Cat MD6420 Rotary Track Blasthole Drill Service Manual 2U67X73 – PDF DOWNLOAD

Description

Cat MD6420 Rotary Track Blasthole Drill Service Manual 2U67X73 – PDF DOWNLOAD

CAT MD6420 ROTARY TRACK BLASTHOLE DRILL SERVICE MANUAL 2U67X73 – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Cat MD6420 Rotary Track Blasthole Drill Service Manual 2U67X73 – PDF DOWNLOAD

Caterpillar Serial Number: 2U67X73

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 Track Blasthole Drill Service Manual 2U67X73 – PDF DOWNLOAD

Parts Ordering and Product Support Int-3
Safety Information Int-4
Contents Int-5
General Locator Int-18
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 Locator1-11
Notes 1-14
Section 2 – Operators Cab / Controls2-1
Contents 2-3
Graphic Symbol Legend 2-5
Graphic Symbol Legend 2-5
Warning Decals 2-9
Warning Decals 2-9
Operator Control and Instrument Panels 2-12
Control Panels 2-12
Right Hand Control Panel 2-12
Instrument Panel 2-14
Circuit Breakers 2-15
Light Switches 2-15
System Pressure Gauge Panel 2-16
Left Hand Control Panels 2-18
Cab Foot Controls 2-22
Thread Grease Switch 2-22
Pipe Safety Arm Override Switch 2-22
Machine Stability 2-23
Tramming Procedure 2-23
Track Adjustments 2-23
New Machine Procedure 2-24
General Maintenance Checks While Tramming 2-24
Roller Locations 2-25
Temperature and Condition Record Chart for Walking 2-26
2U67_X73 Introduction Int-6 January, 2013
Contents
Propelling the Machine 2-27
Stability Limits 2-29
SKSS Transient Stability Limits 2-30
Cab Heater 2-31
Cab Heater Fault Isolation 2-31
Air Conditioner 2-32
T8 Series Split System Air Conditioning 2-32
Section 10 Technical Data and Control Settings 2-33
Section 20 Installation and Commissioning 2-35
Section 30 Routine Maintenance Procedures 2-39
Section 40 Fault Diagnosis 2-40
Section 50 Reference Drawings 2-49
Section 3 – Main Frame Crawlers3-1
Contents 3-3
Main Frame Repair – General 3-5
Main Frame Repair 3-5
Weld Inspection Schedule 3-6
Main Frame 3-6
Levelling Jacks 3-7
Levelling Jack Cylinder 3-7
Levelling Jacks 3-8
Limit Switch 3-8
Levelling Jack Cylinders 3-8
Mast Elevating Cylinders 3-9
Mast Elevating Cylinders 3-9
Internal Counterbalance Valve 3-10
Fuelling Valves 3-12
Hydrau-Flo® Fuelling Valves 3-12
Crawler Assembly 3-14
Crawler Assembly 3-14
Crawler Component Repair 3-15
Tramming 3-16
Maintenance checks for Tramming for SK Series Drills 3-16
Track Adjustments 3-16
New Machine Procedure 3-17
General Maintenance Checks While Tramming 3-17
Roller Locations 3-18
Temperature and Condition Record Chart for Walking 3-19
Metric Bolt Torque Specifications 3-20
Metric Bolt Torque Specifications 3-20
Track Tension Adjustment 3-21
Before Operating the Machine 3-21
General Maintenance 3-21
Track Assembly 3-22
Idler Unit Description 3-23
January, 2013 Int-7 2U67_X73 Introduction
Contents
Hydraulic Tensioner 3-24
Nitrogen Tensioner 3-25
Track Chain 3-28
Track Chain 3-28
Track Shoes Installation 3-31
Track Link Position 3-31
Track Shoe – Mounting to Track Chain 3-31
Track Shoe Bolt Torque (Direct Torque Method) 3-33
Bolt Torque KN111 3-33
Track Shoe Bolt Torque (Torque Turn Method) 3-34
Bolt Torque KN111 3-34
Track Chain and Shoe Installation 3-35
Track Chain with Shoes 3-35
Final Drive Unit 3-37
General Description 3-37
Removal from Track Frame 3-38
Installation into Track Frame 3-39
Final Drive Maintenance 3-40
Final Drive Oil 3-41
F130 Final Drive Assembly 3-42
F130 Final Drive 3-44
General description 3-44
Service Information 3-45
Tightening Torques 3-46
Lubrication / Greasing – Grades and Application Range 3-46
Planetary Gears F130/206-A 3-47
Troubleshooting 3-48
Special Tools 3-48
Idler Unit 3-49
Idler Unit – Assembly 3-49
Idler Unit – Removal 3-52
Track and Support Rollers 3-53
Track Roller Assembly 3-53
General Description 3-53
Track Roller – Removal and Disassembly 3-54
Support Roller – Removal and Disassembly 3-54
Track and Support Roller – Assembly 3-55
Track and Support Roller – Test and Install 3-56
Track and Sprocket Inspection 3-58
Track Inspection and Wear Limit Guide 3-58
Sprocket Wear Patterns 3-62
Auxiliary Crane 3-68
Hydraulic Crane – Rear Deck Crane Palfinger PC1500 3-68
Rear Deck Crane Palfinger PC1500 Service information 3-69
Checking Bolted Connections 3-69
Maintenance Chart 3-70
2U67_X73 Introduction Int-8 January, 2013
Contents
Lubrication 3-72
Hydraulic Fluids 3-75
Oil Change / Oil Maintenance 3-76
Cleaning Agents and Equipment 3-76
Repairing Paint Damage 3-77
Removal From Service and Disposal 3-77
Section 4 – Engine / Drive Train / Compressor4-1
Contents 4-3
Power Group Locator 4-5
Power Group Locator 4-5
Cummins Engine 4-6
Cummins Engine 4-6
QST30 Electric Fuel Supply System 4-7
Construction 4-8
Electric Fuel Supply Pumps 4-8
Combo Fuel Filter Head and Pump Manifold 4-8
FS1006 Fuel Filter with
Water Separator 4-8
Fuel Manifold with Integrated FSO Valve 4-9
Fuel Connections 4-9
Pre-filters 4-9
Pressure and Temperature Sensors 4-10
Wiring with EFS Power Relay 4-10
Operation4-11
QST30 Electric Fuel Supply System Flow Diagram 4-12
QST30 Electric Fuel Supply System Detail 4-13
Oil Reserve Systems 4-14
LED Monitor Readings 4-15
Adjustment of Running Oil Level 4-15
Wiring Diagram – Oil Reserve Basic Circuit 4-16
Oil Pressure Switch 4-16
Oil Reserve System 4-16
Troubleshooting 4-17
Maintenance 4-17
Engine and Compressor Air Cleaners 4-18
Engine and Compressor Air Cleaner Service Assembly 4-18
Engine and Compressor Air Cleaner Service 4-19
Flexible Drive Coupling 4-22
Flexible Drive Coupling Service 4-22
Pump Drive 4-24
Pump Identification 4-24
Pump Drive Assembly – Removal and Replacement 4-25
Pump Drive Gearbox 4-26
Pump Drive Gearbox – Repair 4-27
Pump Drive Gear Box Input Shaft Assembly 4-28
January, 2013 Int-9 2U67_X73 Introduction
Contents
Hydraulic Pumps 4-30
Hydraulic Pumps – Removal and Replacement 4-30
Compressor Installation 4-31
Compressor Installation 4-31
Compressor Drive Coupling 4-33
Compressor Alignment 4-35
Compressor Shaft Seal 4-36
Compressor Shaft Seal 4-36
Low Pressure Compressor 4-38
Safety 4-38
Description 4-41
Compressed Air Functions 4-41
Compressor Oil Circuit – 2400cfm @ 100psi 4-45
Compressor Air Circuit – 2400cfm @ 0psi 4-49
Compressor Air Circuit – 2400cfm @ 50psi 4-50
Compressor Air Circuit – 2400cfm @ 100psi 4-51
Compressor Air Circuit – 2400cfm @ 60psi 4-52
Compressor Functional Description 4-53
Operation 4-55
Low Pressure Compressor Maintenance 4-57
General Maintenance 4-57
Discharge Check Valve 4-59
Compressor Receiver Tank Assembly 4-60
Separator Elements 4-61
Separator Elements – Remove and Replace 4-62
Scavenge Line 4-63
Compressor Discharge Temperature Gauge, Switch and Sender 4-65
Minimum Pressure Valve 4-66
Minimum Pressure / Check Valve Maintenance 4-66
Thermal Bypass Valve 4-67
Thermal Bypass Valve Maintenance 4-68
Compressor Fluid Filter 4-70
Changing Filter Elements 4-71
Bearing Oil Filter 4-72
Oil stop valve 4-73
Compressor Inlet Valve Control System 4-74
Compressor Regulation 4-77
Relieving Regulators 4-78
System Blowdown Valve 4-80
Running Blowdown Valve 4-81
Running Blowdown Maintenance 4-82
Troubleshooting 4-84
Coolers 4-86
Compressor oil cooler 4-86
Hydraulic Oil / Radiator Cooler Assembly 4-87
2U67_X73 Introduction Int-10 January, 2013
Contents
Aluminium Tube Air to Oil Cooler 4-88
Aluminium Tube Air to Oil Cooler – Standard Parts 4-88
Removal and Replacement 4-89
Internal Cleaning 4-91
Radiator Cooler 4-93
Typical Radiator Core – Standard Parts 4-93
Cleaning 4-94
Tube Removal 4-95
Seal Installation 4-96
Lubricating Seals and Tube Ends 4-96
Tube Installation 4-97
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 Circuit5-11
Water Pump 5-12
Water Injection Pump Assembly 5-12
Pump Specifications 5-13
Torque Requirements 5-13
Servicing Instructions 5-13
Servicing the Plunger Packings 5-13
Reassembling Plunger Packings 5-14
Servicing the Pump Valves 5-14
Reassembling Valve Parts 5-14
Servicing the Crankshaft 5-15
Servicing the Crossheads 5-15
Replacing Piston Cup Seals 5-16
Replacing Suction and Discharge Valves 5-17
Replacing Power End Bearings 5-18
Servicing the Wrist Pin Bearings 5-19
Fastener Torque Requirements 5-19
Recommended Lubricants 5-20
Water Pump Motor Repair 5-20
Water Pump Drive Coupling 5-20
Level and Flow Transducer 5-20
January, 2013 Int-11 2U67_X73 Introduction
Contents
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 13m 6-7
Mast Pivot 6-8
Mast Pivot Torque Procedure 6-8
Mast Pivot Bolts 6-10
Mast A-frame and Pivot Shaft6-11
Mast A-frame Pivot Shaft Cap Bolts 6-12
Mast Elevate Cylinders 6-13
Angle Drilling 6-13
Mast / Drill Without Mast 6-14
Mast Assembly 6-15
Raising the Mast 6-15
Feed Cylinders 6-17
Feed Cylinders 6-17
Removal 6-19
Feed Cylinder Assembly 6-20
Repair 6-21
Installation 6-21
Hoist / Pulldown Cable Adjustment with Auto Tension 6-22
Hoist / Pulldown Cable Adjustment with Auto Tension Hydraulic 6-22
Hoist / Pulldown Cables 6-23
Adjustment 6-24
Replacement 6-26
Wire Rope 6-27
Rotary Drive 6-28
Rotary Head Assembly 6-28
Rotary Head Guide Alignment 6-29
Rotary Head Drive System (high speed) 6-31
Rotary Drive – Removal from Mast 6-32
Rotary Drive – Installation 6-32
Rotary Drive Gearbox – Repair 6-33
Rotary Head Bull Shaft Bearing Nut 6-34
Manufacturers Recommendations – Blast Hole Drilling Consumables 6-35
Air Swivel (Single Seal Style) 6-36
Deck Wrench 6-37
Deck Wrench 6-37
HOBO Wrench 6-38
HOBO Wrench 6-38
Breakout System – HOBO 6-39
Hydraulic Operated Bit Basket – HOBB (Optional) 6-39
2U67_X73 Introduction Int-12 January, 2013
Contents
Pipe Safety Arm 6-39
Pipe Positioner 6-40
Pipe Positioner 6-40
Carousel Pipe Rack 6-41
Major Components 6-41
Rod Handling – Carousal Indexing 6-42
Pipe Rack Assembly 6-43
General Information 6-44
Pipe Rack Bearings – Removal 6-44
Pipe Rack Components – Inspection 6-46
Pipe Rack – Assembly and Installation 6-47
Pipe Rack Roller – Remove and Replace 6-48
Pipe Rack Roller – Disassembly and Assembly 6-49
Top Sub Saver 6-51
Top Sub Saver 6-51
Section 7 – Hydraulic Systems 7-1
Contents 7-3
Hydraulic Symbols 7-7
Hydraulic Symbols 7-7
Pressure Setting Sequence 7-9
Pressure Setting Sequence 7-9
Hydraulic Tank 7-10
Hydraulic Tank 7-10
Return hydraulic filters7-11
Main Return and Case Drain Filter 7-12
Routine Maintenance 7-13
Changing Filter Elements 7-13
Main Hydraulic Pumps 7-14
Pump Identification 7-14
Right Track / Left Track / Rotation Pumps 7-15
Hydraulic Piston Pumps – Removal and Replacement 7-15
AA4VG 180 Hydraulic Pump 7-16
Technical Data 7-18
Port Locations 7-22
Brake Setting Procedure 7-23
Charge Pressure, High Pressure, POR and Zero Position settings 7-24
Set Charge Pressure – 450psi (31 bar) 7-24
Set Crossover Relief (High Pressure) – 5500psi (380bar) 7-25
Set Pressure Override (POR) – 5000psi (345bar) 7-26
Set Mechanical Zero Position – EP Pump Control 7-27
Set Hydraulic Zero Position – EP Pump Control 7-28
Removal and Inspection of Charge Pump 7-29
Removal and Installation of Shaft Seal 7-30
Routine Maintenance 7-31
Troubleshooting Procedure 7-32
January, 2013 Int-13 2U67_X73 Introduction
Contents
Brake Test Procedure 7-34
Charge Circuit 7-35
Charge Circuit 7-35
Routine Maintenance 7-36
Changing Filter Elements 7-36
Main Pumps Circuit 7-37
Main Pumps Circuit 7-37
Rotation / Tram Motor Circuit 7-38
Loop Filters 7-39
Loop Filters 7-39
Routine Maintenance 7-39
Loop Filter cross section 7-40
Loop Filter Assembly 7-41
Changing Filter Elements 7-42
Rotary Drive Gearbox Motor 7-43
Rotary Drive Gearbox Motor – Test and Repair 7-43
Rotary Gearbox Rotation Motor 7-44
Shaft Seal Replacement 7-45
Troubleshooting 7-46
Tram Circuit 7-48
Tram circuit 7-48
Main Closed Loop Circuits 7-49
Diverter Valve 7-49
Operation 7-49
Feed and Auxiliary Pump Circuit 7-50
Hydraulic Piston Pumps 7-50
Feed and Auxiliary Functions Pump 7-53
Repair Instructions 7-54
Pump Replacement – Start Up 7-55
Auxiliary Pump Operation 7-56
Auxiliary and Feed Circuits 7-57
Pilot Control Manifold 7-58
Hydraulic Valve Board Assembly 7-58
Pilot Control Manifold 7-59
Pilot Control Manifold Assembly 7-60
Control Valve Assembly 7-61
Hydraulic Feed Circuit 7-68
Hydraulic Feed Circuit 7-68
Feed Valve Assembly 7-70
Directional Control Valve – MP22 Valve 7-72
Control Valve Assembly 7-74
Technical Data 7-74
Jack Control and Mast Elevating Circuit 7-75
Jack Control and Mast Elevating Control Valve 7-75
OEM Controllers / EP Levers 7-76
2U67_X73 Introduction Int-14 January, 2013
Contents
Counterbalance Valve 7-77
Counterbalance Valve Adjustments 7-77
Levelling Jack Cylinders 7-78
Jack Leg Cylinder 7-78
Counterbalance Valve Test Procedure 7-78
Mast Elevating Cylinder 7-79
Mast Elevating Cylinder 7-79
Counterbalance Valve Test Procedure 7-80
Auxiliary Pump Circuit 7-81
Auxiliary Functions Circuit 7-81
AWE6 Auxiliary Valves 7-83
Exploded View 7-85
Hydraulic Operated Breakout Wrench 7-86
HOBO Wrench 7-86
HOBO Wrench Circuit 7-87
Setting of HOBO Sequence Valves 7-88
Hobo Float Valve 7-88
Pipe Positioner 7-89
Pipe Positioner 7-89
Pipe Safety Arm 7-90
Hydraulic Gear Pumps 7-91
Hydraulic Gear Pumps 7-91
Tool List 7-93
Cooler Fan Circuit 7-94
Fan Motor Circuit 7-94
Basic Cooler Fan Circuit (Hot and Cold) 7-95
Cooler Fan Motor 7-96
Hydraulic Motor 7-96
Cooler Fan Motor Assembly 7-98
Hydraulic Thermostatic Valve 7-100
Hydraulic cooler – Thermal valve 7-100
Water Injection 7-101
Water Injection valve 7-101
Water Injection Circuit 7-102
Water Pump Motor 7-103
Water Pump Motor Repair Information 7-103
Shaft Seal Repair 7-104
Air Conditioner 7-107
Air Conditioner Compressor Drive Circuit 7-107
Hydraulic Cylinder Repair 7-108
Hydraulic Cylinders 7-108
General Information 7-109
H Head7-111
N Head7-112
Z Head7-113
Z Head (Two Piece)7-114
January, 2013 Int-15 2U67_X73 Introduction
Contents
K Head7-115
M Head7-116
Z Piston7-117
Z Piston (Threaded)7-118
H and K Piston7-119
M Piston 7-120
N Piston 7-123
Main Hydraulic Schematic 7-124
Section 8 – Electrical Components8-1
Contents 8-3
Electrical Locator 8-5
Electrical Component Locator 8-5
Jump Starting 8-8
Jump Starting 8-8
Batteries 8-10
Batteries 8-10
Welding Precautions8-11
Welding Precautions8-11
Electrical Components 8-12
Electrical Circuits 8-12
Transducers 8-12
EP Levers 8-13
Joystick Adjustments 8-14
Vigilante Guide 8-16
Important Information 8-16
PLC 8-17
Touchscreen 8-20
Laser Depth System 8-21
Start-up and Shutdown 8-24
Hydraulic Function Enable 8-24
Alarms 8-24
Solenoid Control 8-25
Auto Lube 8-27
Gauges 8-28
Level Switches 8-30
Dust Suppression 8-30
Acknowledgements 8-31
Disclaimers 8-31
Notes 8-32
2U67_X73 Introduction Int-16 January, 2013
Contents
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 – Owner / Operator Manual 9-7
Auto Lube Tube Pump – Owner / Operator Manual 9-13
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
Air Service Unit System 9-27
Soft Start Dump Valve 9-28
Filter Regulator 9-29
Air Line Oiler 9-30
Air Service Unit 9-31
Pipe Thread Lubricator 9-32
Air Operated Pipe Thread Pump 9-32
Filter Locator 9-40
Filter Locator Assembly 9-40
Lubrication and Preventive Maintenance 9-41
General Lubrication 9-41
Equipment Lubrication 9-41
Care of Lubrication Points 9-41
Safety 9-42
Isolation – Battery Switch 9-43
Track Gear 9-44
Engine Maintenance 9-45
Air Cleaners 9-46
Air Filter Elements 9-46
Alternator Maintenance 9-46
Pump Drive and Drive Shaft Maintenance 9-47
Compressor Maintenance 9-47
Cooler Packs 9-47
A-frame and Pivot Point Maintenance 9-49
Pulldown and Hoist Ropes and Sheaves Maintenance 9-49
Rotary Head Maintenance 9-49
Hydraulic System Maintenance 9-51
Hydraulic Maintenance 9-51
January, 2013 Int-17 2U67_X73 Introduction
Contents
Water Pump Maintenance 9-51
Cab maintenance 9-51
Air Conditioner Maintenance 9-53
Battery Maintenance 9-53
Lubrication System Maintenance 9-53
Fire Suppression Maintenance 9-53
Drill Folding Stairway – Inspection Requirements 9-55
Weld Inspection Schedule 9-56
Weld Inspection Schedule SK Series 9-56
Track and Sprocket Inspection 9-57
Track Inspection and Wear Limit Guide 9-57
Sprocket Wear Patterns 9-61
Lubrication Recommendations 9-67
Lubrication Recommendations 9-67
Lubrication and Maintenance Chart – 250hr 9-68
Lubrication and Maintenance Chart – 500hr 9-77
Lubrication and Maintenance Chart – 1000hr 9-89
Lubrication and Maintenance Chart – 2000hr 9-100
Lubrication and Maintenance Chart9-112
Lubrication and Maintenance Notations9-112
Lubricant Specifications9-113
Hydraulic System9-113
Hydraulic Tank Capacity9-113
Compressor Lubrication9-114
Compressor Lubricant Specifications 9-114
Lubricating Grease9-115
Gear Lubricant9-115
Scheduled Oil Sampling Analysis9-115
Critical Fasteners9-116
Bolted Joint Maintenance Guide Rotary Drills9-116
Critical Fastener ID and Inspection Schedule9-118
Torque Values9-119
SAE Recommended Torque Values9-119
Externally Threaded SAE – ASTM Fasteners 9-120
Torque Values 9-121
Mast Connection Points 9-122
Mast Connection Points Dimension Reporting 9-122
Notes 9-125

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

S.V