Track Frame.............................................106
Final Drive Unit Installation............................................107
Installation into Track Frame........................................107
Final Drive Maintenance..................................................108
Oil Check / Change...................................................108
Final Drive Oil..........................................................109
Specifications.......................................................109
Recommended Oil......................................................109
Final Drive Assembly.....................................................110
Final Drive - Disconnect & Parking Brake.................................134
Towing Procedure - Gear Drive Disconnect.............................134
Parking Brake - Removal & Installation...............................135
Idler Unit Assembly......................................................136
Idler Unit - Assembly................................................138
Idler Unit Removal.......................................................142
Idler Unit - Removal.................................................142
Track and Support Rollers................................................144
General Description..................................................144
Track Roller - Removal & Disassembly.................................146
Track and Support Roller - Assembly..................................148
Track and Support Roller - Test and Install..........................149
Auxiliary Crane..........................................................151
Hydraulic Crane (Auxiliary Crane)....................................151
Load Lift Capacities.................................................151
Maintenance..........................................................152
Section 4 - Engine / Drive Train / Compressor................................154
Power Group Locator......................................................155
Cummins Engine...........................................................156
Engine Fuel System...................................................157
Construction.........................................................158
Combo Fuel Filter Head & Pump Manifold...............................159
FS1006 Fuel Filter with Water Separator..............................159
Fuel Manifold with Integrated FSO Valve..............................160
Fuel Connections.....................................................160
Pre Filters..........................................................161
Wiring with EFS Power Relay..........................................161
Pressure and Temperature Sensors.....................................161
Operation............................................................162
QST30 Electric Fuel Supply System....................................163
Oil Reserve Systems..................................................165
Engine Oil Reserve System (Basic Circuit)............................165
LED Monitor Readings.................................................166
Adjustment of Running Oil Level......................................166
Oil Reserve Basic Circuit............................................167
Oil Pressure Switch..................................................167
Oil Reserve System...................................................167
Troubleshooting......................................................168
Maintenance..........................................................168
Engine and Compressor Air Cleaner........................................169
Engine and Compressor Air Cleaner Service............................170
Compressor Assembly......................................................173
Flexible Drive Coupling..................................................174
Flexible Drive Coupling Service......................................174
Pump Drive...............................................................176
Pump Identification..................................................176
Pump Drive Assembly - Removal and Replacement........................177
Pump Drive Gearbox.......................................................178
Pump Drive Gearbox Repair............................................179
3" Input Shaft Assembly..............................................181
Hydraulic Pump...........................................................182
Hydraulic Pumps - Removal and Replacement............................182
Compressor Installation..................................................183
Compressor Drive Coupling............................................183
Compressor Installation..............................................185
Compressor Drive Coupling - Removal and Replacement..................187
Compressor Shaft Seal....................................................188
Compressor Shaft Seal................................................188
Low Pressure Compressosr.................................................191
Safety...............................................................191
Description..........................................................194
Compressed Air Functions.............................................194
Compressor Oil Circuit...................................................198
Diagram Legend.......................................................198
Compressor Oil Circuit - COLD........................................199
Compressor Oil Circuit - HOT.........................................200
Compressor Oil Circuit - Shut Down...................................201
Compressor Air Circuits - 2400cfm @ 100psi...............................202
Diagram Legend.......................................................204
Shutdown.............................................................205
Start Up.............................................................206
Run Loaded...........................................................207
Drilling Air On......................................................208
Compressor Functional Description........................................209
Compressor Operation.....................................................211
Operation............................................................211
Compressor Maintenance...................................................213
General Maintenance..................................................213
Discharge Check Valve................................................215
Compressor Receiver Tank Assembly....................................216
Separator Elements...................................................218
Separator Elements - Remove & Replace................................219
Scavenge Line........................................................220
Compressor Discharge Temperature Gauge, Switch and Sender............221
Minimum Pressure Valve...............................................222
Minimum Pressure / Check Valve Maintenance...........................222
Thermal Bypass Valve.................................................223
Thermal Bypass Valve Maintenance.....................................224
Oil Stop Valve.......................................................225
Compressor Fluid Filter..............................................227
Changing Filter Elements.............................................228
Bearing Oil Filter...................................................229
Compressor Inlet Valve Control System................................230
Compressor Inlet Valve Control System................................231
Relieving Regulators.................................................232
System Blowdown Valve................................................235
Running Blowdown Valve...............................................236
Running Blowdown Maintenance.........................................237
Moisture Separator Maintenance.......................................238
Auxiliary Regulators.................................................239
Auxiliary Regulator Maintenance......................................240
Troubleshooting......................................................243
Aluminum Tube Air to Oil Cooler..........................................247
Compressor Oil Cooler................................................247
Radiator Cooler..........................................................248
Radiator Hydraulic Oil Cooler Assembly...............................248
Radiator / Oil Cooler Repair.........................................257
Section 5 - Dust Control System..............................................264
Dust Control System......................................................265
Dust Control Systems.................................................265
Water Injection..........................................................266
Water Tanks..........................................................266
Water Tank Top up Soleniod Valve.....................................267
Water Injection Relief Valve.........................................269
Water Injection Control..............................................270
Water Injection Basic Circuit........................................272
Water Pump...............................................................273
Pump Specifications..................................................273
Servicing Instructions...............................................273
Parts List...........................................................274
Replacing Piston Cup Seals...........................................275
Replacing Suction and Discharge Valves...............................276
Replacing Power End Bearings.........................................277
Servicing the Wrist Pin Bearings.....................................278
Fastener Torque Requirements.........................................278
Recommended Lubricants...............................................279
Water Pump Motor Repair..............................................279
Water Injection Hydraulic Control Valve Repair.......................279
Water Pump Drive Coupling............................................279
Level and Flow Transducer............................................279
Section 6 - Mast / Rotary Drive / Pipe Rack..................................280
Mast Weldment............................................................281
Mast Repair..........................................................281
Mast Assembly............................................................282
Mast Assembly........................................................282
Mast Pivot...........................................................283
Feed Cylinders...........................................................284
Feed Cylinder - Removal..............................................286
Feed Cylinder Assembly...............................................288
Repair...............................................................289
Installation.........................................................289
Hoist / Pulldown Cable Adjustment........................................290
Hosit / Pulldown Cable Adjustment....................................291
Hoist / Pulldown Cable Replacement...................................294
Rotary Drive Assembly....................................................295
Rotary Head Guide Alignment..........................................296
Rotary Head - Drive System...........................................297
Rotary Drive - Removal from Mast.....................................298
Rotary Drive - Installation..........................................298
Rotary Drive Gearbox.....................................................299
Rotary Drive Gearbox - Item Listing..................................300
Rotary Head Bull Shaft Bearing Nut...................................300
Rotary Drive Gearbox - Repair........................................301
Air Swivel...........................................................302
Winch Assembly...........................................................303
Precautions on the use of Winches....................................303
Wedge Socket.........................................................305
Grooved Drums........................................................306
Plain (Smooth) Drums.................................................306
Drums - Multiple Layers..............................................306
Winch Assembly Service...............................................307
BG8A and BG8B Hydraulic Winch Service Manual.........................308
Deck Wrench..............................................................339
H.O.B.O. Wrench..........................................................340
Breakout System - HOBO...............................................341
Pipe Safety Arm......................................................341
Pipe Positioner..........................................................342
Carousel Pipe Rack.......................................................343
Major Components.....................................................343
Rod Handling - Carousel Indexing.....................................344
Carousel Pipe Rack Assembly..........................................345
General Information..................................................346
Pipe Rack Bearings - Removal.........................................346
Pipe Rack Componetns - Inspection....................................349
Pipe Rack - Assembly and Installation................................350
Pipe Rack Roller - Remove and Replace................................351
Pipe Rack Roller - Disassembly and Assembly..........................352
Section 7 - Hydraulic Systems................................................354
Hydraulic Symbols........................................................355
Pressure Setting Sequence................................................357
Pressure Setting Sequence............................................357
Hydraulic Tank...........................................................359
Hydraulic Tank.......................................................359
Return Hydraulic Filters.............................................360
Main Return and Case Drain Filters.......................................361
Routine Maintenance..................................................362
Changing Filter Elements.............................................362
Main Hydraulic Pumps.....................................................363
Pump Identification..................................................363
Right Track, Left Track / Rotation Pumps.................................364
Hydraulic Piston Pumps - Removal and REplacement.....................364
AA4VG 180 Hydraulic Pump HD/D Control................................365
Technical Data.......................................................367
Port Locations.......................................................371
Setting Procedure....................................................372
Charge Pressure, High Pressure, P.O.R. and Zero Position Settings....373
Set Charge Pressure - 450psi (31 bar)................................373
Set Crossover Relief (High Pressure) - 5500psi (380 bar).............374
Set Pressure Override (P.O.R) - 5000psi (345 bar)....................375
Set Mechanical Zero Position - HD Pump Control.......................376
Set Hydraulic Zero Position - HD Pump Control........................377
Removal and Inspection of Charge Pump................................378
Removal and Installation of Shaft Seal...............................379
Routine Maintenance..................................................380
Charge Circuit...........................................................383
Charge Filter............................................................385
Routine Maintenance..................................................385
Changing Filter Elements.............................................385
Main Pumps Circuit.......................................................387
Main Pumps Circuit...................................................387
Loop Filters.............................................................389
Routine Maintenance..................................................389
Changing Filter Elements.............................................392
Rotation Circuit.........................................................393
Rotation Circuit.....................................................393
Rotary Drive Gearbox Motor...............................................395
Rotary Drive Gearbox Motor - Test and Repair.........................395
Shaft Seal Replacement...............................................396
Trouvle Shooting.....................................................398
Tram Circuit.............................................................400
Tram Circuit.........................................................400
Feed and Auxiliary Pump Circuit..........................................402
Hydraulic Piston Pumps - Removal and Replacement.....................402
Feed and Auxiliary Functions Pump....................................405
Repair Instructions..................................................406
Pump Replacement - Start Up..........................................407
Hydraulic Systems........................................................409
Auxiliary and Feed Circuits..........................................409
Main Control Valves......................................................410
Valve Stand Assembly.................................................410
MP18 Valve - Jack and Mast Raise Valve...................................411
MP22 Valve - Hoist and Pulldown Control..................................413
4WE6 - Aux. Functions and Mast Valves....................................416
Repair Kits..........................................................418
Exploded View of 4WE6................................................419
Counterbalance Valves....................................................420
Counterbalance Valve Adjustment......................................420
Pilot Control Manifold...................................................421
Control Valve Assembly...................................................423
Auxiliary Pump Load Solenoid Valve...................................423
Hydraulic Feed Circuit...................................................429
Feed Valve Assembly......................................................434
Jack Control and Mast Elevating Circuit..................................437
Jack Control and Mast Elevating Circuit..............................438
Leveling Jack Cylinders..................................................439
Counterbalance Valve Test Procedure..................................440
Mast Elevating Cylinders.................................................441
Counterbalance Valve Test Procedure..................................442
Auxiliary Functions Circuit..............................................443
Auxiliary Functions Circuit..........................................443
Hydraulic Operated Breakout Wrench.......................................445
Setting of HOBO Sequence Valves......................................446
Cooler Fan Circuit.......................................................447
Fan Motor Circuit....................................................447
Cooler Fan Motor.........................................................450
Hydraulic Motor......................................................450
Hydraulic Thermostatic Valve.............................................454
Hydraulic Cooler - Thermal Valve.....................................454
Central Lube.............................................................455
Hydraulic Circuit....................................................456
Air Conditioner Compressor Drive Circuit.................................457
Air Conditioner Drive Motor..............................................458
Design...............................................................458
Operational Check....................................................458
Shaft Seal Replacement...............................................459
Screw Tightening Torque..............................................459
Gear Backlash........................................................459
Specifications.......................................................459
Parts List...........................................................460
Water Injection Circuit..................................................461
Water Injection Valve................................................462
Water Injection Valve....................................................464
Introduciton.........................................................464
Valve Stack Assembly.................................................465
Segment Alterations..................................................466
Pulsar Solenoid Removal and Plug.....................................468
Recommended Test Stand...............................................469
Final Stack Adjustment...............................................472
Assembly Drawing - VBL Bypass Inlet Segment Parts List...............478
Assembly Drawing - VPL Work Segment Parts List.......................480
Water Pump Motor.........................................................482
Water Pump Motor Repair Information..................................482
Shaft Seal Repair....................................................483
Hydraulic Cylinder Repair................................................486
General Information..................................................487
H Head...............................................................489
N Head...............................................................490
Z Head...............................................................491
Z Head ( Two Piece)..................................................492
K Head...............................................................493
M Head...............................................................494
Z Piston.............................................................495
Z Piston (Threaded)..................................................496
H & K Piston.........................................................497
M Piston.............................................................498
N Piston.............................................................501
Section 8 - Electrical Components............................................504
Electrical Locator.......................................................505
Electrical Locator Parts List........................................507
Jump Starting............................................................508
Batteries................................................................510
Welding Precautions......................................................511
Vigilante Guide..........................................................512
Important Information................................................512
PLC..................................................................513
EEPROM...............................................................514
Output Card..........................................................515
Touchscreen..........................................................516
Laser Depth System...................................................517
Safety Instructions & Precautions....................................518
Pipe in Hole Detection...............................................519
Distance Meter.......................................................519
Start Up and Shut Down...............................................520
Hydraulic Function Enable............................................520
Alarms...............................................................520
Solenoid Control.....................................................521
Auto Lube............................................................524
Hammer Oiler System..................................................524
Gauges...............................................................525
Pressure Transducer..................................................525
Level Transducer.....................................................525
Hammer Oil Level Transducer..........................................525
Temperature Transducer...............................................526
Water Flow Transducer................................................528
Inclinometers........................................................529
Head Speed Module....................................................530
Level Switches.......................................................531
Dust Suppression.....................................................531
Turkey Spray.........................................................531
Water Suppression Tank - Top Up......................................531
Vigilante System Component Information...................................532
Head Speed Module....................................................532
Inclinometer.........................................................534
Ladder Prox Switch...................................................537
LDM 40 A Laser.......................................................538
Level Switches - Capacitive Level Switch (Hydraulic Oil Level).......550
Radiator Level Switch................................................554
Level Transducer - Electronic Level Sensor...........................558
Hammer Oil Level Transducer..........................................568
Pressure Transducer - Combined Pressure Sensor.......................570
Temperature Transducer - Control Monitor for Temperature Sensors.....579
Temperature Sensor...................................................591
Water Flow Transducer - Flow Sensor Analog...........................592
Water Control Module.................................................606
Section 9 - Lubrication and Preventive Maintenance...........................616
Central Lube System......................................................617
Hydraulic Control Schematic..........................................618
Auto Lube............................................................618
Central Lube Pump Module.............................................622
Central Lube Pump....................................................635
Bit Oiler Tank Assembly..................................................661
Bit Oil Circuit..........................................................662
Bit Oil System...........................................................663
Air Service Unit Components..........................................663
Filter Regulator.....................................................664
Air Line Oiler.......................................................665
Fire Ball 425 Pump - Instructions....................................666
Pipe Thread Lubricator...................................................683
Air Service Unit.....................................................683
Filter Regulator.....................................................684
Air Line Lubricator..................................................685
Pipe Thread Pump.....................................................686
Filter Locator...........................................................694
Lubrication General......................................................696
Equipment Lubrication................................................696
Care of Lubrication Points...........................................696
Lubrication and Preventive Maintenance...................................697
Safety...............................................................697
Track Gear...........................................................697
Engine Maintenance...................................................699
Air Cleaners.........................................................700
Air Filter Elements..................................................700
Alternator Maintenance...............................................700
Pump Drive and Drive Shaft Maintenance...............................701
Compressor Maintenance...............................................701
Cooler Packs.........................................................701
A-Frame and Pivot Point Maintenance..................................703
Pull Down and Hoist Ropes and Sheaves Maintenance....................703
Hydraulic System Maintenance.........................................705
Hydraulic Maintenance................................................705
Water Pump Maintenance...............................................705
Cab Maintenance......................................................705
Air Conditioner Maintenance..........................................707
Battery Maintenance..................................................707
Lubrication System Maintenance.......................................707
Fire Suppression Maintenance.........................................707
Lubrication and Maintenance Chart 250hr..................................709
Lubrication and Maintenance Chart 500hr..................................719
Lubrication and Maintenance Chart 1000hr.................................730
Lubricant Specifications.................................................739
Hydraulic System.....................................................739
Hydraulic Tank Capacity..............................................739
Compressor Lubrication...............................................740
Compressor Lubricant Specifications..................................740
Lubricating Grease...................................................741
Gear Lubricant.......................................................741
Scheduled Oil Sampling Analysis......................................741
Torque Valves for Split Flange Connections...............................742
CAT ROTARY TRACK DRILL MD6240 SKSS-12 TEREX INFINITY BLASTHOLE DRILL SERVICE MANUAL – PDF DOWNLOAD:
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Cat Rotary Track Drill MD6240 SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOADCat Rotary Track Drill MD6240 SKSS-12 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
PLEASE NOTE:
This is the SAME exact manual used by your dealers to fix your vehicle.
The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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