Cat MD6420 Rotary Blasthole Track Drill Service Manual SN 2U67X68 – PDF DOWNLOAD

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Cat MD6420 Rotary Blasthole Track Drill Service Manual SN 2U67X68 – PDF DOWNLOAD

CAT MD6420 ROTARY BLASTHOLE TRACK DRILL SERVICE MANUAL SN 2U67X68 – PDF DOWNLOAD:

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DESCRIPTION:

Cat MD6420 Rotary Blasthole Track Drill Service Manual SN 2U67X68 – PDF DOWNLOAD

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 Track Drill Service Manual SN 2U67X68 – PDF DOWNLOAD

Parts Ordering and Product Support Int-3
Safety Information Int-4
Contents Int-5
General Locator Int-18
General Locator Left View Int-18
General Locator Right View Int-19
General Locator (cont) Int-20
Section 1 – Safety 1-1
Contents 1-3
Safety 1-4
Overview of Potential Hazards 1-4
Noise 1-4
Personal Protective Equipment 1-4
Electrical Contact 1-5
Contaminated Air 1-6
Moving and Rotating Parts 1-7
High Pressure Air or Fluid 1-7
Before Operation 1-7
During Operation 1-8
Maintenance 1-10
Equipment Transfer 1-10
Safety Locator Front View1-11
Safety Locator Side Views 1-12
Safety Locator Top View 1-13
Safety Locator Panel Views 1-14
Notes 1-15
Section 2 – Operators Cab / Controls2-1
Contents 2-3
Graphic Symbol Legend 2-5
Graphic Symbol Legend 2-5
Warning Decals 2-8
Warning Decals 2-8
Operator Control and Instrument Panels 2-10
Operator Control Panel 2-10
Switch Panel 2-12
System Pressure Gauge Panel 2-14
Switches / Diagnostic / Control Panel Circuit 2-15
Cab Heater 2-16
Cab Heater Fault Isolation 2-16
Machine Stability 2-17
Tramming Procedure 2-17
Track Adjustments 2-17
New Machine Procedure 2-18
BI014188-01
2U67_X68 Introduction Int-6 September, 2013
Contents
General Maintenance Checks While Tramming 2-18
Roller Locations 2-19
Temperature and Condition Record Chart for Walking 2-20
Propelling the Machine 2-21
Stability Limits 2-23
MD6420 Transient Stability Limits 2-24
Air Conditioner 2-25
T8 Series Split System Air Conditioning 2-25
Section 10 Technical Data and Control Settings 2-26
Section 20 Installation and Commissioning 2-28
Section 30 Routine Maintenance Procedures 2-32
Section 40 Fault Diagnosis 2-33
Section 50 Reference Drawings 2-42
Section 3 – Main Frame Crawlers3-1
Contents 3-3
Main Frame Repair – General 3-6
Main Frame Repair 3-6
Weld Inspection Schedule 3-7
Main Frame 3-7
Levelling Jacks 3-8
Levelling Jack Cylinder 3-8
Levelling Jacks 3-9
Limit Switch 3-9
Levelling Jack Cylinders 3-9
Mast Elevating Cylinders 3-10
Mast Elevating Cylinders 3-10
Internal Counterbalance Valve3-11
Crawler Assembly 3-13
Crawler Assembly 3-13
Parts List 3-14
Crawler Component Repair 3-14
Tramming 3-15
Maintenance Checks for Tramming 3-15
Track Adjustments 3-15
New Machine Procedure 3-16
General Maintenance Checks While Tramming 3-16
Roller Locations 3-17
Temperature and Condition Record Chart for Walking 3-18
Metric Bolt Torque Specifications 3-19
Metric Bolt Torque Specifications 3-19
Track Tension Adjustment 3-20
Before Operating the Machine 3-20
BI014188-01
September, 2013 Int-7 2U67_X68 Introduction
Contents
General Maintenance 3-20
Track Assembly 3-21
Idler Unit Description 3-22
Hydraulic Tensioner 3-23
Repair 3-23
Nitrogen Tensioner 3-24
Nitrogen Tensioner – Filling Instructions 3-25
Nitrogen Tensioner – Pressure Check 3-26
Nitrogen Tensioner – Pressure Release 3-26
Track Chain 3-27
Track Chain – Separate 3-27
Track Link 3-28
Track Link Position 3-30
Track Shoe – Mounting to Track Chain 3-30
Track Shoe Bolt Torque (Direct Torque Method) 3-32
Bolt Torque KN111 3-32
Track Shoe Bolt Torque (Torque Turn Method) 3-33
Bolt Torque KN111 3-33
Track Chain and Shoe Installation 3-34
Track Chain with Shoes 3-34
Track Chain and Shoe – Assembly and Installation 3-34
Final Drive Unit 3-36
General Description 3-36
Removal from Track Frame 3-37
Installation into Track Frame 3-38
Final Drive Maintenance 3-39
Final Drive Oil 3-40
F100 Final Drive Assembly 3-41
Parking Brake – Description 3-42
Final Drive – Disconnect and Parking Brake 3-43
Towing Procedure – Gear Drive Disconnect 3-43
Parking Brake – Description 3-44
Parking Brake – Removal and Installation 3-44
General Description 3-45
General Recommendations for Disassembly and Assembly Operations 3-45
Technical Features 3-47
Sealing Compounds and Adhesives 3-48
Filling and Checks 3-50
Service Schedule 3-50
Tightening Torques 3-51
Lubrication / Greasing –
Grades and Application Range 3-51
General Checks 3-52
Disassembly and Assembly Operations 3-52
Troubleshooting 3-55
BI014188-01
2U67_X68 Introduction Int-8 September, 2013
Contents
Special Tools 3-55
Idler Unit 3-56
Idler Unit – Assembly 3-56
Idler Unit – Removal 3-59
Track and Support Rollers 3-60
Track Roller Assembly 3-60
General Description 3-60
Track Roller – Removal and Disassembly 3-61
Support Roller – Removal and Disassembly 3-61
Track and Support Roller – Assembly 3-62
Track and Support Roller – Test and Install 3-63
Track and Sprocket Inspection 3-65
Track Inspection and Wear Limit Guide 3-65
Sprocket Wear Patterns 3-69
Auxiliary Crane 3-75
Hydraulic Crane – Rear Deck Crane Palfinger PC1500 3-75
Rear Deck Crane Palfinger PC1500 Service Information 3-76
Checking Bolted Connections 3-76
Maintenance Chart 3-77
Lubrication 3-79
Hydraulic Fluids 3-82
Oil Change / Oil Maintenance 3-83
Cleaning Agents and Equipment 3-83
Repairing Paint Damage 3-84
Removal From Service and Disposal 3-84
Section 4 – Engine / Drive Train / Compressor4-1
Contents 4-3
Power Group Locator 4-7
Power Group Locator 4-7
Test Point Locator 4-8
Test Point Locator 4-8
Engine 4-10
Cummins Engine 4-10
QST30 Electric Fuel Supply System4-11
Construction 4-12
Electric Fuel Supply Pumps 4-12
Combo Fuel Filter Head and Pump Manifold 4-12
FS1006 Fuel Filter with
Water Separator 4-12
Fuel Manifold with Integrated FSO Valve 4-13
Fuel Connections 4-13
Pre-filters 4-13
Wiring with EFS Power Relay 4-14
Pressure and Temperature Sensors 4-14
Operation 4-15
BI014188-01
September, 2013 Int-9 2U67_X68 Introduction
Contents
QST30 Electric Fuel Supply System Flow Diagram 4-16
QST30 Electric Fuel Supply System Detail 4-17
Oil Reserve Systems 4-18
LED Monitor Readings 4-19
Adjustment of Running Oil Level 4-19
Wiring Diagram – Oil Reserve Basic Circuit 4-20
Oil Pressure Switch 4-20
Oil Reserve System 4-20
Troubleshooting 4-21
Maintenance 4-21
Engine and Compressor Air Cleaners 4-22
Engine and Compressor Air Cleaner Service Assembly 4-22
Engine and Compressor Air Cleaner Service 4-23
Flexible Drive Coupling 4-26
Flexible Drive Coupling Service 4-26
Pump Drive 4-28
Pump Drive Assembly 4-28
Pump Drive Assembly – Removal and Replacement 4-29
Pump Drive Gearbox 4-30
Pump Drive Gearbox 4-30
Pump Drive Gearbox – Repair 4-31
Pump Drive Gear Box Input Shaft Assembly 4-32
Hydraulic Pumps 4-34
Hydraulic Pumps – Removal and Replacement 4-34
Compressor Installation 4-35
Safety 4-35
Compressor Installation 4-38
Compressor Drive Coupling 4-40
Compressor Alignment 4-41
Mounting Instructions for Arcusaflex™ Flywheel Couplings 4-42
Taper-Loc Bushing Installation – Model AC-T5SN F2 V1 3535 4-43
Tightening Torques for Arcusaflex™ Flywheel Couplings 4-43
Compressor Shaft Seal 4-44
Compressor Shaft Seal 4-44
Low Pressure Compressor 4-46
Description 4-46
Compressed Air Functions 4-46
Compressor Inlet Valve Control System 4-50
Inlet Valve 4-51
Compressor Regulation 4-53
Relieving Regulators 4-54
Reducing Regulators 4-56
System Blowdown Valve 4-58
Running Blowdown Valve 4-59
Running Blowdown Maintenance 4-60
BI014188-01
2U67_X68 Introduction Int-10 September, 2013
Contents
Compressor Air and Oil Circuits – 2000cfm @ 100psi 4-61
Compressor Air Circuit Parts List 4-64
Compressor Air Circuit Legend 4-64
Compressor Control Set-up Vented Poppet Inlet – Shutdown 4-65
Compressor Control Set-up Vented Poppet Inlet – Initial Start-up Below 50psi 4-66
Compressor Control Set-up Vented Poppet Inlet – Initial Start-up Above 50psi 4-67
Compressor Control Set-up Vented Poppet Inlet – Run Unloaded 4-68
Compressor Control Set-up Vented Poppet Inlet – Drilling 4-69
Compressor Control Set-up Vented Poppet Inlet – Shutting Down 4-70
Operation 4-71
Compressor Maintenance 4-73
General Maintenance 4-73
Discharge Check Valve 4-75
Compressor Receiver Tank Assembly 4-76
Separator Elements 4-77
Separator Elements – Remove and Replace 4-78
Scavenge Line 4-79
Compressor Discharge Temperature Gauge, Switch and Sender 4-81
Minimum Pressure Valve 4-82
Minimum Pressure / Check Valve Maintenance 4-82
Thermal Bypass Valve 4-83
Thermal Bypass Valve Maintenance 4-84
Compressor Fluid Filter 4-86
Changing Filter Elements 4-87
Oil Stop Valve 4-88
Troubleshooting 4-89
Coolers 4-91
Hydraulic Oil / Radiator Cooler Assembly 4-91
Compressor Oil Cooler 4-92
Fan Speed 4-92
Engine Cooler / Radiator 4-93
Aluminium Tube Air to Oil Cooler 4-94
Aluminium Tube Air to Oil Cooler – Standard Parts 4-94
Removal and Replacement 4-95
Internal Cleaning 4-97
Radiator Cooler 4-99
Typical Radiator Core – Standard Parts 4-99
Cleaning 4-100
Tube Removal 4-101
Seal Installation 4-102
Lubricating Seals and Tube Ends 4-102
Tube Installation 4-103
BI014188-01
September, 2013 Int-11 2U67_X68 Introduction
Contents
Section 5 – Dust Control System5-1
Contents 5-3
Dust Control System 5-5
Dust Control Systems 5-5
Water Injection 5-7
Water Tanks 5-7
Water Injection Pump 5-8
Water Injection Relief Valve 5-8
Water Injection Control 5-9
Water Injection Basic Circuit5-11
Water Pump 5-12
Pump Specifications 5-12
Servicing Instructions 5-12
Water Injection Pump Assembly 5-13
Replacing Piston Cup Seals 5-14
Replacing Suction and Discharge Valves 5-15
Replacing Power End Bearings 5-16
Servicing the Wrist Pin Bearings 5-17
Fastener Torque Requirements 5-17
Recommended Lubricants 5-18
Water Pump Motor Repair 5-18
Water Injection Hydraulic Control Valve Repair 5-18
Water Pump Drive Coupling 5-18
Level and Flow Transducer 5-18
Section 6 – Mast / Rotary Drive / Pipe Rack6-1
Contents 6-3
Mast Weldment 6-5
Mast Repair 6-5
Weld Inspection Schedule 6-6
Mast Inspection 6-6
Mast Assembly and Installation 6-7
Mast Assembly 10m 6-7
Mast Weldment 6-8
Mast Pivot 6-8
Mast Locking 6-8
Mast / Drill Without Mast 6-9
Mast Assembly 6-10
Raising the Mast 6-10
Hoist / Pulldown Cylinder 6-12
Hoist / Pulldown Cylinder and Parts List 6-12
Removal From Mast Assembly 6-13
Repair 6-14
Installation 6-14
Adjustment 6-16
BI014188-01
2U67_X68 Introduction Int-12 September, 2013
Contents
Replacement 6-18
Wire Rope 6-20
Rotary Drive 6-21
Rotary Head Assembly 6-21
Rotary Head Guide Alignment 6-22
Rotary Head – Drive System 6-23
Removal from Mast 6-24
Installation 6-24
Rotary Drive Gearbox 6-25
Rotary Drive Gearbox Item Listing 6-26
Rotary Drive Gearbox – Repair 6-27
Rotary Head Bull Shaft Bearing Nut 6-28
Manufacturers Recommendations – Blast Hole Drilling Consumables 6-29
Air Swivel 6-30
Deck Wrench 6-31
Deck Wrench 6-31
HOBO Wrench 6-32
HOBO Wrench 6-32
Breakout System – HOBO 6-33
Optional Hydraulic Operated Bit Basket – HOBB 6-33
Pipe Positioner 6-34
Pipe Postioner 6-34
Carousel Pipe Rack 6-35
Major Components 6-35
Rod Handling – Carousal Indexing 6-36
Pipe Rack Assembly 6-37
General Information 6-38
Pipe Rack Bearings – Removal 6-38
Pipe Rack Components – Inspection 6-40
Pipe Rack – Assembly and Installation 6-41
Pipe Rack Roller – Remove and Replace 6-42
Pipe Rack Roller – Disassembly and Assembly 6-43
Top Sub Saver (Optional) 6-45
Replacement Procedure 6-45
Section 7 – Hydraulic Systems 7-1
Contents 7-3
Hydraulic Symbols 7-7
Hydraulic Symbols 7-7
Hydraulic Tank 7-9
Hydraulic Tank 7-9
Return Hydraulic Filters 7-10
Main Hydraulic Pumps7-11
Pump Identification7-11
Right Track / Pulldown, Left Track / Rotation Pumps 7-12
BI014188-01
September, 2013 Int-13 2U67_X68 Introduction
Contents
Hydraulic Piston Pumps – Removal and Replacement 7-12
Main Pumps 7-12
EP (24V DC) Control 7-12
Linde HPV-02 Variable Displacement Pump 7-13
Operational Parameters 7-15
Linde HPV-02 Pump Schematic 7-16
Controls 7-17
Dimensions 7-20
Charge Pumps 7-21
Setting Linde HPV-02 Main Pumps – Neutral Setting 7-22
Setting Linde HPV-02 Main Pumps – Pressure Settings 7-23
Setting Linde HPV-02 Main Pumps – Pre-setup Checks 7-24
Main Pumps Linde HPV-02 7-25
Break Test Procedure 7-26
Setting Procedure 7-26
Charge Circuit 7-28
Charge Pressure, High Pressure, POR and Zero Position Settings 7-28
Set Charge Pressure 7-28
Charge Filter 7-30
Routine Maintenance 7-30
Changing Filter Elements 7-31
Main Pumps Circuit 7-32
Main Pumps Circuit 7-32
Main Return and Case Drain Filter 7-33
Routine Maintenance 7-34
Changing Filter Elements 7-34
Loop Filters 7-35
Loop Filters 7-35
Loop Filter Cross Section 7-36
Filter Assembly Loop 7-37
Changing Filter Elements 7-38
Rotation Circuit 7-39
Rotary Head 7-40
Rotary Head Speed Proximity Switch 7-40
Rotary Drive Gearbox Motor 7-41
Rotary Drive Gearbox Motor – Test and Repair 7-41
Rotary Gearbox Rotation Motor 7-42
Shaft Seal Replacement 7-43
Troubleshooting 7-44
Tram Circuit 7-46
Tram Circuit 7-46
Diverter Valve 7-47
Diverter Valve 7-47
Operation 7-47
BI014188-01
2U67_X68 Introduction Int-14 September, 2013
Contents
Left Track / Rotation Pump 7-48
Basic Left Track / Rotation Pump 7-48
Right Track / Pulldown and Hoist Circuit 7-49
Basic Right Track / Pulldown and Hoist 7-49
Pulldown and Hoist Circuit 7-50
Hoist / Pulldown Cylinder Counterbalance Valve 7-50
Counterbalance Valves 7-51
Counterbalance Valve Adjustments 7-51
Auxiliary Pump Circuit 7-52
Auxiliary Pump 7-52
Auxiliary Functions 7-52
Auxiliary Pump Circuit 7-53
Spools 7-54
Electro – Hydraulic Kit (24V DC) 7-54
Auxiliary Pump Operation 7-56
Jack Control and Mast Elevating Circuit 7-60
Jack Control and Mast Elevating Circuit 7-60
Jack Control and Mast Elevating Circuit 7-61
Levelling Jack Cylinders 7-62
Jack Leg Cylinder 7-62
Counterbalance Valve Test Procedure 7-62
Mast Elevating Cylinders 7-63
Internal Counterbalance Valve 7-63
Internal Counterbalance Valve Test Procedure 7-64
Hydraulic Operated Breakout Wrench 7-65
HOBO Wrench Circuit 7-65
Operation 7-66
Setting of HOBO Sequence Valves 7-67
Cooler Fan Circuit 7-68
Fan Motor Circuit 7-68
Hydraulic Cooler – Thermal Valve 7-70
Basic Cooler Fan Circuit 7-71
Cooler Fan Motor 7-72
Cooler Fan Motor Assembly 7-72
Hydraulic Motor 7-73
Water Pump Motor 7-76
Water Pump Motor Repair Information 7-76
Shaft Seal Repair 7-77
Hydraulic Cylinder Repair 7-80
Hydraulic Cylinders 7-80
General Information 7-81
H Head 7-83
N Head 7-84
Z Head 7-85
Z Head (Two Piece) 7-86
BI014188-01
September, 2013 Int-15 2U67_X68 Introduction
Contents
K Head 7-87
M Head 7-88
Z Piston 7-89
Z Piston (Threaded) 7-90
H and K Piston 7-91
M Piston 7-92
N Piston 7-95
Section 8 – Electrical Components8-1
Contents 8-3
Electrical Locator 8-4
Electrical Component Location 8-4
Jump Starting 8-10
Jump Starting 8-10
Batteries 8-12
Batteries 8-12
Welding Precautions 8-13
Welding Precautions 8-13
Electrical Components 8-14
Electrical Circuits 8-14
Transducers 8-14
EP Levers 8-15
Joystick Adjustments 8-16
Important Information 8-18
PLC 8-19
Touchscreen 8-22
Laser Depth System 8-23
Start Up and Shutdown 8-26
Hydraulic Function Enable 8-26
Alarms 8-26
Solenoid Control 8-27
Auto Lube 8-29
Gauges 8-29
Level Switches 8-31
Dust Suppression 8-31
Acknowledgements 8-32
Disclaimers 8-32
Section 9 – Lubrication & Preventive Maintenance9-1
Contents 9-3
Central Lube System 9-5
Auto Lube Basic Operation 9-5
Central Lube Tank Assembly 9-6
Auto Lube Grease Pump 9-7
Auto Lube Tube Pump 9-13
BI014188-01
2U67_X68 Introduction Int-16 September, 2013
Contents
Graco Vent Valve 9-18
Basic Operating Principles of Auto Lube Injectors 9-20
SL-V and SL-V XL Injectors 9-20
SL-1 and SL-11 Injectors 9-21
SL-32 Injectors 9-22
Typical Grease System Circuit 9-23
First 50 Hour Service 9-24
Lube Faults / Operation 9-25
Auto Lube Timer 9-26
Lube Pressure Screen 9-26
Air Service Units 9-27
Filter Regulator 9-27
Air Line Oiler 9-28
Soft Start Dump Valve 9-29
Air Service Unit 9-30
Pipe Thread Lubricator 9-31
Air Operated Pipe Thread Pump 9-31
Filter Locator 9-39
Filter Locator Assembly 9-39
Lubrication & Preventive Maintenance 9-40
General Lubrication 9-40
Equipment Lubrication 9-40
Care of Lubrication Points 9-40
Safety 9-41
Track Gear 9-42
Engine Maintenance 9-43
Air Cleaners 9-44
Air Filter Elements 9-44
Alternator Maintenance 9-44
Pump Drive and Drive Shaft Maintenance 9-45
Compressor Maintenance 9-45
Cooler Packs 9-45
A-frame and Pivot Point Maintenance 9-47
Pull Down and Hoist Ropes and Sheaves Maintenance 9-47
Rotary Head Maintenance 9-47
Hydraulic System Maintenance 9-49
Hydraulic Maintenance 9-49
Water Pump Maintenance 9-49
Cab Maintenance 9-49
Air Conditioner Maintenance 9-51
Battery Maintenance 9-51
Lubrication System Maintenance 9-51
Fire Suppression Maintenance 9-51
BI014188-01
September, 2013 Int-17 2U67_X68 Introduction
Contents
Lubrication and Preventive Maintenance 9-52
Drill Folding Stairway – Inspection Requirements 9-53
Weld Inspection Schedule 9-54
Weld Inspection Schedule SK Series 9-54
Track and Sprocket Inspection 9-55
Track Inspection and Wear Limit Guide 9-55
Sprocket Wear Patterns 9-59
Lubrication Recommendations 9-65
Lubrication Recommendations 9-65
Lubrication and Maintenance Chart – 250hr 9-66
Lubrication and Maintenance Chart – 500hr 9-74
Lubrication and Maintenance Chart – 1000hr 9-83
Lubrication and Maintenance Chart – 2000hr 9-92
Lubricant Specifications 9-102
Hydraulic System 9-102
Hydraulic Tank Capacity 9-102
Compressor Lubrication 9-103
Compressor Lubricant Specifications 9-103
Lubricating Grease 9-104
Gear Lubricant 9-104
Scheduled Oil Sampling Analysis 9-104
Torque Values 9-105
SAE Recommended Torque Values 9-105
Externally Threaded SAE – ASTM Fasteners 9-106
Torque Values 9-107

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