Cat MD6420B Rotary Blasthole Track Drill Service Manual 2U67X53 – PDF DOWNLOAD

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Cat MD6420B Rotary Blasthole Track Drill Service Manual 2U67X53 – PDF DOWNLOAD

CAT MD6420B ROTARY BLASTHOLE TRACK DRILL SERVICE MANUAL 2U67X53 – PDF DOWNLOAD:

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Cat MD6420B Rotary Blasthole Track Drill Service Manual 2U67X53 – PDF DOWNLOAD

Caterpillar Serial Number: 2U67X53

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 Track Drill Service Manual 2U67X53 – PDF DOWNLOAD

CAT MD6420B X53 REV.04 SERVICE MANUAL.......................................................  1
	Parts Ordering and Product Support......................................................  3
	Safety Information......................................................................  4
	Contents................................................................................  5
	General Locator......................................................................... 25
		General Locator..................................................................... 25
	Notes................................................................................... 28
CAT MD6420B X53 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 X53 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 X53 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 X53 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 X53 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 X53 REV.04 SECTIION 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....................................................354
			Mast A-frame Pivot Shaft Cap Bolts..............................................355
			Bolt Tightening Sequence........................................................355
			Mast Pivot......................................................................356
			Mast A-frame Pivot Shaft Cap Bolts..............................................357
			Mast Elevate Cylinders..........................................................357
			Angle Drilling..................................................................357
			Mast Locking....................................................................357
			Mast Installation - Mast Raise Cylinder Wedges..................................358
			Mast Raise Plumbing Removal.....................................................359
		Cylinder, Hoist / Pulldown..........................................................360
			Cylinder, Hoist / Pulldown......................................................360
			Cylinder, Hoist / Pulldown Assembly.............................................361
			Removal.........................................................................363
		Hoist / Pulldown Cable Adjustment With Auto Tension.................................364
			Hoist / Pulldown Cables.........................................................364
			Cable Tensioner Circuit  .......................................................365
		Manual Hoist / Pulldown Cable Adjustment ...........................................367
			Adjustment......................................................................367
			Replacement.....................................................................369
		Hoist / Pulldown Cable Adjustment With Auto Tension.................................370
			Wire Cable......................................................................370
			Sheave Rollers..................................................................370
		Rotary Drive........................................................................371
			Rotary Head Assembly............................................................371
			Rotary Head Guide Alignment.....................................................372
			Rotary Head Drive System........................................................373
			Rotary Drive....................................................................374
			Removal From Mast...............................................................374
			Installation....................................................................374
			Rotary Drive Gearbox............................................................377
			Repair..........................................................................377
			Main Shaft Bearing Preload......................................................377
			Rotary Head Bull Shaft Bearing Nut..............................................379
			Manufacturers Recommendations – Blast Hole Drilling Consumables ................380
			Top Sub Serviceable.............................................................380
			Lifting Bails...................................................................380
			Air Swivel (Single Seal Style)..................................................381
			Service.........................................................................381
		Winch Assembly......................................................................382
			Precautions On The Use Of Winches...............................................382
			Wire Cable......................................................................382
			Grooved Drums...................................................................384
			Plain (Smooth) Drums............................................................384
			Drums - Multiple Layers.........................................................384
			Winch Assembly Service..........................................................385
			Deck Wrench.....................................................................386
		Deck Wrench.........................................................................387
		H.O.B.O Wrench......................................................................388
			Breakout System – H.O.B.O.......................................................389
			Hydraulic Operated Bit Basket – H.O.B.B (Optional)..............................389
			Pipe Safety Arm.................................................................389
		Pipe Positioner.....................................................................390
		Carousel Pipe Rack..................................................................391
			Major Components................................................................391
			Rod Handling – Carousal Indexing................................................392
			Pipe Rack Assembly..............................................................393
			General Information.............................................................394
			Pipe Rack Bearings – Removal....................................................394
			Pipe Rack Components – Inspection...............................................396
			Pipe Rack – Assembly And Installation...........................................397
			Pipe Rack Roller – Remove And Replace...........................................398
			Pipe Rack Roller – Disassembly And Assembly.....................................399
		Bit Sub Length Adjustment...........................................................401
		Configuration Screen................................................................402
			Configuration - Drill String....................................................402
		Configuration - Drill String........................................................403
			Depth Position System- Linear Transducer .......................................404
		Notes...............................................................................407
CAT MD6420B X53 REV.04 SECTION SEVEN........................................................409
	Section 7 - Hydraulic Systems...........................................................409
		Section 7 Contents..................................................................411
		Hydraulic Symbols...................................................................414
		Pressure Setting Sequence...........................................................416
		Hydraulic Tank......................................................................417
			Return Hydraulic Filters........................................................418
		Main Return and Case Drain Filter...................................................419
			Routine Maintenance.............................................................420
		Main Hydraulic Pumps................................................................421
			Pump Identification.............................................................421
		Linde Bi-Directional Hydraulic Pumps................................................422
			Linde Hydraulics ...............................................................422
		Linde Bi-Directional Hydraulic Pumps................................................423
			Port And Valve Identification ..................................................423
			Linde Hydraulics Schematic......................................................424
		Right Track / Hoist Pull Down Pump..................................................425
			Main Pump Adjustments...........................................................425
			Setting The Hydraulic Neutral...................................................427
			The Regulation ‘Begin’ Adjustment...............................................428
			High Pressure Relief Valves ....................................................430
			Pressure Over Ride (POR) Adjustment.............................................431
		Charge Filter.......................................................................432
			Routine Maintenance.............................................................432
			Changing Filter Elements........................................................433
			Routine Maintenance.............................................................434
			Changing Filter Elements........................................................437
		Main Pump Shaft Seal Replacement....................................................438
			Disassembly Procedure...........................................................440
		Main Pumps Circuit..................................................................442
			Left Track And Rotation Pump....................................................442
			Right Track And Pulldown Pump...................................................442
			Basic Left Track / Rotation Pump Circuit........................................443
		Rotation Circuit....................................................................444
			Rotary Torque Control...........................................................444
			Rotation Circuit................................................................446
		Rotary Drive Gear Box Motor.........................................................448
			Rotary Drive Gearbox Motor – Test And Repair....................................448
			Shaft Seal Replacement..........................................................449
			Trouble Shooting................................................................451
		Right Track / Pulldown And Hoist Circuit............................................453
			Right Hand Main Pump Basic Operation............................................453
			Hoist / Pulldown Cylinder Counterbalance Valve..................................455
		Tram Circuit........................................................................456
		Auxillary Pump Circuit..............................................................458
			Auxiliary Pump..................................................................458
			Pump Replacement – Start Up.....................................................462
		Mast, Jacks, Winch And Water Valve..................................................464
			Load Sense Auxiliary Circuit....................................................464
			K170............................................................................466
			Jack Control And Mast Elevating Circuit.........................................467
		Jacks And Mast / Water And Winch....................................................469
			Jack Control And Mast Elevating Control Valve...................................469
		Jacks and Mast / Water And Foam Injection...........................................470
			Winch Section...................................................................470
			Port Relief.....................................................................470
		Jacks And Mast / Water Injection And Winch..........................................471
			K170LS – A01....................................................................471
			Proportional Pressure Reducing Valve............................................472
		Counterbalance Valves...............................................................473
			Counterbalance Valve Adjustments................................................473
		Levelling Jack Cylinders............................................................475
			Counterbalance Valve Adjustments................................................475
		Mast Elevating Cylinders............................................................477
			Counterbalance Valve Adjustments................................................477
			Mast Elevating Cylinder.........................................................477
		Mast Elevating Cylinders............................................................478
		Auxiliary Functions Circuit.........................................................480
		Auxiliary Functions And Mast Valves.................................................482
			Features........................................................................483
			General Description.............................................................483
		Auxillary Pump Circuit..............................................................484
			Non Load Sense Auxiliary Circuit................................................484
		PWM Proportional Pilot Valves.......................................................485
		Hydraulic Operated Breakout Wrench..................................................488
			Setting Of HOBO Sequence Valves.................................................489
			H.O.B.O Float Cylinder..........................................................489
		Pipe Positioner.....................................................................490
			Setting Of Pipe Positioner Sequence Valves......................................490
		Brake, Drill / Tram And Cable Tensioner Solenoid Valve..............................491
			Brake, Drill / Tram And Cable Tensioner Solenoid Valve..........................491
		Hoist / Pulldown Cable Adjustment with Auto Tension.................................493
			Cable Tensioner Circuit  .......................................................493
		Hydraulic Systems...................................................................495
			Fan Pump – Removal And Replacement..............................................495
			Hydraulic Gear Pumps – Repairs, Operation, Specifications And Adjustment........495
			Tool List.......................................................................497
		Cooler Fan Circuit..................................................................498
			Fan Motor Circuit...............................................................498
			Hydraulic Motor.................................................................502
			General Information.............................................................502
			Specifications And Tools........................................................503
		Hydraulic Thermostatic Valve........................................................506
			Hydraulic Cooler – Thermal Valve................................................506
		Central Lube........................................................................507
			Auto Lube.......................................................................507
		Water Pump Motor....................................................................508
			Water Pump Motor Repair Information.............................................508
			Shaft Seal Repair...............................................................509
		Hydraulic Cylinder Repair...........................................................513
			Hydraulic Cylinders.............................................................513
			General Information.............................................................514
			H Head..........................................................................516
			N Head..........................................................................517
			Z Head..........................................................................518
			N Head..........................................................................519
			K Head..........................................................................520
			M Head..........................................................................521
			Z Piston........................................................................522
			Z Piston (Threaded).............................................................523
			H And K Piston..................................................................524
			M Piston........................................................................525
			N Piston........................................................................528
		Notes...............................................................................529
CAT MD6420B X53 REV.04 SECTION EIGHT........................................................531
	Section 8 - Electrical Components.......................................................531
		Section 8 Contents..................................................................533
		Contents............................................................................533
		Jump Starting.......................................................................537
			Precautions.....................................................................538
			Procedure.......................................................................538
		Batteries...........................................................................539
		Welding Precautions.................................................................540
			Welding Precautions.............................................................540
		General Arrangement Layout..........................................................541
		Transducer Box Detail...............................................................542
		Flow Monitor........................................................................543
			Functions And Features..........................................................543
			Application Area................................................................543
			Operating Principle.............................................................543
		Flow Monitor........................................................................544
			Mounting........................................................................544
			Mounting Operation..............................................................544
			Electrical Connection...........................................................544
			Set-Up And Settings For Water...................................................545
			High Flow Adjustment (Optional).................................................546
			Error During Adjustment.........................................................546
			Lock / Unlock The Unit..........................................................546
			Operation And Maintenance.......................................................547
		Flow Monitor........................................................................548
			Technical Data..................................................................548
			Liquids.........................................................................548
			EMC.............................................................................548
		Limit Switch........................................................................549
		Level Sensor........................................................................550
			Introducing Level Sensor........................................................550
			DX10 Ultrasonic Level Frequency Transmitter.....................................550
			Features........................................................................550
		Compressor Temperature Switches - Shut Down.........................................552
			Compressor Temperature Switches.................................................552
		Air Indicators Engine and Compressor - Alarm........................................553
			Air Filter Indicator Switches...................................................553
			How Does It Work? ..............................................................553
		Air Indicators Engine and Compressor - Shutdown.....................................554
			Air Filter Indicator Switches...................................................554
			How Does It Work? ..............................................................554
		Differential Pressure Switches......................................................555
			Hydraulic Filter Indicator Switches.............................................555
		Compressor Temperature Transducer...................................................557
		Measured Signal Converter For Temperature Sensors...................................558
			Operating Instructions .........................................................558
		40 Bar Electronic Pressure Transducer ..............................................560
			Description.....................................................................560
		250 Bar Electronic Pressure Transducer .............................................562
			Description.....................................................................562
		600 Bar Electronic Pressure Transducer .............................................564
			Description.....................................................................564
		Drill Dash Board ...................................................................565
			General Information.............................................................565
			Monitor.........................................................................565
			Activation......................................................................565
			Cleaning........................................................................565
			Specifications..................................................................565
			Monitor.........................................................................566
			Brightness Control..............................................................566
			LED Status......................................................................567
			Dashboard.......................................................................567
			Log In Screen...................................................................568
			Log In..........................................................................568
			Drill Bit Settings..............................................................569
			Hour Meters.....................................................................570
			Tram Screen.....................................................................571
		Drill Dash Board ...................................................................572
			Tram Function Interlocks........................................................572
			Artificial Horizon Gauges.......................................................574
			Inclinometers...................................................................576
			Leveling Inclinometer...........................................................578
			Auto Level......................................................................582
			Auto Mast / Manual Mast Operation...............................................583
			Auto Mast ......................................................................584
			Auto Mast Info..................................................................585
			Auto Mast – Angle Sensor........................................................586
			Drill Screen....................................................................589
			Depth System Panel..............................................................590
			Pull Down Gauge Operation.......................................................591
			Drill Status....................................................................592
			Interlock Over Ride  ...........................................................593
			Drill Mode Interlocks...........................................................594
			Interlocks  ....................................................................595
			Pipe In Hole....................................................................595
			Tram Interlocks.................................................................596
			Pipe in Hole....................................................................596
			Virtual Feed (Pulldown) Stop  ..................................................597
			Virtual Feed 
Stop Indication ..................................................597
			Virtual Hoist Stop..............................................................598
			Virtual Hoist 
Stop Indication .................................................598
			Depth System....................................................................599
			Depth System – Linear Transducer................................................600
			Depth Position System- Linear Transducer .......................................601
			Carousel Interlock .............................................................603
			Auto Drill......................................................................604
			Engine Screen...................................................................605
			Start Interlock Display.........................................................606
			Event Screen....................................................................607
			Event Acknowledgement...........................................................609
			Status Screen...................................................................610
			Sub Screen - Gauges.............................................................611
			Sub Screen - Network............................................................612
			Sub Screen - Input..............................................................613
			Sub Screen - Input - Cab........................................................614
			Sub Screen - Input - Mast.......................................................615
			Sub Screen - Input - Output.....................................................616
			Cable Break Detection ..........................................................617
			Help Screen  ...................................................................618
			Help Screen - Icons   ..........................................................619
			Configuration Screen ...........................................................627
			Configuration Screen Lubrication................................................628
			Configuration - Depth...........................................................629
			Sensor Calibration .............................................................629
			Calibration.....................................................................630
			Configuration – Depth System....................................................631
			Configuration – Inclinometers...................................................634
			Configuration - Auto Drill......................................................635
			Overrides.......................................................................636
			CAN BUS Network.................................................................637
			Setting Node ID And Baudrate....................................................639
			CAN BUS Network- Data Transmission..............................................640
			CAN BUS Network - Electrical Trouble Shooting...................................641
			Electrical Trouble Shooting.....................................................642
			CAN BUS Network - Electrical Trouble Shooting...................................643
			Mast Removed Switch ............................................................644
			Installing A PCI Can Card In The Monitor .......................................646
			Installing CF Card..............................................................650
			Accessing Special Functions.....................................................653
			Accessing Windows ..............................................................654
			User Data Base..................................................................655
			Add a new User .................................................................656
			File Export.....................................................................657
			Procedure To Backup Log Files Of The Monitor....................................659
			Access levels...................................................................660
			Updating of Manuals in the Monitor..............................................661
			Manual Update...................................................................663
			Shutting Down And Isolation ....................................................665
		Assembling Head Speed Proxy.........................................................666
		SCHEMATICS, ELECTRICAL..............................................................774
		Notes...............................................................................667
CAT MD6420B X53 REV.04 SECTION NINE.........................................................668
	Section 9 - Lubrication & Preventative Medicine.........................................668
		Section 9 Contents..................................................................670
		Filter Locator......................................................................674
			Filter Locator Assembly.........................................................674
		Central Lube System.................................................................675
			Hydraulic Control Schematic.....................................................676
			Central Lube System Circuit.....................................................677
			Central lube Tank Assembly......................................................678
			Typical Installation............................................................679
			Vent Valve Installation Kit.....................................................680
			Control Module Installation Kit.................................................680
			Operation.......................................................................681
			Central Lube Pump...............................................................683
			Technical Data .................................................................683
			Trouble Shooting................................................................684
			Service.........................................................................685
			Reciprocator Repair.............................................................687
			Displacement Pump Repair........................................................691
			Reciprocator Parts..............................................................694
			Instructions – Vent Valve.......................................................695
			Basic Operating Principles Of Auto Lube Injectors...............................696
			SL - V and SL - V XL Injectors .................................................696
			Stage 4.........................................................................696
			SL - 1 and SL - 11 Injectors....................................................697
			SL - 32 Injectors...............................................................698
			Typical Grease System Circuit ..................................................699
			First 50 Hour Service...........................................................700
			50 Hour Service Or When First Setting Addressing Auto Lube System...............700
			First 250 Hour Service And Every 500 Hours After................................700
			Lube Faults / Operation.........................................................701
			Lube Fault .....................................................................701
			Auto Lube Timer.................................................................702
			Auto Lube Pressure..............................................................702
		Hammer Oil System...................................................................703
			Hammer Oiler System Assembly....................................................703
			Hammer Oil System...............................................................704
			Operation.......................................................................705
			Troubleshooting.................................................................706
			Air Motor And Throat Service....................................................707
			Displacement Pump Service.......................................................711
			Parts List......................................................................712
			Parts Drawing...................................................................713
			Dimensions......................................................................714
			Technical Data..................................................................714
		Air Service Units...................................................................715
			Filter / Regulator / Lubricator.................................................715
			Filter Maintenance And Repair...................................................716
			Regulator Maintenance and Repair................................................717
			Lubricator Maintenance and Repair...............................................718
		Pipe Thread Lubricator..............................................................719
			Air Operated Pipe Thread Pump...................................................719
			Specifications..................................................................719
			Description.....................................................................719
			Owner / Operator Responsibility.................................................719
			Safety Information..............................................................719
			Installation....................................................................720
			Typical System Hook Up..........................................................720
			Pressure Relief Procedure.......................................................721
			Operation.......................................................................721
			Using Pump......................................................................721
			Maintenance.....................................................................722
			Lubrication ....................................................................722
			Material Restriction Prevention.................................................722
			Corrosion Prevention............................................................722
			Disassembly.....................................................................722
			Assembly........................................................................723
			Repair..........................................................................724
			Troubleshooting.................................................................725
			Parts List......................................................................725
		Lubrication And Preventive Maintenance..............................................727
			General Lubrication.............................................................727
			Equipment Lubrication...........................................................727
			Care Of Lubrication Points......................................................727
			Safety..........................................................................728
			Isolation – Battery Switch......................................................729
			Track Gear......................................................................730
			Engine Maintenance..............................................................731
			Air Cleaners....................................................................732
			Air Filter Elements.............................................................732
			Alternator Maintenance .........................................................732
			250 hrs.........................................................................732
			Pump Drive And Drive Shaft Maintenance .........................................733
			Compressor Maintenance..........................................................733
			Cooler Packs....................................................................735
			A-frame And Pivot Point Maintenance.............................................737
			
Pulldown And Hoist Cables And Sheaves Maintenance..............................737
			Rotary Head Maintenance ........................................................737
			Hydraulic System Maintenance....................................................739
			Hydraulic Maintenance...........................................................739
			Water Pump Maintenance .........................................................739
			Cab Maintenance ................................................................739
			Air Conditioner Maintenance ....................................................741
			Battery Maintenance.............................................................741
			Lubrication System Maintenance .................................................741
			Fire Suppression Maintenance ...................................................741
			Drill Folding Stairway – Inspection Requirements................................743
			For All Machines Fitted With Folding Stairway...................................743
			Preventative Maintenance........................................................743
		Weld Inspection Schedule............................................................744
		Track And Sprocket Inspection.......................................................745
			Track Inspection And Wear Limit Guide...........................................745
			B8 Track Inspection and Wear Limit Guide........................................745
			Undercarriage Information.......................................................745
			Sprocket Wear Patterns..........................................................749
			Wear On Forward Drive Side......................................................749
			Wear On Reverse Drive Side......................................................750
			Root Wear.......................................................................751
			Wear Of Tooth Tip...............................................................752
			Tooth Tip Broken Off............................................................753
			Facial Wear.....................................................................754
		Lubrication Recommendations.........................................................755
		Lubrication And Maintenance Chart...................................................756
			Lubrication And Maintenance Notations...........................................759
		Lubricant Specifications............................................................760
			Hydraulic System................................................................760
			Selection Of Hydraulic Oil......................................................760
			Hydraulic Tank Capacity.........................................................760
			Compressor Lubricant Specifications  ...........................................760
			Lubricating Grease..............................................................761
			Gear Lubricant..................................................................761
			Scheduled Oil Sampling Analysis.................................................761
		Preventive Maintenance – Weld Inspection............................................762
			Lubrication and Preventative Maintenance........................................762
		Preventative Maintenance – Bolted Joints............................................763
			Bolted Joint Maintenance For Rotary Drills......................................763
			Introduction....................................................................763
			Proper Bolt Tension.............................................................763
			Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance....763
			Critical Bolted Joint Maintenance...............................................764
			Other Bolt Maintenance..........................................................764
			SAE Recommended Torque Values...................................................765
			NORD - LOCK Washers.............................................................765
			Critical Fastener ID And Inspection Schedule....................................766
		Critical Fastener Torque Values.....................................................767
			MD6420B.........................................................................767
		Mast Connection Points..............................................................769
			Mast Connection Points Dimension Reporting......................................769
		Notes...............................................................................772

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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