CAT Bucyrus SKF-98 Infinity Blasthole Drill Service Manual BI620403 – PDF DOWNLOAD

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CAT Bucyrus SKF-98 Infinity Blasthole Drill Service Manual BI620403 – PDF DOWNLOAD

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CAT Bucyrus SKF-98 Infinity Blasthole Drill Service Manual BI620403 – PDF DOWNLOAD

Language : English
Pages : 637
Downloadable : Yes
File Type : PDF

DESCRIPTION:

CAT Bucyrus SKF-98 Infinity Blasthole Drill Service Manual BI620403 – 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
• 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.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

CAT Bucyrus SKF-98 Infinity Blasthole Drill Service Manual BI620403 – PDF DOWNLOAD

Section 1 Contents 1-3
Safety 1-5
Personal Protective Equipment 1-5
Noise 1-5
Electrical Contact 1-5
Contaminated Air 1-6
Moving and Rotating Parts 1-7
High Pressure Air or Fluid 1-7
Before Operation 1-7
During Operation 1-8
Maintenance 1-10
Safety Locator 1-11
Notes 1-14
Section 2 – Operator’s Cab / Controls 2-1
Section 2 Contents 2-3
Graphic Symbol Legend 2-5
Graphic Symbol Legend 2-5
Warning Decals 2-9
Warning Decals 2-9
Operator Control and Instrument Panels 2-12
Control Panels 2-12
Right Hand Control Panel 2-12
Instrument Panel 2-14
Circuit Breakers 2-15
Light Switches 2-15
System Pressure Gauge Panel 2-16
Left Hand Control Panels 2-18
Cab Foot Controls 2-22
Thread Grease Switch 2-22
Pipe Safety Arm Override Switch 2-22
Machine Stability 2-23
Tramming Procedure 2-23
Track Adjustments 2-23
New Machine Procedure 2-24
General Maintenance Checks While Tramming 2-24
Roller Locations 2-25
Temperature and Condition Record Chart for Walking 2-26
Propelling the Machine 2-27
Stability Limits 2-29
SKF Transient Stability Limits 2-30
Cab Heater 2-31
Cab Heater Fault Isolation 2-31
Air Conditioner 2-32
T7 Series Split System Air Conditioning Manual 2-32
Section 1 0 Technical Data and Control Settings 2-33
Section 2 0 Installation and Commissioning 2-35
Section 3 0 Routine Maintenance Procedures 2-41
Section 4 0 Fault Diagnosis 2-42
Section 5 0 Reference Drawings 2-51
Notes 2-56
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
Weld Inspection Schedule 3-6
Main Frame 3-6
Levelling Jacks 3-7
Levelling Jacks Cylinder 3-7
Levelling Jacks 3-8
Limit Switch 3-8
Levelling Jack Cylinders 3-8
Mast Elevating Cylinders 3-9
Mast Elevating Cylinders 3-9
Internal Counterbalance Valve 3-10
Crawler Assembly 3-12
Crawler Assembly 3-12
Parts List 3-13
Crawler Component Repair 3-13
Tramming 3-14
Maintenance checks for Tramming 3-14
Track Adjustments 3-14
New Machine Procedure 3-15
General Maintenance Checks While Tramming 3-15
Roller Locations 3-16
Temperature and Condition Record Chart for Walking 3-17
Metric Bolt Torque Specifications 3-18
Metric Bolt Torque Specifications 3-18
Track Maintenance 3-19
Before Operating the Machine 3-19
General Maintenance 3-19
Track Tension 3-20
Track Assembly 3-20
Hydraulic Tensioner 3-22
Track Tension Unit 3-23
Track and Support Rollers 3-24
Track Roller Assembly 3-24
Track Roller Unit 3-25
Track Roller – Removal and Disassembly 3-25
Track Roller – Assembly 3-26
Track Roller – Test and Install 3-27
Support Roller Assembly 3-29
Support Rollers Unit 3-30
Support Roller – Removal and Disassembly 3-30
Support Roller – Assembly 3-31
Track Chain 3-33
Track Chain – Separate 3-33
Track Chain Repair 3-34
Track Shoes Installation 3-36
Track Link Position 3-36
Track Shoe – Mounting to Track Chain 3-36
Track Shoe Bolt Torque (Direct Torque Method) 3-38
Bolt Torque KN111 3-38
Track Shoe Bolt Torque (Torque Turn Method) 3-39
Bolt Torque KN111 3-39
Track Chain and Shoe Installation 3-40
Track Chain with Shoes 3-40
Track Chain and Shoe – Assembly and Installation 3-40
Final Drive Unit 3-42
Final Drive Unit 3-42
Removal from Track Frame 3-43
Installation into Track Frame 3-44
Final Drive Maintenance 3-45
Final Drive Oil 3-46
F100 Final Drive Assembly 3-48
Parking Brake – Description 3-49
Final Drive – Disconnect and Parking Brake 3-50
Towing Procedure – Gear Drive Disconnect 3-50
Parking Brake – Description 3-51
Parking Brake – Removal and Installation 3-51
General Description 3-52
General Recommendations for Disassembly and Assembly Operations 3-52
Technical Features 3-54
Sealing Compounds and Adhesives 3-55
Filling and Checks 3-57
Service Schedule 3-57
Tightening Torques 3-58
Lubrication / Greasing – Grades and Application Range 3-58
General Checks 3-59
Disassembly and Assembly Operations 3-59
Troubleshooting 3-62
Special Tools 3-62
Idler Unit 3-63
Idler Unit – Assembly 3-63
Idler Unit – Removal 3-64
Track and Sprocket Inspection 3-67
Track Inspection and Wear Limit Guide 3-67
Sprocket Wear Patterns 3-72
Auxiliary Crane 3-78
Hydraulic Crane – Rear Deck Crane Palfinger PC1500 3-78
Rear Deck Crane Palfinger PC1500 Service information 3-79
Checking Bolted Connections 3-79
Maintenance Chart 3-80
Lubrication 3-82
Hydraulic Fluids 3-85
Oil Change / Oil Maintenance 3-86
Cleaning Agents and Equipment 3-86
Repairing Paint Damage 3-87
Removal From Service and Disposal 3-87
Notes 3-88
Section 4 – Engine / Drive Train / Compressor 4-1
Section 4 Contents 4-3
Power Group Locator 4-5
Power Group Locator 4-5
Test Point Locator 4-6
Test Point Locator 4-6
Caterpillar Engine 4-8
Caterpillar C27 Engine 4-8
Engine Mounts – Installation 4-9
Engine and Compressor Air Cleaners 4-10
Engine and Compressor Air Cleaner Service Assembly 4-10
Engine and Compressor Air Cleaner Service 4-11
Flexible Drive Coupling 4-14
Flexible Drive Coupling Service 4-14
Pump Drive 4-16
Pump Drive Assembly – Removal and Replacement 4-16
Pump Drive Gearbox 4-17
Pump Drive Gearbox Repair 4-17
Hydraulic Pumps 4-19
Hydraulic Pumps 4-19
Hydraulic Pumps – Removal and Replacement 4-21
Compressor Installation 4-22
1700cfm / 125psi Compressor 4-22
Safety 4-23
Compressor Installation 4-26
Compressor Drive Coupling 4-27
Compressor Alignment 4-28
Mounting Instructions for Arcusaflex™ Flywheel Couplings 4-29
Taper-Loc Bushing Installation – Model AC-T5 SN F2 V1 3535 4-30
Tightening Torques for Arcusaflex™ Flywheel Couplings 4-30
Compressor Shaft Seal 4-31
Compressor Shaft Seal 4-31
Low Pressure Compressor 4-33
Description 4-33
Compressed Air Functions 4-33
Compressor Inlet Valve Control System 4-37
Inlet Valve 4-38
Compressor Regulation 4-40
Relieving Regulators 4-41
Reducing Regulators 4-43
System Blowdown Valve 4-45
Running Blowdown Valve 4-46
Running Blowdown Maintenance 4-47
Compressor Air and Oil Circuits – 1700cfm @ 125psi 4-48
Compressor Air Circuit Parts List 4-51
Compressor Air Circuit Legend 4-51
Compressor Control Set-up Closed Poppet Inlet – Shutdown 4-52
Compressor Control Set-up Closed Poppet Inlet – Initial Start-up Below 50psi 4-53
Compressor Control Set-up Closed Poppet Inlet – Initial Start-up Above 50psi 4-54
Compressor Control Set-up Closed Poppet Inlet – Run Unloaded 4-55
Compressor Control Set-up Closed Poppet Inlet – Drilling 4-56
Compressor Control Set-up Closed Poppet Inlet – Shutting Down 4-57
Operation 4-58
Compressor Maintenance 4-60
General Maintenance 4-60
Discharge Check Valve 4-62
Compressor Receiver Tank Assembly 4-63
Separator Elements 4-64
Scavenge Line 4-65
Compressor Discharge Temperature Gauge, Switch and Sender 4-67
Minimum Pressure Valve 4-68
Minimum Pressure / Check Valve Maintenance 4-68
Thermal Bypass Valve 4-69
Thermal Bypass Valve Maintenance 4-70
Compressor Fluid Filter 4-72
Changing Filter Elements 4-73
Oil Stop Valve 4-74
Troubleshooting 4-75
Coolers 4-77
Hydraulic Oil / Hydraulic Cooler Assembly 4-77
Compressor Oil Cooler 4-78
Fan Speed 4-78
Engine Cooler / Radiator 4-79
Aluminium Tube Air to Oil Cooler 4-80
Aluminium Tube Air to Oil Cooler – Standard Parts 4-80
Removal Replacement 4-81
Internal Cleaning 4-83
Radiator Cooler 4-85
Typical Radiator Core – Standard Parts 4-85
Cleaning 4-86
Tube Removal 4-87
Seal Installation 4-88
Lubrication Seals and Tube Ends 4-88
Tube Installation 4-89
Notes 4-92
Section 5 – Dust Control System 5-1
Section 5 Contents 5-3
Dust Control System 5-5
Dust Control Systems 5-5
Duraquip Dust Collector 5-7
Dust Collector Assembly 5-10
Fan Wheel 5-11
Routine Maintenance 5-12
Water Injection 5-13
Dust Collector and Water Injection Circuit 5-13
Water Tanks 5-14
Water Injection Pump 5-15
Water Injection Relief Valve 5-15
Water Injection Control 5-16
Water Injection Circuit 5-18
Water Pump 5-19
Water Injection Pump Assembly 5-19
Pump Specifications 5-20
Torque Requirements 5-20
Servicing Instructions 5-20
Servicing the Plunger Packings 5-20
Reassembling Plunger Packings 5-21
Servicing the Pump Valves 5-21
Reassembling Valve Parts 5-21
Servicing the Crankshaft 5-22
Servicing the Crossheads 5-22
Replacing Piston Cup Seals 5-23
Replacing Suction and Discharge Valves 5-24
Replacing Power End Bearings 5-25
Servicing the Wrist Pin Bearings 5-26
Fastener Torque Requirements 5-26
Recommended Lubricants 5-27
Water Pump Motor Repair 5-27
Water Injection Hydraulic Control Valve Repair 5-27
Water Pump Drive Coupling 5-27
Level and Flow Transducer 5-27
Notes 5-28
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Weld Inspection Schedule 6-6
Mast Inspection 6-6
Mast Assembly and Installation 6-7
Mast Assembly 6-7
Mast Pivot Caps 6-8
Mast Elevate Cylinders 6-9
Angle Drilling 6-9
Mast / Drill Without Mast 6-10
Mast Assembly 6-11
Raising the Mast 6-11
Hoist / Pulldown Cylinder 6-13
Hoist / Pulldown Cylinder 6-13
Feed Cylinder Service 6-14
Feed Cylinder Removal 6-15
Installation 6-16
General Information 6-17
Hoist / Pulldown Cable 6-18
Hoist / Pulldown Cable Adjustment 6-18
Hoist / Pulldown Cable Replacement 6-19
Wire Rope 6-20
Rotary Drive 6-21
Alignment Procedure 6-21
Rotary Drive Assembly 6-22
Rotary Drive – Removal from Mast 6-23
Rotary Drive – Installation 6-23
Single Motor Rotary Drive Gearbox 6-24
Manufacturers Recommendations – Blast Hole Drilling Consumables 6-25
Air Swivel 6-26
Rotary Drive Motor – Repair 6-27
Torque Limit Table Grade 8 UNC 6-28
Torque Limit Table Grade 8 UNF 6-29
Rotary Drive Motor 6-30
Deck Wrench 6-31
Deck Wrench 6-31
H O B O Wrench 6-32
H O B O Wrench 6-32
Tong Dies 6-33
Optional Hydraulic Operated Bit Basket – H O B B 6-34
Pipe Positioner 6-35
Pipe Positioner 6-35
Carousel Pipe Rack 6-36
Carousel Pipe Rack 6-3
Chain Drive – Adjustment / Replace 6-36
Pipe Rack Bearings – Replace 6-37
Carousel Top Tube Bearing – Replace 6-38
Carousel Lower Bearing – Replace 6-40
Upper Pivot Support Bearing 6-41
Carousel Pivot Support Upper Bearing – Replace 6-42
Pivot Support Pipe Lower Bushing 6-43
Carousel Pivot Support Lower Bearing – Replace 6-44
Mid Point Carousel Pivot Support 6-45
Top Sub Saver 6-46
Replacement Procedure 6-46
Notes 6-47
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-7
Hydraulic Symbols 7-7
Hydraulic Tank 7-9
Hydraulic Tank 7-9
Hydraulic System 7-10
Pressure Setting Sequence 7-11
Pressure Setting Sequence 7-11
Hydraulic System 7-11
Main Return and Case Drain Filter 7-12
Routine Maintenance 7-13
Changing Filter Elements 7-13
Main Hydraulic Pumps 7-14
Pump Arrangement 7-14
Right Track / Left Track / Rotation Pumps 7-15
Technical Data 7-15
Main Pump Adjustments 7-16
Charge Pressure, High Pressure, P O R and Zero Position settings 7-17
Set Charge Pressure – 350psi (24bar) 7-17
Linde HPR-02 Self-Regulating Pumps 7-18
Operational Parameters 7-20
Linde HPR-02 Pump Schematic 7-21
Controls 7-22
Dimensions 7-25
Charge Pumps 7-26
Hydraulic Piston Pumps – Removal and Replacement 7-27
Main Pumps 7-27
EP (24V DC) Control 7-27
Setting Linde HPR-02 Main pumps – Neutral Setting 7-28
Setting Linde HPR-02 Main pumps – Pressure Settings 7-29
Setting Linde HPR-02 Main pumps – Pre-setup Checks 7-30
Main Pumps Linde HPR-02 7-31
Brake Test Procedure 7-32
Setting Procedure 7-32
Charge Circuit 7-34
Charge Circuit Schematic 7-34
Charge Circuit 7-35
Routine Maintenance 7-36
Changing Filter Elements 7-37
Main Pumps Circuit 7-38
Main Pumps Circuit 7-38
Loop Filters 7-39
Loop Filters 7-39
Routine Maintenance 7-39
Loop Filter Cross Section 7-40
Filter Assembly Loop 7-41
Changing Filter Elements 7-42
Diverter Valve 7-43
Closed Loop Pump Circuit 7-43
Operation 7-43
Diverter Valve 7-43
Rotation Circuit 7-44
Basic Rotation Circuit 7-44
Rotation Circuit Schematic 7-45
Rotation Circuit 7-46
Rotary Drive Gearbox Motor 7-47
Variable Displacement Motor AA6M 7-47
Tram Circuit 7-61
Tram Circuit 7-61
Tram Circuit Schematic 7-62
Pilot Control Manifold 7-63
Pilot Control Manifold 7-63
Pilot Control Manifold Assembly 7-64
Control Valve Assembly 7-65
Electro Proportional Valves 7-72
Proportional Valves Set-up 7-73
Auto Pulldown Card 7-73
Torque Control 7-74
Proportional Pulldown 7-75
OEM Controllers / EP Levers 7-76
Auxiliary Circuit 7-77
Auxiliary Circuit Functions 7-77
Auxiliary Valves 7-79
Auxiliary Pump Circuit 7-82
Feed and Auxiliary Pump Circuit 7-82
Auxiliary Pump Circuit Schematic 7-83
Feed and Auxiliary Functions Pump 7-84
Pump Replacement – Start-up 7-84
Jack Control and Mast Elevating Circuit 7-86
Jack Control and Mast Elevating Circuit Schematic 7-86
Jack Control and Mast Elevating Control Valve 7-87
Jack Control and Mast Elevating Circuit 7-88
Counterbalance Valves 7-89
Counterbalance Valve Adjustments 7-89
Internal Counterbalance Valve 7-90
Levelling Jack Cylinders 7-92
Jack Leg Cylinder 7-92
Counterbalance Valve Test Procedure 7-92
Mast Elevating Cylinders 7-93
Hydraulic Operated Breakout Wrench 7-94
H O B O Wrench 7-94
Setting of H O B O Sequence Valves 7-95
H o b o Float Valve 7-95
Hydraulic Feed Circuit 7-96
Hydraulic Feed Circuit 7-96
Hoist and Pulldown Control 7-98
Directional Control Valve MP22 7-98
Hoist / Pulldown Circuit Schematic 7-100
Feed Valve Assembly 7-101
Feed Valve Assembly 7-101
Control Valve Assembly 7-103
Technical Data 7-103
Cooler Fan Circuit 7-105
Cooler Fan Circuit 7-105
Setting Cooler Fan Speed 7-105
Hydraulic cooler – Thermal valve 7-107
Basic Cooler Fan Circuit 7-108
Cooler Fan Motor 7-109
Cooler Fan Motor Assembly 7-109
Hydraulic Motor 7-110
Water Pump Motor 7-113
Water Pump Motor Repair Information 7-113
Shaft Seal Repair 7-114
Hydraulic Cylinder Repair 7-117
Hydraulic Cylinders 7-117
General Information 7-118
H Head 7-120
N Head 7-121
Z Head 7-122
Z Head (Two Piece) 7-123
K Head 7-124
M Head 7-125
Z Piston 7-126
Z Piston (Threaded) 7-127
H and K Piston 7-128
M Piston 7-129
N Piston 7-132
Notes 7-133
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-5
Electrical Component Location 8-5
Jump Starting 8-8
Jump Starting 8-8
Batteries 8-10
Batteries 8-10
Welding Precautions 8-11
Welding Precautions 8-11
Electrical Components 8-12
Electrical Circuits 8-12
Transducers 8-12
EP Levers 8-13
Joystick Adjustments 8-14
Vigilante Guide 8-16
Important Information 8-16
PLC 8-17
Touchscreen 8-20
Laser Depth System 8-21
Distance Meter 8-24
Start Up and Shutdown 8-24
Hydraulic Function Enable 8-25
Alarms 8-25
Solenoid Control 8-26
Auto Lube 8-29
Gauges 8-29
Head Speed Module 8-32
Engine Speed Card 8-33
Level Switches 8-33
Dust Suppression 8-33
Acknowledgements 8-34
Disclaimers 8-34
Notes 8-35
N B: For further information on specific electronic components, please refer to
Vendor Documents in table of contents on Service Manual CD
Section 9 – Lubrication and Preventive Maintenance 9-1
Section 9 Contents 9-3
Central Lube System 9-5
Auto Lube Basic Operation 9-5
Central Lube Tank Assembly 9-6
Auto Lube Grease Pump 9-7
Auto Lube Tube Pump 9-13
Graco Vent Valve 9-18
Central Lube System Circuit 9-19
Basic Operational Principles of Auto Lube Injectors 9-20
SL-V and SL-V XL Injectors 9-20
SL-1 and Sl-11 Injectors 9-21
SL-32 Injectors 9-22
Typical Grease System Circuit 9-23
First 50 Hours Service 9-24
Lube Faults / Operation 9-25
Auto Lube Timer 9-26
Lube Pressure Screen 9-26
Air Service Units 9-27
Filter Regulator 9-27
Air Line Oiler 9-28
Soft Start Dump Valve 9-29
Air Service Unit 9-30
Pipe Thread Lubricator 9-31
Air Operator Pipe Thread Pump 9-31
Filter Locator 9-39
Filter Locator Assembly 9-39
Lubrication and Preventive Maintenance 9-40
General Lubrication 9-40
Equipment Lubrication 9-40
Care of Lubrication Points 9-40
Safety 9-41
Track Gear 9-42
Engine Maintenance 9-43
Air Cleaners 9-44
Air Filter Elements 9-44
Alternator Maintenance 9-44
Pump Drive and Drive Shaft Maintenance 9-45
Compressor Maintenance 9-45
Cooler Packs 9-45
A-frame and Pivot Point Maintenance 9-47
Pull Down and Hoist Ropes and Sheaves Maintenance 9-47
Rotary Head Maintenance 9-47
Hydraulic System Maintenance 9-49
Hydraulic Maintenance 9-49
Water Pump Maintenance 9-49
Cab Maintenance 9-49
Air Conditioner Maintenance 9-51
Battery Maintenance 9-51
Lubrication System Maintenance 9-51
Fire Suppression Maintenance 9-51
Drill Folding Stairway – Inspection Requirements 9-53
Weld Inspection Schedule 9-54
Weld Inspection Schedule SK Series 9-54
Track and Sprocket Inspection 9-55
Track Inspection and Wear Limit Guide 9-55
Sprocket Wear Patterns 9-60
Lubrication Recommendations 9-66
Lubrication Recommendations 9-66
Lubrication and Maintenance Chart – 250hr 9-67
Lubrication and Maintenance Chart – 500hr 9-77
Lubrication and Maintenance Chart – 1000hr 9-88
Lubrication and Maintenance Chart – 2000hr 9-99
Lubricant Specifications 9-111
Hydraulic System 9-111
Hydraulic Tank Capacity 9-111
Compressor Lubrication 9-112
Compressor Lubricant Specifications 9-112
Lubricating Grease 9-113
Gear Lubricant 9-113
Scheduled Oil Sampling Analysis 9-113
Torque Values for Split Flange Connections 9-114
Torque Values for Split Flange Connections 9-114
Procedure No 1-87 Revision A 9-116
Notes 9-117

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