Cat Rotary Track Drill MD6290 SKF-98 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

Description

Cat Rotary Track Drill MD6290 SKF-98 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

DESCRIPTION:

Cat Rotary Track Drill MD6290 SKF-98 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 MD6290 SKF-98 Terex Infinity Blasthole Drill Service Manual – PDF DOWNLOAD

Section 1 Contents 1-3
Safety 1-5
Personal Protective Equipment 1-5
Noise 1-5
Electrical Contact 1-5
Overhead and Buried Utilities 1-5
Contact with Electric Wires 1-6
Contaminated Air 1-6
Machine Stability 1-7
Moving and Rotating Parts 1-8
High Pressure Air or Fluid 1-8
Before Operation 1-8
During Operation 1-9
Maintenance 1-11
Safety Locator 1-12
Notes 1-13
Section 2 – Operator’s Cab / Controls 2-1
Section 2 Contents 2-3
Graphic Symbol Legend 2-5
Warning Decals 2-9
Operators Controls and Indicators 2-11
Control Panels 2-11
Right Hand Control Panel 2-12
Instrument Panel and Circuit Breakers 2-13
Instrument Panel 2-14
Circuit Breakers 2-14
Light Switches 2-14
System Pressure Gauge Panel 2-15
Left Hand Control Panel 2-17
Foot Control Pedals 2-23
Cab Foot Controls 2-23
Thread Grease Switch 2-23
Pipe Safety Arm Override Switch 2-23
Air Conditioner 2-24
T7 Series Split System Air Conditioning Manual Contents 2-24
Section 1 0 Technical Data and Control Settings 2-25
Section 2 0 Installation and Commissioning 2-27
Section 3 0 Routine Maintenance Procedures 2-35
Section 4 0 Fault Diagnosis 2-36
Section 5 0 Basic Spare Parts Listing 2-45
Section 6 0 Reference Drawings 2-46
Zexel DKS-32 Compressor 2-59
Performance Curve 2-60
Notes 2-61
BI620414
Int-6 SKF Introduction
Contents
Section 3 – Main Frame / Crawlers 3-1
Section 3 Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
Levelling Jacks 3-6
Levelling Jacks 3-7
Levelling Jack Cylinders 3-7
Mast Elevating Cylinders 3-8
Crawler Assembly 3-9
Crawler Component Repair 3-9
Metric Bolt Torque Specifications 3-10
Track Maintenance 3-11
Before Operating the Machine 3-11
General Maintenance 3-11
Track Tension Adjustment 3-12
Idler Unit 3-14
General Description 3-14
Removal and Disassembly 3-16
Assembly and Installation 3-18
Track Tension Unit 3-20
Installation 3-21
Track Rollers 3-22
General Description 3-22
Removal and Disassembly 3-24
Track Roller – Assembly 3-25
Track Roller – Test and Install 3-26
Support Rollers 3-27
General Description 3-27
Support Roller Assembly 3-28
Removal and Disassembly 3-29
Support Roller Assembly 3-30
Track Chain – Separate 3-32
Track Chain – Separate 3-32
Track Chain – Repair 3-33
Track Link – Description 3-33
Track Link – Repair and Replace 3-33
Track Shoes Installation 3-35
Track Link Position 3-35
Track Shoe – Mounting to Track Chain 3-35
Track Shoe Bolt Torque (Direct Torque Method) 3-36
Bolt Torque KN111 3-36
Track Shoe Bolt Torque (Torque Turn Method) 3-37
Bolt Torque KN111 3-37
Track Chain and Shoe Installation 3-38
Track Chain with Shoes 3-38
Track Chain and Shoe – Assembly and Installation 3-38
BI620414
SKF Introduction Int-7
Contents
Track and Support Rollers 3-40
General Description 3-40
Track Roller – Removal and Disassembly 3-41
Support Roller – Removal and Disassembly 3-41
Track and Support Roller – Assembly 3-42
Track and Support Roller – Test and Install 3-43
Final Drive 3-45
Final Drive – General Description 3-45
Final Drive Unit Removal 3-46
Removal from Track Frame 3-46
Final Drive Unit Installation 3-47
Installation into Track Frame 3-47
Final Drive Maintenance 3-48
Oil Check / Change 3-48
Final Drive Oil 3-49
Specifications 3-49
Recommended Oil 3-49
Final Drive Assembly 3-51
Parking Brake – Description 3-53
Parking Brake – Removal and Installation 3-54
Towing Procedure – Gear Drive Disconnect 3-54
A – General Information 3-56
B – Safety Instructions 3-61
C – General Specifications 3-65
D – Disassembly and Assembly Operations 3-74
E – Troubleshooting 3-108
F – Special Tools 3-109
Auxiliary Crane 3-110
Hydraulic Crane (Auxiliary Crane) 3-110
Maintenance 3-111
Notes 3-117
Section 4 – Engine / Drive Train / Compressor 4-1
Section 4 Contents 4-3
Power Group Locator 4-5
Cummins Engine 4-7
Oil Reserve Systems 4-8
Engine Oil Reserve System (Basic Circuit) 4-8
LED Monitor Readings 4-9
Adjustment of Running Oil Level 4-9
Wiring Diagram Oil Reserve Basic Circuit 4-10
Oil Pressure Switch 4-10
Oil Reserve System 4-10
Troubleshooting 4-11
Maintenance 4-11
Engine and Compressor Air Cleaners 4-12
Engine and Compressor Air Cleaner Service 4-12
BI620414
Int-8 SKF Introduction
Contents
Flexible Drive Coupling 4-15
Flexible Drive Coupling Service 4-15
Pump Drive 4-17
Pump Drive Assembly – Removal and Replacement 4-17
Pump Drive Gearbox 4-18
Pump Drive Gearbox – Repair 4-18
Hydraulic Pumps 4-20
Hydraulic Pump Identification 4-20
Hydraulic Pump Removal and Replacement 4-22
Compressor Assembly 4-23
Compressor Service Procedures 4-24
Compressor Drive Coupling 4-24
Compressor Drive Coupling – Removal and Replacement 4-24
Taper-Loc Bushing Installation – Model AC-T5 SN F2 V1 3535 4-26
Before Installation and Start up of New or Rebuilt Compressor 4-27
Compressor Unit – Installation 4-27
Compressor Shaft Seal 4-28
Low Pressure Compressor 4-31
Safety 4-31
Description 4-33
Compressed Air Functions 4-33
Compressor Air and Oil Circuit 4-37
Compressor Air and Oil Circuits – 1700cfm @ 100psi 4-37
Compressor Functional Description 4-39
Section 5 – Dust Control System 5-1
Section 5 Contents 5-3
Dust Control System 5-5
Dust Control System Functions 5-5
Basic Specifications 5-6
Technical Data 5-6
Initial Startup 5-8
Fan Speed Adjustment 5-8
Direction of Fan Rotation 5-8
Compressed Air Supply 5-10
Air Regulator Filter 5-10
Electric Timer 5-12
Filter Maintenance 5-12
Routine Maintenance 5-13
Troubleshooting Guide 5-14
Water Pump 5-15
Parts List 5-15
Servicing Instructions 5-16
Servicing the Plunger Packings 5-16
Parts List 5-17
Reassembling Plunger Packings 5-18
BI620414
SKF Introduction Int-9
Contents
Servicing the Pump Valves 5-18
Parts List 5-19
Pump Specifications 5-20
Torque Requirements 5-20
Reassembling Valve Parts 5-20
Servicing the Crankshaft 5-20
Parts List 5-21
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
Water Injection Circuit 5-28
Pressure Adjustment 5-30
Char-Lynn Hydraulic Motor 5-32
Char-Lynn Hydraulic Motor Repair Manual 5-32
2000 Series Disc Valve Motor 5-33
Disassembly 5-34
Reassembly 5-36
Wheel Motor 5-38
Wheel Motor with Seal Guard 5-38
Production Identification 5-39
Notes 5-40
Section 6 – Mast / Rotary Drive / Pipe Rack 6-1
Section 6 Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Mast Assembly 6-6
Mast Assembly 6-6
Mast Pivot Caps 6-7
Mast Elevate Cylinders 6-7
Angle Drilling 6-8
Feed Cylinders 6-9
Feed Cylinder Assembly 6-9
Feed Cylinder – Removal 6-11
Repair 6-12
Installation 6-13
General Information 6-14
Hoist / Pulldown Cable Assembly 6-15
BI620414
Int-10 SKF Introduction
Contents
Hoist / Pulldown Cable Adjustment 6-16
Hoist / Pulldown Cable Replacement 6-16
Rotary Head Guide Alignment 6-18
Alignment Procedure 6-18
Rotary Drive Assembly 6-19
Rotary Drive – Removal from Mast 6-20
Rotary Drive – Installation 6-20
Rotary Drive Gearbox 6-21
Air Swivel (Single Seal Style) 6-23
Service 6-23
Rotary Drive Gearbox 6-24
Motor Drive Motor – Repair 6-24
Rotary Drive Rebuild Manual 6-25
Rotary Drive Motor 6-64
H O B O Wrench 6-65
Tong Dies 6-66
Deck Wrench 6-67
Pipe Positioner 6-68
Carousel Pipe Rack 6-69
If Pipe Rack Does Not Rotate 6-69
Chain Drive – Adjust / Replace 6-69
Pipe Rack Bearings – Replace 6-70
Carousel Top Tube Bearing – Replace 6-71
Carousel Lower Bearing – Replace 6-73
Carousel Pivot Support Upper Bearing – Replace 6-75
Carousel Pivot Support Lower Bearing – Replace 6-77
Mid Point Carousel Pivot Support 6-78
Carousel Rotate Motor 6-78
Winch Assembly 6-79
Precautions on the use of winches 6-79
Wire rope 6-79
Grooved Drums 6-80
Plain (smooth) Drums 6-80
Drums Multiple Layers 6-80
Notes 6-82
Section 7 – Hydraulic Systems 7-1
Section 7 Contents 7-3
Hydraulic Symbols 7-5
Hydraulic Tank 7-7
Pressure Setting Sequence 7-9
Pressure Setting Sequence 7-9
Main Return and Case Drain Filter 7-10
Routine Maintenance 7-11
Changing Filter Elements 7-11
BI620414
SKF Introduction Int-11
Contents
Main Hydraulic Pump 7-12
Hydraulic Pump Identification – SKF98 7-12
Hydraulic Piston Pumps Removal and Replacement 7-13
Hydraulic Piston Pumps Operation, Specifications, Adjustment and Repairs 7-13
Right Track, Left Track / Rotation Pumps 7-14
Main Pumps 7-14
AA4VG 125 Hydraulic Pump EP2 Control 7-14
AA4VG EP Controller 7-16
Technical Data 7-17
EP (24VDC) Control 7-19
Technical data 7-20
Port Locations 7-22
Main Pump Adjustments 7-23
Change Pressure, High Pressure, P O R and Zero Position Settings 7-24
Set Charge Pressure – 450psi (31bar) 7-25
Set Crossover Relief (High Pressure) – 5000psi (380bar) 7-25
Set Pressure Override (P O R) – 5000psi (345bar) 7-26
Mechanical Zero Position 7-27
Hydraulic Centering 7-28
Removal and Inspection Charge Pump 7-29
Removal and Installation of Shaft Seal 7-30
Routine Maintenance 7-31
Maintenance 7-32
Hydraulic Piston Pumps – Maintenance 7-34
Hydraulic Piston Pumps – Troubleshooting 7-36
Charge Circuit 7-40
Routine Maintenance 7-42
Changing Filter Elements 7-42
Loop Filters 7-43
Loop Filters 7-43
Routine Maintenance 7-46
Changing Filter Elements 7-46
Diverter Valve 7-47
Operation 7-47
Diverter Valve 7-47
Tram Circuit 7-48
Rotation Circuit 7-49
Rotary Drive Gearbox Motor 7-50
Rotation Motor 7-54
Cooler Fan Circuit 7-64
Setting Cooler Fan Speed 7-64
Auxiliary Circuit 7-66
Feed and Auxiliary Pump Circuit 7-66
Hydraulic Piston Pumps – Removal and Replacement 7-68
Feed and Auxiliary Functions Pump 7-71
Repair Instructions 7-72
BI620414
Int-12 SKF Introduction
Contents
Pump Replacement – Start Up 7-73
Pilot Control Manifold 7-75
Control Valve Assembly 7-77
Torque Control 7-83
Parts List 7-84
Jack Control and Mast Elevating Circuit 7-87
Counterbalance Valve Adjustment 7-90
Counterbalance Valve Test Procedure 7-92
Auxiliary Functions Circuit 7-95
Repair Kits 7-97
Exploded View of 4WE6 7-98
Setting of HOBO Sequence Valves 7-100
Hydraulic Feed Circuit 7-101
MP22 Valve – Hoist and Pulldown Control 7-103
Feed Valve Assembly 7-106
Technical Data 7-108
Hydraulic Systems 7-109
Hydraulic Cylinder Repair 7-110
General Information 7-111
H Head 7-113
N Head 7-114
Z Head 7-115
K Head 7-117
M Head 7-118
Z Piston 7-119
H and K Piston 7-120
M piston 7-121
N Piston 7-124
Notes 7-125
Section 8 – Electrical Components 8-1
Section 8 Contents 8-3
Electrical Locator 8-5
Jump Starting 8-7
Batteries 8-9
Welding Precautions 8-10
Vigilante Guide 8-11
Important Information 8-11
PLC 8-12
EEPROM 8-13
Output Card 8-14
Touchscreen 8-15
Laser Depth System 8-16
Safety Instructions and Precautions 8-17
Pipe in Hole Detection 8-18
Distance Meter 8-18
BI620414
SKF Introduction Int-13
Contents
Start Up and Shut Down 8-19
Hydraulic Function Enable 8-19
Alarms 8-19
Solenoid Control 8-20
Auto Lube 8-23
Gauges 8-24
Pressure Transducer 8-24
Level Transducer 8-24
Temperature Transducer 8-25
Water Flow Transducer 8-27
Inclinometers 8-28
Level Switches 8-29
Dust Suppression 8-29
Turkey Spray (optional) 8-29
CAED Electrical Guide 8-30
Vigilante System Component Information 8-50
Inclinometer 8-51
Ladder Prox Switch 8-53
LDM 40 A Laser 8-54
Safety Instructions 8-55
Performance Data 8-56
Working Principle 8-57
Set Up 8-57
Interface Cable Wire Assignment 8-58
Limiting Values for Voltages 8-59
Starting Up 8-59
Parameters 8-60
Functions 8-63
Service, Maintenance, Warranty 8-65
Level Switches – Capacitive Level Switch (Hydraulic Oil Level) 8-66
Radiator Level Switch 8-70
Level Transducers – Electronic Level Sensor 8-74
Pressure Transducers – Combined Pressure Sensor 8-84
Temperature Transducer – Control Monitor for Temperature Sensors 8-93
Temperature Sensor 8-105
Rod Counter and Distance Meter Prox Switch 8-106
Inductive Proximity Switch with Setting Aid 8-106
Notes 8-107
Section 9 – Lubrication and Preventive Maintenance 9-1
Section 9 Contents 9-3
Central Lube System 9-5
Description 9-5
Auto Lube 9-5
Circuit Drawing 9-6
Pneumatically Controlled Central Lube Tank Assembly 9-7
BI620414
Int-14 SKF Introduction
Contents
Owners Manual 9-8
Owners/Operator Manual 9-13
SL-1 injector Assembly 9-17
SL-1 Injector Specification 9-17
SL-1 Injectors 9-18
Pipe Thread Lubricator 9-19
Air Service Unit 9-19
Filter Regulator 9-20
Air Line Lubricator 9-21
Pipe Thread Pump 9-22
Filter Locator 9-30
Filter Location Assembly 9-31
Lubrication General 9-32
Equipment Lubrication 9-32
Care of Lubrication Points 9-32
Lubrication and Preventive Maintenance 9-33
Safety 9-33
Isolation – Battery Switch 9-34
Track Check and Lubrication 9-35
Engine Maintenance 9-36
Air Cleaners 9-37
Air Filter Elements 9-37
Alternator Maintenance 9-37
Compressor Checks and Servicing 9-38
Air Conditioner Checks and Servicing 9-39
Drive Shaft Checks and Maintenance 9-39
Cooler Checks and Servicing 9-40
Hydraulic Checks and Servicing 9-41
A-Frame and Mast Pivot Point checks and Maintenance 9-42
Rotary Head Check and Service Points 9-43
Pulldown / Hoist Sheaves and Ropes Checks and Servicing 9-44
Cabin Checks and Service Points 9-45
Fire Suppression (Optional) Checks and Servicing 9-45
Battery Checks and Servicing 9-46
Bean Pump Checks and Maintenance 9-46
Lubrication System Checks and Servicing 9-47
250hr Lubrication and Maintenance 9-48
500hr Lubrication and Maintenance 9-64
1000hr Lubrication and Maintenance 9-80
2000hr Lubrication and Maintenance 9-96
Notes 9-114

CAT ROTARY TRACK DRILL MD6290 SKF-98 TEREX INFINITY BLASTHOLE DRILL SERVICE MANUAL – PDF DOWNLOAD:

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