Issuu

System Operation Manual

MD6750 Blast Hole Drill

Serial Number 2C71X35

SAFETY.CAT.COM

BI011043

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DANGER:

THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER:

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.

The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER:

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

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Operation Section

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System Operation Section MD6750 Blasthole Drill

Operation Section

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System

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MD6750 Blast Hole Drill

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Operator’s Manual SN 2C71X35 Table of Contents GENERAL INFORMATION ............................................................................................................7 SAFETY ........................................................................................................................................8 SAFETY PRECAUTIONS ........................................................................................................9 FIRE PREVENTION CONSIDERATIONS...................................................................................12 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS............................13 MACHINE PLACARDS ................................................................................................................16 Stored Energy Signs ..................................................................................................................18 OPERATION NEAR ELECTRICAL TRANSMISSION LINES.................................................19 MACHINE OVERVIEW ................................................................................................................20 PROPEL MACHINERY ..........................................................................................................21 MAINFRAME AND DECKS ....................................................................................................22 MACHINERY HOUSE ............................................................................................................23 MAIN AIR SYSTEMS ..............................................................................................................24 OPERATOR’S CAB..............................................................................................................26 MAST .....................................................................................................................................27 ROTARY/PULLDOWN MACHINERY....................................................................................28 ROTARY GEARCASE...........................................................................................................29 PULLDOWN GEARCASE.....................................................................................................29 DRILL TOOL STRING ASSEMBLY........................................................................................30 BREAKOUT WRENCH.........................................................................................................31 CABLE REEL........................................................................................................................31 CONTROLS - LOCATION AND FUNCTION...............................................................................32 OPERATOR’S CONTROL CONSOLE.................................................................................33 Operator’s Control Console - Overall View ..................................................................................33 MAIN CONTROL PANEL .......................................................................................................34 Main Control Panel .....................................................................................................................34 HOIST/PULLDOWN RHEOSTAT....................................................................................35 ROTARY RHEOSTAT.....................................................................................................35 DRILL/PROPEL CONTROLS ON AND OFF PUSHBUTTON.........................................35 HOIST/PULLDOWN SPEED SELECTOR SWITCH......................................................36 ROTARY SPEED SELECTOR SWITCH........................................................................36 HOIST BRAKE SWITCH.................................................................................................37 PIPE RACK SELECTOR SWITCH.................................................................................37 PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL)...................................................37 WINCH/MAST SELECTOR SWITCH..............................................................................38 MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL)..............................................38 TOOL WRENCH SWITCH..............................................................................................39

1-2 System Operation Section MD6750 Blasthole Drill BI011043_EN DUST CURTAIN SWITCH...............................................................................................39 BIT VIEW HATCH SWITCH.............................................................................................39 PROPEL CONTROL PANEL................................................................................................40 Propel Control Panel ..................................................................................................................40 EMERGENCY STOP PUSHBUTTON.............................................................................40 PROPEL SPEED SELECTOR SWITCH........................................................................40 COMPRESSOR STOP PUSHBUTTON.........................................................................41 COMPRESSOR VENT/DRILL SWITCH.........................................................................41 HEATER/VENT/AIR CONDITIONER CONTROLS..........................................................41 OPERATING MODE SELECTOR SWITCH....................................................................41 PROPEL JOYSTICKS.....................................................................................................41 SELECTOR SWITCH PANEL...............................................................................................42 Selector Switch Panel ......42 BREAKOUT WRENCH SWITCH....................................................................................43 PIPE POSITIONER SWITCH..........................................................................................43 DUST SEAL SWITCH.....................................................................................................43 A-FRAME LOCK SWITCH..............................................................................................43 MAST BRACE LOCK SWITCH.......................................................................................43 MAST LOCK SWITCH....................................................................................................44 BOARDING STAIRS SWITCH.........................................................................................44 PEDESTAL HEATER SWITCH.......................................................................................44 FIRE SUPPRESSION SYSTEM INDICATORS...............................................................44 RADIO ...44 LEVELING CONTROL PANEL ..............................................................................................45 Leveling Control Panel ................................................................................................................45 MANUAL LEVELING JOYSTICKS ....................................................................................46 AUTOMATIC LEVELING SWITCH ...................................................................................46 WATER INJECTION ON/OFF SWITCH..........................................................................46 WATER INJECTION FLOW CONTROL.........................................................................46 HORN PUSHBUTTON....................................................................................................47 DEPTH INDICATOR RESET PUSHBUTTON.................................................................47 PROGRAMMED DRILL CONTROL SWITCH.................................................................47 EMERGENCY STOP PUSHBUTTON.............................................................................47 OPERATOR’S DISPLAY TERMINAL.....................................................................................48 Operator’s Display Panel ............................................................................................................48 MACHINERY HOUSE CONTROLS ......................................................................................49 LIGHTING LOAD CENTER ..............................................................................................49 CONTROLS ON THE LOW VOLTAGE START CABINET..............................................49 CONTROLS ON THE LOW VOLTAGE CABINET..........................................................50 Low Voltage Cabinet (Typical) ....................................................................................................50 CONTROL ON THE PROGRAMMABLE CONTROLLER CABINET...............................50 Programmable Control Cabinet ..................................................................................................50 HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS...............................51 Hoist Pulldown and Rotary Drive Cabinets ..................................................................................51 CONTROLS ON OR NEAR THE AIR COMPRESSOR..................................................52 Air Compressor Mounted Controls ..............................................................................................52 MISCELLANEOUS CONTROLS.....................................................................................53 PORTABLE REMOTE PROPEL STATION (OPTIONAL)................................................53

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Portable Remote Propel Station (Optional) .................................................................................53 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL......................................54 Hydraulic Reservoir Remote Fill Control Panel ............................................................................54 LUBE CONTROL PANEL................................................................................................54 Lube Control Panel .......54 PRESTART CHECKS.................................................................................................................55 EXTERNAL INSPECTION .....................................................................................................55 Daily Inspection Items................................................................................................................56 ONBOARD INSPECTION.....................................................................................................58 Onboard Inspection Items..........................................................................................................58 PRESTART LUBRICATION...................................................................................................61 START-UP...................................................................................................................................61 MACHINE START-UP ............................................................................................................61 MACHINERY CHECK ......................................................................................................63 BREAK-IN OF NEW COMPONENTS.............................................................................63 ROTARY DRIVE UNIT BREAK-IN.............................................................................63 HOIST/PULLDOWN GEARCASE BREAK-IN...........................................................63 ELECTRIC MOTOR BREAK-IN................................................................................63 MAINTENANCE DURING OPERATION ......................................................................................64 PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK............................................65 OPERATION ...............................................................................................................................65 PROPELLING ..66 DEFINITIONS ..................................................................................................................66 PROPEL PROCEDURE .................................................................................................67 Operator Controls - Propel .....68 Propel - Forward or Reverse .......................................................................................................69 Propel - Gradual Right Hand Turn............................................................................................... 69 Propel - Gradual Left Hand Turn .................................................................................................70 Propel - Counter-Rotation Left Hand Turn ...................................................................................70 Gradual Turns - 15° Increments..................................................................................................71 TOWING PROCEDURE.................................................................................................72 Tow Bar Detail ...........72 CABLE REEL OPERATION..................................................................................................73 Cable Reel .................................................................................................................................73 LEVELING .............................................................................................................................74 Machine Orientation ...................................................................................................................74 Controls for Leveling the Machine ...............................................................................................76 MAST RAISING AND LOWERING .........................................................................................76 MAST RAISING ................................................................................................................76 Controls for Raising or Lowering the Mast ...................................................................................77 MAST LOWERING ..........................................................................................................78 Controls for Angle Drilling .......79 PULLDOWN MACHINERY OPERATION..............................................................................80 Controls for Hoist / Pulldown ....80 AUXILIARY WINCH OPERATION ..........................................................................................81 Controls for Operating the Winch ............................................................................................... 81 PIPE RACK OPERATION...............................................................................................82 Controls for Operating the Pipe Racks.......................................................................................83

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1-4 System Operation Section MD6750 Blasthole Drill BI011043_EN TOOL HANDLING ..................................................................................................................86 PIPE LOADING AND UNLOADING ..................................................................................86 DRILL TOOL STRING ASSEMBLY..................................................................................88 Stabilizer Installation .........89 Controls for Drill Pipe Installation ....89 Installing Drill Pipe.....................................................................................................................90 Stabilizer Installation .........92 Bit Installation .............93 BREAKOUT WRENCH OPERATION...................................................................................94 DRILL TOOL STRING DISASSEMBLY..................................................................................95 ADDING ADDITIONAL DRILL PIPE ..................................................................................97 REMOVAL OF MULTIPLE SECTION DRILL PIPE...........................................................98 ANGLE DRILLING .................................................................................................................99 Jib Crane ...........100 DUST SUPPRESSION SYSTEM OPERATION..................................................................100 DRILLING ............................................................................................................................101 VERTICAL DRILLING ....................................................................................................101 Controls for Normal Drilling ....102 STARTING THE HOLE (COLLARING)....................................................................102 NORMAL DRILLING .................................................................................................103 ENDING THE HOLE................................................................................................105 ENDING THE HOLE (MULTIPLE PIPE SECTIONS)...............................................106 DRILLING DIFFICULT FORMATIONS ...........................................................................106 UNCONSOLIDATED MATERIALS .................................................................................107 WET OR STICKY FORMATIONS.................................................................................109 ANGLE DRILLING ..........................................................................................................110 PROGRAMMED DRILL CONTROL DRILLING ..............................................................111 Controls for Programmed Drill Control ......................................................................................111 PREPARING TO MOVE................................................................................................112 MACHINE SHUTDOWN ......................................................................................................114 SHUTDOWN PROCEDURE ........................................................................................114 SHORT TERM STORAGE............................................................................................115 LONG TERM STORAGE...............................................................................................116 ATTENDED LONG TERM STORAGE..........................................................................117 UNATTENDED LONG TERM STORAGE.....................................................................117 TOOL RECOVERY...................................................................................................................118 PIPE SIZE LIMITATIONS ......................................................................................................120 Drill Pipe Limitations .......120 DRILL STABILITY CHARTS .................................................................................................121 Drill Stability Chart - Special Propel Conditions ........................................................................121 Drill Stability Chart - Typical Propel Conditions .........................................................................122 TYPICAL MACHINE SPECIFICATIONS .....................................................................................123 Machine Dimensions ................................................................................................................124 COMPONENT SYSTEMS .........................................................................................................127 GENERAL ESTIMATED COMPONENT WEIGHTS..................................................................128

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System Operation Section MD6750 Blasthole Drill

MD6750 Blast Hole Drill Operator’s Manual

GENERAL INFORMATION

This manual is designed to assist the owner in the operation of this machine. By following easy to understand step-by-step procedures, the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.

Safe operation of the machine minimizes production delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgment and the alertness of the entire mining crew.

Throughout this manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied for this purpose.

Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance, contact your regional service representative or:

Caterpillar Global Mining, LLC Mining Products Division

3501 S FM 1417

Denison, TX 75020

903-786-9621

The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development, some procedures, specifications and parts may be altered in a constant effort to improve our machines.

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The safety alert symbols displayed here, and throughout this manual, call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all CAUTION and DANGER placards mounted at various locations on the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definition. In the event you question your ability to safely perform any of the enclosed maintenance and operational procedures contact your regional Caterpillar Global Mining service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert symbols is used.

NOTE: Denotes required information pertaining to the equipment. A loss of time and assets, or a minor injury can result if the appropriate action is not taken.

CAUTION: Serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury.

DANGER:Denotes an imminently dangerous hazard which could result in death, bodily injury, or serious damage to equipment if appropriate action is not taken.

DANGER:Denotes an imminently dangerous electrical hazard which can result in death, bodily injury, or serious damage to equipment if appropriate action is not taken.

Operating, maintaining or servicing this machine can be dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert and has the necessary skills, knowledge, tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Caterpillar Global MiningCustomer Service representatives and/or factory specialists are also available to provide additional information or technical assistance. In addition, the operator must be alert, physically fit, and free from the influence of alcohol, drugs, or any medications that might impair a person’s eyesight, hearing or reaction time.

CAUTION: STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/or damage to the front-end of the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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System Operation Section MD6750 Blasthole Drill

SAFETY

SAFETY PRECAUTIONS

General Precautions:

•The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.

•Keep hands, feet, and clothing away from rotating parts.

•Wear a hard hat, safety shoes and protective lenses at all times.

•Replace any and all safety and warning placards if they are defaced or removed from the machine.

•Think before you act. Carelessness is one luxury the service man cannot afford.

•Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

•Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if they are not functioning properly.

•If a heavy item begins to fall, let it fall, don’t try to catch it.

•Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

•Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.

•Electrical cords and wet metal floors make a dangerous combination.

•Regularly inspect for any loose bolts or locking devices and properly secure them.

•Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified.

•Check limit switches for proper operation.

•After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.

•Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only.

•Use proper interior and exterior lighting.

•Install and maintain proper grounding and ground fault protection systems.

•Perform functional tests of all safety circuits.

•Allow electrical inspection and maintenance to be performed only by a qualified electrician.

•Use extreme caution when working around drilled holes.

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Maintenance Precautions:

•Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

•Always wear a safety belt or harness when the danger of falling exists.

•Always have a second person to monitor the lifeline when working in confined spaces.

•Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

•Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance.

•Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

•Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, pipe arms, etc.). Always work within the limitations of the equipment being utilized.

•Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.

•Utilize guide lines or ropes to minimize the swing of suspended heavy components.

•Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

•Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

•When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

•When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

•Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

•Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

•Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

•Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.

•Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

•Always wear approved rubber gloves, and use insulated hooks or tongs when handling trail cable.

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System Operation Section MD6750 Blasthole Drill

Operating Precautions:

•Wear hearing protection when exposed to the following noise levels in excess of the period indicated:

8 hours at 90 dBa

4 hours at 95 dBa

2 hours at 100 dBa

1 hour at 105 dBa

30 minutes at 110 dBa

15 minutes at 115 dBa

•When in doubt about the noise level, wear approved hearing protection.

•Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine.

•Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine.

•Do not allow unauthorized personnel on board the machine while in operation.

•Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.

•Do not propel until the travel route has been cleared of obstructions.

•Do not propel the machine on a slope greater than specified in the stability limits shown on the STABILITY CHART at the end of this section.

•Do not leave the rotary gearbox suspended in the air when leaving the machine unattended.

•Prevent trail cable from being dragged on the ground for long distances or at high speeds.

•Limit the amount of cable being dragged by the machine. Pulling too much cable will damage both the cable and the machine.

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FIRE PREVENTION CONSIDERATIONS

•Always have a charged fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

•DO NOT smoke while handling flammables or when near batteries.

•Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 ~ PREVENTIVE MAINTENANCE for the scheduled maintenance recommendations.

•Repair or replace loose or damaged lines, tubes, and hoses as soon as possible.

•Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

•DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

•DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

•DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

•Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

•Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.

•NEVER weld, burn, or perform service on the machine alone.

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STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to the signaling used in communication between maintenance personnel and crane operators during the maintenance cycle.

HOIST Extend forearm upward, keeping forefinger extended and pointing up, make small circular movements with hand.

LOWER Extended arm downward, keeping forefinger extended and pointed down, make small circular movements with hand.

MAIN HOIST Tap fist on head until signal received by operator, then use standard signals.

USE WHIP LINE (Auxiliary Hoist) Tap elbow with open hand until signal received by operator, then use standard signals.

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System Operation Section MD6750 Blasthole Drill

• 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.

CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL