Cat MD6420B Rotary Blasthole Drill Service Manual – PDF DOWNLOAD

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Cat MD6420B Rotary Blasthole Drill Service Manual – PDF DOWNLOAD

CAT MD6420B ROTARY BLASTHOLE DRILL SERVICE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Cat MD6420B Rotary Blasthole Drill Service Manual – 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 MD6420B Rotary Blasthole Drill Service Manual – PDF DOWNLOAD

CAT MD6420B X52 REV.04 SERVICE MANUAL.......................................................  0
	Parts Ordering and Product Support......................................................  3
	Safety Information......................................................................  4
	Contents................................................................................  5
	General Locator......................................................................... 25
		General Locator..................................................................... 25
	Notes................................................................................... 28
CAT MD6420B X52 REV.04 SECTION ONE.......................................................... 29
	Section 1 - Safety...................................................................... 29
		Section 1 Contents.................................................................. 31
		Safety.............................................................................. 33
			Overview of Potential Hazards................................................... 33
			Personal Protective Equipment................................................... 33
			Noise........................................................................... 33
			Electrical Contact.............................................................. 33
			Overhead and Buried Utilities................................................... 33
			Clearances from Overhead High Voltage Lines..................................... 34
			Contact with Electric Wires..................................................... 34
			Contaminated Air ............................................................... 34
			Moving and Rotating Parts ...................................................... 35
			High Pressure Air or Fluid...................................................... 35
			Before Operation................................................................ 35
			During Operation................................................................ 36
			Maintenance..................................................................... 38
			Equipment Transfer.............................................................. 38
			Safety Locator.................................................................. 39
		Notes............................................................................... 42
CAT MD6420B X52 REV.04 SECTION TWO.......................................................... 43
	Section 2 - Operators Cab / Controls.................................................... 43
		Section 2 Contents.................................................................. 45
		Graphic Symbol Legend............................................................... 49
		Warning Decals...................................................................... 53
		Operating System Help Table Icons................................................... 55
		Operator Control and Instrument Panels.............................................. 60
			Control Panels.................................................................. 60
			Right Hand Control Panel........................................................ 60
			Instrument Panel................................................................ 62
			Circuit Breakers................................................................ 63
			Light Switches.................................................................. 63
			Operator Controls and Indicators................................................ 64
		Advanced Drill Automation System (ADAS)............................................. 65
			Drill Monitor................................................................... 65
			Operation Controls.............................................................. 66
			Function and Number Keys........................................................ 67
			LED states / Operating States................................................... 67
			Touch Screen Operation And Care................................................. 68
			Touch Screen Operation.......................................................... 68
			Cleaning The Housing............................................................ 68
			Cleaning The Touch Screen....................................................... 68
			Login Screen.................................................................... 69
			Dashboard....................................................................... 69
			Login Screen.................................................................... 69
			Login Screen Updates............................................................ 70
			Login........................................................................... 71
			Bit Settings.................................................................... 72
			Hour Meters..................................................................... 73
			Time Management ................................................................ 73
			Drill Screen.................................................................... 74
			Drill Screen Updates............................................................ 75
			Pull Down Gauge Operation....................................................... 76
			Depth System.................................................................... 77
			Drill Status And Override Updates............................................... 78
			Drill Status And Override....................................................... 78
		Operator Control And Instrument Panels.............................................. 79
			Left Hand Control Panels........................................................ 79
			Thread Grease Switch............................................................ 83
		Machine Stability................................................................... 84
			Tramming Procedure.............................................................. 84
			Requirements For Propelling The Machine......................................... 84
			Track Adjustments............................................................... 84
			New Machine Procedure .......................................................... 85
			General Maintenance Checks While Tramming....................................... 85
			Roller Locations................................................................ 86
			Temperature And Condition Record Chart For Walking.............................. 87
			Propelling The Machine.......................................................... 88
			Propelling Through Turns........................................................ 89
			Propelling Up, Down And Across Grades........................................... 89
			Stability Limits................................................................ 90
			md6420b - 16 Transient Stability Limits......................................... 91
		Cab Heater.......................................................................... 92
			Cab Heater Fault Isolation...................................................... 92
			Specifications.................................................................. 93
			Index........................................................................... 93
			1.0.0 Description Of Unit....................................................... 94
			1.1.0 Specifications............................................................ 95
			2.0.0 Installation And Commissioning............................................ 96
			3.0.0 Servicing.................................................................100
			4.0.0 Fault Finding.............................................................101
			5.0.0 Pressure Temperature Chart................................................103
			6.0.0 Spare Parts / Drawings....................................................103
			7.0.0 Recovery Of Refrigerant...................................................109
			8.0.0 Warranty..................................................................109
			Instructions....................................................................110
			Bergstrom Air Conditioner.......................................................111
		Camera Screen.......................................................................113
			CAT WAVS Work Area Vision System................................................113
			Keypad for the display..........................................................113
			Adjustments For The System Operation Procedure Notes............................114
			Adjustment For Colour...........................................................114
			Adjustment For Brightness.......................................................114
			Adjustment For Contrast.........................................................114
			System Settings.................................................................115
			Display On / Off................................................................115
			Manual Camera Selection.........................................................115
			Standby ON Or OFF...............................................................115
			Automatic Brightness ON Or OFF..................................................115
			Automatic Camera Selection......................................................116
			Activation Delay................................................................116
			System Settings.................................................................116
			Activation of a Mirror Image....................................................116
			System Settings.................................................................117
			Inverted Image..................................................................117
			Marker ON Or OFF................................................................117
			Switch Off The Keyboard.........................................................117
			Indication (LED)................................................................117
			Multiple Camera Selection.......................................................118
			Automatic Mode..................................................................118
			Manual Mode.....................................................................119
			Standby.........................................................................119
			Marker ON / OFF.................................................................120
			Illustration 63.................................................................121
			On / Off Input For The Display..................................................121
			Colour Adjustment...............................................................121
			Delay Activation................................................................122
			Switch Off Keyboard.............................................................122
			Single Camera Operation.........................................................123
			Operation of Multiple Cameras...................................................124
			Completing the Installation.....................................................125
		Notes...............................................................................126
CAT MD6420B X52 REV.04 SECTION THREE........................................................127
	Section 3 - Main Frame Crawlers.........................................................127
		Section 3 Contents..................................................................129
		Main Frame Repair - General.........................................................133
			Main Frame Repair...............................................................133
		Weld Inspection Schedule............................................................134
			Main Frame......................................................................134
		Levelling Jacks.....................................................................135
			Levelling Jack Cylinder.........................................................135
			Limit Switch....................................................................137
			Removal.........................................................................137
		Jack Cylinder Removal / Replacement ................................................138
			Lubricating Jack Casings........................................................138
			Replace Jack Cylinder...........................................................139
		Mast Elevating Cylinders............................................................140
		Mast Raise Cylinders................................................................141
			Mast Raise Cylinder Removal.....................................................142
			Mast Raise Cylinder Installation................................................143
		Mast Elevating Cylinders............................................................145
			Internal Counterbalance Valve...................................................145
		Fuelling Valves.....................................................................146
			Fuelling Valves.................................................................146
			Non-pressurised Fuelling System Operation.......................................146
			Fuelling Valves.................................................................146
			‘Conventional’ Systems..........................................................146
		Fuelling Valves.....................................................................147
			Parts List......................................................................148
			Crawler Assembly................................................................149
			Parts List......................................................................150
			Crawler Component Repair........................................................150
		Tramming............................................................................151
			Maintenance Checks For Tramming For Caterpillar Drills..........................151
			Requirements For Propelling The Machine.........................................151
			Track Adjustments...............................................................151
			New Machine Procedure ..........................................................152
			General Maintenance Checks While Tramming.......................................152
			Roller Locations................................................................153
			Temperature And Condition Record Chart For Walking..............................154
		Metric Bolt Torque Specifications...................................................155
			Metric Bolt Torque Specifications...............................................155
		Track Tension Adjustment............................................................156
			Before Operating The Machine....................................................156
			General Maintenance.............................................................156
			Track Assembly..................................................................157
			Idler Unit Description..........................................................158
			Hydraulic Tensioner.............................................................159
			Proper Track Tension............................................................159
			Nitrogen Tensioner..............................................................160
		Track Chain.........................................................................163
			Track Chain.....................................................................163
			Track Link Position.............................................................166
			Track Shoe – Mounting To Track Chain............................................166
		Track Shoes Installation............................................................167
			Bolt Torque KN111...............................................................168
		Track Shoe Bolt Torque (Direct Torque Method).......................................169
		Track Chain and Shoe Installation...................................................170
			Track Chain With Shoes..........................................................170
		Final Drive Unit....................................................................172
			General Description.............................................................172
			Removal From Track Frame........................................................173
			Installation Into Track Frame...................................................174
			Final Drive Maintenance.........................................................175
			Final Drive Oil.................................................................176
			F130 Final Drive Assembly.......................................................177
			Parts List......................................................................178
			F130 Final Drive................................................................179
			Service Information.............................................................180
			Tightening Torques..............................................................181
			Planetary Gears F130/206-A......................................................182
			Disassembly.....................................................................182
			Troubleshooting.................................................................183
			Idler Unit – Assembly...........................................................184
			Idler Unit – Removal............................................................187
			Track Roller Assembly...........................................................188
			General Description.............................................................188
			Track Roller – Removal And Disassembly..........................................189
			Support Roller – Removal And Disassembly........................................189
			Track And Support Roller – Assembly.............................................190
			Track and Support Roller – Test And Install.....................................191
			Track Inspection and Wear Limit Guide...........................................193
			B8 Track Inspection And Wear Limit Guide Caterpillar Series Drills..............194
			Sprocket Wear Patterns..........................................................197
			Wear on Forward Drive Side......................................................197
			Causes:.........................................................................197
			Effects:........................................................................197
			Remedies:.......................................................................197
			Wear on Reverse Drive Side......................................................198
			Causes:.........................................................................198
			Effects:........................................................................198
			Remedies:.......................................................................198
			Root Wear.......................................................................199
			Causes:.........................................................................199
			Effects:........................................................................199
			Remedies:.......................................................................199
			Wear of Tooth Tip...............................................................200
			Causes:.........................................................................200
			Effects:........................................................................200
			Remedies:.......................................................................200
			Tooth Tip Broken Off............................................................201
			Causes:.........................................................................201
			Effects:........................................................................201
			Remedies:.......................................................................201
			Facial Wear.....................................................................202
			Causes:.........................................................................202
			Effects:........................................................................202
			Remedies:.......................................................................202
		Notes...............................................................................203
CAT MD6420B X52 REV.04 SECTION FOUR.........................................................205
	Section 4 - Engine / Drive Train Compressor.............................................205
		Section 4 Contents..................................................................207
		Power Group Locator.................................................................210
		Cummins Engine......................................................................211
			Engine Fuel System..............................................................212
			QST30 Electric Fuel Supply Flow Diagram.........................................212
			Construction....................................................................213
			Electric Fuel Supply Pumps......................................................213
			Combo Fuel Filter Head And Pump Manifold........................................214
			FS1006 Fuel Filter With Water Separator.........................................214
			Fuel Manifold With Integrated FSO Valve.........................................215
			Fuel Connections................................................................215
			Pre - Filters...................................................................216
			Wiring With EFS Power Relay.....................................................216
			Pressure And Temperature Sensors................................................217
			Operation.......................................................................217
			QST30 Electric Fuel Supply System Flow Diagram..................................218
			QST30 Electric Fuel Supply System Detail........................................219
			Oil Reserve Systems.............................................................220
			Operation.......................................................................220
			Engine Oil Reserve System (Basic Circuit).......................................220
			LED Monitor Readings............................................................221
			Signals.........................................................................221
			Adjustment Of Running Oil Level.................................................221
			Wiring Diagram - Oil Reserve Basic Circuit......................................222
			Oil Pressure Switch.............................................................222
			Oil Reserve System..............................................................222
			R200............................................................................222
			Troubleshooting.................................................................223
			Maintenance.....................................................................223
		Engine and Compressor Air Cleaners..................................................224
			Engine And Compressor Air Cleaner Service ......................................225
		Flexible Drive Coupling.............................................................228
			Flexible Drive Coupling Service.................................................228
		Pump Drive..........................................................................231
			Pump Identification.............................................................231
			Pump Drive Assembly – Removal And Replacement...................................232
			Pump Drive Gearbox..............................................................233
			Pump Drive Gearbox – Repair.....................................................234
			3” Input Shaft Assembly.........................................................236
		Hydraulic Pumps.....................................................................237
			Hydraulic Pumps – Removal And Replacement.......................................237
		Compressor Assembly.................................................................238
			Drill Compressor Model 20/12 1475cfm @ 500psi...................................238
			Compressor Drive Coupling.......................................................241
		Compressor Installation.............................................................242
			Compressor Drive Coupling – Removal And Replacement.............................242
			Compressor Unit – Removal:......................................................243
		Compressor Shaft Seal...............................................................245
			Main Drive Shaft Seal Replacement...............................................245
			Inspection and Preparation For Seal Assembly....................................246
		High Pressure Compressor............................................................248
			Safety..........................................................................248
		Compressor Oil Circuit..............................................................255
			Compressor Oil Circuit - 1475cfm @ 500psi.......................................255
		Compressor Condensation Table.......................................................258
		Compressor Air Circuit..............................................................259
			Compressor Air Circuits – 1475cfm @ 500psi......................................259
		Compressor Functional Description...................................................260
			Compressor Air Circuit..........................................................260
			Compressor Gauge ...............................................................261
			Compressor Control Valve........................................................261
			Compressor Run Valve............................................................262
			Compressor Run..................................................................262
			Compressor Control Pressure Reducing Regulator .................................263
			Compressor Air Circuit..........................................................266
		Compressor Operation................................................................267
			Operation.......................................................................267
			Purpose Of Controls.............................................................268
		Compressor Maintenance..............................................................270
			General Maintenance.............................................................270
			Interstage Tube.................................................................272
			Flexible Pipe Coupling Maintenance..............................................272
			Discharge Check Valve...........................................................273
			Separator / Receiver Tank.......................................................274
			Scavenge Line...................................................................276
			Compressor Discharge Temperature Switches, Senders And Gauges...................277
			Minimum Pressure / Check Valve..................................................278
			Minimum Pressure / Check Valve Maintenance......................................278
			Thermal / Bypass Valve..........................................................279
			Compressor Fluid Filter.........................................................281
			Fluid Stop Valve................................................................283
			Inlet Valve.....................................................................285
			Reducing Regulator..............................................................287
			System Blowdown Valve...........................................................289
			Running Blowdown Valve..........................................................290
			Running Blowdown Maintenance....................................................291
			Moisture Separator Maintenance..................................................292
			Auxiliary Regulator.............................................................293
			Auxiliary Regulator Maintenance.................................................295
			Coolers Locator.................................................................299
			Compressor Oil Cooler...........................................................300
		Compressor / Hydraulic Oil Cooler Service Manual....................................301
		Notes...............................................................................310
CAT MD6420B X52 REV.04 SECTION FIVE.........................................................311
	Section 5 - Dust Control System.........................................................311
		Section 5 Contents..................................................................313
		Dust Control System.................................................................315
		Water Injection.....................................................................316
			Water Tanks.....................................................................316
			Water Injection.................................................................317
			Water Injection Relief Valve....................................................317
		Water Pump..........................................................................321
			Pump Specifications.............................................................321
			Servicing Instructions..........................................................321
			General Care Of The Pump........................................................321
			Care In Freezing Weather........................................................321
			Parts List......................................................................322
			Replacing Piston Cup Seals......................................................323
			Replacing Suction And Discharge Valves..........................................324
			Replacing Power End Bearings....................................................325
			Servicing The Wrist Pin Bearings................................................326
			Fastener Torque Requirements....................................................326
			Recommended Lubricants..........................................................327
			Water Pump Motor Repair.........................................................327
			Water Injection Hydraulic Control Valve Repair..................................327
			Water Pump Drive Coupling.......................................................327
			Level and Flow Transducer.......................................................327
		High Pressure Cleaner...............................................................328
			High Pressure Washdown (Motor and Pump).........................................328
			SAFETY WARNINGS.................................................................328
			Pressure Washer Operation ......................................................329
			Pump Assembly...................................................................333
		Foam System (Optional)..............................................................337
			Foam Pump.......................................................................337
CAT MD6420B X52 REV.04 SECTION SIX..........................................................341
	Section 6 - Mast / Rotary Drive / Pipe Rack.............................................341
		Section 6 Contents..................................................................343
		Mast Weldment.......................................................................345
		Weld Inspection Schedule............................................................346
			Mast Inspection.................................................................346
		Mast Assembly and Installation......................................................347
			Mast Assembly 16m...............................................................347
			Mast............................................................................347
			Mast / Drill Without Mast.......................................................348
			Mast Assembly...................................................................349
			Installing And Removal Of The Mast..............................................349
			Bleeding Mast Raise Cylinders...................................................351
			Mast Set Up For Bolt Tightening Of Pivot Caps...................................352
			Mast Pivot Cap Bolts............................................................353
			Bolt Tightening Sequence........................................................353
			Mast A-frame And Pivot Shaft....................................................356
			Mast A-frame Pivot Shaft Cap Bolts..............................................357
			Bolt Tightening Sequence........................................................357
			Mast Pivot......................................................................358
			Mast A-frame Pivot Shaft Cap Bolts..............................................359
			Mast Elevate Cylinders..........................................................359
			Angle Drilling..................................................................359
			Mast Locking....................................................................359
			Mast Installation - Mast Raise Cylinder Wedges..................................360
			Mast Raise Plumbing Removal.....................................................361
		Cylinder, Hoist / Pulldown..........................................................362
			Cylinder, Hoist / Pulldown......................................................362
			Cylinder, Hoist / Pulldown Assembly.............................................363
			Removal.........................................................................365
		Hoist / Pulldown Cable Adjustment With Auto Tension.................................366
			Hoist / Pulldown Cables.........................................................366
			Cable Tensioner Circuit  .......................................................367
		Manual Hoist / Pulldown Cable Adjustment ...........................................369
			Adjustment......................................................................369
			Replacement.....................................................................371
		Hoist / Pulldown Cable Adjustment With Auto Tension.................................372
			Wire Cable......................................................................372
			Sheave Rollers..................................................................372
		Rotary Drive........................................................................373
			Rotary Head Assembly............................................................373
			Rotary Head Guide Alignment.....................................................374
			Rotary Head Drive System........................................................375
			Rotary Drive....................................................................376
			Removal From Mast...............................................................376
			Installation....................................................................376
			Rotary Drive Gearbox............................................................379
			Repair..........................................................................379
			Main Shaft Bearing Preload......................................................379
			Rotary Head Bull Shaft Bearing Nut..............................................381
			Manufacturers Recommendations – Blast Hole Drilling Consumables ................382
			Top Sub Serviceable.............................................................382
			Lifting Bails...................................................................382
			Air Swivel (Single Seal Style)..................................................383
			Service.........................................................................383
		Winch Assembly......................................................................384
			Precautions On The Use Of Winches...............................................384
			Wire Cable......................................................................384
			Grooved Drums...................................................................386
			Plain (Smooth) Drums............................................................386
			Drums - Multiple Layers.........................................................386
			Winch Assembly Service..........................................................387
			Deck Wrench.....................................................................388
		Deck Wrench.........................................................................389
		H.O.B.O Wrench......................................................................390
			Breakout System – H.O.B.O.......................................................391
			Hydraulic Operated Bit Basket – H.O.B.B (Optional)..............................391
			Pipe Safety Arm.................................................................391
		Pipe Positioner.....................................................................392
		Carousel Pipe Rack..................................................................393
			Major Components................................................................393
			Rod Handling – Carousal Indexing................................................394
			Pipe Rack Assembly..............................................................395
			General Information.............................................................396
			Pipe Rack Bearings – Removal....................................................396
			Pipe Rack Components – Inspection...............................................398
			Pipe Rack – Assembly And Installation...........................................399
			Pipe Rack Roller – Remove And Replace...........................................400
			Pipe Rack Roller – Disassembly And Assembly.....................................401
		Bit Sub Length Adjustment...........................................................403
		Configuration Screen................................................................404
			Configuration - Drill String....................................................404
		Configuration - Drill String........................................................405
			Depth Position System- Linear Transducer .......................................406
		Notes...............................................................................409
CAT MD6420B X52 REV.04 SECTION SEVEN........................................................411
	Section 7 - Hydraulic Systems...........................................................411
		Section 7 Contents..................................................................413
		Hydraulic Symbols...................................................................416
		Pressure Setting Sequence...........................................................418
		Hydraulic Tank......................................................................419
			Return Hydraulic Filters........................................................420
		Main Return and Case Drain Filter...................................................421
			Routine Maintenance.............................................................422
		Main Hydraulic Pumps................................................................423
			Pump Identification.............................................................423
		Linde Bi-Directional Hydraulic Pumps................................................424
			Linde Hydraulics ...............................................................424
		Linde Bi-Directional Hydraulic Pumps................................................425
			Port And Valve Identification ..................................................425
			Linde Hydraulics Schematic......................................................426
		Right Track / Hoist Pull Down Pump..................................................427
			Main Pump Adjustments...........................................................427
			Setting The Hydraulic Neutral...................................................429
			The Regulation ‘Begin’ Adjustment...............................................430
			High Pressure Relief Valves ....................................................432
			Pressure Over Ride (POR) Adjustment.............................................433
		Charge Filter.......................................................................434
			Routine Maintenance.............................................................434
			Changing Filter Elements........................................................435
			Routine Maintenance.............................................................436
			Changing Filter Elements........................................................439
		Main Pump Shaft Seal Replacement....................................................440
			Disassembly Procedure...........................................................442
		Main Pumps Circuit..................................................................444
			Left Track And Rotation Pump....................................................444
			Right Track And Pulldown Pump...................................................444
			Basic Left Track / Rotation Pump Circuit........................................445
		Rotation Circuit....................................................................446
			Rotary Torque Control...........................................................446
			Rotation Circuit................................................................448
		Rotary Drive Gear Box Motor.........................................................450
			Rotary Drive Gearbox Motor – Test And Repair....................................450
			Shaft Seal Replacement..........................................................451
			Trouble Shooting................................................................453
		Right Track / Pulldown And Hoist Circuit............................................455
			Right Hand Main Pump Basic Operation............................................455
			Hoist / Pulldown Cylinder Counterbalance Valve..................................457
		Tram Circuit........................................................................458
		Auxillary Pump Circuit..............................................................460
			Auxiliary Pump..................................................................460
			Pump Replacement – Start Up.....................................................464
		Mast, Jacks, Winch And Water Valve..................................................466
			Load Sense Auxiliary Circuit....................................................466
			K170............................................................................468
			Jack Control And Mast Elevating Circuit.........................................469
		Jacks And Mast / Water And Winch....................................................471
			Jack Control And Mast Elevating Control Valve...................................471
		Jacks and Mast / Water And Foam Injection...........................................472
			Winch Section...................................................................472
			Port Relief.....................................................................472
		Jacks And Mast / Water Injection And Winch..........................................473
			K170LS – A01....................................................................473
			Proportional Pressure Reducing Valve............................................474
		Counterbalance Valves...............................................................475
			Counterbalance Valve Adjustments................................................475
		Levelling Jack Cylinders............................................................477
			Counterbalance Valve Adjustments................................................477
		Mast Elevating Cylinders............................................................479
			Counterbalance Valve Adjustments................................................479
			Mast Elevating Cylinder.........................................................479
		Mast Elevating Cylinders............................................................480
		Auxiliary Functions Circuit.........................................................482
		Auxiliary Functions And Mast Valves.................................................484
			Features........................................................................485
			General Description.............................................................485
		Auxillary Pump Circuit..............................................................486
			Non Load Sense Auxiliary Circuit................................................486
		PWM Proportional Pilot Valves.......................................................487
		Hydraulic Operated Breakout Wrench..................................................490
			Setting Of HOBO Sequence Valves.................................................491
			H.O.B.O Float Cylinder..........................................................491
		Pipe Positioner.....................................................................492
			Setting Of Pipe Positioner Sequence Valves......................................492
		Brake, Drill / Tram And Cable Tensioner Solenoid Valve..............................493
			Brake, Drill / Tram And Cable Tensioner Solenoid Valve..........................493
		Hoist / Pulldown Cable Adjustment with Auto Tension.................................495
			Cable Tensioner Circuit  .......................................................495
		Hydraulic Systems...................................................................497
			Fan Pump – Removal And Replacement..............................................497
			Hydraulic Gear Pumps – Repairs, Operation, Specifications And Adjustment........497
			Tool List.......................................................................499
		Cooler Fan Circuit..................................................................500
			Fan Motor Circuit...............................................................500
			Hydraulic Motor.................................................................504
			General Information.............................................................504
			Specifications And Tools........................................................505
		Hydraulic Thermostatic Valve........................................................508
			Hydraulic Cooler – Thermal Valve................................................508
		Central Lube........................................................................509
			Auto Lube.......................................................................509
		Water Pump Motor....................................................................510
			Water Pump Motor Repair Information.............................................510
			Shaft Seal Repair...............................................................511
		Hydraulic Cylinder Repair...........................................................515
			Hydraulic Cylinders.............................................................515
			General Information.............................................................516
			H Head..........................................................................518
			N Head..........................................................................519
			Z Head..........................................................................520
			N Head..........................................................................521
			K Head..........................................................................522
			M Head..........................................................................523
			Z Piston........................................................................524
			Z Piston (Threaded).............................................................525
			H And K Piston..................................................................526
			M Piston........................................................................527
			N Piston........................................................................530
		Notes...............................................................................531
CAT MD6420B X52 REV.04 SECTION EIGHT........................................................533
	Section 8 - Electrical Components.......................................................533
		Section 8 Contents..................................................................535
		Contents............................................................................535
		Jump Starting.......................................................................539
			Precautions.....................................................................540
			Procedure.......................................................................540
		Batteries...........................................................................541
		Welding Precautions.................................................................542
			Welding Precautions.............................................................542
		General Arrangement Layout..........................................................543
		Transducer Box Detail...............................................................544
		Flow Monitor........................................................................545
			Functions And Features..........................................................545
			Application Area................................................................545
			Operating Principle.............................................................545
		Flow Monitor........................................................................546
			Mounting........................................................................546
			Mounting Operation..............................................................546
			Electrical Connection...........................................................546
			Set-Up And Settings For Water...................................................547
			High Flow Adjustment (Optional).................................................548
			Error During Adjustment.........................................................548
			Lock / Unlock The Unit..........................................................548
			Operation And Maintenance.......................................................549
		Flow Monitor........................................................................550
			Technical Data..................................................................550
			Liquids.........................................................................550
			EMC.............................................................................550
		Limit Switch........................................................................551
		Level Sensor........................................................................552
			Introducing Level Sensor........................................................552
			DX10 Ultrasonic Level Frequency Transmitter.....................................552
			Features........................................................................552
		Compressor Temperature Switches - Shut Down.........................................554
			Compressor Temperature Switches.................................................554
		Air Indicators Engine and Compressor - Alarm........................................555
			Air Filter Indicator Switches...................................................555
			How Does It Work? ..............................................................555
		Air Indicators Engine and Compressor - Shutdown.....................................556
			Air Filter Indicator Switches...................................................556
			How Does It Work? ..............................................................556
		Differential Pressure Switches......................................................557
			Hydraulic Filter Indicator Switches.............................................557
		Compressor Temperature Transducer...................................................559
		Measured Signal Converter For Temperature Sensors...................................560
			Operating Instructions .........................................................560
		40 Bar Electronic Pressure Transducer ..............................................562
			Description.....................................................................562
		250 Bar Electronic Pressure Transducer .............................................564
			Description.....................................................................564
		600 Bar Electronic Pressure Transducer .............................................566
			Description.....................................................................566
		Drill Dash Board ...................................................................567
			General Information.............................................................567
			Monitor.........................................................................567
			Activation......................................................................567
			Cleaning........................................................................567
			Specifications..................................................................567
			Monitor.........................................................................568
			Brightness Control..............................................................568
			LED Status......................................................................569
			Dashboard.......................................................................569
			Log In Screen...................................................................570
			Log In..........................................................................570
			Drill Bit Settings..............................................................571
			Hour Meters.....................................................................572
			Tram Screen.....................................................................573
		Drill Dash Board ...................................................................574
			Tram Function Interlocks........................................................574
			Artificial Horizon Gauges.......................................................576
			Inclinometers...................................................................578
			Leveling Inclinometer...........................................................580
			Auto Level......................................................................584
			Auto Mast / Manual Mast Operation...............................................585
			Auto Mast ......................................................................586
			Auto Mast Info..................................................................587
			Auto Mast – Angle Sensor........................................................588
			Drill Screen....................................................................591
			Depth System Panel..............................................................592
			Pull Down Gauge Operation.......................................................593
			Drill Status....................................................................594
			Interlock Over Ride  ...........................................................595
			Drill Mode Interlocks...........................................................596
			Interlocks  ....................................................................597
			Pipe In Hole....................................................................597
			Tram Interlocks.................................................................598
			Pipe in Hole....................................................................598
			Virtual Feed (Pulldown) Stop  ..................................................599
			Virtual Feed 
Stop Indication ..................................................599
			Virtual Hoist Stop..............................................................600
			Virtual Hoist 
Stop Indication .................................................600
			Depth System....................................................................601
			Depth System – Linear Transducer................................................602
			Depth Position System- Linear Transducer .......................................603
			Carousel Interlock .............................................................605
			Auto Drill......................................................................606
			Engine Screen...................................................................607
			Start Interlock Display.........................................................608
			Event Screen....................................................................609
			Event Acknowledgement...........................................................611
			Status Screen...................................................................612
			Sub Screen - Gauges.............................................................613
			Sub Screen - Network............................................................614
			Sub Screen - Input..............................................................615
			Sub Screen - Input - Cab........................................................616
			Sub Screen - Input - Mast.......................................................617
			Sub Screen - Input - Output.....................................................618
			Cable Break Detection ..........................................................619
			Help Screen  ...................................................................620
			Help Screen - Icons   ..........................................................621
			Configuration Screen ...........................................................629
			Configuration Screen Lubrication................................................630
			Configuration - Depth...........................................................631
			Sensor Calibration .............................................................631
			Calibration.....................................................................632
			Configuration – Depth System....................................................633
			Configuration – Inclinometers...................................................636
			Configuration - Auto Drill......................................................637
			Overrides.......................................................................638
			CAN BUS Network.................................................................639
			Setting Node ID And Baudrate....................................................641
			CAN BUS Network- Data Transmission..............................................642
			CAN BUS Network - Electrical Trouble Shooting...................................643
			Electrical Trouble Shooting.....................................................644
			CAN BUS Network - Electrical Trouble Shooting...................................645
			Mast Removed Switch ............................................................646
			Installing A PCI Can Card In The Monitor .......................................648
			Installing CF Card..............................................................652
			Accessing Special Functions.....................................................655
			Accessing Windows ..............................................................656
			User Data Base..................................................................657
			Add a new User .................................................................658
			File Export.....................................................................659
			Procedure To Backup Log Files Of The Monitor....................................661
			Access levels...................................................................662
			Updating of Manuals in the Monitor..............................................663
			Manual Update...................................................................665
			Shutting Down And Isolation ....................................................667
		Assembling Head Speed Proxy.........................................................668
		SCHEMATIC, ELECTRICAL...............................................................669
		Notes...............................................................................  0
CAT MD6420B X52 REV.04 SECTION NINE.........................................................711
	Section 9 - Lubrication & Preventative Medicine.........................................711
		Section 9 Contents..................................................................713
		Filter Locator......................................................................717
			Filter Locator Assembly.........................................................717
		Central Lube System.................................................................718
			Hydraulic Control Schematic.....................................................719
			Central Lube System Circuit.....................................................720
			Central lube Tank Assembly......................................................721
			Typical Installation............................................................722
			Vent Valve Installation Kit.....................................................723
			Control Module Installation Kit.................................................723
			Operation.......................................................................724
			Central Lube Pump...............................................................726
			Technical Data .................................................................726
			Trouble Shooting................................................................727
			Service.........................................................................728
			Reciprocator Repair.............................................................730
			Displacement Pump Repair........................................................734
			Reciprocator Parts..............................................................737
			Instructions – Vent Valve.......................................................738
			Basic Operating Principles Of Auto Lube Injectors...............................739
			SL - V and SL - V XL Injectors .................................................739
			Stage 4.........................................................................739
			SL - 1 and SL - 11 Injectors....................................................740
			SL - 32 Injectors...............................................................741
			Typical Grease System Circuit ..................................................742
			First 50 Hour Service...........................................................743
			50 Hour Service Or When First Setting Addressing Auto Lube System...............743
			First 250 Hour Service And Every 500 Hours After................................743
			Lube Faults / Operation.........................................................744
			Lube Fault .....................................................................744
			Auto Lube Timer.................................................................745
			Auto Lube Pressure..............................................................745
		Hammer Oil System...................................................................746
			Hammer Oiler System Assembly....................................................746
			Hammer Oil System...............................................................747
			Operation.......................................................................748
			Troubleshooting.................................................................749
			Air Motor And Throat Service....................................................750
			Displacement Pump Service.......................................................754
			Parts List......................................................................755
			Parts Drawing...................................................................756
			Dimensions......................................................................757
			Technical Data..................................................................757
		Air Service Units...................................................................758
			Filter / Regulator / Lubricator.................................................758
			Filter Maintenance And Repair...................................................759
			Regulator Maintenance and Repair................................................760
			Lubricator Maintenance and Repair...............................................761
		Pipe Thread Lubricator..............................................................762
			Air Operated Pipe Thread Pump...................................................762
			Specifications..................................................................762
			Description.....................................................................762
			Owner / Operator Responsibility.................................................762
			Safety Information..............................................................762
			Installation....................................................................763
			Typical System Hook Up..........................................................763
			Pressure Relief Procedure.......................................................764
			Operation.......................................................................764
			Using Pump......................................................................764
			Maintenance.....................................................................765
			Lubrication ....................................................................765
			Material Restriction Prevention.................................................765
			Corrosion Prevention............................................................765
			Disassembly.....................................................................765
			Assembly........................................................................766
			Repair..........................................................................767
			Troubleshooting.................................................................768
			Parts List......................................................................768
		Lubrication And Preventive Maintenance..............................................770
			General Lubrication.............................................................770
			Equipment Lubrication...........................................................770
			Care Of Lubrication Points......................................................770
			Safety..........................................................................771
			Isolation – Battery Switch......................................................772
			Track Gear......................................................................773
			Engine Maintenance..............................................................774
			Air Cleaners....................................................................775
			Air Filter Elements.............................................................775
			Alternator Maintenance .........................................................775
			250 hrs.........................................................................775
			Pump Drive And Drive Shaft Maintenance .........................................776
			Compressor Maintenance..........................................................776
			Cooler Packs....................................................................778
			A-frame And Pivot Point Maintenance.............................................780
			
Pulldown And Hoist Cables And Sheaves Maintenance..............................780
			Rotary Head Maintenance ........................................................780
			Hydraulic System Maintenance....................................................782
			Hydraulic Maintenance...........................................................782
			Water Pump Maintenance .........................................................782
			Cab Maintenance ................................................................782
			Air Conditioner Maintenance ....................................................784
			Battery Maintenance.............................................................784
			Lubrication System Maintenance .................................................784
			Fire Suppression Maintenance ...................................................784
			Drill Folding Stairway – Inspection Requirements................................786
			For All Machines Fitted With Folding Stairway...................................786
			Preventative Maintenance........................................................786
		Weld Inspection Schedule............................................................787
		Track And Sprocket Inspection.......................................................788
			Track Inspection And Wear Limit Guide...........................................788
			B8 Track Inspection and Wear Limit Guide........................................788
			Undercarriage Information.......................................................788
			Sprocket Wear Patterns..........................................................792
			Wear On Forward Drive Side......................................................792
			Wear On Reverse Drive Side......................................................793
			Root Wear.......................................................................794
			Wear Of Tooth Tip...............................................................795
			Tooth Tip Broken Off............................................................796
			Facial Wear.....................................................................797
		Lubrication Recommendations.........................................................798
		Lubrication And Maintenance Chart...................................................799
			Lubrication And Maintenance Notations...........................................802
		Lubricant Specifications............................................................803
			Hydraulic System................................................................803
			Selection Of Hydraulic Oil......................................................803
			Hydraulic Tank Capacity.........................................................803
			Compressor Lubricant Specifications  ...........................................803
			Lubricating Grease..............................................................804
			Gear Lubricant..................................................................804
			Scheduled Oil Sampling Analysis.................................................804
		Preventive Maintenance – Weld Inspection............................................805
			Lubrication and Preventative Maintenance........................................805
		Preventative Maintenance – Bolted Joints............................................806
			Bolted Joint Maintenance For Rotary Drills......................................806
			Introduction....................................................................806
			Proper Bolt Tension.............................................................806
			Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance....806
			Critical Bolted Joint Maintenance...............................................  0
			Other Bolt Maintenance..........................................................  0
			SAE Recommended Torque Values...................................................  0
			NORD - LOCK Washers.............................................................  0
			Critical Fastener ID And Inspection Schedule....................................807
		Critical Fastener Torque Values.....................................................  0
			MD6420B.........................................................................  0
		Mast Connection Points..............................................................  0
			Mast Connection Points Dimension Reporting......................................  0
		Notes...............................................................................808
Untitled....................................................................................  0
Untitled....................................................................................  0
Blank Page..................................................................................354
Blank Page..................................................................................355

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

 S.V