CAT MD6540 Rotary Blasthole Drill Operation & Maintenance Manual EM027298-0 – PDF DOWNLOAD

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

ProductandDealerInformation

Note: For product identification plate locations, see “Product Identification Information” in the Operation and Maintenance Manual.

Delivery Date

ProductInformation

Model

Product Identification Number

Engine Model/Serial Number

Compressor Model/Serial Number

Undercarriage Model/Serial Number

Rotary Drive Model/Serial Number

Pump Drive Model/Serial Number

Rock Drill Model/Serial Number

Customer Equipment Number

Dealer Equipment Number

DealerInformation

Name Branch

Address

Sales Parts Service

Caterpillar Global Mining LLC Mining Products Division 3501 S. FM Hwy 1417

Denison, TX 75020

Dealer Contact Hours

Phone Number

For Factory Spare Parts Ordering, Contact Your Local Cat Dealer Technical Parts Support Technical

Intended Use

This machine and its approved attachments are designed to drill blast holes for surface quarry, mining and construction applications. Use of this machine in any other way is prohibited and contrary to its intended use.

This safety alert symbol indicates important SAFETY MESSAGES in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

DO NOT weld on any part of this machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. Disconnect the connections to the Electronic Control Module (ECM) on the engine before welding.

Before Starting Engine, Study Operator's Manual

* Read and understand the warnings and cautions shown in Section 1

* Practice All Safety Precautions

* Make Pre-Operations Check

* Learn Controls Before Operating

It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws, and regulations.

California Proposition 65 Warnings

The following warning applies to equipment supplied with lead-acid batteries:

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Product Description

The MD6540 Rotary Blasthole Drill is specifically designed for Blast Hole Drilling Operations.

The MD6540 is a crawler mounted drill rig, which consist of two (2) major assemblies:

1.Rotary Drill Assembly

2.Excavator Type Undercarriage (Crawlers)

The Rotary Drill assembly is made up of the Diesel Engine or Electric Motor Package, Compressor Package, Hydraulic System, Rotary Drive, Pull-Down and Hoisting System and Drill Pipe Handling mechanism.

The Crawlers are powered by two (2) hydrostatic motors. Each Crawler has its own independent, variable and reversible speed control, and is equipped with 35.4 in. (900 mm) wide triple bar grousers.

Manual Contents

This manual is furnished with your machine to acquaint you with the correct operating procedures and to provide the necessary daily equipment maintenance information required to maintain your machine in a reasonable condition.

NOTE

This manual should be considered a permanent part of the machine and must remain with the machine at all times.

The instructions in this manual are not intended to cover all details about this machine, nor do they intend to provide for every possible contingency that may be encountered in connection with the daily operation or maintenance of this machine.

Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this manual. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to the manufacturer.

Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be stopped, mast lowered and machine shutdown.

Hazard Classification

The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's must read this manual and have been trained to use the machine in an appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer at 1-800-258-0009

Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Hazard Classification

A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. All are used as attention-getting devices on decals and labels fixed to the machine to assist in potential hazard recognition and prevention.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property or equipment damage.

Safety Alert Symbol

Overview of Potential Hazards

Potential Hazard Prevention

Crush Hazard. Falling objects can cause severe injury or death.

Do not exceed hoist capacity & stay away from lifted loads. (3500 lbs./1587 kg.) Do not use damaged cable.

Crush Hazard. Falling pipe carousel can cause severe injury or death.

Place carousel against lower stops before servicing hydraulic circuit. Purge air from circuit after servicing carousel circuit.

Entanglement Hazard. Death or serious injury can result from contact with rotating drivelines.

Entanglement Hazard. Rotating parts can cause personal injury.

Keep clear of rotating drivelines. Switch off engine before performing service. Do not operate with guard removed.

Keep away from fan and belt when engine is running. Stop engine before servicing.

Crush Hazard. Falling mast can cause severe injury or death.

Purge air from circuit after servicing mast raising cylinder(s).

Burn Hazard. Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

Crush Hazard. Contact with moving parts can cause severe injury.

Keep hands clear of moving parts during equipment operation.

Crush Hazard. Contact with moving breakout wrench can result in serious injury or death.

Stay clear of moving breakout wrench. Be sure personnel are clear before actuating breakout wrench.

Overview of Potential Hazards

Potential Hazard Prevention

Fall Hazard. Death or serious injury may result from climbing raised mast.

Do not climb raised mast. Lower mast completely to service.

Improper operation or maintenance can result in serious injury or death.

Read and understand operator's manual and all safety signs before using or maintaining machine.

If you do not understand the information in the manuals, consult your supervisor, the owner or the manufacturer.

Electrocution Hazard. Death or serious injury can result from contacting electric power lines.

Maintain required clearance.

Always contact the electric power line owner. The electric power shall be disconnected or the power lines moved or insulated before machine operations begin.

Crush / Fall Hazard. Riding rotary head can cause severe injury or death.

Do not ride rotary head. Lower mast completely to service.

Flying Object & Spray Hazard. Death or serious injury can result from release of pressurized liquids.

Shut off live air at source, and relieve all pressure before removing filler plug.

Entanglement Hazard. Rotating parts can cause severe injury.

Do not operate with guard removed. Keep all guards in place.

Crush Hazard. Falling rotary head can cause severe injury or death.

Purge air from circuit after servicing feed cylinder(s).

Overview of Potential Hazards

Potential Hazard Prevention

Explosion / Burn Hazard. Can cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.

Keep all open flames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt.

READ MANUALS

Read all manuals prior to operation.

DO NOT OPERATE equipment if you do not understand the information in the manuals.

Consult your supervisor, the owner or the manufacturer.

Explosion Hazard. Combustible gas can cause severe injury or death.

Do not spray "High Energy" starting aid into compressor air inlet or engine grid heaters.

Fall Hazard. Death or serious injury can result from falling.

Use the access system provided when servicing the machine.

Crush Hazard. Standing on stairway when raising or lowering can cause severe injury or death.

Electrocution Hazard. Contact with electrical power will result in death or serious injury.

Keep clear of moving stairway.

Lockout/Tagout all electrical equipment before adjusting or performing maintenance. Read manuals.

Electrical Shock Hazard. Can cause severe injury or death.

Disconnect battery prior to electrical system service work or any welding to avoid electrical shock and machine damage. Refer to service operator manual.

Before Operation

• Do study this manual and fully understand the controls and safety hazards.

• Do be sure all safety guards are securely in place.

• Do wear safety helmet, safety glasses, hearing protection and gloves, as appropriate, when working on machine.

• Do be sure all personnel are clear of the machine and work area before starting the engine or operating machine.

• Do be sure drill area is clear of all obstructions before operating machine.

• Do attach safety chain when using towbar.

• Do Not operate machine with:

• A hydraulic leak

• Broken or damaged electrical wiring

• Damaged hydraulic hoses or fittings

Operation

• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses contain carbon monoxide, a deadly poison, which is colorless and odorless.

• Do make sure the drill pipe is secured in the loader before raising or lowering the mast, if your machine is equipped with a drill pipe loader.

• Do make sure the mast lock pins are engaged in the mast base before starting drilling operations.

• Do examine the surface before drilling to determine the possible presence of unfired explosives.

• Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g. safety helmet, safety glasses, hearing protection, gloves, respirator.

• Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing, hands and hair clear of moving parts.

• Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.

• Do Not use the machine for any other purpose than what it was designed for. This machine is designed for rotary blasthole drilling operations only.

• Do Not travel on steep inclines, soft or unstable ground or close to unsupported excavations.

• Do Not move machine if drill is in a potentially unstable position.

After Operation

Normal Shutdown

1.Be sure machine is on solid level ground. Lower jacks, so the jack pads just touch the ground, but do not lift machine up.

2. Be sure all controls are in the OFF or NEUTRAL position.

3.On diesel machines, allow engine to idle for a minimum of five (5) minutes before stopping.

4.Turn the ignition key to OFF position.

5.Check machine for any unusual conditions.

6.Report any defects to your immediate supervisor.

Maintenance

• Do be sure two people are present when performing service work, both being fully trained on the safety issues. One person shall supervise from the operator's position and have immediate access to an emergency stop in all situations. Visual, audible or verbal communication signals must be established and understood by both persons.

• Do be sure each person is adequately trained to perform service and maintenance procedures.

• Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.

• Do be sure you have adequate lighting when performing service work at night.

• Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.

• Do be sure machine and components are well supported before servicing or replacing parts.

• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank. This will prevent sparks and the possibility of an explosion.

• Do Not hammer bit or drill pipe. Use only proper tools to make repair or adjustments.

• Do Not weld or grind near oil lines.

• Do Not attempt to remove radiator cap when engine is hot or has overheated.

• Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can give off hydrogen which is a highly explosive gas.

• Do Not leave tools or other loose objects on the engine, mast, drive mechanisms or drilling platform. They could be thrown by this equipment with a powerful force.

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.