Cat Rotary Track Drill MD6240 SKSS-13 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
DESCRIPTION:
Cat Rotary Track Drill MD6240 SKSS-13 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 SKSS-13 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD\
SKSS-13_T07 Service Manual.pdf................................................... 0
Introduction................................................................. 3
Safety Information....................................................... 3
Parts Ordering and Product Support....................................... 4
Table of Contents........................................................ 5
General Locator
......................................................... 17
Section 1 - Safety
.......................................................... 20
Section 2 - Operator's Cab / Controls........................................ 32
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
Air Conditioner.......................................................... 53
T8 Series Split System Air Conditioning Manual....................... 53
Section 3 - Main Frame / Crawlers............................................ 84
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
Mast Elevating Cylinders............................................. 92
Remove............................................................... 93
Repair............................................................... 93
Replace.............................................................. 93
Crawler Assembly......................................................... 94
Crawler Component Repair............................................. 95
Metric Bolt Torque Specifications........................................ 96
Track Maintenance........................................................ 97
Before Operating the Machine......................................... 97
General Maintenance.................................................. 97
Track Tension Adjustment................................................. 98
Hydraulic Tensioner.................................................. 99
Description..........................................................100
Nitrogen Tensioner...................................................101
Hydraulic Tensioner......................................................102
Repair...............................................................102
Nitrogen Tensioner Assembly..............................................103
Nitrogen Tensioner - Fitting Instructions................................104
Nitrogen Tensioner - Pressure Check..................................106
Nitrogen Tensioner - Pressure Release................................106
Track Chain - Separate...................................................107
Track Chain - Repair.....................................................108
Track Link - Repair & Replace........................................108
Track Link - Description.............................................109
Track Shoes Installation.................................................110
Track Link Position..................................................110
Track Shoe - Mounting to Tracsk Chain................................111
Track Shoe Bolt Torque (Direct Torque Method)............................112
Track Shoe Bolt Torque (Torque Turn Method)..............................113
Track Chain and Shoe Installation........................................114
Track Chain with Shoes...............................................114
Track Chain & Shoe - Assembly & Installation.........................114
Final Drive..............................................................116
Final Drive - General Description....................................116
Final Drive Unit Removal.................................................117
Removal from Track Frame.............................................117
Final Drive Unit Installation............................................118
Installation into Track Frame........................................118
Final Drive Maintenance..................................................119
Oil Check / Change...................................................119
Final Drive Oil..........................................................120
Specifications.......................................................120
Recommended Oil......................................................120
Final Drive Assembly.....................................................121
Parking Brake - Description..........................................144
Final Drive - Disconnect & Parking Brake.................................145
Towing Procedure - Gear Drive Disconnect.............................146
Parking Brake - Removal & Installation...............................146
Idler Unit Assembly......................................................147
Idler Unit - Assembly................................................149
Idler Unit Removal.......................................................153
Idler Unit - Removal.................................................153
Track and Support Rollers................................................155
General Description..................................................155
Track Roller - Removal & Disassembly.................................157
Track and Support Roller - Assembly..................................159
Track and Support Roller - Test and Install..........................160
Auxiliary Crane..........................................................162
Hydraulic Crane (Auxiliary Crane)....................................162
Load Lift Capacities.................................................162
Maintenance..........................................................163
Section 4 - Engine / Drive Train / Compressor................................164
Contents.................................................................166
Power Group Locator......................................................169
Cummins Engine...........................................................170
Engine Fuel System...................................................171
Construction.........................................................172
Combo Fuel Filter Head & Pump Manifold...............................173
FS1006 Fuel Filter with Water Separator..............................173
Fuel Manifold with Integrated FSO Valve..............................174
Fuel Connections.....................................................174
Pre Filters..........................................................175
Wiring with EFS Power Relay..........................................175
Pressure and Temperature Sensors.....................................175
Operation............................................................176
QST30 Electric Fuel Supply System....................................177
Oil Reserve Systems..................................................179
Engine Oil Reserve System (Basic Circuit)............................179
LED Monitor Readings.................................................180
Adjustment of Running Oil Level......................................180
Oil Reserve Basic Circuit............................................181
Oil Pressure Switch..................................................181
Oil Reserve System...................................................181
Troubleshooting......................................................182
Maintenance..........................................................182
Engine and Compressor Air Cleaner........................................183
Engine and Compressor Air Cleaner Service............................184
Compressor Assembly......................................................187
Flexible Drive Coupling..................................................188
Flexible Drive Coupling Service......................................188
Pump Drive...............................................................190
Pump Identification..................................................190
Pump Drive Assembly - Removal and Replacement........................191
Pump Drive Gearbox.......................................................192
Pump Drive Gearbox Repair............................................193
3" Input Shaft Assembly..............................................195
Hydraulic Pump...........................................................196
Hydraulic Pumps - Removal and Replacement............................196
Compressor Installation..................................................197
Compressor Drive Coupling............................................197
Compressor Installation..............................................199
Compressor Drive Coupling - Removal and Replacement..................201
Compressor Shaft Seal....................................................202
Compressor Shaft Seal................................................202
Low Pressure Compressosr.................................................205
Safety...............................................................205
Description..........................................................208
Compressed Air Functions.............................................208
Compressor Oil Circuit...................................................212
Diagram Legend.......................................................212
Compressor Oil Circuit - COLD........................................213
Compressor Oil Circuit - HOT.........................................214
Compressor Oil Circuit - Shut Down...................................215
Compressor Air Circuits - 2400cfm @ 100psi...............................216
Diagram Legend.......................................................218
Shutdown.............................................................219
Start Up.............................................................220
Run Loaded...........................................................221
Drilling Air On......................................................222
Compressor Functional Description........................................223
Compressor Operation.....................................................225
Operation............................................................225
Compressor Maintenance...................................................227
General Maintenance..................................................227
Discharge Check Valve................................................229
Compressor Receiver Tank Assembly....................................230
Separator Elements...................................................232
Separator Elements - Remove & Replace................................233
Scavenge Line........................................................234
Compressor Discharge Temperature Gauge, Switch and Sender............235
Minimum Pressure Valve...............................................236
Minimum Pressure / Check Valve Maintenance...........................236
Thermal Bypass Valve.................................................237
Thermal Bypass Valve Maintenance.....................................238
Oil Stop Valve.......................................................239
Compressor Fluid Filter..............................................241
Changing Filter Elements.............................................242
Bearing Oil Filter...................................................243
Compressor Inlet Valve Control System................................244
Compressor Inlet Valve Control System................................245
Relieving Regulators.................................................246
System Blowdown Valve................................................249
Running Blowdown Valve...............................................250
Running Blowdown Maintenance.........................................251
Moisture Separator Maintenance.......................................252
Auxiliary Regulators.................................................253
Auxiliary Regulator Maintenance......................................254
Troubleshooting......................................................257
Aluminum Tube Air to Oil Cooler..........................................261
Compressor Oil Cooler................................................261
Radiator Cooler..........................................................262
Radiator Hydraulic Oil Cooler Assembly...............................262
Radiator / Oil Cooler Repair.........................................271
Section 5 - Dust Control System..............................................278
Contents.................................................................280
Dust Control System......................................................281
Dust Control Systems.................................................281
Dust Collector.......................................................282
Dust Collector Assembly..............................................286
Water Injection..........................................................290
Water Tanks..........................................................290
Water Tank Top up Soleniod Valve.....................................291
Water Injection Relief Valve.........................................293
Water Injection Control..............................................294
Water Injection Basic Circuit........................................296
Water Pump...............................................................297
Pump Specifications..................................................297
Servicing Instructions...............................................297
Parts List...........................................................298
Replacing Piston Cup Seals...........................................299
Replacing Suction and Discharge Valves...............................300
Replacing Power End Bearings.........................................301
Servicing the Wrist Pin Bearings.....................................302
Fastener Torque Requirements.........................................302
Recommended Lubricants...............................................303
Water Pump Motor Repair..............................................303
Water Injection Hydraulic Control Valve Repair.......................303
Water Pump Drive Coupling............................................303
Level and Flow Transducer............................................303
Section 6 - Mast / Rotary Drive / Pipe Rack..................................304
Mast Weldment............................................................307
Mast Repair..........................................................307
Mast Assembly............................................................308
Mast Assembly........................................................308
Mast Pivot...........................................................309
Feed Cylinders...........................................................310
Feed Cylinder - Removal..............................................312
Feed Cylinder Assembly...............................................314
Repair...............................................................315
Installation.........................................................315
Hoist / Pulldown Cable Adjustment........................................316
Hosit / Pulldown Cable Adjustment....................................317
Hoist / Pulldown Cable Replacement...................................320
Rotary Drive Assembly....................................................321
Rotary Head Guide Alignment..........................................322
Rotary Head - Drive System...........................................323
Rotary Drive - Removal from Mast.....................................324
Rotary Drive - Installation..........................................324
Rotary Drive Gearbox.....................................................325
Rotary Drive Gearbox - Item Listing..................................326
Rotary Head Bull Shaft Bearing Nut...................................326
Rotary Drive Gearbox - Repair........................................327
Air Swivel...........................................................328
Winch Assembly...........................................................329
Precautions on the use of Winches....................................329
Wedge Socket.........................................................331
Grooved Drums........................................................332
Plain (Smooth) Drums.................................................332
Drums - Multiple Layers..............................................332
Winch Assembly Service...............................................333
BG8A and BG8B Hydraulic Winch Service Manual.........................334
Deck Wrench..............................................................365
H.O.B.O. Wrench..........................................................366
Breakout System - HOBO...............................................367
Hydraulic Operated Bit Basket - HOBB.................................367
Pipe Safety Arm......................................................367
Pipe Positioner..........................................................368
Carousel Pipe Rack.......................................................369
Major Components.....................................................369
Rod Handling - Carousel Indexing.....................................370
Carousel Pipe Rack Assembly..........................................371
General Information..................................................372
Pipe Rack Bearings - Removal.........................................372
Pipe Rack Componetns - Inspection....................................375
Pipe Rack - Assembly and Installation................................376
Pipe Rack Roller - Remove and Replace................................377
Pipe Rack Roller - Disassembly and Assembly..........................378
Section 7 - Hydraulic Systems................................................380
Hydraulic Symbols........................................................385
Pressure Setting Sequence................................................387
Pressure Setting Sequence............................................387
Hydraulic Tank...........................................................389
Hydraulic Tank.......................................................389
Return Hydraulic Filters.............................................390
Main Return and Case Drain Filters.......................................391
Routine Maintenance..................................................392
Changing Filter Elements.............................................392
Main Hydraulic Pumps.....................................................393
Pump Identification..................................................393
Right Track, Left Track / Rotation Pumps.................................394
Hydraulic Piston Pumps - Removal and REplacement.....................394
AA4VG 180 Hydraulic Pump HD/D Control................................395
Technical Data.......................................................397
Port Locations.......................................................401
Setting Procedure....................................................402
Charge Pressure, High Pressure, P.O.R. and Zero Position Settings....403
Set Charge Pressure - 450psi (31 bar)................................403
Set Crossover Relief (High Pressure) - 5500psi (380 bar).............404
Set Pressure Override (P.O.R) - 5000psi (345 bar)....................405
Set Mechanical Zero Position - HD Pump Control.......................406
Set Hydraulic Zero Position - HD Pump Control........................407
Removal and Inspection of Charge Pump................................408
Removal and Installation of Shaft Seal...............................409
Routine Maintenance..................................................410
Charge Circuit...........................................................413
Charge Filter............................................................415
Routine Maintenance..................................................415
Changing Filter Elements.............................................415
Main Pumps Circuit.......................................................417
Main Pumps Circuit...................................................417
Loop Filters.............................................................419
Routine Maintenance..................................................419
Changing Filter Elements.............................................422
Rotation Circuit.........................................................423
Rotation Circuit.....................................................423
Rotary Drive Gearbox Motor...............................................425
Rotary Drive Gearbox Motor - Test and Repair.........................425
Shaft Seal Replacement...............................................426
Trouvle Shooting.....................................................428
Tram Circuit.............................................................430
Tram Circuit.........................................................430
Feed and Auxiliary Pump Circuit..........................................432
Hydraulic Piston Pumps - Removal and Replacement.....................432
Feed and Auxiliary Functions Pump....................................435
Repair Instructions..................................................436
Pump Replacement - Start Up..........................................437
Hydraulic Systems........................................................439
Auxiliary and Feed Circuits..........................................439
Main Control Valves......................................................440
Valve Stand Assembly.................................................440
MP18 Valve - Jack and Mast Raise Valve...................................441
MP22 Valve - Hoist and Pulldown Control..................................443
4WE6 - Aux. Functions and Mast Valves....................................446
Repair Kits..........................................................448
Exploded View of 4WE6................................................449
Counterbalance Valves....................................................450
Counterbalance Valve Adjustment......................................450
Pilot Control Manifold...................................................451
Control Valve Assembly...................................................453
Auxiliary Pump Load Solenoid Valve...................................453
Hydraulic Feed Circuit...................................................459
Feed Valve Assembly......................................................464
Jack Control and Mast Elevating Circuit..................................467
Jack Control and Mast Elevating Circuit..............................468
Leveling Jack Cylinders..................................................469
Counterbalance Valve Test Procedure..................................470
Mast Elevating Cylinders.................................................471
Counterbalance Valve Test Procedure..................................472
Auxiliary Functions Circuit..............................................473
Auxiliary Functions Circuit..........................................473
Hydraulic Operated Breakout Wrench.......................................475
Setting of HOBO Sequence Valves......................................476
Cooler Fan Circuit.......................................................477
Fan Motor Circuit....................................................477
Cooler Fan Motor.........................................................480
Hydraulic Motor......................................................480
Hydraulic Thermostatic Valve.............................................484
Hydraulic Cooler - Thermal Valve.....................................484
Central Lube.............................................................485
Hydraulic Circuit....................................................486
Air Conditioner Compressor Drive Circuit.................................487
Air Conditioner Drive Motor..............................................488
Design...............................................................488
Operational Check....................................................488
Shaft Seal Replacement...............................................489
Screw Tightening Torque..............................................489
Gear Backlash........................................................489
Specifications.......................................................489
Parts List...........................................................490
Water Injection Circuit..................................................491
Water Injection Valve................................................492
Water Injection Valve....................................................494
Introduciton.........................................................494
Valve Stack Assembly.................................................495
Segment Alterations..................................................496
Pulsar Solenoid Removal and Plug.....................................498
Recommended Test Stand...............................................499
Final Stack Adjustment...............................................502
Assembly Drawing - VBL Bypass Inlet Segment Parts List...............508
Assembly Drawing - VPL Work Segment Parts List.......................510
Water Pump Motor.........................................................512
Water Pump Motor Repair Information..................................512
Shaft Seal Repair....................................................513
Hydraulic Cylinder Repair................................................516
General Information..................................................517
H Head...............................................................519
N Head...............................................................520
Z Head...............................................................521
Z Head ( Two Piece)..................................................522
K Head...............................................................523
M Head...............................................................524
Z Piston.............................................................525
Z Piston (Threaded)..................................................526
H & K Piston.........................................................527
M Piston.............................................................528
N Piston.............................................................531
Section 8 - Electrical Components............................................534
Electrical Locator.......................................................537
Electrical Locator Parts List........................................539
Jump Starting............................................................540
Batteries................................................................542
Welding Precautions......................................................543
Vigilante Guide..........................................................544
Important Information................................................544
PLC..................................................................545
EEPROM...............................................................546
Output Card..........................................................547
Touchscreen..........................................................548
Laser Depth System...................................................549
Safety Instructions & Precautions....................................550
Pipe in Hole Detection...............................................551
Distance Meter.......................................................551
Start Up and Shut Down...............................................552
Hydraulic Function Enable............................................552
Alarms...............................................................552
Solenoid Control.....................................................553
Auto Lube............................................................556
Hammer Oiler System..................................................556
Gauges...............................................................557
Pressure Transducer..................................................557
Level Transducer.....................................................557
Hammer Oil Level Transducer..........................................557
Temperature Transducer...............................................558
Water Flow Transducer................................................560
Inclinometers........................................................561
Head Speed Module....................................................562
Level Switches.......................................................563
Dust Suppression.....................................................563
Turkey Spray.........................................................563
Water Suppression Tank - Top Up......................................563
Vigilante System Component Information...................................564
Head Speed Module....................................................564
Inclinometer.........................................................566
Ladder Prox Switch...................................................569
LDM 40 A Laser.......................................................570
Level Switches - Capacitive Level Switch (Hydraulic Oil Level).......582
Radiator Level Switch................................................586
Level Transducer - Electronic Level Sensor...........................590
Hammer Oil Level Transducer..........................................600
Pressure Transducer - Combined Pressure Sensor.......................602
Temperature Transducer - Control Monitor for Temperature Sensors.....611
Section 9 - Lubrication and Preventive Maintenance...........................648
Central Lube System......................................................651
Hydraulic Control Schematic..........................................652
Auto Lube............................................................652
Central Lube Pump Module.............................................656
Central Lube Pump....................................................669
Bit Oiler Tank Assembly..................................................695
Bit Oil Circuit..........................................................696
Bit Oil System...........................................................697
Air Service Unit Components..........................................697
Filter Regulator.....................................................698
Air Line Oiler.......................................................699
Fire Ball 425 Pump - Instructions....................................700
Pipe Thread Lubricator...................................................717
Air Service Unit.....................................................717
Filter Regulator.....................................................718
Air Line Lubricator..................................................719
Pipe Thread Pump.....................................................720
Filter Locator...........................................................728
Lubrication General......................................................730
Equipment Lubrication................................................730
Care of Lubrication Points...........................................730
Lubrication and Preventive Maintenance...................................731
Safety...............................................................731
Track Gear...........................................................731
Engine Maintenance...................................................733
Air Cleaners.........................................................734
Air Filter Elements..................................................734
Alternator Maintenance...............................................734
Pump Drive and Drive Shaft Maintenance...............................735
Compressor Maintenance...............................................735
Cooler Packs.........................................................735
A-Frame and Pivot Point Maintenance..................................737
Pull Down and Hoist Ropes and Sheaves Maintenance....................737
Hydraulic System Maintenance.........................................739
Hydraulic Maintenance................................................739
Water Pump Maintenance...............................................739
Cab Maintenance......................................................739
Air Conditioner Maintenance..........................................741
Battery Maintenance..................................................741
Lubrication System Maintenance.......................................741
Fire Suppression Maintenance.........................................741
Lubrication and Maintenance Chart 250hr..................................743
Lubrication and Maintenance Chart 500hr..................................753
Lubrication and Maintenance Chart 1000hr.................................764
Lubricant Specifications.................................................773
Hydraulic System.....................................................773
Hydraulic Tank Capacity..............................................773
Compressor Lubrication...............................................774
Compressor Lubricant Specifications..................................774
Lubricating Grease...................................................775
Gear Lubricant.......................................................775
Scheduled Oil Sampling Analysis......................................775
Torque Valves for Split Flange Connections...............................776
CAT ROTARY TRACK DRILL MD6240 SKSS-13 TEREX INFINITY BLASTHOLE DRILL SERVICE MANUAL – PDF DOWNLOAD:
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Cat Rotary Track Drill MD6240 SKSS-13 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOADCat Rotary Track Drill MD6240 SKSS-13 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD
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