Description

CAT MD6420B Rotary Blasthole Drill SERVICE MANUAL

index

Section Safety
Section Contents
Safety
Overview of Potential Hazards
Personal Protective Equipment
Noise
Electrical Contact
Overhead and Buried Utilities
Clearances from Overhead High Voltage Lines
Contact with Electric Wires
Contaminated Air
Moving and Rotating Parts
High Pressure Air or Fluid
Before Operation
During Operation
Maintenance
Equipment Transfer
Safety Locator
Notes
Section Operators Cab / Controls
Section Contents
Graphic Symbol Legend
Warning Decals
Operating System Help Table Icons
Operator Control and Instrument Panels
Control Panels
Right Hand Control Panel
Instrument Panel
Circuit Breakers
Light Switches
Operator Controls and Indicators
Advanced Drill Automation System (ADAS)

CAT MD6420B Rotary Blasthole Drill SERVICE MANUAL

Drill Monitor
Operation Controls
Function and Number Keys
LED states / Operating States
BI
MD B_X Introduction Int February,
Touch Screen Operation And Care
Touch Screen Operation
Cleaning The Housing
Cleaning The Touch Screen
Login Screen
Dashboard
Login Screen
Login Screen Updates
Login
Bit Settings
Hour Meters
Time Management
Drill Screen
Drill Screen Updates
Pull Down Gauge Operation
Depth System
Drill Status And Override Updates
Drill Status And Override
Operator Control And Instrument Panels
Left Hand Control Panels
Thread Grease Switch
Machine Stability
Tramming Procedure
Requirements For Propelling The Machine
Track Adjustments
New Machine Procedure
General Maintenance Checks While Tramming
Roller Locations
Temperature And Condition Record Chart For Walking
Propelling The Machine
Propelling Through Turns
Propelling Up, Down And Across Grades
Stability Limits
md b Transient Stability Limits
Cab Heater
Cab Heater Fault Isolation
Specifications
CAT MD6420B Rotary Blasthole Drill SERVICE MANUAL
Description Of Unit
Specifications
Installation And Commissioning
Servicing
Contents
BI
February, Int MD B_X Introduction
Fault Finding
Pressure Temperature Chart
Spare Parts / Drawings
Recovery Of Refrigerant
Warranty
Instructions
Section Main Frame Crawlers
Section Contents
Main Frame Repair General
Main Frame Repair
Weld Inspection Schedule
Main Frame
Levelling Jacks
Levelling Jack Cylinder
Limit Switch
Removal
Jack Cylinder Removal / Replacement
Lubricating Jack Casings
Replace Jack Cylinder
Mast Elevating Cylinders
Mast Raise Cylinders
Mast Raise Cylinder Removal
Mast Raise Cylinder Installation
Mast Elevating Cylinders
Internal Counterbalance Valve
Fuelling Valves
Fuelling Valves
Non pressurised Fuelling System Operation
Fuelling Valves
‘Conventional’ Systems
Fuelling Valves
Parts List
Crawler Assembly
Parts List
Crawler Component Repair
Tramming
Maintenance Checks For Tramming For Caterpillar Drills
Requirements For Propelling The Machine
Track Adjustments
New Machine Procedure
General Maintenance Checks While Tramming
Roller Locations
Temperature And Condition Record Chart For Walking
Contents
BI

CATERPILLAR MD6420B Rotary Blasthole Drill SERVICE MANUAL
MD B_X Introduction Int February,
Metric Bolt Torque Specifications
Metric Bolt Torque Specifications
Track Tension Adjustment
Before Operating The Machine
General Maintenance
Track Assembly
Idler Unit Description
Hydraulic Tensioner
Proper Track Tension
Nitrogen Tensioner
Track Chain
Track Chain
Track Link Position
Track Shoe – Mounting To Track Chain
Track Shoes Installation
Bolt Torque KN
Track Shoe Bolt Torque (Direct Torque Method)
Track Chain and Shoe Installation
Track Chain With Shoes
Final Drive Unit
General Description
Removal From Track Frame
Installation Into Track Frame
Final Drive Maintenance
Final Drive Oil
F Final Drive Assembly
Parts List
F Final Drive
Service Information
Tightening Torques
Planetary Gears F / A
Disassembly
Troubleshooting
Idler Unit – Assembly
Idler Unit – Removal
Track Roller Assembly
General Description
Track Roller – Removal And Disassembly
Support Roller – Removal And Disassembly
Track And Support Roller – Assembly
Track and Support Roller – Test And Install
Track Inspection and Wear Limit Guide
B Track Inspection And Wear Limit Guide Caterpillar Series Drills
Sprocket Wear Patterns
Wear on Forward Drive Side

Remedies:
Root Wear
Causes:
Effects:
Remedies:
Wear of Tooth Tip
Causes:
Effects:
Remedies:
Tooth Tip Broken Off
Causes:
Effects:
Remedies:
Facial Wear
Causes:
Effects:
Remedies:
Notes
Section Engine / Drive Train Compressor
Section Contents
Power Group Locator
Cummins Engine
Engine Fuel System
QST Electric Fuel Supply Flow Diagram
Construction
Electric Fuel Supply Pumps
Combo Fuel Filter Head And Pump Manifold
FS Fuel Filter With Water Separator
Fuel Manifold With Integrated FSO Valve
Fuel Connections
Pre Filters
Wiring With EFS Power Relay
Pressure And Temperature Sensors
Operation
QST Electric Fuel Supply System Flow Diagram
QST Electric Fuel Supply System Detail
Oil Reserve Systems

Operation
Engine Oil Reserve System (Basic Circuit)
LED Monitor Readings
Signals
Adjustment Of Running Oil Level
Wiring Diagram Oil Reserve Basic Circuit
Oil Pressure Switch
Oil Reserve System
R
Troubleshooting
Maintenance
Engine and Compressor Air Cleaners
Engine And Compressor Air Cleaner Service
Flexible Drive Coupling
Flexible Drive Coupling Service
Pump Drive
Pump Identification
Pump Drive Assembly – Removal And Replacement
Pump Drive Gearbox
Pump Drive Gearbox – Repair
” Input Shaft Assembly
Hydraulic Pumps
Hydraulic Pumps – Removal And Replacement
Compressor Assembly
Drill Compressor Model / cfm @ psi
Compressor Drive Coupling
Compressor Installation
Compressor Drive Coupling – Removal And Replacement
Compressor Unit – Removal:
Compressor Shaft Seal
Main Drive Shaft Seal Replacement
Inspection and Preparation For Seal Assembly
High Pressure Compressor
Safety
Compressor Oil Circuit
Compressor Oil Circuit cfm @ psi
Compressor Condensation Table
Compressor Air Circuit
Compressor Air Circuits – cfm @ psi
Compressor Functional Description
Compressor Air Circuit
Compressor Gauge
Compressor Control Valve
Compressor Run Valve
Compressor Run

Compressor Control Pressure Reducing Regulator
Compressor Air Circuit
Compressor Operation
Operation
Purpose Of Controls
Compressor Maintenance
General Maintenance
Interstage Tube
Flexible Pipe Coupling Maintenance
Discharge Check Valve
Separator / Receiver Tank
Scavenge Line
Compressor Discharge Temperature Switches, Senders And Gauges
Minimum Pressure / Check Valve
Minimum Pressure / Check Valve Maintenance
Thermal / Bypass Valve
Compressor Fluid Filter
Fluid Stop Valve
Inlet Valve
Reducing Regulator
System Blowdown Valve
Running Blowdown Valve
Running Blowdown Maintenance
Moisture Separator Maintenance
Auxiliary Regulator
Auxiliary Regulator Maintenance
Coolers Locator
Compressor Oil Cooler
Compressor / Hydraulic Oil Cooler Service Manual
Notes
Section Dust Control System
Section Contents
Dust Control System
Water Injection
Water Tanks
Water Injection
Water Injection Relief Valve
Water Pump
Pump Specifications
Servicing Instructions
General Care Of The Pump
Care In Freezing Weather
Parts List

Replacing Piston Cup Seals
Replacing Suction And Discharge Valves
Replacing Power End Bearings
Servicing The Wrist Pin Bearings
Fastener Torque Requirements
Recommended Lubricants
Water Pump Motor Repair
Water Injection Hydraulic Control Valve Repair
Water Pump Drive Coupling
Level and Flow Transducer
High Pressure Cleaner
High Pressure Washdown (Motor and Pump)
SAFETY WARNINGS
Pressure Washer Operation
Pump Assembly
Foam System (Optional)
Foam Pump
Section Mast / Rotary Drive / Pipe Rack
Section Contents
Mast Weldment
Weld Inspection Schedule
Mast Inspection
Mast Assembly and Installation
Mast Assembly m
Mast
Mast / Drill Without Mast
Mast Assembly
Raising the Mast
Mast Raise Plumbing Removal
Mast Pivot Torque Procedure
Mast Pivot Bolts
Bolt Tightening Sequence
Mast A frame And Pivot Shaft
Mast A frame Pivot Shaft Cap Bolts
Bolt Tightening Sequence
Mast Pivot
Mast A frame Pivot Shaft Cap Bolts
Mast Elevate Cylinders
Angle Drilling
Mast Locking
Mast Installation Mast Raise Cylinder Wedges
Mast Raise Plumbing Removal

Feed Cylinder
Feed Cylinder
Feed Cylinder Assembly
Removal
Hoist / Pulldown Cable Adjustment With Auto Tension
Hoist / Pulldown Cables
Cable Tensioner Circuit
Manual Hoist / Pulldown Cable Adjustment
Adjustment
Replacement
Hoist / Pulldown Cable Adjustment With Auto Tension
Wire Cable
Sheave Rollers
Rotary Drive
Rotary Head Assembly
Rotary Head Guide Alignment
Rotary Head Drive System
Rotary Drive
Removal From Mast
Installation (Without Dowel Guides)
Rotary Drive Gearbox
Repair
Main Shaft Bearing Preload
Rotary Head Bull Shaft Bearing Nut
Manufacturers Recommendations – Blast Hole Drilling Consumables
Top Sub Serviceable
Lifting Bails
Air Swivel (Single Seal Style)
Service
Winch Assembly
Precautions On The Use Of Winches
Wire Cable
Grooved Drums
Plain (Smooth) Drums
Drums Multiple Layers
Winch Assembly Service
Deck Wrench
Deck Wrench
H O B O Wrench
Breakout System – H O B O
Hydraulic Operated Bit Basket – H O B B (Optional)
Pipe Safety Arm
Pipe Positioner

Carousel Pipe Rack
Major Components
Rod Handling – Carousal Indexing
Pipe Rack Assembly
General Information
Pipe Rack Bearings – Removal
Pipe Rack Components – Inspection
Pipe Rack – Assembly And Installation
Pipe Rack Roller – Remove And Replace
Pipe Rack Roller – Disassembly And Assembly
Bit Sub Length Adjustment
Configuration Screen
Configuration Drill String
Configuration Drill String
Depth Position System Linear Transducer
Notes
Section Hydraulic Systems
Section Contents
Hydraulic Symbols
Pressure Setting Sequence
Hydraulic Tank
Hydraulic Tank
Return Hydraulic Filters
Main Return and Case Drain Filter
Routine Maintenance
Main Hydraulic Pumps
Pump Identification
Brake, Drill / Tram And Cable Tensioner Solenoid Valve
Linde Bi Directional Hydraulic Pumps
Linde Hydraulics
Linde Bi Directional Hydraulic Pumps
Port And Valve Identification
Linde Hydraulics Schematic
Right Track / Hoist Pull Down Pump
Main Pump Adjustments
Setting The Hydraulic Neutral
The Regulation ‘Begin’ Adjustment
High Pressure Relief Valves
Pressure Over Ride (POR) Adjustment
CAT MD6420B Rotary Blasthole Drill SERVICE MANUAL
Charge Filter
Routine Maintenance
Changing Filter Elements
Routine Maintenance
Changing Filter Elements
Main Pump Shaft Seal Replacement
Disassembly Procedure
Main Pumps Circuit
Main Pumps Circuit
Left Track And Rotation Pump
Right Track And Pulldown Pump
Basic Left Track / Rotation Pump Circuit
Rotation Circuit
Rotation Circuit
Rotary Torque Control
Rotation Circuit
Rotary Drive Gear Box Motor
Rotary Drive Gearbox Motor – Test And Repair
Shaft Seal Replacement
Trouble Shooting
Right Track / Pulldown And Hoist Circuit
Right Hand Main Pump Basic Operation
Hoist / Pulldown Cylinder Counterbalance Valve
Tram Circuit
Tram Circuit
Auxillary Pump Circuit
Auxiliary Pump
Pump Replacement – Start Up
Mast, Jacks, Winch And Water Valve
Load Sense Auxiliary Circuit
K
Jack Control And Mast Elevating Circuit
Jacks And Mast / Water And Winch
Jack Control And Mast Elevating Control Valve
Jacks and Mast / Water And Foam Injection
Winch Section
Port Relief
Jacks And Mast / Water Injection And Winch
K LS – A
Proportional Pressure Reducing Valve
Counterbalance Valves
Counterbalance Valve Adjustments
Levelling Jack Cylinders
Counterbalance Valve Adjustments

Mast Elevating Cylinders
Counterbalance Valve Adjustments
Mast Elevating Cylinder
Mast Elevating Cylinders
Auxiliary Functions Circuit
Auxiliary Functions And Mast Valves
Features
General Description
Auxillary Pump Circuit
Non Load Sense Auxiliary Circuit
PWM Proportional Pilot Valves
Hydraulic Operated Breakout Wrench
Setting Of HOBO Sequence Valves
H O B O Float Cylinder
Pipe Positioner
Setting Of Pipe Positioner Sequence Valves
Hydraulic Systems
Fan Pump – Removal And Replacement
Hydraulic Gear Pumps – Repairs, Operation, Specifications And Adjustment
Tool List
Cooler Fan Circuit
Fan Motor Circuit
Hydraulic Motor
General Information
Specifications And Tools
Hydraulic Thermostatic Valve
Hydraulic Cooler – Thermal Valve
Central Lube
Auto Lube
Water Pump Motor
Water Pump Motor Repair Information
Shaft Seal Repair
Hydraulic Cylinder Repair
Hydraulic Cylinders
General Information
H Head
N Head
Z Head
N Head
K Head
M Head
Z Piston
Z Piston (Threaded)

H And K Piston
M Piston
N Piston
Notes
Section Electrical Components
Section Contents
Contents
Jump Starting
Precautions
Procedure
Batteries
Welding Precautions
Welding Precautions
General Arrangement Layout
Transducer Box Detail
Flow Monitor
Functions And Features
Application Area
Operating Principle
Flow Monitor
Mounting
Mounting Operation
Electrical Connection
Set Up And Settings For Water
High Flow Adjustment (Optional)
Error During Adjustment
Lock / Unlock The Unit
Operation And Maintenance
Flow Monitor
Technical Data
Liquids
EMC
Limit Switch
Level Sensor
Introducing Level Sensor
DX Ultrasonic Level Frequency Transmitter
Features
Compressor Temperature Switches Shut Down
Compressor Temperature Switches
Air Indicators Engine and Compressor Alarm
Air Filter Indicator Switches
How Does It Work?

Air Indicators Engine and Compressor Shutdown
Air Filter Indicator Switches
How Does It Work?
Differential Pressure Switches
Hydraulic Filter Indicator Switches
Compressor Temperature Transducer
Compressor Temperature Transducer
Measured Signal Converter For Temperature Sensors
Operating Instructions
Bar Electronic Pressure Transducer
Description
Bar Electronic Pressure Transducer
Description
Bar Electronic Pressure Transducer
Description
Drill Dash Board
General Information
Monitor
Activation
Cleaning
Specifications
Monitor
Brightness Control
Drill Dash Board
LED Status
Dashboard
Log In Screen
Log In
Drill Dash Board
Drill Bit Settings
Drill Dash Board
Hour Meters
Tram Screen
Drill Dash Board
Tram Function Interlocks
Artificial Horizon Gauges
Inclinometers
Leveling Inclinometer
Auto Level
Auto Mast / Manual Mast Operation
Auto Mast
Auto Mast Info
Auto Mast – Angle Sensor
Drill Screen
Depth System Panel

Compressor Gauge Operation
Drill Status
Interlock Over Ride
Drill Mode Interlocks
Interlocks
Pipe In Hole
Tram Interlocks
Pipe in Hole
Virtual Feed (Pulldown) Stop
Virtual Feed
Stop Indication
Virtual Hoist Stop
Virtual Hoist
Stop Indication
Depth System
Depth system – Linear Transducer
Depth Position System Linear Transducer
Carousel Interlock
Auto Drill
Engine Screen
Start Interlock Display
Event Screen
Event Acknowledgement
Status Screen
Sub Screen Gauges
Sub Screen Network
Sub Screen Input
Sub Screen Input Cab
Sub Screen Input Mast
Sub Screen Input Output
Cable Break Detection
Help Screen
Help Screen Icons
Configuration Screen
Configuration Depth
Sensor Calibration
Calibration
Configuration – Depth System
Configuration – Inclinometers
Configuration Auto Drill
Overrides
CAN BUS Network
Setting Node ID And Baudrate

CAN BUS Network Data Transmission
CAN BUS Network Electrical Trouble Shooting
Electrical Trouble Shooting
CAN BUS Network Electrical Trouble Shooting
Mast Removed Switch
CAN BUS Network Electrical Trouble Shooting
Installing a PCI CAN card in the Monitor
Installing CF Card
Accessing Special Functions
Accessing Windows
User Data Base
Add a new User
File Export
Procedure To Backup Log Files Of The Monitor
Access levels
Updating of Manuals in the Monitor
Manual Update
Manual Update
Shutting Down And Isolation
Notes
Section Lubrication & Preventative Medicine
Section Contents
Filter Locator
Filter Locator Assembly
Central Lube System
Central Lube System
Hydraulic Control Schematic
Operation
Central Lube System Circuit
Central lube Tank Assembly
Typical Installation
Vent Valve Installation Kit
Control Module Installation Kit
Operation
Central Lube Pump
Technical Data
Trouble Shooting
Service
Reciprocator Repair
Displacement Pump Repair
Reciprocator Parts
Instructions – Vent Valve
Basic Operating Principles Of Auto Lube Injectors
SL V and SL V XL Injectors

Contents
Stage
SL and SL Injectors
SL Injectors
Typical Grease System Circuit
First Hour Service
Hour Service Or When First Setting Addressing Auto Lube System
First Hour Service And Every Hours After
Lube Faults / Operation
Operation
Lube Fault
Auto Lube Timer
Lube Pressure Screen
Hammer Oil Tank
Hammer Oiler Tank Assembly
Hammer Oil Circuit
Auto Mode
Manual Mode
Operation
Troubleshooting
Air Motor And Throat Service
Displacement Pump Service
Parts List
Parts Drawing
Dimensions
Technical Data
Auto Lube System
Filter / Regulator / Lubricator
Filter Maintenance And Repair
Regulator Maintenance and Repair
Lubricator Maintenance and Repair
Pipe Thread Lubricator
Air Operated Pipe Thread Pump
Specifications
Description
Owner / Operator Responsibility
Safety Information
Installation
Typical System Hook Up
Pressure Relief Procedure
Operation
Using Pump
Maintenance
Lubrication
Material Restriction Prevention
Corrosion Prevention

Contents
Disassembly
Assembly
Repair
Troubleshooting
Parts List
To Lubricate Air Valve Mechanism
Lubrication And Preventive Maintenance
General Lubrication
Equipment Lubrication
Care Of Lubrication Points
Safety
Isolation – Battery Switch
Track Gear
Engine Maintenance
Air Cleaners
Air Filter Elements
Alternator Maintenance
hrs
Pump Drive And Drive Shaft Maintenance
Compressor Maintenance
Cooler Packs
A frame And Pivot Point Maintenance
Pulldown And Hoist Cables And Sheaves Maintenance
Rotary Head Maintenance
Hydraulic System Maintenance
Hydraulic Maintenance
Water Pump Maintenance
Cab Maintenance
Air Conditioner Maintenance
Battery Maintenance
Lubrication System Maintenance
Fire Suppression Maintenance
Drill Folding Stairway – Inspection Requirements
For All Machines Fitted With Folding Stairway
Preventative Maintenance
Weld Inspection Schedule
Track And Sprocket Inspection
Track Inspection And Wear Limit Guide
B Track Inspection and Wear Limit Guide
Undercarriage Information
Sprocket Wear Patterns
Wear On Forward Drive Side
Wear On Reverse Drive Side

Contents
Root Wear
Wear Of Tooth Tip
Tooth Tip Broken Off
Facial Wear
Lubrication Recommendations
Lubrication And Maintenance Chart
Lubrication And Maintenance Notations
Lubricant Specifications
Hydraulic System
Selection Of Hydraulic Oil
Hydraulic Tank Capacity
Compressor Lubricant Specifications
Lubricating Grease
Gear Lubricant
Scheduled Oil Sampling Analysis
Preventive Maintenance – Weld Inspection
Lubrication and Preventative Maintenance
Preventative Maintenance – Bolted Joints
Bolted Joint Maintenance For Rotary Drills
Introduction
Proper Bolt Tension
Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance
Bolted Joint Maintenance For Rotary Drills (cont )
Critical Bolted Joint Maintenance
Other Bolt Maintenance
SAE Recommended Torque Values
NORD LOCK Washers
Critical Fastener ID And Inspection Schedule
Critical Fastener Torque Values
MD
Mast Connection Points
Mast Connection Points Dimension Reporting
Notes