Cat MD6420 Rotary Blasthole Drill Service Manual SN 2E67F21 – PDF DOWNLOAD
CAT MD6420 ROTARY BLASTHOLE DRILL SERVICE MANUAL SN 2E67F21 – PDF DOWNLOAD:
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Cat MD6420 Rotary Blasthole Drill Service Manual SN 2E67F21 – PDF DOWNLOADCat MD6420 Rotary Blasthole Drill Service Manual SN 2E67F21 – PDF DOWNLOAD
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Cat MD6420 Rotary Blasthole Drill Service Manual SN 2E67F21 – PDF DOWNLOAD
Caterpillar Serial Number: 2E67F21
PARTS ORDERING AND PRODUCT SUPPORT :
Use only genuine Bucyrus parts in the maintenance, rebuild or repair of these machines. The manufacturer shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also not obligated or liable for a machines or parts that have been improperly handled; that have not been operated, maintained or repaired according to furnished manuals or other written instructions, and that have been operated with other than genuine Bucyrus parts or authorized OEM components.
IDENTIFICATION OF THE MACHINE
Always furnish the Model Number and Serial Number when ordering parts. This information is found on the machine nameplate. PART NUMBER AND DESCRIPTION
In addition to the Model and Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensioned sketch or return the part to be replaced, transportation charges prepaid. SHIPMENT
Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our accounting department.
Safety Information :
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 MD6420 Rotary Blasthole Drill Service Manual SN 2E67F21 – PDF DOWNLOAD
MD6420 F21 SERVICE MANUAL.......................................................................... 1
Parts Ordering and Product Support............................................................. 3
Safety Information............................................................................. 4
Contents....................................................................................... 5
General Locator................................................................................ 27
General Locator............................................................................ 27
Notes.......................................................................................... 30
MD6420 F21 SECTION ONE............................................................................. 31
Section 1 - Safety............................................................................. 31
Section 1 Contents......................................................................... 33
Safety..................................................................................... 35
Overview of Potential Hazards.......................................................... 35
Personal Protective Equipment.......................................................... 35
Noise.................................................................................. 35
Electrical Contact..................................................................... 35
Overhead and Buried Utilities.......................................................... 35
Clearances from Overhead High Voltage Lines............................................ 36
Contact with Electric Wires............................................................ 36
Contaminated Air ...................................................................... 36
Moving and Rotating Parts ............................................................. 37
High Pressure Air or Fluid............................................................. 37
Before Operation....................................................................... 37
During Operation....................................................................... 38
Maintenance............................................................................ 40
Equipment Transfer..................................................................... 40
Safety Locator......................................................................... 41
Notes...................................................................................... 44
MD6420 F21 SECTION TWO............................................................................. 45
Section 2 - Operators Cab / Controls........................................................... 45
Section 2 Contents......................................................................... 47
Graphic Symbol Legend...................................................................... 51
Graphic Symbol Legend.................................................................. 51
Warning Decals............................................................................. 55
Warning Decals......................................................................... 55
Operating System Help Table Icons.......................................................... 57
Operator Control and Instrument Panels..................................................... 62
Control Panels......................................................................... 62
Right Hand Control Panel............................................................... 62
Instrument Panel....................................................................... 64
Circuit Breakers....................................................................... 65
Light Switches......................................................................... 65
Right Hand Upper Console............................................................... 66
Bucyrus Operating System (BOS)............................................................. 67
Drill Monitor.......................................................................... 67
Operation Controls..................................................................... 68
Function and Number Keys............................................................... 69
LED states / Operating states.......................................................... 69
Touch Screen Operation and Care........................................................ 70
Touch Screen Operation................................................................. 70
Cleaning The Housing................................................................... 70
Cleaning The Touch Screen.............................................................. 70
Login Screen........................................................................... 71
Dashboard.............................................................................. 71
Login Screen........................................................................... 71
Login Screen Updates................................................................... 72
Login.................................................................................. 73
Bit Settings........................................................................... 74
Hour Meters............................................................................ 75
Time Management ....................................................................... 75
Drill Screen........................................................................... 76
Drill Screen Updates................................................................... 77
Drilling Pressures and Rotation Speed.................................................. 78
Pressure And Rotation Section.......................................................... 78
Depth System........................................................................... 79
Drill Status and Override Updates...................................................... 80
Drill Status and Override.............................................................. 80
Overriding Interlocks.................................................................. 82
Override Function...................................................................... 82
Auto Drill and Water................................................................... 83
Interlocks............................................................................. 84
Auto Drill............................................................................. 84
Pipe in Hole........................................................................... 84
Drill Functions........................................................................ 84
Interlocks............................................................................. 85
Auto Level ............................................................................ 85
Interlocks............................................................................. 86
Tram................................................................................... 86
Tram Screen............................................................................ 87
Tram screen- Mast angle Indication Updates............................................. 88
Tram screen- Distance Display Updates.................................................. 89
Artificial Horizon Gauges.............................................................. 90
Level Screen........................................................................... 91
Engine Screen.......................................................................... 92
Engine Screen Display.................................................................. 92
Engine Screen Updates.................................................................. 93
Engine Diagnostics Screen- added features ............................................. 93
Event Screen........................................................................... 94
Status Screen.......................................................................... 95
Status Sub Screens - Gauges............................................................ 96
Status Sub-Screens - Network........................................................... 97
Status Sub Screens - Input............................................................. 98
Status Sub-Screen - Cab Input.......................................................... 99
Status Sub-Screen - Cab Input Updates..................................................100
Status Sub Screen - Mast Input.........................................................101
Status Sub-Screen Output...............................................................102
The Help Screen........................................................................103
The Configuration Screen...............................................................104
Drill Screen Other Updates.............................................................104
Operator Control and Instrument Panels.....................................................105
Left Hand Control Panels...............................................................105
Thread Grease Switch...................................................................109
Machine Stability..........................................................................110
Tramming Procedure.....................................................................110
Requirements for Propelling the Machine................................................110
Track Adjustments......................................................................110
New Machine Procedure .................................................................111
General Maintenance Checks While Tramming..............................................111
Roller Locations.......................................................................112
Temperature and Condition Record Chart for Walking.....................................113
Propelling the Machine.................................................................114
Propelling Through Turns:..............................................................115
Propelling Up, Down and Across Grades:.................................................115
Stability Limits.......................................................................116
SKSS-16 Transient Stability Limits.....................................................117
Cab Heater.................................................................................118
Cab Heater Fault Isolation.............................................................118
Air Conditioner............................................................................119
T8 Series Split System Air Conditioning................................................119
Section 1.0 Techincal Data and Control Settings........................................120
1.1 Refrigeration System Settings......................................................120
1.2.1 Electrical Demand (Amps).........................................................120
1.2.3 Thermostat.......................................................................120
1.3 Performance Specifications.........................................................121
1.3.1 Cooling..........................................................................121
1.3.2 Heating (using hot water) (Tfc8bx1)..............................................121
1.3.3 Heating (using electrical elements) (Tfc8bx2)....................................121
1.3.4 Pressuriser......................................................................121
1.4 Unit Mass (Kg).....................................................................121
Section 2.0 Installation and Commissioning.............................................122
2.1 Unit Installation..................................................................122
2.2 Compressor Installation............................................................122
2.2.1 Open Type Compressor (TFC8BX1)...................................................122
2.3 Nitrogen Leak Testing – General Instructions.......................................123
2.4 System Evacuation..................................................................123
2.5 System Charging....................................................................124
Section 3.0 Routine Maintenance Procedures.............................................126
3.1 Replenishing Refrigerant...........................................................126
Section 4.0 Fault Diagnosis............................................................127
4.1 Fault Analysis Charts..............................................................127
4.1 Fault Analysis Charts (cont.)......................................................131
4.2 Fault Analysis Chart Notes.........................................................133
4.2.1 Clogged Strainer Or Filter.......................................................133
4.3 Fault Diagnosis For Electronic Thermostat.........................................134
4.3.3 Fault Finding....................................................................135
Section 5.0 Reference Drawings.........................................................136
5.1 Evaporator Fan Assembly............................................................136
5.2 Electrical Schematic...............................................................137
5.3 Compressor.........................................................................140
5.4 Performance Curve..................................................................141
RESPA Service and Installation.........................................................142
RESPA Installation Guidelines..........................................................144
RESPA Maintenance......................................................................147
Notes......................................................................................152
MD6420 F21 SECTION THREE...........................................................................154
Section 3 - Main Frame Crawlers................................................................154
Section 3 Contents.........................................................................156
Main Frame Repair - General................................................................160
Main Frame Repair......................................................................160
Weld Inspection Schedule...................................................................161
Main Frame.............................................................................161
Levelling Jacks............................................................................162
Levelling Jack Cylinder................................................................162
Levelling Jacks........................................................................163
Limit Switch...........................................................................163
Levelling Jack Cylinders...............................................................163
Removal................................................................................163
Repair.................................................................................163
Replace................................................................................163
Lubricating Jack Casings...............................................................163
Mast Elevating Cylinders...................................................................164
Mast Elevating Cylinders...............................................................164
Remove.................................................................................165
Repair.................................................................................165
Replace................................................................................165
Bleeding Mast Raise Cylinders .........................................................165
Internal Counterbalance Valve..........................................................166
Fuelling Valves............................................................................167
Fuelling Valves........................................................................167
Non-pressurised Fuelling System Operation..............................................167
Crawler Assembly...........................................................................169
Crawler Assembly.......................................................................169
Parts List.............................................................................170
Crawler Component Repair...............................................................170
Tramming...................................................................................171
Maintenance checks For Tramming For Caterpillar Drills.................................171
Requirements For Propelling The Machine................................................171
Track Adjustments......................................................................171
New Machine Procedure .................................................................172
General Maintenance Checks While Tramming..............................................172
Roller Locations.......................................................................173
Temperature And Condition Record Chart For Walking.....................................174
Metric Bolt Torque Specifications..........................................................175
Track Tension Adjustment...................................................................176
Before Operating the Machine...........................................................176
Track Tension Adjustment...................................................................177
Track Assembly.........................................................................177
Idler Unit Description.................................................................178
Hydraulic Tensioner....................................................................179
Filling Instructions...................................................................181
Pressure Check.........................................................................182
Pressure Release.......................................................................182
Track Chain................................................................................183
Track Link – Description...............................................................184
Track Link – Repair And Replace........................................................184
Track Shoes Installation...................................................................186
Track Link Position....................................................................186
Track Shoe – Mounting To Track Chain...................................................186
Direct Torque Method...................................................................186
Torque Turn Method.....................................................................186
Track Shoes Installation...................................................................187
Track Shoe Bolt Torque (Direct Torque Method)..............................................188
Bolt Torque KN111......................................................................188
Track Chain and Shoe Installation..........................................................190
Track Chain With Shoes.................................................................190
Final Drive Unit...........................................................................192
General Description....................................................................192
Final Drive Unit...........................................................................193
Removal From Track Frame...............................................................193
Installation Into Track Frame..........................................................194
Final Drive Maintenance................................................................195
Final Drive Oil........................................................................196
F130 Final Drive Assembly..............................................................197
Parts List.............................................................................198
Service Information....................................................................200
Tightening Torques.....................................................................201
Lubrication / Greasing – Grades And Application Range..................................201
Planetary Gears F130/206-A.............................................................202
Disassembly............................................................................202
Procedure For Disengagement Of Gearing.................................................202
Troubleshooting........................................................................203
Special Tools..........................................................................203
Idler Unit.................................................................................204
Idler Unit – Assembly..................................................................204
Idler Unit – Removal...................................................................207
Track and Support Rollers..................................................................208
Track Roller Assembly..................................................................208
General Description....................................................................208
Track Roller – Removal And Disassembly.................................................209
Support Roller – Removal And Disassembly...............................................209
Track And Support Roller – Assembly....................................................210
Track And Support Roller – Test And Install............................................211
Track and Sprocket Inspection..............................................................213
Track Inspection And Wear Limit Guide..................................................213
B8 Track Inspection And Wear Limit Guide Caterpillar Series Drills.....................213
Undercarriage Information..............................................................213
Sprocket Wear Patterns.................................................................217
Causes:................................................................................217
Effects:...............................................................................217
Remedies:..............................................................................217
Wear On Reverse Drive Side.............................................................218
Causes:................................................................................218
Effects:...............................................................................218
Remedies:..............................................................................218
Root Wear..............................................................................219
Causes:................................................................................219
Effects:...............................................................................219
Remedies:..............................................................................219
Wear Of Tooth Tip......................................................................220
Causes:................................................................................220
Effects:...............................................................................220
Remedies:..............................................................................220
Tooth Tip Broken Off...................................................................221
Causes:................................................................................221
Effects:...............................................................................221
Remedies:..............................................................................221
Facial Wear............................................................................222
Causes:................................................................................222
Effects:...............................................................................222
Remedies:..............................................................................222
Auxiliary Crane............................................................................223
Hydraulic Crane........................................................................223
Load Lift Capacities...................................................................223
Maintenance............................................................................224
Checking Of Worm Gear..................................................................224
Notes......................................................................................225
MD6420 F21 SECTION FOUR............................................................................226
Section 4 - Engine / Drive Train Compressor....................................................226
Section 4 Contents.........................................................................228
Power Group Locator........................................................................231
Cummins Engine.............................................................................232
Engine Fuel System.....................................................................233
QST30 Electric Fuel Supply Flow Diagram................................................233
Construction...........................................................................234
Electric Fuel Supply Pumps.............................................................234
Combo Fuel Filter Head And Pump Manifold...............................................235
FS1006 Fuel Filter With Water Separator................................................235
Fuel Manifold With Integrated FSO Valve................................................236
Fuel Connections.......................................................................236
Pre - Filters..........................................................................237
Wiring With EFS Power Relay............................................................237
Pressure And Temperature Sensors.......................................................238
Operation..............................................................................238
QST30 Electric Fuel Supply System Flow Diagram.........................................239
QST30 Electric Fuel Supply System Detail...............................................240
Oil Reserve Systems....................................................................241
Operation..............................................................................241
Engine Oil Reserve System (Basic Circuit)..............................................241
LED Monitor Readings...................................................................242
Signals................................................................................242
Adjustment Of Running Oil Level........................................................242
Wiring Diagram - Oil Reserve Basic Circuit.............................................243
Oil Pressure Switch....................................................................243
Oil Reserve System.....................................................................243
R200...................................................................................243
Troubleshooting........................................................................244
Maintenance............................................................................244
Engine And Compressor Air Cleaners.........................................................245
Engine And Compressor Air Cleaner Service .............................................246
Flexible Drive Coupling....................................................................249
Flexible Drive Coupling Service........................................................249
Pump Drive.................................................................................252
Pump Identification....................................................................252
Pump Drive Assembly – Removal And Replacement..........................................253
Pump Drive Gearbox.....................................................................254
Pump Drive Gearbox – Repair............................................................255
3” Input Shaft Assembly................................................................257
Hydraulic Pumps............................................................................258
Hydraulic Pumps – Removal And Replacement..............................................258
Compressor Assembly........................................................................259
Drill Compressor Model 20/12 1475cfm @ 500psi..........................................259
Compressor Installation....................................................................260
Compressor Drive Coupling..............................................................261
Compressor Drive Coupling – Removal And Replacement....................................262
Compressor Installation....................................................................263
Compressor Unit – Removal:.............................................................263
Compressor Shaft Seal......................................................................265
Main Drive Shaft Seal Replacement......................................................265
Compressor Shaft Seal......................................................................266
Inspection and Preparation For Seal Assembly...........................................266
High Pressure Compressor...................................................................268
Safety.................................................................................268
Compressor Oil Circuit.....................................................................275
Compressor Oil Circuit - 1475cfm @ 500psi..............................................275
Compressor Condensation Table..............................................................278
Compressor Condensation Table..........................................................278
Compressor Air Circuit.....................................................................279
Compressor Air Circuits – 1475cfm @ 500psi.............................................279
Compressor Functional Description..........................................................280
Compressor Air Circuit.................................................................280
Compressor Gauge ......................................................................281
Compressor Control Valve...............................................................281
Compressor Run Valve...................................................................282
Compressor Run.........................................................................282
Compressor Control Pressure Reducing Regulator ........................................283
Compressor Air Circuit.................................................................284
Compressor Operation.......................................................................285
Operation..............................................................................285
Compressor Operation.......................................................................286
Purpose Of Controls....................................................................286
Compressor Maintenance.....................................................................288
General Maintenance....................................................................288
Interstage Tube........................................................................290
Flexible Pipe Coupling Maintenance.....................................................290
Discharge Check Valve..................................................................291
Separator / Receiver Tank..............................................................292
Scavenge Line..........................................................................294
Compressor Discharge Temperature Switches, Senders And Gauges..........................295
Minimum Pressure / Check Valve.........................................................296
Minimum Pressure / Check Valve Maintenance.............................................296
Thermal / Bypass Valve.................................................................297
Compressor Fluid Filter................................................................299
Fluid Stop Valve.......................................................................301
Inlet Valve............................................................................303
Reducing Regulator.....................................................................306
System Blowdown Valve..................................................................308
Running Blowdown Valve.................................................................309
Running Blowdown Maintenance...........................................................310
Moisture Separator Maintenance.........................................................311
Auxiliary Regulator....................................................................312
Auxiliary Regulator Maintenance........................................................314
Coolers Locator........................................................................318
Compressor Oil Cooler..................................................................319
Compressor / Hydraulic Oil Cooler Service Manual...........................................320
Notes......................................................................................329
MD6420 F21 SECTION FIVE............................................................................330
Section 5 - Dust Control System................................................................330
Section 5 Contents.........................................................................332
Dust Control System........................................................................334
Dust Control Systems...................................................................334
Water Injection............................................................................335
Water Tanks............................................................................335
Water Injection........................................................................336
Water Injection Relief Valve...........................................................336
Water Injection Basic Circuit..........................................................338
Pump Specifications....................................................................339
Servicing Instructions.................................................................339
General Care Of The Pump...............................................................339
Care In Freezing Weather...............................................................339
Parts List.............................................................................340
Replacing Piston Cup Seals.............................................................341
Replacing Suction And Discharge Valves.................................................342
Replacing Power End Bearings...........................................................343
Servicing The Wrist Pin Bearings.......................................................344
Fastener Torque Requirements...........................................................344
Recommended Lubricants.................................................................345
Water Pump Motor Repair................................................................345
Water Injection Hydraulic Control Valve Repair.........................................345
Water Pump Drive Coupling..............................................................345
Level And Flow Transducer..............................................................345
High Pressure Cleaner......................................................................346
High Pressure Washdown (Motor And Pump)................................................346
Foam System................................................................................351
Foam Pump..............................................................................351
Notes......................................................................................354
MD6420 F21 SECTION SIX.............................................................................356
Section 6 - Mast / Rotary Drive / Pipe Rack....................................................356
Section 6 Contents.........................................................................358
Mast Weldment..............................................................................360
Mast Repair............................................................................360
Weld Inspection Schedule...................................................................361
Mast Inspection........................................................................361
Mast Assembly and Installation.............................................................362
Mast Assembly 16m......................................................................362
Mast...................................................................................362
Mast Pivot.............................................................................363
Mast Set Up For Bolt Tightening Of Pivot Caps..........................................364
Mast Pivot CAP Bolts...................................................................365
Bolt Tightening Sequence...............................................................365
Mast A-frame and Pivot Shaft...........................................................366
Mast A-frame Pivot Shaft Cap Bolts.....................................................367
Bolt Tightening Sequence...............................................................367
Mast Elevate Cylinders.................................................................368
Angle Drilling.........................................................................368
Mast Locking...........................................................................368
Mast / Drill Without Mast..............................................................369
Mast Assembly..........................................................................370
Raising the Mast.......................................................................370
Cylinder, Hoist / Pulldown.................................................................372
Cylinder, Hoist / Pulldown.............................................................372
Removal................................................................................374
Hoist Pulldown Cylinder Assembly.......................................................375
Repair.................................................................................376
Installation...........................................................................376
Hoist / Pulldown Cable Adjustment With Auto Tension........................................377
Hoist / Pulldown Cables................................................................377
Cable Tensioner Circuit ..............................................................378
Manual Hoist / Pulldown Cable Adjustment ..................................................380
Adjustment.............................................................................380
Replacement............................................................................382
Hoist / Pulldown Cable Adjustment With Auto Tension........................................383
Wire Cable.............................................................................383
Sheave Rollers.........................................................................383
Rotary Drive...............................................................................384
Rotary Head Assembly...................................................................384
Rotary Head Guide Alignment............................................................385
Rotary Head Drive System...............................................................386
Rotary Drive...........................................................................387
Removal From Mast......................................................................387
Installation...........................................................................387
Rotary Drive Gearbox...................................................................389
Repair.................................................................................389
Main Shaft Bearing Preload.............................................................389
Rotary Head Bull Shaft Bearing Nut.....................................................390
Manufacturers Recommendations – Blast Hole Drilling Consumables .......................391
Top Sub Serviceable....................................................................391
Lifting Bails..........................................................................391
Air Swivel (Single Seal Style).........................................................392
Service................................................................................392
Winch Assembly.............................................................................393
Precautions On The Use Of Winches......................................................393
Wire Cable.............................................................................393
Wedge Sockets..........................................................................395
Grooved Drums..........................................................................396
Plain (Smooth) Drums...................................................................396
Drums - Multiple Layers................................................................397
Deck Wrench................................................................................398
Winch Assembly Service.................................................................398
Deck Wrench............................................................................399
H.O.B.O Wrench.............................................................................401
H.O.B.O Wrench.........................................................................401
Breakout System – H.O.B.O..............................................................402
Hydraulic Operated Bit Basket – H.O.B.B (Optional).....................................402
Pipe Safety Arm........................................................................402
Pipe Positioner............................................................................403
Pipe Positioner........................................................................403
Carousel Pipe Rack.........................................................................404
Major Components.......................................................................404
Rod Handling – Carousal Indexing.......................................................405
Pipe Rack Assembly.....................................................................406
Carousel Pipe Rack.........................................................................407
General Information....................................................................407
Pipe Rack Bearings – Removal...........................................................407
Pipe Rack Components – Inspection......................................................409
Pipe Rack – Assembly And Installation..................................................410
Pipe Rack Roller – Remove And Replace..................................................411
Pipe Rack Roller – Disassembly And Assembly............................................412
Bit Sub Length Adjustment..................................................................414
Bit Sub Length Adjustment..............................................................414
Notes......................................................................................415
MD6420 F21 SECTION SEVEN...........................................................................416
Section 7 - Hydraulic Systems..................................................................416
Section 7 Contents.........................................................................418
Hydraulic Symbols..........................................................................421
Pressure Setting Sequence..................................................................423
Pressure Setting Sequence..............................................................423
Hydraulic Tank.............................................................................424
Hydraulic Tank.........................................................................424
Return Hydraulic Filters...............................................................425
Main Return and Case Drain Filter..........................................................426
Routine Maintenance....................................................................427
Main Hydraulic Pumps.......................................................................428
Pump Identification....................................................................428
Right Track, Left Track / Rotation Pumps...................................................429
Hydraulic Piston Pumps – Removal And Replacement.......................................429
Main Pumps.............................................................................430
AA4VG EP Controller....................................................................432
Technical Data.........................................................................433
EP (24V DC) Control....................................................................435
Schematic Drawing – Standard Model.....................................................435
Pressure Cut-Off.......................................................................435
Brake, Drill / Tram And Rope Tensioner Solenoid Valve......................................436
Brake, Drill /tram And Rope Tensioner Solenoid Valve...................................436
Right Track, Left Track / Rotation Pumps...................................................437
Port Locations.........................................................................438
Main Pump Adjustments..................................................................439
Charge Pressure, High Pressure, P.O.R. And Zero Position Settings......................440
Mechanical Zero Position...............................................................443
Hydraulic Centering....................................................................444
Removal And Inspection Of Charge Pump..................................................445
Removal And Installation Of Shaft Seal.................................................446
Routine Maintenance....................................................................447
Maintenance............................................................................448
Charge Filter..............................................................................450
Routine Maintenance....................................................................450
Charge Filter..............................................................................451
Changing Filter Elements...............................................................451
Main Pumps Circuit.........................................................................452
Main Pumps Circuit.....................................................................452
Rotation / Tram Motor Circuit..........................................................453
Loop Filters...............................................................................454
Routine Maintenance....................................................................454
Changing Filter Elements...............................................................457
Rotation Circuit...........................................................................458
Rotation Circuit.......................................................................459
Rotary Drive Gear Box Motor................................................................460
Rotary Drive Gearbox Motor – Test And Repair...........................................460
Shaft Seal Replacement.................................................................461
Trouble Shooting.......................................................................463
Tram Circuit...............................................................................465
Tram Circuit...........................................................................465
Feed and Auxillary Pump Circuit............................................................467
Hydraulic Piston Pumps – Removal And Replacement.......................................467
Feed and Auxillary Pump Circuit............................................................469
Non Load Sense Auxiliary Circuit.......................................................469
Repair Instructions....................................................................473
Hydraulic Systems..........................................................................476
Auxiliary And Feed Circuits............................................................476
Main Control Valves........................................................................477
Valve Stand Assembly...................................................................477
PWM Proportional Pilot Valves..............................................................478
PWM Proportional Pilot Valves..........................................................478
Mast, Jacks, Winch And Water Valve.........................................................479
Hoist And Pulldown Control.................................................................480
Hoist / Pulldown Valve.................................................................484
Pulldown Chart.........................................................................487
Mast Jacks Winch And Water Injection Circuit...............................................488
K170...................................................................................488
Proportional Pressure Reducing Valve...................................................489
Jack Control and Mast Elevating Circuit....................................................492
Mast Jacks Winch And Water Injection Circuit...............................................493
Jacks & Mast / Water & Winch / Hoist & Pulldown Valves.....................................494
Jacks & Mast / Water & Foam Injection / Hoist & Pulldown Valves............................495
Winch Section..........................................................................495
Proportional Pressure Reducing Valve...................................................497
Levelling Jack Cylinders...................................................................498
Counterbalance Valves......................................................................499
Mast Elevating Cylinders...................................................................501
Auxiliary Functions Circuit................................................................503
4WE6 - Auxiliary Functions and Mast Valves.................................................505
Hydraulic Operated Breakout Wrench.........................................................509
Hydraulic Operated Breakout Wrench.....................................................509
Setting of HOBO Sequence Valves........................................................510
H.O.B.O Float Valve....................................................................510
Pipe Positioner........................................................................511
Setting of Pipe Positioner Sequence Valves.............................................511
Hydraulic Systems..........................................................................512
Pipe Safety Arm........................................................................512
Setting of Pipe Safety Arm Sequence Valves.............................................512
Hydraulic Systems..........................................................................513
Hydraulic Gear Pumps – Removal and Replacement.........................................513
Hydraulic Gear Pumps – Repairs, Operation, Specifications and Adjustment...............513
Tool List..............................................................................515
Cooler Fan Circuit.........................................................................516
Fan Motor Circuit......................................................................516
Cooler Fan Motor...........................................................................520
Hydraulic Motor........................................................................520
General Information....................................................................520
Specifications and Tools...............................................................521
Hydraulic Thermostatic Valve...............................................................524
Hydraulic Cooler – Thermal Valve.......................................................524
Central Lube...............................................................................525
Auto Lube..............................................................................525
Air Conditioner Drive Circuit..............................................................526
Air Conditioner Compressor Drive Circuit...............................................526
Air Conditioner Driver Motor...............................................................527
Design.................................................................................527
Operational Check......................................................................527
Shaft Seal Replacement.................................................................528
Gear Backlash..........................................................................528
Parts List.............................................................................529
Water Pump Motor...........................................................................530
Water Pump Motor Repair Information....................................................530
Shaft Seal Repair......................................................................531
Water Pump Motor...........................................................................533
Hydraulic Cylinder Repair..................................................................534
Hydraulic Cylinders....................................................................534
General Information....................................................................535
H Head.................................................................................537
N Head.................................................................................538
Z Head.................................................................................539
N Head.................................................................................540
K Head.................................................................................541
M Head.................................................................................542
Z Piston...............................................................................543
Z Piston (Threaded)....................................................................544
H and K Piston.........................................................................545
M Piston...............................................................................546
N Piston...............................................................................549
Notes......................................................................................550
MD6420 F21 SECTION EIGHT...........................................................................551
Section 8 - Electrical Components..............................................................551
Section 8 Contents.........................................................................553
Contents...................................................................................553
Jump Starting..............................................................................557
Jump Starting..........................................................................557
Precautions............................................................................558
Procedure..............................................................................558
Batteries..................................................................................559
Batteries..............................................................................559
Welding Precautions........................................................................560
Welding Precautions....................................................................560
General Arrangement Layout.................................................................561
General Arrangement Layout.............................................................561
Transducer Box Detail......................................................................562
Transducer Box Detail..................................................................562
Flow Monitor...............................................................................563
Functions And Features.................................................................563
Application Area.......................................................................563
Operating Principle....................................................................563
Flow Monitor...............................................................................564
Mounting...............................................................................564
Mounting Operation.....................................................................564
Electrical Connection..................................................................564
Set-Up And Settings For Water..........................................................565
High Flow Adjustment (Optional)........................................................566
Error During Adjustment................................................................566
Lock / Unlock The Unit.................................................................566
Operation And Maintenance..............................................................567
Flow Monitor...............................................................................568
Technical Data.........................................................................568
Liquids................................................................................568
EMC....................................................................................568
Limit Switch...............................................................................569
Limit Switch...........................................................................569
Level Sensor...............................................................................570
Introducing Level Sensor...............................................................570
DX10 Ultrasonic Level Frequency Transmitter............................................570
Features...............................................................................570
Compressor Temperature Switches - Shut Down................................................572
Compressor Temperature Switches........................................................572
Air Indicators Engine and Compressor - Alarm...............................................573
Air Filter Indicator Switches..........................................................573
How Does It Work? .....................................................................573
Air Indicators Engine and Compressor - Shutdown............................................574
Air Filter Indicator Switches..........................................................574
How Does It Work? .....................................................................574
Differential Pressure Switches.............................................................575
Hydraulic Filter Indicator Switches....................................................575
Compressor Temperature Transducer..........................................................577
Compressor Temperature Transducer......................................................577
Measured Signal Converter For Temperature Sensors..........................................578
Operating Instructions ................................................................578
40 Bar Electronic Pressure Transducer .....................................................580
Description............................................................................580
250 Bar Electronic Pressure Transducer ....................................................581
Description............................................................................581
600 Bar Electronic Pressure Transducer ....................................................583
Description............................................................................583
Drill Dash Board ..........................................................................584
Drill Monitor..........................................................................584
Operating Controls ....................................................................584
Brightness Control.....................................................................584
Function And Number Keys...............................................................585
LED Status.............................................................................585
Touch Screen...........................................................................586
Touch Screen Operation.................................................................586
Cleaning The Touch Screen..............................................................586
User Data Base.........................................................................587
Edit The Dashboard User Data Base......................................................587
Functional Description Of Operation....................................................588
Interlocks.............................................................................589
Pipe In Hole...........................................................................589
Tram Protection .......................................................................589
Mast And Jack Lowering Protection......................................................590
Solenoid Control.......................................................................591
Tram...................................................................................591
Carousel...............................................................................591
Drill..................................................................................591
Auto Drill.............................................................................592
Auto Level.............................................................................593
Login Screen...........................................................................594
Dashboard..............................................................................594
Login Screen...........................................................................594
Login..................................................................................595
Drill Bit Settings.....................................................................596
Bit Settings...........................................................................596
Hour Meters............................................................................597
Time Management........................................................................597
Drill Screen...........................................................................598
Pressure And Rotation Panel............................................................599
Depth System...........................................................................600
Drill Status...........................................................................601
Drill Status and Override..............................................................601
Tram Screen............................................................................602
Tram...................................................................................603
Artificial Horizon Gauges..............................................................604
Level Screen...........................................................................605
Engine Screen..........................................................................606
Event Screen...........................................................................607
File Export............................................................................608
Operator Acknowledgment................................................................608
File Export............................................................................608
Status Screen..........................................................................609
Sub Screen - Gauges....................................................................610
Sub Screen - Network...................................................................611
Sub Screen - Input.....................................................................612
Sub Screen – Cab Input.................................................................613
Sub Screen – Mast Input................................................................614
Sub Screen - Output....................................................................615
Virtual Representation Of Control Outputs..............................................615
Help Screen............................................................................616
Configuration Screen...................................................................617
Configuration..........................................................................618
Lubrication Setting....................................................................618
Sensor Calibration.....................................................................618
Depth System Settings..................................................................620
Auto Drill Settings....................................................................620
Overrides..............................................................................621
Table..................................................................................622
Mechanical Training - Can Bus..............................................................623
Can Bus................................................................................623
Trouble Shooting.......................................................................624
Can Bus Node..............................................................................627
Setting Node ID And Baud Rate..........................................................627
Can Bus Node...............................................................................628
How To Reset ICN - Controller..........................................................628
Electrical Mast Removal (Can - Bus)........................................................629
Electrical Mast Removal (Can - Bus)....................................................629
Event Screen...............................................................................630
File Export............................................................................630
Operator Acknowledgment................................................................630
File Export............................................................................630
Procedure To Back - Up Log Files...........................................................631
Procedure To Backup Log Files Of The Monitor...........................................631
Interlock Function Check List..............................................................634
Interlock Function Check List..........................................................634
Procedure To Add New User To Existing Dashboards...........................................636
Procedure To Add New User To Existing Dashboards.......................................636
Procedure To Backup User Database..........................................................639
Procedure To Backup User Database From Old Monitor For Installation Of New Monitor.....639
Using A Bootloader (Small).................................................................642
Using A Bootloader (Small).............................................................642
Mast Angle Encoder.........................................................................648
Mast Angle Encoder.....................................................................648
Mast Angle Encoder Replacement.............................................................654
Mast Angle Encoder Replacement.........................................................654
Installing / Replacing CF Card In Dlog Monitor.............................................656
Installing PCI CAN Card In DLOG Monitor................................................656
Notes......................................................................................659
MD6420 F21 SECTION NINE............................................................................660
Section 9 - Lubrication & Preventative Medicine................................................660
Section 9 Contents.........................................................................662
Central Lube System........................................................................666
Hydraulic Control Schematic............................................................667
Central Lube System Circuit............................................................668
Central lube Tank Assembly.............................................................669
Technical Data.........................................................................670
Symbols................................................................................671
Installation...........................................................................674
Typical Installation...................................................................675
Vent Valve Installation Kit............................................................676
Control Module Installation Kit........................................................676
Operation..............................................................................677
Central Lube Pump......................................................................679
Technical Data ........................................................................680
Symbols................................................................................681
Operation..............................................................................684
Trouble Shooting.......................................................................686
Service................................................................................687
Reciprocator Repair....................................................................689
Displacement Pump Repair...............................................................693
Reciprocator Parts.....................................................................696
Instructions – Vent Valve..............................................................697
Basic Operating Principles Of Auto Lube Injectors......................................698
SL-V and SL-V XL Injectors ............................................................698
Stage 4................................................................................698
SL-1 and SL-11 Injectors...............................................................699
SL-32 Injectors........................................................................700
Typical Grease System Circuit .........................................................701
First 50 Hour Service..................................................................702
Lube Faults / Operation................................................................703
Lube Fault ............................................................................703
Auto Lube Timer........................................................................704
Lube Pressure Screen...................................................................704
Hammer Oil Tank............................................................................705
Hammer Oil Tank Assembly...............................................................705
Hammer Oil Tank System.................................................................706
Hammer Oil System......................................................................706
10:1 Hammer Oil Pump Instructions......................................................707
Symbols................................................................................707
Installation...........................................................................709
Operation..............................................................................712
Troubleshooting........................................................................713
Air Motor And Throat Service...........................................................714
Displacement Pump Service..............................................................718
Parts List.............................................................................719
Parts Drawing..........................................................................720
Dimensions.............................................................................721
Technical Data.........................................................................721
Performance Chart......................................................................722
Air Service Units..........................................................................723
Air Service Unit System...............................................................723
Air Service Unit Components............................................................723
Soft Start Dump Valve..................................................................724
Technical Data.........................................................................724
ISO Symbols............................................................................724
Filter Regulator.......................................................................725
Technical Data.........................................................................725
ISO Symbols............................................................................725
Air Line Oiler.........................................................................726
Technical Data.........................................................................726
ISO Symbols............................................................................726
Air Service Unit.......................................................................727
Pipe Thread Lubricator....................................................................728
Air Operated Pipe Thread Pump..........................................................728
Specifications.........................................................................728
Description............................................................................728
Owner / Operator Responsibility........................................................728
Safety Information.....................................................................728
Installation...........................................................................729
Typical System Hook Up.................................................................729
Pressure Relief Procedure..............................................................730
Operation..............................................................................730
Using Pump.............................................................................730
Maintenance............................................................................731
Lubrication ...........................................................................731
Material Restriction Prevention........................................................731
Corrosion Prevention...................................................................731
Disassembly............................................................................731
Assembly...............................................................................732
Repair.................................................................................733
Troubleshooting........................................................................734
Parts List.............................................................................734
To Lubricate Air Valve Mechanism.......................................................735
Filter Locator.............................................................................736
Filter Locator Assembly................................................................736
Lubrication And Preventive Maintenance.....................................................737
General Lubrication....................................................................737
Equipment Lubrication..................................................................737
Care Of Lubrication Points.............................................................737
Safety.................................................................................738
Isolation – Battery Switch.............................................................739
Track Gear.............................................................................740
Engine Maintenance.....................................................................741
Air Cleaners...........................................................................742
Air Filter Elements....................................................................742
Alternator Maintenance ................................................................742
250 hrs................................................................................742
Pump Drive And Drive Shaft Maintenance ................................................743
Compressor Maintenance.................................................................743
Cooler Packs...........................................................................745
A-frame And Pivot Point Maintenance....................................................747
Pulldown And Hoist Cables And Sheaves Maintenance.....................................747
Rotary Head Maintenance ...............................................................747
Hydraulic System Maintenance...........................................................749
Hydraulic Maintenance..................................................................749
Water Pump Maintenance ................................................................749
Cab Maintenance .......................................................................749
Air Conditioner Maintenance ...........................................................751
Battery Maintenance....................................................................751
Lubrication System Maintenance ........................................................751
Fire Suppression Maintenance ..........................................................751
Drill Folding Stairway – Inspection Requirements.......................................753
Weld Inspection Schedule...................................................................754
Track And Sprocket Inspection..............................................................755
Track Inspection And Wear Limit Guide..................................................755
B8 Track Inspection And Wear Limit Guide...............................................755
Undercarriage Information..............................................................755
Sprocket Wear Patterns.................................................................759
Wear On Forward Drive Side.............................................................759
Wear On Reverse Drive Side.............................................................760
Root Wear..............................................................................761
Wear Of Tooth Tip......................................................................762
Tooth Tip Broken Off...................................................................763
Facial Wear............................................................................764
Lubrication Recommendations................................................................765
Lubrication And Maintenance Chart..........................................................766
Lubrication And Maintenance Notations..................................................769
Lubricant Specifications...................................................................770
Hydraulic System.......................................................................770
Selection Of Hydraulic Oil.............................................................770
Hydraulic Tank Capacity................................................................770
Compressor Lubricant Specifications....................................................770
Lubricating Grease.....................................................................771
Gear Lubricant.........................................................................771
Scheduled Oil Sampling Analysis........................................................771
Preventive Maintenance – Weld Inspection...................................................772
Lubrication And Preventative Maintenance...............................................772
Preventative Maintenance – Bolted Joints...................................................773
Bolted Joint Maintenance For Rotary Drills.............................................773
Introduction...........................................................................773
Proper Bolt Tension....................................................................773
Critical Bolted Joint Maintenance......................................................774
Other Bolt Maintenance.................................................................774
SAE Recommended Torque Values..........................................................775
NORD - LOCK Washers....................................................................775
Critical Fastener ID And Inspection Schedule...........................................776
Critical Fastener Torque Values............................................................777
MD6420B................................................................................777
Mast Connection Points.....................................................................779
Mast Connection Points Dimension Reporting.............................................779
Notes......................................................................................782
PLEASE NOTE:
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