Bucyrus MD6420 Rotary Blasthole Drill Operation & Maintenance Manual - CAT Rotary Track Drill MD6420

December 2016

EM005761-2 (EN-US)

Operation and Maintenance Manual

MD6420 Rotary Blasthole Drill DS7 1-Up DT7 1-Up DT9 1-Up DN9 1-Up DR4 1-Up

SAFETY.CAT.COM

PARTS ORDERING AND PRODUCT SUPPORT

Use only genuine Cat® parts in the maintenance, rebuild or repair of these machines. The manufacturer shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also not obligated or liable for any machines or parts that have been improperly handled; that have not been operated, maintained or repaired according to furnished manuals or other written instructions, and that have been operated with other than genuine Cat parts or authorized OEM components.

IDENTIFICATION OF THE MACHINE

Always furnish the Model Number and Serial Number when ordering parts. This information is found on the machine nameplate.

PART NUMBER AND DESCRIPTION

In addition to the Model and Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensional sketch or return the part to be replaced, transportation charges prepaid. Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.

SHIPMENT

Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our accounting department.

PARTS ORDERING

In North America Telephone 1-800-854-9030 or Telefax 1-800-582-6570 Telephone (903) 786-2981 Telefax (903) 786-6407

PRODUCT SERVICE AND WARRANTY

In North America Telephone 1-800-258-0009 Telephone (903) 786-2981 Telefax (903) 786-6408

Caterpillar Global Mining LLC Mining Products Division 3501 S. FM Hwy 1417, Denison, TX 75020 Mining.cat.com © 2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Printed in U.S.A.

Contents SECTION 1....................................................................................................................SAFETY SECTION 2.................................................. MACHINE SPECIFICATIONS AND TRANSPORT SECTION 3.........................................................................................OPERATOR CONTROLS SECTION 4........................................................... PRE-START CHECKS AND LUBRICATION SECTION 5.................................................................................OPERATING INSTRUCTIONS SECTION 6.......................................................................................DRILLING PROCEDURES SECTION 7.............................................................................. OPTIONS AND ACCESSORIES

Drill Model : Drill Serial No. : Date Drill Delivered : Dealer : Customer :

Specif cations are subject to change without notice.

Information contained in this manual was current at the time of printing.

7/1/2011 i

Introduction Intended Use This machine and its approved attachments are specif cally designed to drill blast holes for 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.

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 maintenance, 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.

ii

Product Description Manual Contents This manual is furnished with your rotary blasthole drill to acquaint you with the correct operating procedures and to provide the necessary safety and daily equipment maintenance information required to maintain this 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.

Periodic additions or revisions may be made to this manual. Should further information be desired or should particular problems arise which are not covered suff ciently in this manual, the matter should be referred to the manufacturer.

Blasthole Drills Each rotary drill offers a wide range of hole diameter capabilites and drilling depths ensur-ing exibility, versatility and productivity. Models available are described in Table i-1.

f

The rotary drill is a crawler mounted drill rig, which consist of two (2) major assemblies: 1.

2.

Rotary Drill Assembly Excavator Type Undercarriage (Crawlers)

The rotary drill assembly is made up of the engine 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 29.5 inch (750 mm) wide triple cleated grousers.

Receiving and Inspection Upon receipt of the machine, Owner/Operator is required to inspect the machine and all items listed on the Warranty Registration/Delivery Service Report included with the machine, complete the report and return to manufacturer within 15 days of the In Service date.

iii

Product Description Table i-1 Rotary Blashole Drills

MODEL

SKS-W

SKS-13

SKS-16

MAX HOLE DIA (inch) 12 1/4

12 1/4

12 1/4

MAX HOLE DEPTH (feet)

MAX PULLDOWN (lbs)

33.9 SP 210 MP

86,000

44 SP 244 MP

84,101

54 SP 104 MP

86,000

MAX HOIST (lbs) 86,000

43,745

35,207

COMPRESSOR (cfm@psi)

ENGINE

2000 & 2400@100 1475@350 or 500

CAT C27 800 HP

2000 & 2400@100 1475@350 or 500

CAT C27 800 HP

2000 & 2400@100 1475@350 or 500

CAT C27 800 HP

Cummins QST30/C,Tier1&2 850–1050 HP

Cummins QST30/C,Tier1&2 850–1050 HP

Cummins QST30/C,Tier1&2 850–1050 HP

SKSS-13

12 1/4

44 SP 244 MP

84,010

43,745

2000 & 2400@100 1475@350 or 500

Cummins QST30/C,Tier1&2 850–1050 HP

SKSS-16

12 1/4

54 SP 104 MP

86,000

35,207

2000 & 2400@100 1475@350 or 500

Cummins QST30/C,Tier1&2 850–1050 HP

SP – Single Pass MP – Miltiple Pass

iv

Introduction

Section 1 Safety Safety Hazards 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 your Cat dealer.

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

Electrical Storm Injury Prevention When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures: • Mount the machine.

• Dismount the machine.

If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

Safety

1-1

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.

Safety Alert Symbol

Hazard Classif cation A multi-tier hazard classif cation system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specif c level of severity of the potential hazard. All are used as attention-getting devices on decals and labels f xed 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.

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

Orange

Yellow

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.

Blue 1-2

Safety

Overview of Potential Hazards Potential Hazard

Safety

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.

Keep clear of rotating drivelines.

Switch off engine before performing service. Do not operate with guard removed.

Entanglement Hazard. Rotating parts can cause personal injury.

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 f uid can cause severe burns.

Allow to cool before opening.

1-3

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.

1-4

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

Maintain required clearance.

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 f ller 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).

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

Safety

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

Prevention Keep all open f ames 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.

Keep clear of moving stairway.

Electrical Shock Hazard. Can Disconnect battery prior to electrical system service cause severe injury or death. work or any welding to avoid electrical shock and machine damage. Refer to service operator manual.

Safety

1-5

Safety Guidelines Before Operation •

Do study this manual and fully understand the controls.

•

Do be sure all safety guards are securely in place and all access doors are closed and locked.

•

Do wear safety helmet, glasses and hearing protection when operating or 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 and know the size limitations of the 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 f ttings

Operation •

Do provide suff cient 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 unf red 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 f tting 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 Shut Down 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.

Allow engine to idle for a minimum of f ve (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.

1-6

Safety

Safety Guidelines 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 f ll nozzle and fuel tank when f lling 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 f ame 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, drive mechanisms or drilling platform.

They could be thrown by this equipment with a powerful force.

Equipment Transfer •

If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics from the operator's manual: • Safety Section • Operation Instructions including: • Pre-Start Checks • Start-up • After Start Checks • Shutdown Procedure • Propelling Machine

Clearances from High Voltage Lines Line Voltage

Minimum Clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv

45 ft (13.7 m) Table 1-1

Safety

1-7

Safety Sign List Refer to Figures 1-1 and 1-2 for locations Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Description WARNING - Falling Objects (Winch) WARNING - Falling Objects (Carousel) WARNING - Rotating Shaft WARNING - Entanglement WARNING - Falling Mast WARNING - Hot Pressurized Fluid WARNING - Climbing Raised Mast WARNING - Modif cation or Alteration WARNING - Hazardous Voltage WARNING - Riding Rotary Head WARNING - Flying Objects & Spray WARNING - Rotating Parts WARNING - Falling Rotary Head WARNING - Combustible Gas (Batteries) WARNING - Combustible Gas (Ether)

Part No. 429414 429448 429406 428893 429418 429449 429404 429445 429437 429420 429141 429431 429426 429439 429444

Qty. 1 2 2 5 2 1 2 1 1 1 1 2 2 2 1

(ref. 429469)

Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety sign material.

1-8

Safety

Safety Sign Locator

Fig. 1-1 Safety

1-9

Safety Sign Locator

Fig. 1-2 1-10

Safety

Safety Signs

WARNING

WARNING

Entanglement Hazard Rotating parts can cause personal injury.

XXXX lbs/ XXXX kg

Crush Hazard Falling objects can cause severe injury or death.

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

Do not exceed hoist capacity & stay away from lifted loads. Do not use damaged cable.

428893

429414

428893

429414

WARNING

WARNING

Crush Hazard

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.

Falling mast can cause severe injury or death.

429418

429448

429448

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

429406

429418

WARNING

WARNING Entanglement Hazard

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

Keep clear of rotating drivelines.

Switch off engine before performing service. Do not operate with guard removed.

429406

Burn Hazard Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

429449

429449 Safety

1-11

Safety Signs DANGER

WARNING

Maintain required clearance.

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

Always contact the electric power line owner.

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

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

429437

Line voltage

Required clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv 45 ft (13.7 m)

429437

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

429404

429404

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

Do not ride rotary head.

Lower mast completely to service.

429420

429420

WARNING

WARNING Flying Object & Spray Hazard

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.

Death or serious injury can result from release of pressurized liquids.

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

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

429445

429141

429445 429141

1-12

Safety

Safety Signs

WARNING

WARNING

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

Entanglement Hazard Rotating parts can cause severe injury.

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 with guard removed.

Keep all guards in place.

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

Consult your supervisor, the owner or the manufacturer.

429431

429431

429439

429439

WARNING

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

WARNING

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

Explosion Hazard

429426

429426

Combustible gas can cause severe injury or death.

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

429444

429444

Safety

1-13

Safety Signs (International)

429740

Flying Object & Spray Hazard (429740)

4 29712 429720

Fall Hazard–Mast (429715)

Explosion/Burn Hazard (429720)

T104915

Fall Hazard (T104915)

429713

Explosion Hazard–Ether (429713)

429705

Entanglement Hazard (429705) 1-14

Safety

Safety Signs (International)

XXXX lbs/ XXXX kg 429718

Crush Hazard–Carousel (429718)

429721

Crush Hazard–Winch (429721)

429715

Crush Hazard–Mast (429715)

Safety

429719

Crush Hazard–Rotary Head (429719)

1-15

Safety Signs (International)

429709

Electrocution Hazard (429719)

429722

429717

Modif cation or Alter Hazard (429722)

Burn Hazard–Pressurized Fluids (429717)

429714

Crush/Fall Hazard–Rotary Head (429714)

429710

Entanglement Hazard (429710) 429738

Entanglement Hazard (429738) 1-16

Safety

Section 2

Machine Specifications and Transport

Specifications and Transport

2-1

Specifications Cooler Assembly

13 or 16 Meter Mast Configuratio

Radiator-CAC-Oil Cooler Assembly C27

Rated Capacity Bit/Hole diameter

Up to 311 mm (12.25 in)

Depth single-pass (16 m config Max depth multi-pass

16.46 m (54 ft) Up to 65.2 m (214 ft)

Depth single-pass (13 m config Max depth multi-pass

13.4 m (44 ft) Up to 74.4 m (244 ft)

Deep-hole package required for max hole depth

Pull-down/Hoisting Capacity Pull-down capacity

Up to 39,009 kg (86,000 lb)

Hoist capacity (16 m config

Up to 15,970 kg (35,207 lb)

Hoist capacity (13 m config

Up to 19,842 kg (43,745 lb)

Drilling feed rate

0-33.5 m/min (0-110 fpm)

Retract rate

0-33.5 m/min (0-110 fpm)

Pull-down cylinder stroke (16 m config Head travel (16 m config Pull-down cylinder stroke (13 m config Head travel (13 m config Type

914.40 cm (360 in) 1,828.80 cm (720 in) 762.00 cm (300 in) 1,524.00 cm (600 in)

Open-loop hydraulic (stationary barrel, moving rod)

Number of cylinders Cylinder bore

2 16.51 cm diameter (6.5 in)

Cylinder rod

16 m config: 12.70 cm dia (5 in), 13 m config: 11.43 cm dia (4.5 in

Cable type

2.85 cm (1.125 in) DYFORM 8

Tier 2 800 hp and 2,000 cfm compressor; single, front-end mounted Cooler width

289.60 cm (114 in) dual fan

Cooler height Fan

165.00 cm (65 in) dual fan 116.84 cm (46 in) diam, two fans, 16 blades

Fan speed

1,700 rpm

Fan guard

Welded

Engine radiator Top tank

Sealed deaeriation tank, pressure cap, overflow tube and sight glas

Standard ambient rating

52º C (125º F)

Radiator-Oil Cooler Assembly QST-30 Tier I; 850 hp and 2,000 cfm compressor; single, front-end mounted Cooler width

289.60 cm (114 in) dual fan

Cooler height Fan

165.00 cm (65 in) dual fan 101.60 cm (40 in) diam, two fans, 12 blades

Fan speed

1,700 rpm

Fan guard

Welded

Engine radiator Top tank

Sealed deaeriation tank, pressure cap, overflow tube & sight glas

Standard ambient rating

52° C (125º F)

Radiator-CAC-Oil Cooler Assemblies QST-30

Cable sheaves (cylinder)

45.72 cm OD (18 in)

Split-mounted on opposite sides of the deck

Cable sheaves (top and bottom)

45.72 cm OD (18 in)

Cooler width

Sheave pins with roller bearing Sheave guards Adjustable head guide shoes

6.98 cm (2.75 in) diameter Standard at bottom plate Steel with replaceable Nylatron

Torque Horsepower capacity Gearbox

0-110 rpm, 0-150 rpm optional 15,185 m (0-11,200 ft-lb)

Taper roller Oil-floode

Drive motor

2-2

Fan speed

1,525 rpm

Fan guard

Welded

Standard ambient rating

Sealed deaeriation tank, pressure cap, overflow tube & sight glas 52° C (125° F)

Casting design

Lubrication

Ratio

183.50 cm (72.25 in) each unit 48 in diameter; 10 blades, 1 per cooler

172 kW (230 hp)

Main thrust bearing

Gearing

Fan

Engine radiator Top tank

Rotary Drive System Rotation speed

Cooler height

183.50 cm (72.25 in) each unit

Straight spur 16 to 1 See hydraulic system

Specifications and Transport

Specifications Compressor

Engine

Compressor (Standard)

Engine (Standard)

Type

Oil-flooded, single-stage sc ew 56.6 m 3/min (2,000 cfm)

Discharge air flow (sea level Max operating pressure

6.9 bar (100 psi)

Air cleaner Type Model Oil cooling

Manufacturer Model

C27 Tier II

Rated horsepower

597 kW (800 hp)

Full load Dry-type with safety element SRG 20 Air-to-oil cooler, thermostatically controlled

Oil separation

Vertical barrier element, pre-separation in 167 l (44 gal) sump, vertical tank

Oil filtratio

12 micron replaceable element

Automatic with safety shut-down

Muffler guard

Air shut-off

Hydraulic cylinder-operated from operator’s seat

Fuel tank

67.9 m 3/min (2,400 cfm)

Discharge air flow (sea level Max operating pressure

6.9 bar (100 psi)

Air cleaner Type Model

Dry-type with safety element SRG 29 Air-to-oil cooler, thermostatically controlled

Oil separation

Vertical barrier element, pre-separation in 167 l (44 gal) sump, vertical tank

Oil filtratio

12 micron replaceable element

Drive

Direct coupled to engine flywhee

Controls

Automatic with safety shut-down

Air shut-off

Hydraulic cylinder-operated from operator’s seat

Type (high-pressure)

Oil-flooded, two-stage sc ew

10 ga. for personal protection 1,514 l (400 gal), optional 1,703 l (450 gal) Blankets and/or exhaust wrap

Engine (Optional) Manufacturer

Cummins

Model Rated horsepower

QST-30 (Tier I) 634 and 783 kW (850 and 1,050 hp) (Tier II) 672 and 783 kW (900 and 1,050 hp)

Full-load

2,100 rpm

Starting system

24 V DC

Safety shut-down system

Energized to run

Air cleaner Type Model

Dry-type with safety element SRG 29

Batteries

Four (4) 8-D

Muffle

127 mm (5 in) inlet and outlet

Jacket water cooling and/or CAC

Turbo and manifold covers

1,514 l (400 gal), optional 1,703 l (450 gal) Blankets and/or exhaust wrap

42.5 m 3/min (1,500 cfm)

Discharge air flow (sea level Oil separation

Four (4) 8-D 127 mm (5 in) inlet and outlet

Turbo and manifold covers

Fuel tank

Compressor (Optional)

Dry-type with safety element SRG 20

Batteries

Controls

Oil-flooded, single-stage sc ew

Energized to run

Air cleaner Type Model

Muffle

Type

24 V DC

Safety shut-down system

Direct coupled to engine flywhee

Compressor (Optional)

2,100 rpm

Starting system

Drive

Oil cooling

Caterpillar ®

Vertical barrier element, pre-separation in 189 l (50 gal) horizontal sump (T-tank)

Maximum operating pressure

10.3/24.1 bar (150/350 psi)

Compressor (Optional) Type (high-pressure)

Oil-flooded, two-stage sc ew 42.5 m 3/min (1,500 cfm)

Discharge air flow (sea level) Oil separation Maximum operating pressure

Vertical barrier element, pre-separation in 189 l (50 gal) horizontal sump (T-tank) 10.3/24.1/34.4 bar (150/350/500 psi)

Specifications and Transport

2-3

Specifications Operator’s Controls

Mast Construction

Location

ASTM 500 grade B rectangular tubing, welding

Main chord size Front 20.32 cm (8 in) x 10.16 cm (4 in) x 0.95 cm (0.375 in) Rear 10.16 cm (4 in) x 15.24 cm (6 in) x 0.95 cm (0.375 in) Pivot and raising area

Rectangular tubing "A" frame, reinforced in high-stress areas

Hydraulic lines

Pressure-rated steel hydraulic tubing

Hose rack

Standard Engine Controls Coolant temperature/high temperature shut-off, oil pressure, (low pressure shut-off), auto shut-down bypass, start button, stop button, tachometer, throttle control, engine hourmeter, fuel level, voltmeter

Standard Compressor Controls

Sheet steel trough for moving hoses

Compressor temperature, air pressure gauge, air shut-off control (electric) (high air temperature)

Mast-Elevating Cylinders Number of cylinders

Console at front and side cab wall, placed 45° to the deck

2

Standard drilling controls

Cylinder bore

25.40 cm (10 in) diameter

Leveling jacks controls (hydraulic)

Cylinder rod

11.43 cm (4.5 in) diameter

HOBO/Break-out wrench control (electric)

Cylinder stroke

111.76 cm (44 in)

Lift capacity each cylinder

88,904 kg (196,000 lb)

Mast elevation control (hydraulic) Pull-down control (electric over hydraulic)

Cylinder connection pins

8.89 cm (3.5 in) diameter

Pull-down pressure control (pilot hydraulic)

Check valves

Internal for each cylinder

Rotation control (electric over hydraulic) Propel controls (electric over hydraulic)

Operator’s Cab Location

To the right from the mast if facing rear deck from the rear end

Type

Shock-mounted; two-man, integrated FOPS certified

Length at floo

198.12 cm (78 in)

Width at floo

151.76 cm (59.75 in) 3 m 2 (32.40 ft 2)

Floor area Height inside

194.31 cm (76.50 in)

Construction Windows

Carousel in/out control (electric)

12 ga. steel welded to formed 12 ga. channel and angle supports .64 cm (0.25 in) tinted safety glass in rubber mounting

Number of windows

10

Number of doors

2 with windows (included in above)

Left door to work deck

Swing-type HD hinge

Right door

Swing-type HD hinge

Operator’s seat

Dust curtain (electric) Deck wrench control (electric) Level indicator (bubble) On/off light switch (electric) Drill hourmeter (gauge) Wiper/washer controls (electric)

Optional Filter indicators for engine and compressor intake, filter indicators for hydraulic fluid system, indicator lights for interlocks, water injection flow cont ol, rotary torque control, rotary head rpm gauge and heating systems control

.95 cm (0.375) in closed-cell foam with .318 cm (0.125) in pyramid vinyl surface Heavy-duty latches with lockable handles

Air conditioner, heater, pressurizer

2-4

Dust/water injection (electric)

2.54 cm (1 in) thermal

Sound levels

Other

Mast lock (electric)

Fixed folding jump seat

Insulation, wall and ceiling

Door latches

Carousel lock (electric)

One swivel-type with armrests, headrest and retractable seat belt

Helper’s seat

Insulation, floo

Carousel indexing control (electric)

82 dB(A) or less Wall-mounted Window wipers and washers

Specifications and Transport

Specifications Undercarriage

Drill Table & Work Deck

Type

Excavator type

Pad width

750 mm (29.5 in)

Pad type

Triple grouser

Rollers

Sealed, oil-floode

Number of rollers on each side

Three (3) carrier rollers

Rock guards/chain guides Overall length

Non-skid floor plat

Drill deck length

215.90 cm (85 in) work deck 281.94 cm (111 in) 6.1 m 2 (65.5 ft 2)

Drill deck area Hand rails

48 mm x 1.22 m (1.9 in diam. x 48 in) height

Standard full-length guards 594.36 cm (234 in) (variable with adjustment)

Width over tracks

410.21 cm (161.5 in)

Final drive

139.70 cm (55 in)

Deck floor materia

Drill deck width

10

Upper track chain support

Table height off ground

Independent hydrostatic motors

Drive horsepower per track

216 kW (290 hp) maximum

Brakes

Spring-set, hydraulic release

Brake release

Automatic

Tram speed max

2.01 km/h (1.25 mph)

Rear axle

25.40 cm (10 in)

Front

Wide walkways Viewing hatch

Dust Curtain (Optional Hydraulic Lifters, Front and Rear) Material Enclosed area Split for excess Dust deflecto

Three-point oscillating type

Track adjustment means

Hydraulic with grease gun

Track drive disconnect

Around the drill deck In the rear deck; hydraulically operated from the cab

Location

6.4 mm (0.25 in) rubber nylon reinforced 4.2 m 2 (45.14 ft 2) Front and rear with 30.50 cm (12 in) overlap Natural rubber seal, 1.27 cm (0.5 in) thick, 35.56 cm (14 in) diameter Directly below table bushing

Standard (manual)

Mainframe, Decks & Walkways Main rails

20.32 cm (8 in) x 40.64 cm (16 in) x 1.27 cm (0.5 in) ASTM 500 grade B

Rectangular tubing heavily cross-braced and reinforced at high-stress areas Construction

Electric welded

Jacks, mast pivot and deck

Welded integrally to main frame

Tool and battery box

Lockable door, below front deck

Machine deck

Access both sides

Hand rails

48 mm (1.9 in) diameter x 1.22 m (48 in) high

Tow hooks

Welded, two (2) front

Leveling Jacks Number

4

Location

2 front, 2 rear

Cylinder bore

17.78 cm (7 in)

Cylinder rod diameter

10.16 cm (4 in)

Cylinder stroke

121.92 cm (48 in), 152.40 cm (60 in) optional

Lift capacity

43,619 kg (96,163 lb) each

Pad connection

Ball and socket

Pad diameter

76.20 cm (30 in) (non-drill end) 91.44 cm (36 in) (drill end)

Safety check valves Inner extension boot

External at each cylinder 22.86 cm (9 in) OD, 12.7 mm (0.5 in) wall thickness

Specifications and Transport

2-5

Specifications Hydraulic System (cont.)

Hydraulic System

Rotation Drive Motors (2)

Left Track/Rotation (Closed-Loop) Type

Axial piston, variable volume

Maximum flo

378.5 l/min (100 gpm)

Pressure rating

413.7 bar (6,000 psi)

Right Track/Pull-down (Open-Loop) Type

Axial piston, variable volume

Maximum flo

378.5 l/min (100 gpm)

Pressure rating

413.7 bar (6,000 psi)

Axial piston fixed displacement, qt . 2

Pressure rating

344.7 bar continuous (5,000 psi); 413.7 bar intermittent (6,000 psi)

Fan Drive Motors Type

Piston

Pressure rating

413.7 bar (6,000 psi)

Pump Drive Gearbox Type

Accessory Circuit Pump (Open-Loop) Type

Type

Axial piston, variable volume

Drive

4 pad Rubber coupler/drive shaft to front of engine

Max flo

397 l/min (105 gpm)

Filtration

Pressure rating

413.7 bar (6,000 psi)

All filters have indicators and bypass Loop

Fan Circuit Pump (Open-Loop) Type Maximum flo Pressure rating

Gear 246 l/min (65 gpm) dual fan 172.4 bar (2,500 psi)

Track Drive Motors (2) Type Pressure rating

Axial piston 344.7 bar (5,000 psi)

12 micron 2 per loop (optional)

Charge

3 micron 1 per loop

Main return

12 micron

Case return

12 micron

Oil-Cooling System (Hydraulic tank) Reservoir Reservoir pressure Reservoir refill syste

1,208 l (319 gal) with sight and temperature gauge Atmospheric, filte ed breather 1,385 l (366 gal) through return filte

Lubrication Centralized manual (optional auto lubrication)

2-6

Specifications and Transport

Specifications Accessories, Tools & Handling Equipment

Deck Wrench

Drill Pipe (optional) Diameter

17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in) or 23.50 cm (9.25 in)

Wall thickness

25.4 mm (1 in)

Length

(standard for 16 m config) 7.62 m (25 ft), two pipes coupled together plus bit sub

Length

(standard for 13 m config) 12.19 m (40 ft), one pipe plus bit sub

Threads Diameter

Depends on pipe OD Wall

Accessories, Tools & Handling Equipment (cont.)

thickness

Thread

Pipe

Length

17.78 cm (7.0 in)

2.54 cm (1 in)

4.5 Beco

7.62 m (25 ft)

17.78 cm (7.0 in)

2.54 cm (1 in)

4.5 Beco

12.19 m (40 ft)

19.37 cm (7.625 in)

2.54 cm (1 in)

6 Beco

7.62 m (25 ft)

19.37 cm (7.625 in)

2.54 cm (1 in)

6 Beco

12.19 m (40 ft)

21.91 cm (8.625 in)

2.54 cm (1 in)

6 Beco

7.62 m (25 ft)

21.91 cm (8.625 in)

2.54 cm (1 in)

6 Beco

12.19 m (40 ft)

23.50 cm (9.25 in)

2.54 cm (1 in)

6 Beco

7.62 m (25 ft)

Location

Drill deck

Wrench plate

7.62 cm (3 in) T1- steel

Wrench positioning

Hydraulic cylinder

Impact means

Stationary jaw, flats at 15° o f axis

HOBO Break-Out Wrench Location

Lower left, outside mast

Support Wrench type

Mast-mounted Patented HOBO (Hydraulically Operated Break-Out)

Power

Carousel with stationary pods and breaker plates 16 m configuration (standard) 4 pipes: 7.62 m (25 ft) pipe 16 m configuration (optional) 4 pipes: 12.19 m (40 ft) pipe

Top Adapter Sub Diameter

Depends on pipe diameter

Wall thickness

25.4 mm (1 in)

Length

91.44 cm (36 in)

Top thread

13.97 cm (5.5 in) API Reg.

Bottom thread

13 m configuration (standard) 4 pipes: 12.19 m (40 ft) pipe 13 m configuration (standard) 5 pipes: 12.19 m (40 ft) pipe

Depends on pipe diameter Pipe rack swing

Bit Sub Diameter

Depends on pipe diameter

Wall thickness Length

Pipe rack index

17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in) OD 17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in), 23.50 cm (9.25 in) OD 17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in) OD Hydraulic cylinders (2) Hydraulic cylinder with locking pin

25.4 mm (1.0 in) Up to 2.286 m (90.0 in)

Location

Mounted on mast

1,588 kg (3,500 lb)

Top thread

Depends on pipe diameter

Bottom thread

Depends on pipe diameter

Cable size

Roller-type or two-piece with replaceable liner

Safety hook Brakes

Specifications and Transport

17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in), 23.50 cm (9.25 in) OD

Winch Rating

Table bushing

Hydraulic cylinders (4)

Pipe Rack (Inside the Mast)

13 mm (0.5 in) Swivel-type positive lock Automatic

2-7

Specifications Cooler Assembly

35 Foot Mast Configuration

Radiator-CAC-Oil Cooler Assembly C27

Rated Capacity Bit/hole diameter

Up to 311 mm (12.25 in)

Depth single-pass with 5-pod carousel

10.29 m (33 ft 9 in) 63.4 m (208 ft)

Pull-down/Hoisting Capacity

Tier II; 800 hp and 2,000 cfm compressor; single, front-end mounted Cooler width

289.60 cm (114 in) dual fan

Cooler height

165.00 cm (65 in) dual fan

Fan

Pull-down capacity

Up to 39,009 kg (86,000 lb)

Fan speed

Hoist capacity (10 m config

Up to 39,009 kg (86,000 lb)

Fan guard

Drilling feed rate

0-33.5 m/min (0-110 fpm)

Retract rate

0-33.5 m/min (0-110 fpm)

Pull-down cylinder stroke (10 m config Head travel (10 m config Type

609.60 cm (240 in) 1,219.20 cm (480 in)

Closed-loop hydraulic (stationary rod, moving barrel)

Number of cylinders (10 m config Cylinder bore (10 m config

1 20.32 cm diameter (8 in)

Cylinder rod (10 m config

11.43 cm diameter (4.5 in)

Cable type

2.85 cm (1.125 in) DYFORM 8

Cable sheaves (cylinder)

45.72 cm OD (18 in)

Cable sheaves (top and bottom)

45.72 cm OD (18 in)

Sheave pins

6.98 cm (2.75 in) diameter with roller bearing

Sheave guards Adjustable head guide shoes

Engine radiator Top tank

1,700 rpm Welded Sealed deaeriation tank, pressure cap, overflow tube and sight glas

Standard ambient rating

52º C (125º F)

Radiator-Oil Cooler Assembly QST-30 Tier I; 850 hp and 2,000 cfm compressor; single, front-end mounted Cooler width

289.60 cm (114 in) dual fan

Cooler height Fan

165.00 cm (65 in) dual fan 101.60 cm (40 in) diam, two fans, 12 blades

Fan speed

1,700 rpm

Fan guard

Welded

Engine radiator Top tank

Standard at bottom plate Steel with replaceable Nylatron

101.60 cm (46 in) diam, two fans, 16 blades

Sealed deaeriation tank, pressure cap, overflow tube and sight glas

Standard ambient rating

52° C (125º F)

Radiator-CAC-Oil Cooler Assembly QST-30

Rotary Drive System Rotation speed Torque Horsepower capacity Gearbox Main thrust bearing Lubrication Gearing Ratio Drive motor

2-8

Split-mounted on opposite sides of the deck

0-110 rpm, 0-150 rpm optional 15,185 Nm (0-11,200 ft-lb) 172 kW (230 hp) Casting design Taper roller Oil-floode

Cooler width Cooler height Fan

183.50 cm (72.25 in) each unit 48 in diameter; 10 blades, 1 per cooler

Fan speed

1,525 rpm

Fan guard

Welded

Engine radiator Top tank

Straight spur 16 to 1

183.50 cm (72.25 in) each unit

Standard ambient rating

Sealed deaeriation tank, pressure cap, overflow tube and sight glas 52° C (125° F)

See hydraulic system

Specifications and Transport

Specifications Engine

Compressor Compressor (Standard)

Engine (Standard)

Type

Oil-flooded, single-stage screw 56.6 m /min (2,000 cfm)

Discharge air flow (sea level)

3

Max operating pressure

6.9 bar (100 psi)

Air cleaner Type Model Oil cooling

Manufacturer Model

C27 Tier II

Rated horsepower

597 kW (800 hp)

Full load Dry-type with safety element SRG 20 Air-to-oil cooler, thermostatically controlled

Oil separation

Vertical barrier element, pre-separation in 167 l (44 gal) sump, vertical tank

Oil filtratio

12 micron replaceable element

Automatic with safety shut-down

Muffler gua d

Air shut-off

Hydraulic cylinder-operated from operator’s seat

Fuel tank

67.9 m 3/min (2,400 cfm)

Discharge air flow (sea level) Max operating pressure

6.9 bar (100 psi)

Air cleaner Type Model

Dry-type with safety element SRG 29 Air-to-oil cooler, thermostatically controlled

Oil separation

Vertical barrier element, pre-separation in 167 l (44 gal) sump, vertical tank

Oil filtratio

12 micron replaceable element

Drive

Direct coupled to engine flywhee

Controls

Automatic with safety shut-down

Air shut-off

Hydraulic cylinder-operated from operator’s seat

Type (high-pressure)

Oil-flooded, two-stage screw

10 ga. for personal protection 1,514 l (400 gal), optional 1,703 l (450 gal) Blankets and/or exhaust wrap

Engine (Optional) Manufacturer

Cummins

Model Rated horsepower

QST-30 (Tier I) 634 and 783 kW (850 and 1,050 hp) (Tier II) 672 and 783 kW (900 and 1,050 hp)

Full-load

2,100 rpm

Starting system

24 V DC

Safety shut-down system

Energized to run

Air cleaner Type Model

Dry-type with safety element SRG 29

Batteries

Four (4) 8-D

Muffle

127 mm (5 in) inlet and outlet

Jacket water cooling and/or CAC

Turbo and manifold covers

1,514 l (400 gal), optional 1,703 l (450 gal) Blankets and/or exhaust wrap

42.5 m 3/min (1,500 cfm)

Discharge air flow (sea level) Oil separation

Four (4) 8-D 127 mm (5 in) inlet and outlet

Turbo and manifold covers

Fuel tank

Compressor (Optional)

Dry-type with safety element SRG 20

Batteries

Controls

Oil-flooded, single-stage screw

Energized to run

Air cleaner Type Model

Muffle

Type

24 V DC

Safety shut-down system

Direct coupled to engine flywhee

Compressor (Optional)

2,100 rpm

Starting system

Drive

Oil cooling

Caterpillar ®

Vertical barrier element, pre-separation in 189 l (50 gal) horizontal sump (T-tank)

Maximum operating pressure

10.3/24.1 bar (150/350 psi)

Compressor (Optional) Type (high-pressure)

Oil-flooded, two-stage screw 42.5 m 3/min (1,500 cfm)

Discharge air flow (sea level) Oil separation Maximum operating pressure

Vertical barrier element, pre-separation in 189 l (50 gal) horizontal sump (T-tank) 10.3/24.1/34.4 bar (150/350/500 psi)

Specifications and Transport

2-9

Specifications Mast Construction

Operator’s Controls

ASTM 500 grade B rectangular tubing, welding

Location

Main chord size Front 20.32 cm (8 in) x 10.16 (4 in) x 0.95 cm (0.375 in) Rear 10.16 cm (4 in) x 15.24 cm (6 in) x 0.95 cm (0.375 in) Pivot and raising area

Rectangular tubing "A" frame, reinforced in high-stress areas

Hydraulic lines

Sheet steel trough for moving hoses

Standard Compressor Controls

Mast-Elevating Cylinders Number of cylinders

2

Cylinder bore

20.32 cm (8 in) diameter

Cylinder rod

10.16 cm (4 in) diameter

Cylinder stroke

111.76 cm (44 in)

Lift capacity each cylinder

56,994 kg (125,650 lb)

Cylinder connections pins

5.71 cm (2.25 in)

Check valves

Internal for each cylinder

Location

Shock-mounted; two-man, integrated FOPS certified

Length at floo

198.12 cm (78 in)

Width at floo

151.76 cm (59.75 in) 3 m 2 (32.40 ft 2)

Floor area Height inside

194.31 cm (76.50 in)

Construction

12 ga. steel welded to formed 12 ga. channel and angle supports .64 cm (0.25 in) tinted safety glass in rubber mounting

Number of windows

10

Number of doors

Standard drilling controls Leveling jacks controls (hydraulic) HOBO/Break-out wrench control (electric) Mast elevation control (hydraulic) Pull-down control (electric over hydraulic)

Rotation control (electric over hydraulic)

To the right from the mast if facing rear deck from the rear end

Type

Compressor temperature, air pressure gauge, air shut-off control (electric) (high air temperature)

Pull-down pressure control (pilot hydraulic)

Operator’s Cab

Windows

Standard Engine Controls Coolant temperature/high temperature shut-off, oil pressure, (low pressure shut-off), auto shut-down bypass, start button, stop button, tachometer, throttle control, engine hourmeter, fuel level, voltmeter

Pressure-rated steel hydraulic tubing

Hose rack

Console at front and side cab wall, placed 45° to the deck

2 with windows (included in above)

Propel controls (electric over hydraulic) Carousel in/out control (electric) Carousel indexing control (electric) Carousel lock (electric) Mast lock (electric) Dust/water injection (electric) Dust curtain (electric) Deck wrench control (electric) Level indicator (bubble) On/off light switch (electric) Drill hourmeter (gauge) Wiper/washer controls (electric)

Left door to work deck

Swing-type HD hinge

Optional

Right door

Swing-type HD hinge

Filter indicators for engine and compressor intake, filter indicators for hydraulic fluid system, indicator lights for interlocks, water injection flow control, rotary torque control, rotary head rpm gauge and heating systems control

Operator’s seat

One swivel-type with armrests, headrest and retractable seat belt

Helper’s seat

Fixed folding jump seat

Insulation, wall and ceiling Insulation, floo Door latches

2.54 cm (1 in) thermal .95 cm (0.375) in closed-cell foam with .318 cm (0.125) in pyramid vinyl surface Heavy-duty latches with lockable handles

Sound levels Air conditioner, heater, pressurizer Other

2-10

82 dB(A) or less Wall-mounted Window wipers and washers

Specifications and Transport

Specifications Undercarriage

Leveling Jacks

Type Pad width Pad type

Excavator type

Number

4

750 mm (29.5 in)

Location

2 front, 2 rear

Triple grouser

Rollers

Sealed, oil-floode

Number of rollers on each side Upper track chain support

Three (3) carrier rollers

Rock guards/chain guides Overall length

10

Standard full-length guards 594.36 cm (234 in) (variable with adjustment)

Width over tracks

Cylinder bore Cylinder rod diameter Cylinder stroke

Independent hydrostatic motors

Drive horsepower per track

216 kW (290 hp) maximum

Brakes

Pad diameter

Inner extension boot

66%

Rear axle

25.40 cm (10 in)

Front

Three-point oscillating type

Track adjustment means

Hydraulic with grease gun

Track drive disconnect

Standard (manual)

External at each cylinder 22.86 cm (9 in) OD, 12.7 mm (0.5 in) wall thickness

Drill Table & Work Deck

2.01 km/h (1.25 mph)

Gradeability mast down

Ball and socket 76.20 cm (30 in) (non-drill end) 91.44 cm (36 in) (drill end)

Safety check valves

Automatic

Tram speed max

43,619 kg (96,163 lb) each

Pad connection

Spring-set, hydraulic release

Brake release

10.16 cm (4 in) 121.92 cm (48 in), 152.40 cm (60 in) optional

Lift capacity

410.21 cm (161.5 in)

Final drive

17.78 cm (7 in)

Table height off ground

139.70 cm (55 in)

Deck floor materia

Non-skid floor plat

Drill deck length

215.90 cm (85 in) work deck

Drill deck width

281.94 cm (111 in) 6.1 m 2 (65.5 ft 2)

Drill deck area Hand rails

Mainframe, Decks & Walkways

Main rails

20.32 cm (8 in) x 40.64 cm (16 in) x 1.27 cm (0.5 in) ASTM 500 grade B

Rectangular tubing heavily cross-braced and reinforced at high-stress areas Construction Jacks, mast pivot and deck

Welded integrally to main frame

Tool and battery box

Lockable door, below front deck Access both sides

Hand rails

48 mm (1.9 in) diameter x 1.22 m (48 in) high

Tow hooks

Welded, two (2) front

Specifications and Transport

Wide walkways Viewing hatch

Around the drill deck In the rear deck; hydraulically operated from the cab

Dust Curtain Electric welded

Machine deck

48 mm x 1.22 m (1.9 in diam. x 48 in) height

(Optional Hydraulic Lifters, Front and Rear) Material Enclosed area Split for excess Dust deflecto Location

6.4 mm (0.25 in) rubber nylon reinforced 4.2 m 2 (45.14 ft 2) Front and rear with 30.50 cm (12 in) overlap Natural rubber seal, 1.27 cm (0.5 in) thick, 35.56 cm (14 in) diameter Directly below table bushing

2-11

Specifications Hydraulic System

Hydraulic System (cont.)

Rotation Drive Motors (2)

Left Track/Rotation (Closed-Loop) Type

Axial piston, variable volume

Maximum flo

378.5 l/min (100 gpm)

Pressure rating

413.7 bar (6,000 psi)

Type

Axial piston fixed displacement, qty. 2

Pressure rating

344.7 bar continuous (5,000 psi); 413.7 bar intermittent (6,000 psi)

Right Track/Pull-down (Closed-Loop)

Fan Drive Motors

Type

Type

Axial piston, variable volume

Maximum flo

378.5 l/min (100 gpm)

Pressure rating

413.7 bar (6,000 psi)

Type

Type

Drive

Pressure rating

Double gear 114/64 l/min (30/17 gpm) 206.8 bar (3,000 psi)

Type Maximum flo Pressure rating

Gear

Pressure rating

All filters have indicators and bypass 12 micron 2 per loop (optional)

Charge

3 micron 1 per loop

246 l/min (65 gpm) dual fan

Main return

12 micron

172.4 bar (2,500 psi)

Case return

12 micron

Oil-Cooling System (Hydraulic tank)

Track Drive Motors (2) Type

4 pad Rubber coupler drive shaft to front of engine

Filtration Loop

Fan Circuit Pump (Open-Loop)

413.7 bar (6,000 psi)

Pump Drive Gearbox

Accessory Circuit Pump (Open-Loop) Maximum flo

Piston

Pressure rating

Axial piston 344.7 bar (5,000 psi)

Reservoir Reservoir pressure Reservoir refil system

1,007 l (266 gal) with sight and temperature gauge Atmospheric, filte ed breather 1,185 l (313 gal) through return filte

Lubrication Centralized manual (optional auto lubrication)

2-12

Specifications and Transport

Specifications Accessories, Tools & Handling Equipment

Accessories, Tools & Handling Equipment (cont.)

Deck Wrench

Drill Pipe (optional) Diameter

17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in) or 23.50 cm (9.25 in)

Wall thickness

2.54 cm (1 in)

Length

10.67 m (35 ft)

Threads Diameter

Depends on pipe OD Wall

Thickness

Thread

Pipe

Length

17.78 cm (7.0 in)

2.54 cm (1 in)

4.25 Beco

10.67 m (35 ft)

19.37 cm (7.625 in)

2.54 cm (1 in)

6 Beco

10.67 m (35 ft)

21.91 cm (8.625 in)

2.54 cm (1 in)

6 Beco

10.67 m (35 ft)

23.50 cm (9.25 in)

2.54 cm (1 in)

6 Beco

10.67 m (35 ft)

Top Adapter Sub Diameter

Depends on pipe diameter

Wall thickness

25.4 mm (1 in)

Length Top thread Bottom thread

91.44 cm (36 in) 13.97 cm (5.5 in) API Reg. Depends on pipe diameter

Depends on pipe diameter

Wall thickness

25.4 mm (1 in)

Length (10 m config Top thread Bottom thread Table bushing

Drill deck

Wrench plate

7.62 cm (3 in) T1- steel

Wrench positioning

Hydraulic cylinder

Impact means

Stationary jaw, flats at 15° o f axis

HOBO Break-Out Wrench Location

Lower left, outside mast

Support Wrench type

Mast-mounted Patented HOBO (Hydraulically Operated Break-Out)

Power

Hydraulic cylinders (4)

Pipe Rack (Inside the Mast) Type

Carousel, with stationary pods and breaker plates

Size of drill pipe 7.0 in, 7.625 in, 8.625 in/ 5 pipes 17.78 cm (7.0 in), 19.37 cm (7.625 in), 21.91 cm (8.625 in) 4 pipes 23.50 cm (9.25 in) Length of drill pipe Pipe rack swing Pipe rack index

Bit Sub Diameter

Location

76.20 cm (30 in)

Hydraulic cylinders (2) Hydraulic cylinder with locking pin

Winch Location

Mounted on mast

Rating (machine application)

1,588 kg (3,500 lb)

Depends on pipe diameter

Cable size

Depends on pipe diameter

Safety hook

Roller-type or two-piece with replaceable liner

10.67 m (35 ft)

Brakes

12.7 mm (0.5 in) Swivel-type positive lock Automatic

General Arrangement The following f gures show the general arrangment and locations of major components of the various mod-els of the MD6420 rotary blasthole drills. Due to the variety of options offered, not all conf gurations are shown.

SKS Specif cations and Transport

2-13

SKS-W Component Locator

2-14

Specifications and Transport

SKS-13 Component Locator

Specifications and Transport

2-15

SKS-16 Component Locator

2-16

Specifications and Transport

SKSS Component Locator

Specifications and Transport

2-17

SKS 13-16 Dimensions

2-18

Specifications and Transport

4.93 m (194.2 in)

1

3 1/4

Specifications and Transport

16.88 m (664.6 in)

11.73 m (461.8 in)

5.63 m (221.6 in)

4.93 m (194 in)

SKS-W Dimensions

2-19

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

BE SURE to observe if any overhead power lines are in the area. Contact with overhead high voltage power lines can cause severe injury or death. Follow the minimum safe distance requirements in Section 1 of this manual.

With 13–16 Meter Mast

25°

12°

14°

18°

10°

7°

With 10 Meter Mast

18°

23°

NOTE

2-20

20°

12°

28°

7°

The values contained here are given only as guidelines, and are not intended as a recommendation for safe operation. Safe operation is dependent on operator experience and judgement, ground conditions and proper preparation of ground surfaces, and accelerations due to sudden change of direction or speed of movement, either from operator input or ground conditions on which machines are operating.

Machines are typically much more stable operating with the mast down anytime a machine is operating on rough ground conditions, significant slopes, or there is any doubt about the machine stability or its ability to be operated safely in the conditions in question.

Line of Sight Limits 17° 30 °

13°

52°

9°

Defines the Operator’s general line of sight when in the seated position.

10 °

23°

7°

F R O N T O F M A C H I N E

23°

8°

6°

TRAMMING

25°

31° 14°

30 °

27°

13°

66°

52°

9°

17°

10 °

8°

23°

6°

23°

7°

DRILLING Specifications and Transport

2-21

Machine Transport Mast Removal and Installation Generally, when transporting the machine, it will be necessary to remove the mast and ship it on a separate truck, due to weight and height restrictions. Follow the steps outlined below for removal and installation.

BE SURE machine is on level and solid ground before performing any service procedures.

BE SURE hydraulic and pneumatic systems are not pressurized before removing any f ttings or connections.

Mast Removal 1.

Remove drill pipe from mast (refer to "loading and unloading drill pipe" in Section 4) and swing carousel all the way in.

2.

Lower mast to horizontal position, so that mast is resting on mast support.

3.

Shut down the machine and be sure pressure has been relieved before removing any connections or f ttings. Tag and remove all hydraulic, pneumatic and grease lines to the mast. Use numbered or lettered caps and plugs to aid in reassembly. Disconnect electrical plug from mast valve bank.

NOTE

If using one crane for lifting the mast, the lifting slings should be positioned at about a 45o angle from the mast.

4.

Attach four (4) steel cable lifting slings to the mast at the lifting points (f g. 6-1). Use a crane capable of supporting the weight of the mast and able to lift the mast high enough to clear the height of the machine (refer to machine specif cations on previous pages). Attach two guide ropes to mast to control swinging of mast.

5.

Remove the two capscrews that secure the mast pivot lug cap and remove cap from each side of mast (f g. 6-1).

6.

Support the mast cylinders to prevent movement after the cylinder pins are removed. Raise the mast slightly to take weight off the mast cylinder pins and remove the cotter pins and cylinder pins from mast.

Keep all personnel clear of mast when lifting. Do not allow anyone under mast when lifting.

2-22

7.

Lift mast clear of machine and tram machine out from under mast. Position trailer under mast and lower mast onto trailer and secure for transport (refer to loading and unloading procedures).

8.

Using a suitable lifting device lean the mast cylinders forward and secure to the "A" Frame if the machine is being transported.

Specifications and Transport

Machine Transport Keep all personnel clear of mast when lifting. Do not allow anyone under mast when lifting.

Fig. 6-1 Mast Assembly Typical Example

Mast Installation NOTE

Mast pivot bolt torque: SKS 1 in": Dry = 900 Ft. Lbs. (1220 Nm) Lub = 680 Ft. Lbs. (922 Nm) SKSS 1 1/4": Dry = 1219 Ft. Lbs. (1653 Nm) Lub = 914 Ft. Lbs. (1240 Nm) SKS-W 1 1/2": Dry = 3160 Ft. Lbs. (4284 Nm) Lub = 2360 Ft. Lbs. (3200 Nm)

NOTE

If using one crane for lifting the mast, the lifting slings should be positioned at about a 45o angle from the mast.

1.

Attach four (4) steel cable lifting slings to the mast at the lifting points (f g. 6-1). Use a crane capable of supporting the weight of the mast and able to lift the mast high enough to clear the height of the machine (refer to machine specif cations on previous pages). Attach two guide ropes to mast to control swinging of mast.

2.

Be sure area of mast installation is level and ground is solid. Apply a coat of grease to the mast pivot bushings. Position machine under mast and carefully lower mast, aligning the mast pivot lugs with the pivot bushings on the "A" Frame. Mast should be resting on the pivot bushings and the mast rest at the front of the machine.

3.

Position the mast lift cylinders to line up with the holes in the mast. The mast may have to be lifted slightly to align the holes. Install pins, washers and cotter pins.

4.

Install the pivot lug caps with capscrews and washers. Torque as noted above.

5.

Connect all hoses, by matching the numbered or lettered caps and plugs. Be sure all grease lines are installed (if used). Connect electrical connection to mast valve bank. Be sure all connections are tight. Start machine and check for any leaks.

Specifications and Transport

2-23

Machine Transport This machine is to be operated only by trained personnel, or a copy of the Operator Manual must be provided to personnel involved with loading and unloading of machine. Operator must read and understand the safety, start-up, shutdown and operation sections of the manual.

Loading Machine 1.

Raise dust curtains and secure with rope to prevent interference with trailer wheels.

2.

Place any loose items into tool box, such as brass bushings from mast pivot, bit sub, etc.

3.

Place mast raise cylinders against mast "A" frame and secure with rope to keep them from moving.

4.

If necessary (due to travel width restrictions in your area) the cab extension and walkway can be removed for transport. Support walkway with forklift or overhead lifting device and remove the bolts that secure walkway to frame. Support cab extension by attaching lifting straps to lifting eyes on cab roof. Disconnect wiring for lights on cab extension. Remove all bolts that secure cab extension to main cab inside. Remove the bolts that hold the two lower supports to the cab extension.

NOTE

Silicone sealant is used when joining the cab extension to the cab to prevent leakage at the joint. Clean old sealant from surfaces and apply new sealant when joining cab sections together.

5.

If cab extension was removed for transport, cover cab opening with plywood. Use same screws that were removed from cab extension.

6.

Cross tape all windows with duct tape.

7.

Be sure jacks are raised all the way up. Tram machine onto trailer in reverse for greater visibility. If possible, lower jacks to trailer f oor, but do not raise tracks. If jacks cannot be lowered, then secure jack pads with chain and nut (provided on each pad).

8.

If lifting machine onto trailer or ship, use the lifting lugs welded to the jack housings (f g. 6-2)

9.

Tape exhaust(s) closed, to prevent turbo charger from spinning dry. Clip all chains on handrail openings, check to see that all doors are closed tight and ignition is turned off. If unit is equipped with a battery disconnect switch, turn switch OFF.

10. Machine should be secured to trailer at four places on each side. Secure frame to trailer at front and rear and secure track to trailer at front and rear.

2-24

Specifications and Transport

Machine Transport This machine is to be operated only by trained personnel, or a copy of the Operator Manual must be provided to personnel involved with loading and unloading of machine.

1 1

Fig. 6-2 Lifting Lugs 1. Two rear lugs are welded jack housings, two front lugs are welded to jack housings.

Unloading Machine 1.

Inspect machine for damage before unloading.

2.

Remove tape from exhaust(s) and switch battery disconnect switch on (if so equipped).

3.

With all tie-downs removed and jacks raised, propel machine off trailer and position on solid level ground.

4.

Install cab extension and walkway (if removed). Installation is reverse of removal as explained previously.

5.

Install mast (refer to mast installation on previous page).

6.

Complete checklist on "Commissioning A New Machine" in Section 4 of this manual or complete the "Pre Start" checklist also in Section 4 of this manual.

SKS Specif cations and Transport

2-25

Machine Transport Loading and Unloading Mast Keep all personnel clear of mast when lifting. Do not allow anyone under mast when lifting.

Lifting Points

Fig. 6-3 Mast Ready for Transport.

Loading Mast NOTE

If using one crane for lifting the mast, the lifting slings should be positioned at about a 45o angle from the mast.

1.

Attach four (4) steel cable lifting slings to the mast at the lifting points. Two are located at the mast crown and two are located at the mast base. Use a crane capable of supporting the weight of the mast and able to lift the mast high enough to clear the height of the machine (refer to machine specif cations on previous pages). Attach two guide ropes to mast to control swinging of mast.

2.

Secure mast to trailer in several places, use the lifting lugs as tiedown points whenever possible. Secure cab extension and walkway (if removed).

Unloading Mast 1.

2-26

Refer to "Mast Removal and Installation" as discussed previously.

Specifications and Transport

Safety Stand Placement Support (Jack Stand) Guidelines for Rotary Drills

SKSW AND SKSS

IF DURING MAINTENANCE MACHINE REQUIRES ADDITIONAL SAFETY SUPPORTS, PLACE SUPPORTS (JACK STANDS) AS CLOSE TO LEVELING JACKS AS POSSIBLE. THESE AREAS SUPPORT THE MACHINE DURING DRILLING OPERATIONS.

SKF AND SKFX NEVER SUPPORT THE MACHINE BY PLACING SUPPORTS UNDER MEMBERS OF THE REAR DECK OR COOLER SUPPORT DECK. THESE AREAS ARE NOT STRUCTURALLY ROBUST AND ARE NOT INTENDED TO SUPPORT THE ENTIRE MACHINE WEIGHT. Specifications and Transport

2-27

Notes

2-28

Specifications and Transport

Section 3

Operator Controls

Operator Controls

3-1

Graphic Symbol Legend The following is a listing of the graphic symbols found on the cab control consoles and their basic description. The control functions are described in detail following the symbol descriptions.

Drill Functions

HOBO Swing

HOBO Lock

Deck Wrench

Auto Pulldown

Holdback

Hoist Pulldown

Winch

Drill Pipe Support

Oil Injection

Pipe Rack Swing

Pipe Rack Rotate

Pipe Rack Lock

Thread Lube

Mast Lock

Dust Curtain/Blower

Main Air

Drill/Propel

Dust/Water

Mast Lower/Raise

Front Jack–UP/DOWN

Left Rear/Right Rear Jack–Up/Down

ON

OFF

3-2

Operator Controls

Graphic Symbol Legend Drill Functions

Rotation/Left Track Pressure

Pulldown Pressure

Drilling Air Pressure

Hydraulic System Pressure

Rotation–Forward/Reverse

Pulldown Pressure–Increase/Decrease

Compressor Discharge Temperature

Engine Coolant Temperature

Engine Oil Pressure

Fuel Level

Battery Charge

Engine Hourmeter

Engine Tachometer

Engine Start

Drill Hourmeter

Ether Injection

Engine Stop

Ignition–On/Off

Water Injection–Increase/Decrease

Operator Controls and Indicators

Throttle–Fast/Slow Operator Controls

3-3

Control Console

Fig. 3-1 Operator Control Panel

NOTE

NOTE

1.

"PUSH" LEVER–Move lever AWAY FROM OPERATOR "PULL" LEVER–Move lever TOWARDS OPERATOR Options are used along with or in place of standard equipment on some machines.

Although every effort has been made to be as complete and thorough as possible in the following pages, not every photo and item described herein may be used on your machine and your machine may have different controls than those shown. Consult with manufacturer if you are unsure about any function or control prior to use.

Level Indicator Indicates when the machine is level.

2.

Throttle Used to control the engine speed (Cat engines).

3.

Engine Diagnostic Lamp Light f ashes to indicate engine fault.

Refer to engine manual for fault codes and remedy.

3-4

Operator Controls

Control Console 4.

Jack Levers Used for lowering and raising the jacks to level the machine. Pull the levers to lower the jacks.

Push the levers to raise the jacks. Machines equipped with "tram interlock" option have an indicator light under the jack levers. When jacks are fully retracted, the green light comes on. If light is not on, jacks are not fully retracted, and machine will not tram until jacks are fully retracted.

4a.

Right Rear Jack

4b.

Front Jacks

4c.

Left Rear Jack

5.

Mast Lever Controls the lowering and raising of the mast.

• Pull lever to raise mast.

• Push lever to lower mast.

6.

Propel Levers Controls the speed and the direction of the tracks.

• Push levers to propel forward (radiator end).

• Pull levers to propel in reverse (cab end).

6a.

Right Track Lever

6b.

Left Track Lever

7.

Rotation Lever Controls rotary head speed and direction.

• Push lever for forward rotation.

• Pull lever for reverse rotation.

8.

Hoist/Pulldown System Lever Controls the raising and lowering of the rotary head.

• Push lever to raise the rotary head.

• Pull lever to lower the rotary head.

Operator Controls

3-5

Control Console

Fig. 3-2 Instrument Panel

9.

Compressor Air Filter Indicator Shows RED when f lter element needs to be changed. Indicates differential pressure across f lter element.

10.

Engine Air Filter Indicator Shows RED when f lter element needs to be changed. Indicates differential pressure across f lter element.

11.

Rotation/Left Track Pressure Gauge indicates hydraulic pressure required to rotate the drill string and when in propel mode, indicates pressure to left track motor.

Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended periods.

12.

Rotary Head Tachometer (Optional) Gives digital reading of rotary drive RPM.

13.

Pulldown Pressure Gauge indicates hydraulic pressure at feed cylinder.

Maximum pressure 5000 PSI (345 bar). Higher pressures may cause the machine to tip.

3-6

Operator Controls

Control Console 14.

Drilling Air Pressure Gauge indicates the air pressure in the drilling air line and receiver tank.

15.

Hydraulic System Pressure Indicates auxiliary pump pressure.

16.

Compressor Discharge Temperature Gauge indicates the temperature of the compressor discharge air.

17.

Engine Coolant Temperature Gauge indicates the temperature of the engine coolant.

18.

Engine Tachometer Gauge indicates engine revolutions per minute.

19.

Engine Oil Pressure Gauge indicates engine oil pressure.

20.

Engine Hourmeter Meter records total engine hours.

21.

Drill Hourmeter Meter records actual drilling hours.

22.

Engine Stop (optional)

23.

Ether Injection (optional) Aids in starting cold engine. (a) Press for 3 seconds. (b) Release to discharge. (c) Wait 3 seconds to start engine.

24.

Starter The Start button is used to start the engine. (a) Press Start button to start the engine. (b) Release button once engine is running.

25.

Voltage Gauge indicates voltage output of the electrical charging system.

26.

Fuel Level Gauge indicates fuel level in tank.

Operator Controls

3-7

Control Console

Fig. 3-3 Instrument/Control Panel

27.

Compressor Start-Run Valve, Low Pressure Machines (optional) When starting machine, valve should be in the "Start" position and selector #28 in low position (if used) so compressor is unloaded or in low pressure mode. When machine is warmed up, turn valve to "Run" position.

28.

Compressor Start-Run Valve, High Pressure Machines (350/500 PSI) (optional) When starting machine, valve should be in the "Low" position. When machine is warmed up, turn valve to "Med" or "High" position as required.

29.

Compressor Low Oil Pressure Light used on High Pressure Machines Light ON indicates low oil pressure at compressor bearings.

30.

Rotary Torque Control used on Low Pressure Machines or Holdback Control on High Pressure Machines Turn knob clockwise to increase rotary torque.

3-8

Operator Controls

Control Console 31.

Test Switch (optional) Turn switch ON to check f lter indicator lights.

32.

Loop Filter Indicator Lights (4) (optional) Light ON, indicates f lter needs to be changed.

33.

Charge Filter Indicator Lights (2) (optional) Light ON, indicates f lter needs to be changed.

34.

Main Hydraulic Return Filter Indicator Light (optional) Light ON, indicates f lter needs to be changed.

35.

Case Drain Filter Indicator Light (optional) Light ON, indicates f lter needs to be changed.

36.

Compressor Oil Filter Indicator Light (optional) Light ON, indicates f lter needs to be changed.

37.

10 AMP Circuit Breaker–Air Conditioner

38.

15 AMP Circuit Breaker–Heater

Operator Controls

3-9

Control Console

Fig. 3-4 Operator Control Panel

NOTE

39.

Some machines have options for which additional switches are required to operate.

Generally, these functions are self-explanatory. In some cases switch functions may not be in the location shown in Fig. 3-4. Just be sure of the label or graphic symbol associated with the switch.

Remote Pulldown Relief Controls the pressure to the feed system to increase or decrease the weight on bit.

• Turn control clockwise to increase pressure.

• Turn counterclockwise to decrease pressure.

40.

Oil Injection Light (optional) Light comes on when oil injection pump for down-the-hole hammer is running.

3-10

Operator Controls

Control Console 41.

Not Used

42.

Drill Pipe Loader–Swing This switch is used to swing the drill pipe loader out from and into the center of the mast when adding and retracting drill pipe and for storing the drill pipe loader when propelling or lowering the mast.

43.

Water Injection/Dust Collector This switch is used to engage the water injection or dust collector systems to control drilling dust.

• Push switch up to engage water injection system.

• Push switch down to engage dust collector system.

44.

Hydraulically Operated Break-Out Wrench (HOBO)–Swing The break-out wrench is used to undo tight thread connections. This switch is used to swing the break-out wrench into or away from the drill pipe.

• Push and hold switch up to swing break-out wrench out.

• Push and hold switch down to swing break-out wrench in.

45.

Drill Pipe Support The drill pipe support is used to support the drill pipe in the center of the mast when using the drill pipe loader for multiple pass drilling.

• Push and hold switch up to engage drill pipe support. Red light will come on.

• Push and hold switch down to disengage drill pipe support. Red light will go out.

46.

Hydraulically Operated Break-Out Wrench (HOBO)–Clamp The break-out wrench is used to undo tight thread connections. This switch is used to clamp and unclamp the break-out wrench and to turn the wrench.

• Push and hold switch right to disengage (open) break-out and unclamp wrench.

• Push and hold switch left to clamp wrench and engage (close) break-out.

47.

Remote Tram (optional) When switch is toward pendant symbol, machine can be trammed using remote pendant control.

48.

Viewing Hatch Push switch DOWN to open viewing hatch. Push switch UP to close viewing hatch.

49.

Drill Stem Thread Lube (optional) Push and hold switch down to activate grease pump to lubricate drill pipe threads.

50.

Dust Curtain Switch is used to raise or lower the dust curtain at the rear of the machine.

• Push and hold switch up to lift dust curtain.

• Push and hold switch down to lower dust curtain.

51.

Air Line Lubricator (high pressure machines) Push switch down to activate lubricator pump to provide lubrication for "In The Hole Hammers".

Operator Controls

3-11

Control Console Continued from previous page

Fig. 3-4 Operator Control Panel

52.

Mast Lock Switch UNLOCKS or LOCKS mast in the vertical or angle drilling positions.

• Push and hold switch left to unlock (retract) mast pins. Green light will come on.

• Push and hold switch right to lock (engage) mast pins into mast. Red light will come on.

BE SURE to visually check to see that the mast lock pins are fully engaged in the holes in the mast before drilling. Also be sure pins are fully retracted from holes before lowering mast.

53.

Drill Pipe Loader–Lock This switch is used to lock or unlock the drill pipe loader so the loader can be indexed left or right to the next position.

• Push and hold switch down to lock pin IN. • Push and hold switch up to move pin OUT.

3-12

Operator Controls

Control Console 54.

Drilling Air Turns the air ON/OFF for drilling procedures.

• Push switch up to turn drilling air ON. • Push switch down to turn drilling air OFF

55.

Drill/Propel Switch Engages the drill controls or propel system.

• Push switch up to engage the propel system.

• Push switch down to engage the drilling controls.

Drill mode must be selected if not propelling the machine or when the machine is unattended. Drill mode engages the propel brakes.

56.

Tool (Deck) Wrench Switch retracts or extends the deck wrench to hold the drill pipe when breaking thread joints or when multiple pass drilling is required.

• Push and hold switch up to retract tool wrench.

• Push and hold switch down to engage tool wrench.

57.

Drill Pipe Loader–Rotate This switch is used to rotate the drill pipe loader left or right to the next position.

• Push and hold switch left to rotate drill pipe loader left.

• Push and hold switch right to rotate drill pipe loader right..

58.

Winch • Push and hold switch up to raise winch hook.

• Push and hold switch down to lower winch hook.

59.

Drill Pipe Loader–Interlock This switch is connected to a proximity switch in the mast. If the pipe rack moves off it's stop inside the mast the proximity switch will activate and stop the pulldown, rotation, and auto feed. This is to prevent the rotary head from hitting the pipe rack. When this happens, use the pipe loader swing switch (40) to swing pipe rack back against stop, then drilling can resume. When adding drill pipe however, you need to use pulldown and rotation with the pipe loader out. To do this, place the switch in the OVERRIDE position (towards the UNLOCK symbol). This will allow the rotation and pulldown functions to work when the pipe loader is out.

60.

Pulldown System (Auto Feed) The pulldown system switch engages and disengages the pulldown for drilling operations.

• Push switch up to disengage pulldown.

• Push switch down to engage pulldown.

DO NOT engage this switch on unless you are actually drilling. Once drilling is f nished, this switch must be disengaged.

Operator Controls

3-13

Control Console

Fig. 3-5 Instrument Panel–Light Switches and Circuit Breakers

61.

Light Switches Turns drilling lights, cab lights and other additional lights on and off.

62.

15 AMP Circuit Breaker–Cab Lights

63.

15 AMP Circuit Breaker–Ignition 24V

64.

10 AMP Circuit Breaker–Wipers

65.

50 AMP Circuit Breaker–Main Power

66.

15 AMP Circuit Breaker–Control Panel

67.

5 AMP Circuit Breaker–Heater & Drill Lights

68.

15 AMP Circuit Breaker–Starter

69.

5 AMP Circuit Breaker–12 Volt Circuit

70.

50 AMP Circuit Breaker–Drill Lights

71.

15 AMP Circuit Breaker–Additional Lights

72.

15 AMP Circuit Breaker–ECM

73.

10 AMP Circuit Breaker–Front Lights

3-14

Operator Controls

Control Console

Fig. 3-6 Instrument Panel with optional Murphy Power View display.

74.

Fig. 3-7 Cummins Engine Panel

Murphy Power View (optional) The "power view" system is an option in place of the engine hourmeter. It monitors several engine functions, including: RPM, Engine Hours, Coolant Temperature, Oil Pressure, Fuel Consumption, Throttle Position, and Engine Service Codes.

75.

Ether Injection (optional) Aids in starting cold engine.

76.

Engine Pre-Lube Switch Prior to starting engine, place switch in the START position (toward operator). With ignition switch ON, push Engine Start Button, this activates the engine pre-lube system. You will hear the pre-lube pump running, when it stops, the engine starter will activate. After engine starts, f ip switch to RUN position (ISC).

77.

Engine Fault Code Switch Turn switch ON (towards operator) to activate fault code signals from amber light (80).

78.

Engine Throttle Switch This is a 3-position switch. Position switch all the way DOWN (toward operator) for LOW IDLE, MIDDLE position for MEDIUM IDLE, UP for HIGH IDLE.

79.

Engine Protection Light (Green) Light comes on at start-up to indicated engine systems are normal.

80.

Engine Fault Code Light (Amber) When light is on, it indicates there is a fault in the engine system.

81.

Engine Stop Light (Red) Flashes in a sequence to indicate fault codes. The engine fault codes are listed in the engine operator/maintenance manual. The fault codes can also be accessed using the Power View (74) display.

Operator Controls

3-15

Cab Controls

Fig. 3-8 Water Control under Control Console

82.

Fig. 3-9 Cab Heater/Air Conditioner Unit

Water Injection Pump Motor Flow Control (optional) Controls hydraulic f ow to water pump motor. Turn COUNTERCLOCKWISE to INCREASE f ow.

83.

Heater–A/C Temperature Control Controls temperature of A/C or heat.

84.

OFF–Heat–A/C Switch Selects OFF, HEAT, or A/C.

85.

Fan Switch (3 position) Selects fan speed, LOW–MEDIUM–HIGH.

86.

Vent Control Selects FRESH AIR or RECIRCULATION.

3-16

Operator Controls

Cat EMS Caterpillar EMS (Electronic Monitoring System) Panel

Fig. 3-10 Optional Instrument Panel with Caterpillar EMS Panel installed.

Figure 2-10 shows the optional Caterpillar EMS panel installed.

This is an electronic monitoring system that displays various engine parameters. Each time the engine is started, the EMS undergoes an automatic self-test. Refer to Caterpillar instructions in the optional equipment manual for complete information.

This panel replaces the engine hour meter (20), engine oil pressure gauge (19), engine tachometer (18), engine coolant temperature gauge (17), and voltage gauge (25) shown in Fig. 3-2.

Operator Controls

3-17

Cab Heater Cab Heater Fault Isolation Check out the heater as follows: 1.

Check blower motor by operating console switch, checking all three positions and observing blower operation. Check for tripped circuit breaker and reset if tripped. Check for possible shorts in wiring or loose connections.

2.

Check for heating by f rst allowing diesel engine to warm up thoroughly, then turning on blower and assuring that the circulated air is warm.

3.

If heater fails to heat, check cutoff valves at plumbing connections to engine (Fig. 3-11) to be sure they are turned on, then check the heater plumbing.

Fig. 3-11 Heater Connections and Cutoff Valves (Cat. C27 Engine shown) 1. Water Outlet to Heater 2. Water Inlet from Heater

3-18

Operator Controls

AC/Heater/Pressurizer Unit

Fig. 3-12 AC/Heater/Pressurizer Unit (ref. 425136)

Operator Controls

3-19

Air Conditioner Maintenance and Servicing Schedule Although the systems are of heavy duty, industrial design, they still need maintenance and service. They will not run indef nitely and the warranty is conditional upon these services being carried out.

Daily

Weekly

Monthly

Every 3

Every 6

Yearly

Service

Service

Service

Months

Months

Service

X

X

X

X

X

X

X

X

X

X

X

Check for Cleanliness of Condensing Coil.

X

X

X

X

Clean Condenser Fan Motor With Dry Compressed Air.

X

X

X

X

Check for Correct Setting of Thermostat.

X

X

X

X

Check Refrigeration and Water Lines for Damaged Lines

X

X

X

X

Check Condensing Coil: 1. Refrigerant connections against leakage 2. Fixing bolts and screws

X

X

X

Check Condenser Fan Motor 1. Seal on motor shaft 2. Fixing clamps and screws 3. Inspect motor brushes for wear 4. Electrical Connections

X

X

X

Check Condenser Fan 1. For damage 2. For securing screws 3. For excessive noise

X

X

X

Check Compressor 1. Refrigerant piping and connections 2. Electrical connections 3. Check securing screws & bolts 4. Welds on mounting bracket

X

X

X

Check for Cleanliness of Fresh Air and Return Air Filters.

Check Compressor Clutch: 1. Fixing screws & bracket 2. Clutch electrical connections 3. Belt tension and wear

3-20

Operator Controls

Air Conditioner Maintenance and Servicing Schedule Daily Service

Every 3 Months

Every 6 Months

Yearly Service

Check Liquid Receiver/Drier 1. Refrigerant lines & connections 2. Securing bolts 3. For possible need of replacement 4. For refrigerant leakage 5. Sight glass during operation

X

X

X

Check High Pressure & Low Pressure Controls 1. For correct setting 2. Securing screws tightness 3. Electrical connections

X

X

X

Check Securing Fasteners on Fresh Air and Return Air Filters

X

X

X

X

X

Check Evaporator Fan Motor 1. For tightness of securing screws 2. For electrical connections

X

X

X

Check Evaporator Blower 1. For tightness 2. For damaged blades 3. For excessive noise during operation

X

X

X

X

X

Check Electrical Connections of Thermostat

X

X

X

Check Control Switch 1. Electrical connections 2. Operation

X

X

X

Check Heater Control Valve 1. For water leakage 2. Tightness of securing screws 3. Operation

X

X

X

Check for Damage and Cleanliness of Louvers

X

X

X

Check Evaporator Coil 1. For cleanliness 2. For refrigerant leakage 3. For tightness of securing screws

Check Against Refrigerant Leakage of the Thermal Expansion Valve

Operator Controls

Weekly Service

Monthly Service

X

X

3-21

Air Conditioner Maintenance and Servicing Schedule Daily Service

Weekly Service

Monthly Service

Every 3 Months

Every 6 Months

Yearly Service

Check Condensate Drip Tray 1. For cleanliness 2. For drain pipe blockage

X

X

X

Check Securing Screws & Bolts for Tightness on Main Frame & Panels

X

X

X

Check for Leakage of Refrigeration and Water Lines

X

X

X

Check Evaporator Pressure Regulator 1. For leakage 2. Evaporator pressure setting

X

X

X

Check Fresh Air Fan Motor 1. For excessive noise during operation 2. Brushes for wear 3. For electrical connections 4. For tightness of securing screws

x

X

X

x

x

Inspect Motor Brushes for Wear on Evaporator Fan Motor

General Service Information System should be thoroughly serviced before and after the cooling system. Breakdown maintenance is invariably more expensive, extensive and is not carried out to the same level as preventive maintenance.

This can lead to more problems down the line.

Compressor Oil Level It is not necessary to frequently check or change the compressor oil. However, it may be necessary to replenish or replace the compressor oil in the following cases: 1.

Whenever the compressor, evaporator, condenser or receiver-drier is replaced.

2.

Whenever the refrigerant has leaked from the system.

3.

Whenever the refrigerant is suddenly released from the cooling cycle.

4.

Whenever any oil-related problems occur in the cooling cycle.

Follow the component manufacturer's recommended procedures for repairs or replacements to the system.

3-22

Operator Controls

Air Conditioner Troubleshooting I. System Produces No Cooling CAUSE

INDICATIONS

REMEDY

Fuse blown or circuit breaker tripped

Electrical components will not operate.

Replace fuse or reset circuit breaker.

Broken or disconnected electrical wire

Electrical components will not operate.

Check all terminals for loose connections; check wiring for hidden breaks.

Broken or disconnected ground wire

Electrical components will not operate.

Check ground wire to see if loose, broken, or disconnected.

Clutch coil burned out or disconnected

Compressor clutch inoperative.

Check current f ow to clutch; replace if inoperative.

Electric switch contacts in pressure switches burned excessively, or clutch relay not working

Compressor clutch inoperative.

Replace low pressure or high pressure switches or clutch relay.

Blower motor disconnected or burned out

Blower motor inoperative.

Check current f ow to blower motor; repair or replace if inoperative.

Loose or broken drive belt

Visual inspection.

Replace drive belts and/or tighten to specif cations.

Compressor partially or completely frozen

Compressor pulley slips on belt or will not turn when clutch is engaged.

Remove compressor for service or replacement.

Compressor reed valves inoperative

Only slight variations of both gauge readings at any engine speed.

Service or replace compressor reed valves.

Expansion valve stuck in open position

Head pressure normal, suction pressure high evaporator f ooding.

Replace expansion valve.

Broken refrigeration line

Complete loss of refrigerant.

Examine all lines for evidence of breakage by stress or rubbing wear.

Safety valve

Complete or partial refrigerant loss.

Examine valve on drier.

Leak in system

No pressure on high and low gauges (applies to any system having complete loss of refrigerant).

Evacuate system, apply static charge leak test system, & repair leak as necessary.

Compressor shaft seal leaking

Clutch and front of compressor oily; system low or out of refrigerant.

Replace compressor shaft seal.

Clogged screen or screens in receiver dehydrator or expansion valve; plugged hose or coil

High gauge normal or may read high.

Low gauge usually shows vacuum or very low pressure reading. Frosting usually occurs at point of blockage.

Repair as necessary.

Mechanical:

Refrigeration:

Operator Controls

3-23

Air Conditioner Troubleshooting II. System Will Not Produce Suff cient Cooling CAUSE

INDICATIONS

REMEDY

Electrical: Blower motor sluggish in operation

Small displacement of air from discharge duct; blower motor possibly noisy.

Remove blower motor for service or replacement.

Compressor clutch slipping

Visual inspection.

Remove clutch assembly for service or replacement.

Obstructed blower discharge passage

Blower operates at high speed but air displacement very small.

Examine entire discharge passage for kinks, waddings or failure to open passage during installation. Correct as necessary.

Clogged air intake f lter

Insuff cient air displacement by blower.

Replace air f lter screens and service, or replace if necessary.

Insuff cient air circulation over condenser coils; f ns clogged with dirt or bugs.

Insuff cient cooling at discharge outlet; excessive high pressure gauge reading.

Clean condenser.

Evaporator clogged

Fins clogged with lint, dust, or coated with cigarette tars.

Remove cover and clean with compressed air. Use cleaning solvent to remove cigarette tars.

Evaporator pressure regulator defective or improperly adjusted

High pressure gauge readings normal; low gauge usually reads too high.

Repair or adjust as necessary.

Insuff cient refrigerant in system

Bubbles in sight glass; high gauge readings excessively low.

Test for leaks. Repair as necessary.

Recharge system until bubbles disappear and gauge readings stabilize to specif cations.

Clogged screen in expansion valve

Gauge pressures may be normal or may Purge system, remove screen, clean show slightly increased head pressure and replace. and low suction pressure; discharge output temperature higher than specif ed.

Expansion valve thermal bulb has lost charge

Excessively high or low gauge readings; may cool in excess or not enough.

Clogged screen in receiver

High pressure gauge usually higher than Purge system; replace receiver. normal; receiver cold to touch and may frost.

Excessive moisture in system

Excessive high and low gauge reading.

Lack of cooling.

Mechanical:

Refrigeration:

NOTE

3-24

Purge system; replace expansion valve.

Inspect system for refrigerant overcharge. Correct.

If gauges still read high, inspect condenser for oil clogging.

After completing repairs above, system MUST have dehydrator replaced purged, evacuated and charged.

Operator Controls

Air Conditioner Troubleshooting II. System Will Not Produce Suff cient Cooling (cont.)

CAUSE

INDICATIONS

REMEDY

Refrigeration (cont.): Air in system

Excessive high and low gauge reading.

Sight glass shows bubbles or is cloudy.

System contaminated.

Purge system, replace f lter/drier, evacuate and charge system with new refrigerant.

Evaporator pressure control valve improperly set

High air temperature off of evaporator coil, high evaporator coil temperature.

Adjust pressure setting on valve to 28–30 psi. (1.9–2.1 bar).

NOTE

When a unit must be removed from the system for service or replacement, the system must have the dehydrator replaced also, and the system must be purged, evacuated and recharged to remove excess moisture.

III. System Cools Intermittently CAUSE

INDICATIONS

REMEDY

Electrical: Defective fuse or circuit breaker, blower switch, or blower motor

Electrical units operate intermittently.

Remove defective part for service or replacement.

Partially open, improper ground or loose connections in compressor clutch coil

Clutch disengages prematurely during operation.

Check connections or remove clutch coil for service or replacement.

Visual inspection operates until head pressure builds up (as viewed on high pressure gauge) at which time clutch begins slipping, may or may not be noisy.

Slippage over a prolonged period will require that clutch be removed for service; may require readjustment for proper spacing.

Mechanical: Compressor clutch slipping

Refrigeration: Unit icing up may be caused by excesUnit ices up intermittently. sive moisture in system, incorrect superheat adjustment in expansion valve or thermostat adjusted too low

Replace expansion valve if excess moisture present, adjust thermostat.

Purge system, evacuate, recharge.

Thermostat defective

Low side pressure may be low or excessively high; adjustments will not correct.

Replace thermostat.

Stuck regulator valve

Both head and suction pressures low; moisture in system usually indicated.

Purge system and evacuate and replace dehydrator to remove moisture; if still stuck, replace regulator valve.

Operator Controls

3-25

Air Conditioner Troubleshooting IV. Excessively Noisy System CAUSE

INDICATIONS

REMEDY

Electrical: Effective winding or improper connection in compressor clutch coil

Visual inspection; clutch vibrates.

Replace or repair as necessary.

Loose or excessively worn drive belts

Belts slip and are noisy.

Tighten or replace as required.

Noisy clutch

May or may not slip; noisy when engaged

Remove clutch for service or replacement as necessary.

Compressor noisy

Loose mounting, worn part inside compressor.

Check mountings and repair; remove compressor for service or replacement.

Loose panels

Excessive rattles during operations.

Check and tighten all panels; hose hold down clamps, or rubbing or vibrations of hoses or pipes.

Compressor oil level low

Compressor noisy and lower portion hot to touch.

If oil level low, determine cause of loss.

If correction made, f ll with specif ed oil.

Blower fan noisy; excessive wear in blower motor.

Blower motor noisy.

Remove blower motor for service or replacement as necessary.

Mechanical:

Refrigeration: Excessive charge in system

Rumbling noise or vibration in high pres- Discharge excess freon until high pressure line; thumping noise in compressor; sure gauge drops within specif cations. excessive head pressure and suction pressure; bubbles in sight glass.

Low charge in system

Hissing in evaporator case at expansion valve; bubbles or cloudiness in sight glass, low head pressure.

Check system leaks, charge system.

Excessive moisture in system

Expansion valve noisy; suction pressure low.

Replace dehydrator, purge system, evacuate and charge system.

High pressure service valve closed

Compressor has excessive knocking noise; high pressure gauge reads above normal.

Open valve immediately.

3-26

Operator Controls

Operator Seat

Operator Controls

3-27

Operator Seat

3-28

Operator Controls

Section 4

Pre-Start Checks and Lubrication Before attempting to operate this machine, read and understand the warnings and cautions listed in Section 1.

NOTE

This section contains recommended procedures and instructions which the Operator will need in order to properly perform necessary pre-start checks and lubrication. This information should be considered as the manufacturer's recommendations only and are based upon normal operation. For severe or unusual conditions the recommended lubrication instructions should be varied in accordance with extended hours of operation, climate and drilling conditions.

Refer to the Service Manual for more in-depth lubrication and maintenance procedures.

Pre-Start Checks and Lubrication

4-1

Pre-Start Checks Walk Around Inspection The operator must complete the pre-start inspection before starting and operating the machine.

Check for defects and damage to machine If any one part of the pre-start check does not pass or meet Manufactures Operating and Safety Standards, and Client, Site and Act regulations, then the machine is not to be operated until defects have been repaired by an authorized person. Report damage and defects as soon as possible. Check work area to ensure safety to the operator while completing the pre-start inspections.

Electrical Cables •

Proximity to electrical cables

•

Condition of electrical cable (electric)

Access stair, Walkway and Handrails •

Check emergency stops

•

Check for damage

•

Cleanliness

•

Serviceable

•

Check all signage

Undercarriage •

Condition of track chains and rollers and stone guards

•

Broken or loose grouser plates

•

Loose or missing bolts

•

Main pivot point bolts

•

Lubrication of main pivot point and stabilizer pins

•

Condition of f nal drive and propel motors

•

Excess build up of debris

•

Check under machine for leaks

•

Check damage to water and fuel tanks

•

Check jacks for damage and lubrication

•

Check dust curtains and lifter

4-2

Pre-Start Checks and Lubrication

Pre-Start Checks Walk Around Inspection (cont.)

Mast •

Mast cap bolts If mast cap bolts are missing or appear loose, the drill must not be used until checked by authorized person.

•

Check pipe safety arm is closed and locked

•

Rope condition and tension

•

Check retaining plate in top of carousel for damage

•

Check bull hose whips check in place

•

Check rotary head guides, loose bolts missing slides

•

Check rotary head for oil leaks

•

Check mast crown for damage

•

Check carousel indexing cylinders pins

•

Check lubrication of all pivot points

•

Check mast grates for loose or missing bolts

On Deck Checks •

Hydraulic system condition and leaks

•

Engine condition and leaks

•

Compressor condition and leaks

•

Cooler pack for leaks, damage and cleanliness

•

Dust collector

•

Ensure guards and covers are in place and secure

•

Structural integrity

•

Fire suppression and extinguishers are charged and within service date

•

Drain water from control air manifold and water traps

Fire Extinguishers

Fire extinguishers shall comply with EN79:1995 paragraph 5.12.2 and EN 3:1975. Each f re extinguisher shall have an agent with a mass of not less than 13.2 lbs (6 kg). Fire extinguishers shall be suitable for extinguishing both oil and electrical f res. As part of pre-start checks, check that f re extinguishers are fully charged.

Pre-Start Checks and Lubrication

4-3

Pre-Start Checks Walk Around Inspection (cont.)

Fluid Levels

Ensure machine is levelled prior to checking f uid levels. Check the following f uid levels and f ll as required. Refer to the Recommended Lubricants chart in this section for lubricant type and capacities.

•

Hydraulic oil level

•

Pump drive gear case oil level

•

Engine oil level

•

Receiver tank oil level

•

Coolant level

•

Rotary head oil level

•

Auto lube level

•

Thread lube level

•

Water tank level

•

In-line air tool lubricators, auto lube and thread grease

In Cab Checks •

Check seat for condition and adjustment

•

Check seat belt for operation and condition

•

Ensure all controls are in the Off/Neutral position

•

Check windows for damage

•

Check cab for cleanliness

•

Complete all site required documentation

SAFETY FIRST Operators MUST •

Be trained by an Approved Trainer and authorized to operate the machine

•

Be familiar with all controls and their functions BEFORE use

Post Start Checks •

Check all gauges and screens after start-up for correct operating parameters

•

Check compressor builds to correct pressure

•

Check for un-usual sounds and vibration

•

Check outside machine for leaks

•

Raise mast to vertical position, lower rotary head to bottom of mast and check rotary head gearcase oil level

•

Grease rotary head swivel seal and shock sub (if f tted)

•

Ensure engine and compressor temperature is above 170°F (77°C), before operating

4-4

Pre-Start Checks and Lubrication

Lubrication Equipment Lubrication Determination of when oil changes are made, f lters and f lter elements are to be cleaned and/or replaced, and lubrication of equipment is required, should be based on the severity of operation.

Recommended lubrication instructions provided herein are based upon normal operation, and should be varied in accordance with other than normal operating conditions.

A maintenance chart has been included to list the general location of points and equipment which require scheduled and periodic lubrication. The maintenance chart list the various lube and check points and provides data such as quantities, types of lubricants recommended and the recommended frequency of lubrication. Frequency may be modif ed as required when using synthetic lubricants.

NOTE

For additional lubrication information, refer to vendor manuals provided with the machine.

Care of Lubrication Points Before lubricating, or f lling hydraulic f uids, the f ttings, caps, and f ller plugs should be thoroughly cleaned to prevent contamination.

After lubrication and f lling, remove excess spills. Always keep f ttings, caps and f ll plugs clean of foreign matter.

Lubricating Grease Use SAE designation MPGM which contains 9-5% Molybdenum disulf de conforming to MIL-M-7866 and a suitable corrosion inhibitor.

From 30 to 125oF (-1 to 51.6oC) ambient use NLGI No. 2 From 10 to 100oF (-12 to 37.7oC) ambient use NLGI No. 1 From -20 to 50oF (-289 to 10oC) ambient use NLGI No. 0 From -65 to 50oF (-54 to 10oC) ambient use Mobiltemp SHC 32 synthetic

Gear Lubricant Use any oil which meets EP gear lubricant specif cation MIL-L-2105C or API-GL-5 of SAE J3083C. Lubricant Grades: Below -10oF (-23oC) ambient use 75W Above -10oF (-23oC) and up to 100oF (37.8oC) ambient use 80W-90 or EP90 Above 100oF (37.8oC) ambient use 85W-140 Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges) Pre-Start Checks and Lubrication

4-5

Recommended Lubricants Component Description Compressor Only use lubricants that meet the performance requirements of the lubricants listed

Lubricant Required 1 Mobil SHC 1024 Cat ATF-HD Mobil SHC 1026

Note: Consult your lubricant supplier in order to determine a compatible lubricant.

Hydraulic Tank

Operating Temperature Range (Ambient) -20–120 deg F (-29–49 deg C) -20–120 deg F (-29–49 deg C) (10-52 deg C) 50–125 deg F

Mobil Synthetic ATF

Below -10–100 deg F (-12.2–37.8 deg C)

AW ISO 32

-10–90 deg F (-23.3–32.2 deg C)

AW ISO 46

10–105 deg F (-12.2–40.5 deg C)

AW ISO 68

15–125 deg F (-9.4–51.7 deg C)

Rotary Head

GL-4 Full PAO-based ISO 150 Synthetic Gear Oil 3

-50–125 deg F (-45.5–51.7 deg C)

Pump Drive Gearbox

Mobil Delvac Synthetic Gear Oil

Undercarriage Gear Final Drive

General Grease Lubrication Points

Pipe Thread Grease

50 gal (189L)

SKS-W 250 gal (946 L) SKS 13,16 300 gal (1135 L)

13 gal (49 L)

3.5 gal (13 L)

Synthetic 75W-90

-67–100 deg F (-55–37.8 deg C)

Synthetic 85W-140

0–125 deg F (-17.8–51.7 deg C)

Mobil Delvac Synthetic Gear Oil

5 gal (19 L)

75W-90

-67–100 deg F (-55–37.8 deg C)

80W-140

0–125 deg F (-17.8–51.7 deg C

Mobiltemp SHC32

-65–50 deg F (-53.9–10 deg C)

NLGI 0

-20–50 deg F (-28.9–10 deg C)

NLGI 1

10–100 deg F (-12.2–37.8 deg C)

NLGI 2

30–125 deg F (-1.1–51.7 deg C)

NLGI 1

-30–350 deg F (-34.4–176.7 deg C)

NLGI 2 2

System Capacity

N/A

N/A

-10–350 deg F (-12.2–176.7 deg C)

1.

Fluid types will be temperature dependant (see Service Manual for lubricant specif cations.)

2.

Lithium Base with 3% Molybdenum Disulf de.

3.

No EP oil allowed.

4-6

Pre-Start Checks and Lubrication

Lubrication and Maintenance Chart Interval

Service Point Engine Oil (Cummins QST30)

Check/Add if required

Engine Oil (Cat C27)

Check/Add if required

Fuel Tank

Check/Fill if required 1

Fuel/Water Separator

Drain water

Hydraulic Oil Tank

Check/Fill if required 2 Check/Add if required 3

Air/Oil Separator Tank

Check/Add if required

Engine Coolant

Daily or Each Shift

Service Required

Water Tank

Check/Add if required

Pump Drive Gearcase

Check/Add if required

Air Cleaners

Check Gauge Reading

Oil Filters

Check Service Indicators

Radiator & Coolers

Check/Clean

Shock Sub & Air Swivel

Lubricate

Tracks, Rollers, Sprockets

Check/Clean

Track Frames, Axles, Mounts

Inspect Integrity/Damage

Mast & A-Frame

Inspect Integrity/Damage

Cab Mountings

Inspect Integrity/Damage

Deck & Surrounds

Inspect Integrity/Damage

Rotary Head & Motor(s)

Check

Pulldown/Hoist Ropes

Inspect

Pulldown Sheaves

Check that they are getting grease

Grease Pump Lubricator

Top Up

Pipe Thread Lubricator

Top Up

Fire Suppression System

Charged

Fire Extinguishers

Charged/Secure

Operating Controls

Check that all function correctly

Walk Around Inspection

Report any leaks, damage, etc.

Notes: 1.

No. 1-D or No. 2-D diesel fuels as listed in ASTM D975 are acceptable fuels.

2.

Distilled water or deionized water is recommended for use in engine cooling systems. Do not use hard water, softened water that has been conditioned with salt or sea water. Use a 1:1 mixture of water/glycol for optimum performance.

3.

Fluid level should be at halfway point on the sight gauge on the tank, when all cylinders are fully extended.

Fluid level should be near the top of the sight gauge, when all cylinders are fully retracted.

Pre-Start Checks and Lubrication

4-7

Lubricant Specif cations Engine Oil (Caterpillar) Caterpillar Diesel Engine Oil (DEO) is the preferred oil for use in Caterpillar engines. If Caterpillar DEO multigrade is not used, use only commercial oils that meet the following classif cations.

•

API CH-4 multigrade oils and API CI-4 multigrade oils are acceptable if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid-1 specif cation) are met. API CH-4 oils and API CI-4 oils that have not met the requirements of ECF-1 specif cation may cause reduced engine life.

•

API CG-4 multigrade oils are acceptable for all Caterpillar diesel engines. When API CG-4 oils are used, the oil drain interval should not exceed the standard oil drain interval for your engine.

Engine Oil Viscosities For Ambient Temperatures o

Min.

-40

10

-40

50

SAE 0W-30

-40

30

-40

86

SAE 0W-40

-40

40

-40

104

SAE 5W-30

-30

30

-22

86

SAE 5W-40

-30

50

-22

122

SAE 10W-30

-18

40

0

104

SAE 10W-40

-18

50

0

122

SAE 15W-40

-9.5

50

15

122

Min.

SAE 0W-20

C

o

Max.

Viscosity Grade

F

Max.

Engine Oil (Cummins) Cummins recommends the use of oil that meets American Petroleum Institute (API) performance categories of CF-4, CG-4, CF-4/SG, or CG-4/SH. Special break-in oils are not recommended for new or rebuilt Cummins engines. Synthetic or partially synthetic oils can not be used during break-in period. Use standard recommended petroleum based oil for the f rst drain interval. After that, synthetic oils may be used.

4-8

Pre-Start Checks and Lubrication

Lubricant Specif cations Compressor Lubrication • •

•

Drain Receiver Condensate–In periods of cold weather and/or high humidity, crack receiver drain valve prior to start-up to remove water. Close when oil appears.

Check oil level each shift. The level is checked at the upper sight glass with machine leveled. To check the oil level, the machine must be shut down long enough to permit oil foam to settle or check before start-up at the beginning of the shift. Oil level should cover the lower sight glass and be at the center of the upper sight glass (f g. 4-1).

Change oil after f rst 50 hours, then change oil as specif ed. Consult your dealer for specif c recommendations if extremely severe duty is encountered.

Fig. 4-1- Receiver Tank Sight Glass

Water Pump (Cat Pump)

The Cat Pump is f lled from the factory with ISO 68. This is suitable for temperatures below 0oF (-17.8oC).

Special oil is available from Cat Pump dealers.

•

Fill with oil to red dot in sight window on back of pump (Fig. 4-2).

•

Lubricate the wicks monthly with 2–3 drops of oil in each hole on top of the crankcase (Fig. 4-3).

DO NOT lubricate the wicks at initial start-up. Operate pump for 10–15 minutes, then lubricate the wicks. Use crankcase oil as lubricant.

Fig. 4-2 Cat Pump Oil Level Sight Window (back of pump)

Pre-Start Checks and Lubrication

Fig. 4-3 Cat Pump Oil Filler Cap and Wick Lubrication Points

4-9

Auto Lube System Auto Lube The machine can be provided with an optional auto lube system which consists of an air powered pump assembly f tted to a grease container. The pump supplies grease under pressure to manifolds containing injectors which supply grease to points required. A f lter/regulator/lubricator supplies 60 PSI (4.1 bar) to the pump.

The system is controlled by the Drill PLC System. The system will verify delivery of lubricant into a bearing and also controls the lubrication system.

In most cases, the lubrication points in the following table are connected to the auto lube system or will be connected to lubrication lines from a remote lube bulkhead.

The operator must check all lube points daily to ensure an adequate supply of grease is available to each.

Fig. 4-4 Auto Lube Filter/Regulator/Lubricator Set to 60 PSI Check that auto lube oiler is working properly each shift.

Fig. 4-5 Auto Lube Pump and Grease Container

Fig. 4-6 Auto Lube Pump Controller in Cab

4-10

Pre-Start Checks and Lubrication

Auto Lube System Auto Lubrication Points Description

Number of Points

Crown Sheaves

4

Bottom Pl sheaves

4

Pipe Rack Top

1

Pipe Rack Lower

1

Carousel Top

1

Carousel Lower

1

Pipe Rack Roller

1

Mast Pivot

2

Elevation Cylinder

4

Rear Axle

2

Front Axle Center

1

Front Axle Ends

2

Rear Jacks

2

Front Jacks

2

Pipe Rack Lock

1

Pipe Rack Swing

6

Mast Lock

2

Pipe Positioner

2

Breakout Wrench

3

Operation The lube cycle time and lube pressure setting can be set from the password protected area. The time is set in minutes. If a 60 minute cycle is set, the lube solenoid is activated each 60 minutes (lube solenoid will run for 2 minutes). If the lube pressure switch is not up to pressure within 2 minutes, a lube alarm will occur. If the manual lube is activated, the lube solenoid will run for 30 seconds. If pressure is not reached in 30 seconds, a lube alarm will occur. If the lube alarm continually occurs, then inspect for broken grease lines or faulty f eld devices.

An under lubricated component will fail very quickly; an over lubricated component will: • hide many other faults • contaminate other components • cause the level of maintenance in general to decline as is unpleasant to work on • will increase cleaning time of the drill and those employed in association with the drill.

Lube Fault A lube fault will only be active if a cycle fails to make pressure. Likely causes are: • low supply of lube in tank • pump failure • air supply failure to pump • delivery hose from pump to injectors failed

Note: These same points are connected to centralized bulkheads with grease f ttings for the centralized manual lube system. (ref. 401271 [auto] and 441326 [manual])

NOTE

If an individual point fails to deliver the system will not fault, hence every delivery point should be checked regularly for lubrication.

Pre-Start Checks and Lubrication

4-11

Auto Lube System

Fig. 4-7 Auto Lube Injector Layout Note: Actual layout varies from drill to drill including size, type and location of injectors.

4-12

Pre-Start Checks and Lubrication

Preventive Maintenance In order for an operator to be sure his drill is ready for operation at any time, a regular program of preventive maintenance should be adopted. It is recommended that such a maintenance program be established on the basis of the operator and/or maintenance personnel performing specif c maintenance work during various periods of equipment operations, at intervals during which the equipment will be idle, and during extended periods of time when the equipment will be in storage.

When the drill is in continual, daily use, it is further recommended that a program of daily service requirements be established with preventive maintenance being performed on a "before operation", "during operation", and "after operation" schedule.

NOTE

For additional preventive maintenance information, refer to vendor manuals provided in the drill Service Manual.

Hydraulic System Maintenance The hydraulic components of the drill are built for many years of trouble-free operation. Only one preventive maintenance step is necessary to ensure the expected life of the system—CLEANLINESS. When dirty f lters are indicated, change the f lter as follows: •

Clean the area around the f lter covers to prevent dirt entering the f lter housings.

•

Pull f lters from the housings. Install new f lter and install the covers making sure the cover O-ring is in place.

Sight gauges are provided on the sides of the tank for checking oil levels.

•

Oil level should be at the halfway point of the sight gauge when all cylinders are extended.

•

A temperature gauge is also provided on the sight gauge.

CLEANLINESS cannot be overstressed: •

Use new oil only from previously unopened containers.

•

Clean all tank openings.

•

Fill tank through return f lter.

Fig. 4-9 Hydraulic Loop Filter–Two f lters mounted on each side of mast "A" frame.

Pre-Start Checks and Lubrication

Fig. 4-8 Hydraulic Tank Oil Level and Temperature Gauge

Fig. 4-10 Hydraulic Pump Charge Filter–One f lter mounted on each side of pump drive.

4-13

Preventative Maintenance Extended Machine Shutdown If machine is to be shut down for a long period of time (more than 30 days), there are certain precautions that should be followed to minimize the possibility of damage to the machine.

1.

Position the machine in a safe place on level and solid ground. Do not park close to a high wall where the machine would be in danger of rock fall or slides. Do not park in an area prone to f ooding. Extend the jacks to contact the ground, but the tracks should also be in contact with ground.

2.

If freezing temperatures are expected, be sure cooling system has adequate anti-freeze to protect system from freezing temperatures.

3.

Check all f uid levels, keep fuel tank full to avoid condensation.

4.

Follow pre-start checks in section 4 before starting machine. Make walk around inspection of machine.

5.

Start the machine at least once per month. Allow system to warm up and cycle all hydraulic cylinders to their full stroke and back. Follow proper shutdown procedures, allowing engine to idle for at least f ve minutes before shutdown.

Service Center Oil f ll and evacuation facilities are provided through the Wiggins service center (f g. 4-11) located at the front corner of the machine. Fill and drain points provided in the service center are optional. Oil evacuation from the Rotary Head and Final Drive gearboxes are from the components themselves. The fuel f ll point is also located at the service center. A sight gauge gives indication of fuel level in percentage.

The service center provides connections for servicing and evacuating the following points (not all points on all machines): •

Engine oil

•

Engine oil reserve

•

Engine coolant

•

Hydraulic oil

•

Compressor oil

•

Pump Drive oil

•

Fuel Fig. 4-11 Wiggins Service Center (different options shown)

Do not attempt to drain or f ll the receiver tank with compressor oil until the pressure gauge on the receiver tank reads zero.

4-14

Pre-Start Checks and Lubrication

Preventative Maintenance Bolted Joint Maintenance for Rotary Drills Introduction

To properly maintain bolted joints, some technical understanding of threaded fasteners will be helpful.

Threaded fasteners are often taken for granted and are seldom viewed as the highly engineered items that they are. Their proper selection and proper joint design are critical to ensure structures and machine elements perform as intended. This is a detailed subject and what is intended here, is to present a few highlights to assist with good maintenance practices for rotary drills. This guide is not all inclusive.

Proper Bolt Tension

Proper “Preload” or residual tension in a tightened bolt means more to assembly strength than actual bolt strength. In a bolted joint, a bolt torqued to its proper load level can resist a maximum amount of external load without loosening. Ensuring that the intended preload is achieved and maintained is the objective of this guide.

These rotary drills typically use SAE guidelines which are commonly recognized throughout most industries, for non-permanent connections. All bolted joints in the drills are non-permanent joints (bolted joints of a bridge or building structure would be considered permanent joints.) Standard SAE torque specif cations for bolt tensioning recommends that bolts be pre-tensioned to 75% of yield strength or “Proof Load.” Bolts torqued to this level are reusable if in good condition otherwise.

There are a couple of exceptions in these drills where bolts are tightened beyond this value, and these will be identif ed. See the following chart for recommended torque values for different bolt sizes.

Reasons Properly Tensioned Bolts Loose Their Preload and Require Maintenance • Surface Degradation

Surfaces under bolt heads can degrade due to creep failure, embedment, high bearing stress, corrosion or a combination of these. These rotary drills use hardened washers in many situations to help prevent surfaces from degrading. Critical joints may use “Nordlock” washers which are a hardened, zinc coated, two-piece serrated washer incorporating inclined planes at the mating boundary of the two pieces. To loosen a bolt using this locking device, the bolt must be signif cantly stretched. Critical bolted joints are identif ed in the “Critical Fastener ID and Inspection Schedule” drawing in this manual. Joints that are assembled with Nordlock washers and hardened washers are less likely to experience surface degradation, as the hardness of the washer is close to the hardness of the fastener and is harder than the surface of most nuts used in these drill assemblies.

• Corrosion

Most critical bolted joints on these rotary drills contain components that are made from steel.

Most bolts used are also steel, and therefore susceptible to rusting. Water is a small molecule and can f nd its way into the smallest spaces to attack the surfaces of a bolted joint and the bolt head, body and threads. We recommend that all critical fasteners be lubricated using a lubricant that contains Molybdenum Disulf de (NLGI 2 Molycoat or Never-Seize are readily available Worldwide. Good quality NLGI 2 grease can be substituted if a Moly product is not available at the time of service.)Bolted Joint

• Vibratory Overload

Abusive, unusual or unforeseen loads can cause bolted joint separation. This can result in the loosening of bolts, which in turn can cause bolt fatigue failure. Bolt fatigue will generally result in a fracture surface and ultimately failure at the f rst engaged thread of the bolt or sometimes in the f llet under the bolt head.

Loose bolts can also fail quickly in fatigue. As an example, tests conducted by a bolt manufacturer indicated that a bolt tightened to 1420 lb tension and stressed cyclically to 9215 lb failed after 5960

Preventative Maintenance Bolted Joint Maintenance for Rotary Drills (cont.) load cycles. Identical bolts tightened to 8420 lb and stressed to the same 9215 lb survived 4.65 million cycles before failure. If the bolts had been tightened beyond 9215 lb, it would have been impractical to cycle them to failure.

• Thermal Relaxation

Bolted joints exposed to high temperatures or thermal cycling have a tendency relax or lose bolt tension over time, due to stress creep. Since pre-loading stretches bolts, and only stretches them a few thousandths of an inch. It is easy to imagine that a bolt heated to the operating temperature limits of an air compressor could increase the plasticity of the bolt material, allowing it to lose some of its initial loading. Bolted joints of a new machine that are subjected to high heat should be checked and re-torqued to specif cation after the f rst 500 hours of operation.

Critical Bolted Joint Maintenance Critical bolted joints are those joints which hold major structures together or hold overhead loads.

Failure of these joints could endanger personnel or seriously damage equipment. As stated earlier, these are identified in Figure 2.

Caterpillar Drills recommends that critical bolted joints of drills should be checked for proper torque every 120 days or 2000 operating hours for machines that have less than 10,000 operating hours, and every 90 days or 1500 operating hours for machines that have greater than 10,000 operating hours.

If a bolt is found to be loose (less than 90% of specified torque value), it should be removed and replaced. If the joint contains more than one bolt, all bolts in the joint should be replaced.

The joint mating surfaces and bolts should be inspected for signs of corrosion, surface degradation, and the presence of hardened washers or Nordlock washers. Joints with Nordlock washers require the replacement of the washers as well. Hardened washers can generally be reused as long as the washer is undamaged.

Bolts should be replaced with the Grade 8 bolts.

Refer to SENR3130 for proper torque specifications.

Bolts in critical joints should also be removed and replaced every 2.5 years or 15,000 hours of operation, regardless of apparent condition.

Other Bolt Maintenance

All bolts contained in these drills are subject to the same topics described above, but generally do not have the same degree of risk involved should a bolt failure occur. Every machine should have a “walkaround” inspection performed at the beginning of each operating shift, which includes looking for loose hardware. Other signif cant bolted joints include all pressurized f ttings, f ange connections and all bolted pin retainer/keeper plate bolts. All machine bolts should be inspected for proper torque specif cation annually at a minimum.

SEE BOLTED JOINT MAINTENANCE IN THE SERVICE MANUAL FOR ADDITIONAL INFORMATION CONCERNING BOTH GENERAL AND CRITICAL FASTENERS.

RECOMMENDED INTERVALS FOR PRE-LOAD VALIDATION BY VERIFYING FASTENER TORQUE RECOMMENDED INTERVALS FOR VISUAL INSPECTION AND RE-LUBRICATION RECOMMENDED INTERVALS FOR REPLACEMENT

A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE START OF EACH SHIFT.

LESS THAN 10,000 HOURS VERIFY EVERY 120 DAYS OR 2000 HRS

REPLACE BOLTS EVERY 2.5 YEARS OR 15000 HRS REGARDLESS OF CONDITION

GREATER THAN 10,000 HOURS VERIFY EVERY 90 DAYS OR 1500 HRS

MACHINE SERVICE HOURS:

WINCH MOUNTING FASTENERS

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

SEE MACHINE PARTS BOOK FOR PART NUMBERS OF SPECIFIC FASTNERS, WASHERS AND NUTS.

LEVELING JACK CAP FASTENERS

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS

UNDERCARRIAGE MAIN AXLE FASTENERS

ALL MAST MOUNTING FASTENERS FLOATING SHAFT OR FIXED SHAFT

CRITICAL FASTENER ID & INSPECTION SCHEDULE

Preventive Maintenance

4-15

Preventive Maintenance CRITICAL FASTENER ID & INSPECTION SCHEDULE Contintued

Typical example of grates located on the mast.

Torque the bolts for each mast grate to 102 Nm (75 lb ft) Every 6 Months OR 3000 hours

Mast Grate Bolts

4-16

Pre-Start Checks and Lubrication

4-17

A

A

A

A

A

B

C

INSPECT EVERY 3000 HRS

C INSPECT EVERY 9000 HRS

B INSPECT EVERY 6000 HRS

A

LESS THAN 30,000 HOURS

INSPECT EVERY 1500 HRS

C INSPECT EVERY 4500 HRS

B INSPECT EVERY 3000 HRS

A

GREATER THAN 30,000 HOURS

INTERVALS FOR MAGNETIC PARTICLE INPECTION IN ACCORDANCE WITH AS1171 MACHINE SERVICE HOURS:

A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE START OF EACH OPERATORS SHIFT.

ALL UPPER MAST LACING JOINTS

WELDS CONNECTING LEVELING JACKS TO MAIN FRAME

MAIN FRAME CROSSMEMBER WELDS CONNECTING CROSSMEMBER TO MAIN BEAMS AND GUSSETS AT OSCILLATION YOKE

C

MAST PIVOT TRUNION & CYLINDER LUG WELDS

MAIN SHAFT TO MAIN FRAME WELDS AND GUSSETS

C

A

C

C

WELD INSPECTION SCHEDULE

ALL LACING JOINTS TO MAIN MAST CHORDS BETWEEN PIVOT SHAFT AND LIFT CYLINDER AND THE NEXT HIGHER CELL BEYOND THE LIFT CYLINDER LUGS

B

MAIN FRAME CROSSMEMBER WELDS CONNECTING CROSSMEMBER TO MAIN BEAMS AND GUSSETS AT OSCILLATION YOKE

ALL JOINTS CONNECTING MAST CYLINDER LUGS TO THE MAIN FRAME

ALL AFRAME WELDS AND WELDS CONNECTING AFRAME TO MAIN FRAME

C

C

WELDS CONNECTING LEVELING JACKS TO MAIN FRAME

ALL CONNECTING JOINTS TO THE PIVOT SHAFT

Weld Inspection Schedule

Pre-Start Checks and Lubrication

Section 5

Operating Instructions Before attempting to operate this machine, read and understand the warnings and cautions listed in Section 1.

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

Operating Instructions

5-1

Fire Suppression System Description The machine can be equipped with an optional f re suppression system. The system is manually activated by pushing a button located on one of the two actuators. The actuators are located in the operator's cab (f g. 5-1) and on the front of the machine (f g. 5-2). The Operator must become familiar with the location of these actuators.

In addition, there is a battery cut-off switch which automatically cuts off power to the machine when the f re suppression system is activated.

NOTE

At any time if any part of the f re suppression system is suspected of not being fully operational or has suffered damage, it shall only be serviced by a professional f re protection service.

Fig. 5-1 Actuator Mounted in Cab

Fig. 5-2 Actuator Mounted on Front of Machine

Operation

When the system is activated, the f re suppression agent in three (3) tanks is released and discharged through a series of nozzles, located in critical areas around the machine. At the same time, the battery cut-off switch cuts off voltage to the machine.

After a f re, or accidental discharge, the system must be checked and serviced by a professional f re protection service. In addition, the battery cut-off must be reset by relieving all pressure in the system through the pressure relief valve and pushing the reset button on the cut-off valve.

5-2

Operating Instructions

Fire Suppression System In Case of Fire Locate the nearest actuator.

1.

Turn ignition switch OFF if possible.

2.

Pull ring pin and push red button on actuator.

3.

Get away from machine and call for help.

After System Has Been Discharged After a f re, or accidental discharge, the system must be checked and serviced by a professional f re protection service.

• Be sure the f re is completely out and there are no "hot spots" before getting near the machine.

It's good idea to keep a portable f re extinguisher on hand ( see f re extinguisher specif cations on previous page). When approaching the machine, have a f re extinguisher with you.

•

Determine the cause of the f re and make necessary repairs, before putting machine back into service.

•

After discharge, and when it is safe to return to the machine, the battery cutoff valve needs to be reset. This is done by f rst pulling the ring on the pressure relief valve (f g. 5-3) to relieve all pressure in the system. When all pressure is relieved, push the reset button on the battery cutoff valve IN. You will not be able to push the reset button in with pressure still in the system.

Fig. 5-3 Pneumatic Battery Cutoff Valve

Operating Instructions

5-3

Start-Up Procedure Before starting the machine, warn nearby members of the work crew that you are starting the machine. DO NOT USE ETHER on engines equipped with air inlet heaters.

To Start Engine: 1.

Be sure all controls are in the Off or Neutral position.

2.

Place the air control valve (10) or air control switch (39) in the start position for low pressure systems or low for high pressure systems. Some machines, use switch (39) in place of valve (10).

3.

Place throttle lever (2) in low position.

4.

Turn the ignition key (15) on.

5.

Push and hold the engine start button (16) until the engine starts, when engine is started, release start button. The engine pre-lube pump will operate for a few seconds before the starter cranks the engine. Do not crank engine for more than 30 seconds, then allow starter to cool for two minutes before attempting to start again.

6.

If it is necessary to use the optional ether injection (17) for starting, use caution not to use too much as engine damage can occur. Press button for 3 seconds and release, then allow 3 seconds before starting engine. DO NOT USE ETHER on engines equipped with air inlet heaters.

DO NOT SPRAY ETHER into compressor inlet.

Fig. 5-4 Operator's Control Panel–Right Side

5-4

Operating Instructions

Start-Up Procedure After-Start Checks After start checks are carried out to ensure that the machine is in a safe working condition before the operator commences drilling procedures.

1.

Check to ensure engine oil pressure is in normal operating range (consult engine manual).

2.

After system has warmed up, turn the compressor Start-Run Valve or switch to Run for low pressure machines or High for high pressure machines.

Check to ensure compressor air pressure is at least 100 PSI (7 bar) for low pressure machines or 300 PSI (21 bar) for high pressure machines.

Fig. 5-5 Operator's Control Panel–Left Side

Compressor air pressure must not exceed 100 PSI (7 bar) for low pressure machines, or 350 PSI (24 bar) for high pressure machines.

3.

Check the compressor air temperature, hydraulic oil temperature and engine coolant temperature readouts. The drill should not be operated until the hydraulic oil temperature reaches 100oF (37.8oC).

4.

Let the engine warm up to 170oF (77oC) prior to activating full rpms. Perform a walk around inspection. Check entire machine for oil leaks and any abnormal engine noises.

5.

Check all f lter indications at operating temperature.

6.

Raise mast to vertical position. Lower rotary head to bottom of mast and check gearcase oil level in sight glass.

7.

Check rotation motors and head guide bolts and slides.

8.

Grease swivel seal and shock sub (if f tted).

NOTE

The shock sub only requires two pumps of grease with a hand held grease gun every two days.

Ensure correct machine leveling and mast-raising procedures are followed (as outlined in this section) prior to bringing the rotary head to the bottom of the mast.

Operating Instructions

5-5

Shutdown Procedure DO NOT use the emergency STOP switch to stop the machine, except in an emergency.

Stopping the engine without the proper idle down period can cause engine damage.

To shutdown the machine, proceed as follows: 1.

Fully retract the drill string from the drill hole.

2.

Ensure the machine is in a safe position, parked in accordance with site procedures, and; •

On level and stable ground not too close to a high wall or free face;

•

Away from areas that can obstruct movement of mine traff c;

•

With mast either resting on supports or locked in vertical position by mast pin locks;

•

With leveling jacks on the ground supporting the weight of the machine.

3.

Ensure the air compressor is in the START conf guration. Place all controls in OFF or NEUTRAL.

4.

Reduce engine speed to LOW idle. Allow the machine to idle for f ve (5) minutes before stopping.

5.

Turn off air conditioning, any lights, radios and electronic equipment.

6.

Turn ignition key to OFF.

7.

When the engine stops, the air receiver will automatically "blow down." Do Not open the service valve to dump air.

8.

Check the air pressure gauge to ensure all air pressure has been relieved. Should there still be air pressure in the system, open the manual blow down valve on the air receiver.

9.

Inspect the machine for obvious damage or wear and report any unusual conditions to the immediate Supervisor.

5-6

Operating Instructions

Emergency Shutdown Description The machine can be equipped with optional devices which enable the Operator to shut down the engine in case of an emergency. There is an emergency stop button in the operator's cab right hand gauge panel (f g. 4-6). There are also ground level engine stop buttons (f g. 5-7) located on the right side of the machine in close proximity of the cab, in the engine/motor area and at the front of the machine.The Operator must become familiar with the location of these devices if the machine is so In the event of emergency shutdown, the Operator should notify the Supervisor and be sure corrective equipped. action is taken to remedy the fault that caused the emergency shutdown, before restarting the machine.

1.

Take necessary corrective action to correct the fault.

2.

Make a walk around inspection of the machine to be sure no additional damage has been done or could occur. Pay particular attention to the engine and compressor systems.

3.

Check circuit breakers and reset the emergency stop device (pull out to reset).

Fig. 5-6 Emergency Stop Switch on Cab Gauge Panel

Fig. 5-7 Ground Level Engine Stop Switch

Operating Instructions

5-7

Cold Weather Start-Up Hydraulic System Warm-Up (without cold weather package) BE SURE machine does not overheat. Observe hydraulic and water temperature gauges.

1.

2.

Start engine and warm up for 5 minutes or up to 170oF (77oC).

•

Set the throttle at approximately 1600 RPM and lower all jack pads to the ground by operating the rear and front jack control levers to the DOWN position.

•

Operate rear right and rear left jack controls to DOWN position until rear of machine track is clear of the ground and approximately level by watching level indicator (refer to Leveling Machine).

•

Operate the front jack control to DOWN position, until front of machine track is clear of the ground, approximately level.

Raise the mast.

LOOK UP before raising or lowering mast.

See Section 1 for Clearances from High Voltage Lines table.

ALWAYS level machine before raising or lowering mast and before drilling.

•

Be sure the machine is level and solidly stabilized with all leveling jacks before attempting to raise the mast.

•.

Be absolutely sure that the mast will not come in contact with power lines, telephone lines or any other obstructions.

•

Be sure the winch lines, hydraulic hoses and air hoses are clear and that all equipment stowed in the mast is secured.

•

Place mast raising control lever in MAST UP position.

•

As mast approaches the break-over point, reduce the speed of the mast to gently bring the mast against the base of the drill.

3.

5-8

•

Engage mast locks.

•

Set Drill/Propel switch to DRILL.

Hold rotation control to one-quarter and operate rotation in FORWARD position.

Operating Instructions

Cold Weather Start-Up Hydraulic System Warm-Up (cont.)

4.

Work all hydraulic controls to distribute warming oil and to help elevate oil temperature. Pay particular attention to winch warm-up by cycling several times without load.

5.

When hydraulic oil temperature reaches 100oF (37.8oC) the system is operational.

Compressor Warm-Up (Low Pressure) 1.

Run machine with compressor in the START position until temperature reaches 160oF (71.1oC).

2.

After warm-up, turn selector to RUN position.

3.

Gradually increase engine speed to 1800 RPM. Compressor pressure should read 100 PSI (6.9 bar) and temperature should be 160–200oF (71.1–93.3oC). Temperature should be monitored and maintained by the air f ow direction through the cooler.

Compressor Warm-Up (High Pressure) 1.

Run machine with compressor selector valve in the LOW position until temperature reaches 180oF (82oC).

2.

After warm-up, turn selector to HIGH position.

3.

Place throttle lever (2) at full throttle position (2100 RPM). Compressor pressure should read 350 PSI (24.1 bar) and temperature should be 210oF (99oC). Temperature will be monitored and maintained by the thermostatic valve and compressor oil cooler.

Operating Instructions

5-9

Propelling Machine ALWAYS propel the machine in reverse (towards operator's cab) where possible to provide maximum visibility, propel the machine slowly when working on slopes, ramps or rough terrain. Be extremely careful when working around trenches or banks.

Propelling the machine across rough/undulating terrain or across grades should never be carried out with the mast raised. The mast must be lowered prior to propelling over rough ground.

•

The machine should never be propelled over areas that could potentially collapse or subside.

•

Do not travel on steep slopes or crosswise to grades.

•

Visually inspect the path to be taken.

•

Adhere to all precautions relating to underground workings.

•

Never tram through areas of soft unconsolidated materials holding water.

Failure to follow these recommendations could result in a machine roll over.

NOTE

When propelling this machine, forward is towards the radiator end of the machine and reverse is towards the operator's cab.

1.

Select PROPEL mode with the Drill/Propel switch.

2.

Engage left and right propel levers together slowly in the required direction of travel. Propel speed is varied by the degree of travel, forwards or backwards of the propel levers. To propel in a straight line, the propel levers must be operated equally from the neutral positions.

3.

To turn the machine left or right, one propel lever may be engaged more than the other to make the machine turn. For very tight turns one propel lever may be engaged to the full forward position and the opposite lever engaged to the full reverse position.

Both tracks must be operated when propelling the machine. Never allow either track to drag while propelling in a straight line or turning.

4.

To stop propelling machine once at destination, move the propel levers back to the neutral position.

5.

Place the Drill/Propel switch in the NEUTRAL position unless drilling is to commence.

If propelling on an incline or decline, the machine should always be trammed up or down the slope where possible. Traveling across the grade should be avoided.

5-10

Operating Instructions

Propelling Machine Propelling Up, Down and Across Grades NOTE

Refer to Section 2 for Transient Stability Limits.

1.

The mast should always be lowered before propelling the machine down or across grades.

2.

When propelling up or down a grade, index the pipe loader to a mid position, so drill pipes cannot slide forward out of the carousel.

3.

When propelling up or down a steep grade, the operator's cab should be facing downhill. With the mast down, the front end of the machine is heavier than the rear (cab end). This makes the machine more stable.

4.

When propelling up a steep grade, a spotter should be used to guide you, as visibility is restricted to the operator.

5.

Always be careful when propelling machine across grades, as the machine is more unstable sideways than it is lengthways. Propel with the operator's cab facing uphill when crossing grades whenever possible.

Propelling Over Cables 1.

Always use an approved crossing point, if one has been constructed. Always cross at right angles and do not turn machine while crossing.

NEVER propel machine across electric cables. Severe personal injury or death could occur, as well as property damage.

2.

If no approved crossing point exists, then the following procedure should be used to cross electric cables: •

Use a spotter as a guide. Approach the cable at 90o and stop machine when cable is between the jack pads and the tracks.

•

Carefully lower jacks, making sure the jack pads will not rest on the cable. Raise machine up on the jacks until tracks are clear of the ground.

•

Move cable under tracks until it is between the opposite end of the tracks and jack pads at the other end of machine.

•

Carefully lower machine, making sure cable is not under tracks and retract jacks fully before continuing to propel machine.

Operating Instructions

5-11

Leveling Machine Leveling the Machine for Drilling NEVER ATTEMPT to commence drilling unless the machine has been leveled and is supported by all four jacks on stable ground conditions. Machine can turn over, causing serious injury or death.

DO NOT position jacks on cribbing or timber bridging.

DO NOT position machine close to a highwall.

ALWAYS extend front (radiator end) jacks to equalize pressure in both front jacks after re-leveling machine.

Raising Machine (lowering jacks) When raising machine, level the rear (cab end) of the machine f rst, then level the front (radiator end).

Refer to leveling procedure that follows.

Lowering Machine (raising jacks) When lowering machine, lower using front and rear jacks together, keeping jack pads close to the ground.

When tracks are on the ground and machine is stable, jacks may be raised fully. Refer to leveling procedure on following page. The drill is equipped with jack retract indication on the drill monitor.

Leveling Procedure When leveling or “setting up” the drill, there are two things to remember: •

Distribute the weight evenly on the jacks

•

Keep the machine as close to the ground as possible

Good leveling techniques require an understanding of the jack design of the machine and how they operate. There are four jacks. The two rear jacks (drill end) are independently controlled; that is, there is a controller for each one. The front jacks operate in parallel, both operate from one controller.

The operator will need to use the front jack function as the last step in the jacking procedure to ensure the torsional stress in the chassis is minimized as the pressure is equalized in the front jacks.

In Ideal situations, lower the rear jacks to the ground and level side to side, then lower the front jacks to level front to back.

ALWAYS keep the machine as low to the ground as possible when leveling the machine. This machine has safety check valves in the leveling system to prevent the jacks from moving in the case of a power failure. Should it be noticed that the jacks are creeping, the machine should not be operated and repairs completed immediately.

Failure to follow these instructions could lead to serious personal injury or equipment damage.

5-12

Operating Instructions

Leveling Machine Leveling Procedure (cont.)

When addressing slopes, the machine should be aligned with the rear of the machine facing up the slope and the cab on the high side.

The machine must then be leveled from the lowest point f rst; and quite often the need to use two controllers at the same time will be necessary to evenly distribute the weight of the machine on the jacks as the machine is being raised. This is to prevent the jack casing binding up from friction created from the twist in the chassis, and leaving the highest point jack until last allowing the machine to be supported by all jacks and still be as close as possible to the ground.

Lowering the Machine Use all three controllers together to raise the jacks; this will allow the machine to stabilize as it comes in contact with the ground. Hold each controller ON until the relevant jack is fully retracted.

Re-Leveling Machine If machine needs to be re-leveled after it is already on all four jacks: • FIRST level rear (cab end) of machine.

•

ALWAYS extend front (radiator end) jacks to equalize pressure in both front jacks after re-leveling machine.

If machine has been leveled and is up on all four jacks and the machine needs to be re-leveled, use the following procedure: 1.

Level the rear (cab end) of the machine f rst using rear jack levers.

2.

Level the front (radiator end) of the machine using front jacks lever even if it appears level. This must be done to equalize the hydraulic pressure to the front jacks.

Operating Instructions

5-13

Raising Mast LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death.

Refer to the Clearances from High Voltage Lines chart below.

ALWAYS check that the deck area is clear of dirt and obstructions before raising the mast.

ALWAYS level machine before raising or lowering mast and before drilling. Make sure tracks are always raised from the ground.

Clearances from High Voltage Lines Line Voltage

Minimum Clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv

45 ft (13.7 m)

1.

Level the machine, using the Leveling Machine procedure previously outlined.

2.

Check mast for loose drilling tools or parts.

3.

Be sure mast lock pins are retracted and drill bit will clear work deck area.

4.

Look up before raising mast. Be sure you are clear of any overhead obstructions and clear of any power lines. Raise mast by engaging the mast lever to the RAISE position. The mast should start to lift; if not, check the auxiliary hydraulic pressure gauge to see if any other functions are engaged.

5.

As the mast approaches the vertical position, the mast raising speed will tend to increase. It is necessary to slow the speed to stop the mast from hitting into the base of the machine too hard.

6.

The mast angle may be set from 60o to the vertical depending on drilling applications. Use the angle indicator on the mast to set the correct angles.

7.

Once the mast has been set at the desired angle, lock the mast into position by switching the Mast Lock/Unlock switch to the LOCK position.

NOTE

5-14

Be sure to visually check to see that mast locking pins are fully engaged in the holes in the mast lock brackets before drilling. Also be sure that the pins are fully retracted before lowering the mast. Red or green LED indicators should also conf rm the visual check, when equipped.

Operating Instructions

Lowering Mast LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death.

Refer to the Clearances from High Voltage Lines chart on previous page.

ALWAYS check that the deck area is clear of dirt and obstructions before raising the mast.

ALWAYS level machine before raising or lowering mast and before drilling. Make sure machine is supported by all four jacks.

1.

Retract the drill string from the hole, ensuring that the drill bit will clear the work deck area.

NOTE

If the drill pipe and drill bit are not above the Pipe in Hole Sensor, it will automatically lock-out the mast and jack lever functions.

2.

Rotate the drill pipe loader to the stored position.

3.

Unlock the mast by pushing the Mast Lock/Unlock switch to the UNLOCK position.

4.

Lower the mast by engaging the mast lever to the LOWER position, controlling the lowering speed with the mast lever, in order that the mast gently comes to rest on the mast support.

Operating Instructions

5-15

Loading Drill Pipe Ensure that the drill pipe to be loaded is the correct diameter and length to suit the carousel to be loaded.

Load drill pipe using a crane whenever possible; this is the best and safest method. If a crane is not available when drill pipe is being loaded, follow the procedure outlined below.

Equipment Required 1.

Service truck with service winch capable of lifting male end of pipe above the drilling platform of the machine, front end loader or auxiliary crane mounted on rear deck of machine.

2.

Adequate lifting straps.

Procedure 1.

Be sure machine is on level and solid ground.

2.

Check all pipe rack control functions to be sure they operate according to labels on control panel.

Switch hoses if necessary. Check f uid level in rotary gearbox.

3.

Lift the male end of the pipe to approximately the height of the middle railing around the drilling platform. Be sure pipe is secure and won't slip.

4.

Raise mast to the same angle as pipe and back machine up to the pipe.

5.

Apply grease to drill pipe threads and lower the rotary head until the top sub-adapter engages the threads of the pipe. Thread the pipe all the way to the shoulder of the pipe and top sub-adapter.

6.

Stabilize machine by lowering all four jacks to the ground. Machine does not have to be lifted off the ground, but jack pads should be in solid contact with ground.

7.

Raise the rotary head up the mast with the pipe, but do not let the pipe go above the deck bushing in the mast base. Use the pipe support if you have an angle hole machine.

8.

When the lower end of the drill pipe approaches the deck bushing, stop the rotary head and raise the mast to the vertical position. Use the pipe rack controls to rack the pipe (refer to instructions on Retracting Drill Pipe in this section).

9.

Repeat steps 3–8 for the remaining pipe sections.

5-16

Operating Instructions

Preparing to Drill Installing and Removing Drill Bit Always use approved lifting equipment and methods to lift bits and equipment on and off the drill deck and to lift drill bits out of bit baskets. Do not use a crane unless proper training has been conducted on its use.

Before commencing this operation, ensure that the drill pipe is secured to the rotary head and that the rotary head is in a secure stationary position.

THE DRILL PIPE MUST NOT BE ROTATING WHEN ANYONE IS ON THE DECK AND PERFORMING BIT CHANGING PROCEDURES. INJURY OR DEATH MAY OCCUR. Before drilling can commence, drill bit sub and the drill bit must be installed as follows: 1.

Remove the rotary deck bushing from the work deck and insert the drill bit breakout basket into the work deck.

2.

Place the drill bit into the bit basket.

3.

Place the bit sub onto the drill bit and make-up thread joint "hand" tight.

4.

Engage the drill pipe to the bit sub and rotate drill pipe clockwise slowly until the thread joint becomes tight. Tighten thread joint to 3000 PSI (207 bar) on the rotary hydraulic pressure gauge.

5.

For removal of drill bit, place bit breakout basket into the work deck.

6.

Lower drill bit into the breakout basket and use the breakout wrench to break the thread joint.

7.

Once thread joint is loose, simultaneously rotate drill pipe counterclockwise and slowly raise drill pipe until the drill bit is unscrewed.

Shock Sub If a shock (cushion) sub is used, be sure to follow manufacturer's recommended maintenance. Normally this includes daily greasing (5 to 10 strokes with a hand grease gun).

Operating Instructions

5-17

Drilling Operations ALWAYS level machine before raising or lowering mast and before drilling.

DO NOT operate machine when wind speed is above 75 MPH (120.8 Km/h).

Rotary Drilling IMPORTANT: Become familiar with all the controls and their functions prior to any operation. Take it slow at f rst and as the machine and drilling cycle become more familiar, the full operating capability of the machine can be gradually achieved. The most important reason to operate slowly at f rst is safety.

Operating at full speed means that things happen very quickly. This unexpected operation of equipment can very easily lead to an accident.

Once the drill pipe, bit sub, and drill bit have been coupled up, drilling operations are ready to commence.

The machine MUST be level and supported by all four jacks before mast is raised.

1.

Lower the drill bit until it comes in contact with the ground.

2.

Zero the Actual Depth and log the hole number on the drill monitor.

3.

Turn on the drilling air by engaging the Drilling Air Control Switch to the ON position. Note the air pressure registered on the Drilling Air Pressure Gauge on the drill monitor.

4.

Start rotating the drill string forward "slowly" 30–40 RPM using Rotation Lever. Forward rotation is clockwise.

5.

Slowly lower the drill string using Hoist/Pulldown Lever until the hole is collared and the drill bit is in solid ground. Collaring of the hole should be done slowly and carefully to ensure that the hole is started straight. This will help avoid problems as the drill hole gets deeper.

6.

Once the hole is collared, start increasing the pulldown pressure and rotation speed until a satisfactory rate of penetration is achieved. Pulldown pressure and rotation speed will be dictated by the type of ground being drilled. Then engage the Auto Pulldown Switch by pushing the switch to the engage position, Refer to Section 6–Drilling Practices for more information.

NOTE 7.

Pulldown pressure and rotation speed must be continuously adjusted to suit the drilling conditions.

Monitor the rotation pressure and air pressure gauges for abnormal readings.

NOTE

8.

If the drilling air pressure rises higher than normal or the rotation pressure is higher than normal, disengage the pulldown and lift the drill bit off the bottom of the hole and allow the hole to clear, if necessary work the drill string up and down to assist in cleaning the hole. Decrease the amount of pulldown if the drill bit or hole continues to block up.

Switch on either the dust collector or water injection system. Engage Water Injection/Dust Collector Switch–RIGHT for dust collector, LEFT for water injection. Adjust water f ow for water injection with Flow Control Valve.

NOTE

5-18

Applying excessive weight or using too fast of rotation speed will result in premature wear to all consumables.

Do not use the dust collector if ground water is encountered.

Excessive water injection will reduce drill bit service life.

Operating Instructions

Drilling Operations Rotary Drilling (cont.)

9.

Drill down until the desired depth of the hole is reached, then disengage the Auto Pulldown Switch and start raising the drill string out of the hole using the Hoist/Pulldown Lever. As the drill bit approaches the top of the hole, turn off the air and stop rotation with Rotation Lever. Lift the drill bit clear of the ground, high enough to allow good clearance when moving to the next hole.

NOTE

If depths of more than one drill pipe are required, follow the operating procedures for multiple pass drilling.

Multiple Pass Drilling When depths of more than one length of drill pipe are required, drill pipe from the drill pipe loader will need to be used to continue drilling.

Adding Drill Pipe 1.

Drill down until the rotary head stops at the bottom of the mast.

2.

Disengage the pull-down system and slow rotation with the rotation lever.

3.

Lift the drill string and align the tooling on the drill pipe with the deck wrench.

4.

Stop rotation and extend deck wrench fully, ensuring there is enough room between top of tooling f ats and top of deck wrench to allow the threads to unscrew without binding or falling too far.

5.

Turn off drilling air control switch.

6.

Using reverse rotation, break the thread joint and undo the threads slowly.

7.

Apply thread grease to the drill pipe threads.

8.

Raise the rotary head until head clear indicator changes to green.

9.

Swing the drill pipe loader to load position.

10.

Lower rotary head until light contact is made with drill pipe thread. Forward rotate slowly to make up the joint, ensuring cross threading does not occur by watching drill pipe lift in carousel. Torque joint up.

Carousel must be LOCKED to add/retract drill pipe.

11.

Lift pipe clear of pot and align pipe tooling to allow pipe to be removed from carousel. Retract pipe loader to parked position.

12.

Lower pipe slowly until light contact is made with bottom pipe thread. Forward rotate slowly to make up joint.

13.

Reverse rotate to align tooling and retract deck wrench from pipe.

14.

Turn drilling air on and re-commence drilling activity.

DO NOT allow drill pipe to drop in deep holes, thread damage will occur.

Operating Instructions

5-19

Drilling Operations To Rotate Drill Pipe Loader 1.

Switch the carousel locking pin to Index.

2.

Index the carousel to the next position.

3.

Switch the carousel locking pin to lock position.

DO NOT tighten threads or attempt to breakout with the carousel in Index position, ensure the carousel locking pin is engaged.

ALWAYS torque the drill pipe joints in the pipe loader.

Retracting Drill Pipe NEVER leave the machine unattended with drill pipe in the hole. Failure to follow these procedures could result in damaged equipment.

1.

Once the desired hole depth is reached, disengage the pull-down system and raise the rotary head until the drill pipe thread joint is above the deck wrench.

2.

Align the tooling on the lower drill pipe with the deck wrench, the top of the tooling should be approximately 2 inches above the deck wrench. Engage the deck wrench.

3.

Turn off drilling air.

4.

Using rotation control lever in reverse, allow the rotation pressure to increase until the drill pipe joint breaks. A light slapping action is used to break the joint.

5.

If the joint breaks at the top, re-tighten and use the HOBO to break the joint.

6.

Unthread and align tooling f ats with carousel breakout plate.

7.

Raise pipe to a position to enable pipe to clear carousel pot and breakout plate.

8.

Swing pipe loader to load position.

DO NOT force carousel onto pipe.

9.

Lower pipe into carousel then raise enough to un-thread pipe without binding. Reverse rotate and unthread top thread.

10.

Raise rotary head above head clear position.

11.

Retract pipe loader to parked position.

12.

Lower rotary head until light contact is made with lower thread. Forward rotate to tighten thread.

13.

Reverse rotate to align tooling and retract deck wrench, (leave wrench covering deck bush).

14.

Turn on drilling air and raise pipe to next joint or top of hole.

If the upper thread joint becomes loose before the lower joint, retighten the upper joint and use the breakout wrench to loosen the lower joint.

DO NOT allow the upper drill pipe joint to unscrew unless positioned in the carousel.

ALWAYS make sure that all drill pipes have been removed from the hole before attempting to lower the mast.

5-20

Operating Instructions

Cold Weather Operation Description For machines operating in arctic type conditions an optional cold weather package can be installed to pre-heat f uids and lubricants. With the cold weather option, the machine can operate down to temperatures of -40oF (-40oC).

The cold weather option includes the appropriate lubricants in the compressor, engine, hydraulic system and gearboxes. See the Recommended Cold Weather Lubricants on the following page for lubricant recommendations.

An optional diesel f red heater/pump unit, using fuel from the machine's diesel tank, circulates a water/anti-freeze mixture through heat exchanger tubes located in the hydraulic tank, fuel tank, water tank, radiator and engine block.

The heating system can also be powered by a generator (GenSet) mounted on the machine, or an external power source, to provide 120 or 240 VAC to the system to thermostatically control heating elements and silicone heating pads. A heater/controller supplies power to a distribution breaker box and pumps heated water/anti-freeze through the engine block.

The heating elements for this type of system are installed in the hydraulic tank, fuel tank and engine while the heating pads are installed in the compressor control box, receiver tank, auto lube grease container and under the batteries in the battery tray.

Additional measures included for extreme cold protection are: • Thermo-glass cab windows • Additional heater in cab • Spray-on insulating material under the cab, water and fuel tanks • Cold weather wiring for AC/DC systems including low temperature conduit There are no additional f uid additives required for cold weather operation.

NOTE

When cold weather operation is specif ed, the options discussed above may be used separately or in combination to suit a specif c operating environment.

Heater/Pump Unit The heater/pump unit heats and circulates water and anti-freeze through the engine, radiator, hydraulic tank and fuel tank. Fig. 5-9 shows a typical installation. A 24VDC motor operates the water pump.

Diesel fuel is used to fuel the heating system.

Fig. 5-9 Heater/Pump Installation 1. Heater/Pump Unit 2. Manifold Operating Instructions

5-21

Cold Weather Operation Recommended Cold Weather Lubricants The following table lists replacement lubricants that are recommended for the temperature ranges shown, typically in extreme cold weather operating conditions. Equivalent f uids may be used as long as they meet the same requirements. Consult the machine manufacturer for proper application.

Component Description

Operating Temperature Range (Ambient)

Lubricant Required

Compressor

Mobil SHC 1024 Synthetic

Below 10oF (-12.2oC)

Engine Crankcase Oil

SAE 5W-40 Synthetic

Below -10oF (-23.3oC)

Hydraulic Tank

Mobil Synthetic ATF

Below -10 to 100oF (-23 to 37oC)

Pump Drive Gearbox

Mobillube SHC 75W-90 Synthetic

-67 to 100oF (-55 to 37oC)

Rotary Head

Mobillube SHC 75W-90 Synthetic

-67 to 100oF (-55 to 37oC)

Undercarriage Final Drive

Mobillube SHC 75W-90 Synthetic

-67 to 100oF (-55 to 37oC)

General Grease Lubrication Points

NLGI 1 Mobil Temp SHC32

10 to 100oF (-12 to 37oC) -65 to 50oF (-54 to 10oC)

Drill Rod Thread Grease

Mobil CM-L NLGI 1

-30 to 350oF (-34.4 to 177oC)

DTH Hammer Oiler

Rock Drill Oil

All

Note: These recommendations are based on each systems component manufacturer's recommendations, requirements and/or manufacturer's requirements for maximum and minimum oil viscosity values during start-up and continuous operation.

5-22

Operating Instructions

Cold Weather Operation Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts.

Operation The pre-heat system is energized prior to starting the machine in temperatures less than 32oF. (0oC) by a switch located on the front of the operator console. Warm up periods are in relation to outside temperatures, but normally suff cient warm up can be accomplished in approximately one hour prior to starting machine.

If the machine is supplied by a GenSet, the GenSet is switched on to provide power for preheating. After the GenSet warms up to operating temperature, the heater/controller is switched on and the Operator can then select which system is to be energized via the distribution breaker box. Refer to the GenSet operating manual in Section 10 of the Service Manual for operation and maintenance.

If the heater/controller is supplied power from an external source, the Operator plugs in the system and then switches on the heater/controller.

ON/OFF Switch

Heater

Pump

Fig. 5-11 Heat Exchanger Element in Hydraulic Tank

Fig. 5-10 Heater/Controller Installation

Fig. 5-12 Heating Pad on Auto Lube Grease Container

Operating Instructions

5-23

Cold Weather Operation Maintenance BE SURE there are no fuel leaks near the burner unit.

DISCONNECT BATTERY or unplug cable to heater controller before doing any welding on machine. Damage to controller unit will result.

Allow time for burner unit to cool before doing any repair work.

Heater/Pump Unit–Maintenance and Repair Refer to the Espar repair manual for the Hydronic 30 compact heater in Section 10 of the Service Manual.

Order repair parts from Parts Manual for your specif c machine.

Cooling System Freeze Protection In the late fall, before temperatures drop below 32oF. (0oC), the complete cooling system should be drained and f ushed. The thermostat should be removed during f ushing. Check for proper operation or replace before reinstalling. When ref lling, add a suff cient amount of anti-freeze for your climate. A 50/50 mixture is recommended for maximum protection

Water Injection System Freeze Protection To blow water out of the lines and pump before shutting machine down, the following steps need to be done with the machine in idle mode.

1.

Turn the optional handle on the cab side crawler frame to open ball valve to drain water tank. After water tank is drained, leave ball valve on bottom of water tank open until time to add water to tank, then close valve.

2.

After water tank is drained, open shut off valve on top of air receiver to release air into water system. With the water injection switch in the cab in OFF position, this will blow water through the pump and back to the tank. After 5 seconds, switch the water injection switch to ON. This will blow water into the main air line.

3.

Turn main air ON to blow water out of standpipe and drill pipe. Let run for about 15 seconds. At this time all water is out of lines and pump.

4.

Shut machine down. While the machine's air receiver is in blowdown mode, leave shut off valve on top of air receiver open to blow into water injection system.

5.

After air receiver has blown down, close shut off valve on top of air receiver to close line.

6.

Before starting machine, prime the water pump by pouring water into the pipe nipple on suction side of pump inlet.

Receiver Tank Drain water from the receiver tank daily or whenever the machine is shut down for more than one hour.

NOTE 5-24

BE SURE to evacuate all the remaining water from the water injection pump to prevent the pump from freezing.

Operating Instructions

Section 5

Drilling Practices

Drilling Practices

5-1

Drilling Terminology A.P.I. Thread

American Petroleum Industry Standard type thread.

Beco Thread A heavy duty thread type used on Blast Hole drill pipe.

Bit Basket Used to hold the drill bit when adding or removing the bit.

Blade Bit A drill bit with three or four f xed cutting edges.

Bootleg The portion of the bore hole remaining after the blast.

Carousel The carousel is used to hold spare drill pipe in the mast for deeper drilling requirements.

Compressed Air Used to blow drilled cuttings from the hole and to cool the bit bearings.

Pipe Loader Pipe loader is used to swing the carousel from parked position to load position.

Pulldown The amount of weight that is being applied to the bit.

Stabilizers Stabilizers are used to reduce possible hole def ection.

Substitutes (Subs) Subs or adapters are used where different thread sizes or types are required to be joined together.

T.C.I. Tungsten Carbide Inserts, used on Tri-Cone roller bits.

Thread Grease Thread Grease is used to lubricate the threads on the pipe.

Tri-Cone Roller Bit A drill bit with three rolling cones, inserted with tungsten carbide buttons or milled teeth.

Drill Bit Drill bits are used to break the rock by a chipping or cutting action U.H.V. Up Hole Velocity, is the speed at which the drill cutDrill Pipe tings are being blown out of the hole, Drill pipe is used as a modem to rotate the drill bit, this speed is usually referred to in feet per minute. transfer force to the drill bit and to pass air or water to the bit to aid in hole cleaning.

Water Injection Used to help with dust suppression and aid hole Dust Collector cleaning.

Used to control dust exiting the drill hole.

Nozzles Orif ces in the bit used to control air f ow and pressure.

Penetration Rate The speed at which the drill bit is cutting.

5-2

Drilling Practices

Bit Weight & Rotary Speeds Many variations in formation characteristics can affect the weight on bit and rotary speed requirements.

Field experience is the best guideline for determining the appropriate weight on bit and rotation speed combination for a particular drilling operation. However, bit force and rotation speeds must be kept within the safe and economic limits of the drill rig and drill string.

When calculating the pulldown force on the drill bit, the weights of the rotary head and drill string must be included into the calculation, because when more drill pipes are added, the weight on the bit will increase and in some cases it may be necessary to reduce the hydraulic pulldown force being supplied to avoid blocking or damaging the drill bit.

Drill bit manufacturers suggest that a pulldown force of 3500–7000 pounds per inch of drill bit diameter can be exerted to the drill bit in the right drilling conditions, however this is only a guideline and ground conditions will dictate how much weight can be applied.

PULLDOWN FORCE CALCULATION Bit Diameter = 7 7/8 in.

7.875 x 3500 = 23,600 Pounds Force 7.875 x 7000 = 55,125 Pounds Force The Rotary Blasthole Drills utilize hydraulic pressure to exert pulldown force on the drill bit; this pressure is indicated on the pulldown system pressure gauge. However, the pressure readings on this gauge indicate hydraulic pressure only and must be converted into actual Weight on Bit (pounds force) per square inch of drill bit diameter.

Do not compare or use the same hydraulic pressure settings when using different drill rigs as the weight or hydraulic pressure may vary. In most cases the hydraulic pressures on varying drill rigs will indicate different weights on the drill bit.

Laboratory experiments have shown that uniform rock formations, when drilled with rotary drill bits react as follows: 1.

Penetration rate is at least directly proportional to the weight on bit.

2.

Penetration rate is directly proportional to the rotary speed.

In principal, the faster that we could rotate and the more weight we put on the drill bit, the higher the rate of penetration. Although in actual drilling practices it is important to note that the many variations in formation characteristics, drill bit condition and chip removal affect the rate of penetration, therefore statements 1 and 2 must only serve as a guideline.

In soft, easily drilled formations, the use of high pulldown pressures are restricted due to the drill bit's tendency to "Ball Up" thereby reducing its eff ciency. However, it is usually possible to offset the reduction in pulldown force by increasing the rotary speed. The danger of bit damage is reduced in low strength formations.

The extent to which the rotary speed can be increased is limited by the presence of abrasive properties and the ability to clear the cuttings immediately from the bit face, which would prematurely erode the cutting structure or bit bearings under excessive rotary speeds.

Drilling Practices

5-3

Bit Weight & Rotary Speeds In hard formations, it is necessary to use higher pulldown pressures to overcome the compressive strength of the rock formation. The operation of tri-cone roller bits in hard rock is complicated by the sliding and skipping of the bit cutters as the rock breaks away unevenly. Failure to get complete clearing of the drill cuttings becomes a larger problem when high rotation speeds are used. The use of excessive rotation speeds can cause increased abrasive wear and create shock loads too great for the drill bit, pipe and drill rig. Therefore, there may be little advantage in increasing rotary speeds above recommended levels.

Smooth vibration free drilling produces holes most eff ciently and possible gains from high rotation speeds may need to be sacrif ced to get a constant rate of penetration and economical bit life.

0–110 RPM = High Torque Rotation 0–150 RPM = Low Torque Rotation

5-4

Drilling Practices

Rotary Drill Bits The two main bit types available for rotary blast hole drilling are: 1.

Drag or Blade Bits

2.

Tri-Cone Roller Bits

Rotary drill bits operate using a combination of two forces: 1.

Thrust "Weight on Bit"

2.

Torque "Rotation"

Drill bits must make chips or cuttings and combined with air pressure and volume contribute to the clearing of the drilled cuttings.

Drag Bits Drag bits are used in soft formations like clay, shale, and soft overburden materials. These bits make maximum use of rotary torque for chip making.

Drag bits generally have 3 or 4 cutting wings which are tipped with tungsten carbide inserts to resist heat during drilling.

Advantages of Drag Bits 1.

Relatively low in cost compared to tri-cone roller bits.

2.

High penetration rates in soft formations.

3.

Good penetration of diff cult formations such as clay.

Disadvantages of Drag Bits 1.

Shorter service life than tri-cone bits.

2.

Not good for drilling hard formations.

3.

Unstabilized drag bits are prone to drill crooked holes.

Tri-Cone Roller Bits Tri-Cone roller bits are made for four general types of drilling conditions—soft, medium, hard and very hard ground formations.

Roller bits consist of a bit body with three cones equipped with steel teeth or tungsten carbide buttons.

The teeth or buttons are distributed over the three roller cones in such a manner that the entire bottom of the hole is worked when the bit is rotated.

General characteristics for soft formation bits are that the bits have larger, more widely spaced teeth or buttons and differing cone centering geometry, while hard formation bits have smaller tungsten carbide inserts for cutting teeth which are closely spaced to reduce torque and the size of chips in hard material.

Drilling Practices

5-5

Rotary Drill Bits Tri-Cone Roller Bits (cont.)

The cones of the drill bit are mounted on bearings which are designed to withstand the thrust and rotation forces exerted on the bit. The gauge or size for the bit is protected by hard facing or tungsten compacts on the outer surface of the cones and the shirt tails of the bit body.

Tri-cone bits are f tted with air tubes and nozzles which allow air to pass through the bit. The air tubes are designed to allow air to pass through the bit. The air tubes are designed to allow air to f ow through to the bit bearings; the air then aids in cooling and cleaning the bearings.

The bit nozzles allow the main volume of air to f ow through the bit for cleaning the cuttings from the hole. These nozzles are designed so that different sized orif ces can be installed for different drilling conditions.

To make sure air gets down to the bearing air tubes, ensure a certain amount of working air pressure at the bit face. Change this pressure by changing the size of the nozzles, which might be needed if the drilling conditions get softer. The orif ce size would probably need to be increased to allow more air to pass through the bit for better hole cleaning.

Advantages of Tungsten Carbide, Tri-Cone Roller Bits 1.

4 to 10 times more footage per bit than conventional hard formation steel tooth bits.

2.

The penetration rate will usually equal or exceed that of conventional hard formation bits.

3.

Higher feed pressures can be used in hard formations.

4.

Bits can be used in both soft and hard formations.

Disadvantages of Tungsten Carbide, Tri-Cone Roller Bits 1.

More expensive than conventional bits.

2.

Generally not good for drilling clay formations. Tungsten carbide bits may cost more than steel tooth bits and economics must be considered when choosing the correct bits for each application and should enter into your decision when to use them.

All tungsten carbide bit designs incorporated the use of compacts in the gauge surface or the cones, and varying combinations of compacts and hard facing on the gauge surface of the bit leg to provide increased resistance to abrasive wear.

When the formation is relatively uniform, these bits characteristically drill at a constant penetration rate throughout their life.

Suff cient weight must be applied to the bit to produce an effective chipping-crushing action of the formation. However, you should be aware that weights in excess of "suff cient" are not necessarily economical, as they may result in breakage of the compacts as well as reducing the life of the bearings.

Normally the weights used on tri-cone roller bits range from 3,500 to 7,000 pounds per inch of bit diameter with rotary speeds varying from 100 to 500 revolutions per minute.

5-6

Drilling Practices

Rotary Blast Hole Drill Strings Drill Pipe Drill pipe is used as a modem to transfer rotation to the drill bit and to convey air to clean the cuttings from the hole.

Blast hole drill pipe is selected to suit the diameter of the hole being drilled, the pulldown and hoisting capacity of the machine, and up-hole velocity requirements to clean the hole.

Standard drill pipe is designed to be run in tension. Drill pipe run in tension is held relatively straight, bending and wear are therefore kept to a minimum. However, blast hole rigs apply pressure to the bit through the pull-down system on the machine.

Since blasthole drill pipe is run in compression it must be made from heavy wall tubing to resist forces which not only may be high, but are also changing rapidly. The pipe must continue to do this in spite of abrasive wear and continual bending stresses. Drilling operations often place great stresses on the drill string, therefore the drill pipe must be manufactured to the highest degree to achieve the ultimate service life.

Periodic inspections should be made of the condition of your drill pipe and should include the following items: 1.

Outside diameter measurement of pipe.

2.

Welded joints for cracks or excess wear.

3.

Threads for excessive wear or galling.

4.

Pipe for bends or eccentric joints.

Fabricated Drill Pipe Blast hole drill pipe design features tool joints made from steels selected specif cally for the application and heat treated to obtain optimum strength and toughness.

The tool joints are designed with long tangs that are internally tapered, which enables them to be forced or shrink f tted to the tubing and then welded. Wrench slots or f ats are milled to suit the break-out requirements of the drill.

Thread Grease Precision machined threads and shoulders must be protected from damage. Threads are subjected to a lot of abuse, therefore it is imperative that they are inspected and greased regularly. Prior to each use, clean and visually inspect each pin and box for thread and shoulder damage. Check carefully for galls, burrs, scratches and particularly for cracks. Clean or repair if necessary. Use a zinc, lead or copper based lubricant that is recommended for rotary connections and apply thoroughly to all thread and shoulder surfaces. Ensure grease is clean and free of dust and debris.

Substitutes Substitutes (subs) or adapters are used where threads of one size or type must be coupled with threads of another size or type. They are also used at points of heat wear to provide readily replaceable threads.

Changes in drill pipe diameter must occur gradually. Subs should be gently tapered.

Drilling Practices

5-7

Rotary Blast Hole Drill Strings Pipe Threads There are many different types of threads available for drill pipe connections, most of which are not acceptable for blast hole drilling because of their vulnerability to damage from excessive forces to the drill string in blast hole drilling.

The two most commonly used threads are: 1.

A.P.I. Regular (American Petroleum Industry Standard)

2.

BECO style thread

With the increase in demand for eff cient, economical blast hole drilling, it was observed that several factors caused greater thread wear on blast hole drills.

1.

The drilling of multiple pass holes demands frequent pipe changes. This increased frequency greatly contributes to thread wear.

2.

The coupling of the rotary head to a drill pipe in the pipe loader often occurs at an elevation high in the mast, affording very poor visibility to the Operator. This operation is often done by feel and cross threading is not an uncommon result.

3.

Thread loading during joint make-up should be instrument controlled. The rotary head used on blast hole drills can generate very high torque and the skills of the Operator usually determines the actual magnitude of the axial forces used. A careless Operator can destroy the threads if care is not exercised.

4.

All drill pipe that operates in compression has the tendency to bend and rub on the walls of the hole. These bending forces also act on the threads which increases the possibility of cracks, breaks and tool joint failures.

A.P.I. Regular Threads Field experiences have shown that the normal A.P.I. regular threads have displayed less than satisfactory life under the above conditions. The majority of drill bits are provided with A.P.I. regular pins, but since bit changes are less frequent than pipe changes, thread wear is less, making the A.P.I. regular threads acceptable for bit connections.

BECO Threads The primary feature of the BECO thread series is that 2 threads per inch pitch is utilized. This coarser thread survives much better under adverse conditions. The coarse threads are stronger, less susceptible to damage, more tolerant to wear and easier to loosen from a tight condition. Since the incorporation of the BECO thread system in the early 1960's, the thread has become an unoff cial world wide standard for drill pipe used in rotary blast hole drilling operations.

5-8

Drilling Practices

Rotary Blast Hole Drill Strings

API Box Thread API Thread

1 2

BECO Thread

3

5

4

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

6

Rotary Head Spindle Shock Sub Crossover Sub Top Sub Drill Pipe Bit Sub Bit Basket Deck Bushing Tri-Cone Drill Bit

7

9

8

10 Fig. 5-2 Drill String Make-up–Bit Sub and Drill Bit

Drilling Practices

5-9

Drill Bit Stabilizers Drill bit stabilizers are used to reduce possible hole def ection and to ensure that the drill bit runs concentrically (evenly in the center of the hole) about its axis and thereby optimizes bit life and penetration rates.

There are two main types of stabilizers available, blade and roller. Blade stabilizers have f xed wings that have been either hard faced or mounted with tungsten carbide inserts. Roller stabilizers are mounted with replaceable rollers which are built up with a special tungsten carbide weld and held in place by long lasting non grease bearings.

Advantages of Blade Type Stabilizers 1.

Generally cheaper.

2.

May use replaceable wear bars for rapid rebuilding.

3.

Can use replaceable sleeves.

Disadvantages of Blade Type Stabilizers 1.

Require rebuilding for each new drill bit.

2.

Have relatively high torque requirements.

3.

In hard ground they may provide little stabilization after the f rst couple of holes.

Advantages of Roller Type Stabilizers 1.

Lower torque requirements than blades.

2.

Better stabilization.

3.

Generally give more economical life.

4.

Throw away or replaceable rollers.

Disadvantages of Roller Type Stabilizers 1.

High purchase cost.

2.

Expensive replacement of parts.

5-10

Drilling Practices

Compressed Air Compressed air is the most common method used with blast hole drills for clearing chips from the hole.

The advantages of drilling blast holes with compressed air are fast chip removal, and that holes are normally left dry.

In some circumstances a controlled amount of water or foam can be injected into the air stream to aid chip removal, enhance hole stability and control dust problems.

Chips not cleared immediately will be broken into smaller pieces. Secondary breaking wastes energy and increases bit wear.

Air Requirements In rotary blast hole drilling we must always be concerned with delivery of air in suff cient volume and at the proper pressure to assure optimum bit life when drilling with recommended bit weight and RPM. Suff cient air volume should be provided to produce an up-hole velocity of 4,000 to 6,000 feet per minute (1220 to 1830 meters per minute).

Up-Hole Velocity Calculations Cubic Feet Per Minute Velocity =

Free Air CFM x 183.4 (Bit Diameter 2 - Pipe Diameter 2) in inches

Meters Per Minute Velocity =

Drilling Practices

Free Air L.P.M. x 2 (Bit Diameter 2 - Pipe Diameter 2 ) in inches

5-11

Drilling Related Problems The majority of drilling problems originate from errors in judgement or simply from making a bad decision.

Drilling problems generally offer several courses or action to overcome the problem, therefore we must make a decision to try another method of operation to rectify the problem. Drilling decisions often avert or accelerate the complex drilling diff culties which we refer to as drilling problems.

EXAMPLE a.

A decision may be made a long time before the problem is evident, like deciding to use inadequate up hole air velocity. This may lead to slow, ineff cient drilling or stuck drill strings.

b.

Or the decision can bring immediate problems, like a decision to increase the pulldown pressure may result in premature failure of the drill bit.

During drilling operations every action taken may have consequences. Operators must recognize that their job involves a continuous sequence of making decisions and the quality of these decisions determines the quality of the Operator's performance.

Drilling consists of a continuing sequence of: 1.

Being aware

2.

Interpreting indicators or messages

3.

Making decisions

4.

Monitoring results

Many drilling problems are revealed to the Operator by an indicator. This indicator can take almost any form (e.g. a reduction in the volume of drill cuttings being cleared from the hole.) This may not be a problem in itself, but it could be an indicator of a problem developing down the hole, therefore if the Operator knows the indicators, they are then made aware of the pending problem.

Human Error Problems These problems have a direct and usually short term connection with a decision (e.g. the Operator decides to try and drill one more hole with a badly worn bit before changing the bit.)

Operational Related Problems These problems are connected with the failure of the drilling equipment (e.g. engine fails while drill string is in the hole, possibly leading to the drill string becoming stuck while engine is repaired.)

Formation Related Problems Some formations present problems that are not readily solved using the available drilling equipment or skills (e.g. swelling ground formations due to high levels of ground water.) These situations should be viewed as a challenge rather than a problem.

5-12

Drilling Practices

Operating Problems and Indicators 1.

Drill Bit Penetration Slows or Stops This is a statement of an indicator rather than a problem. The solution depends on the correct diagnosis of the problem, which could be:

2.

a.

Formation Change

b.

Drill Bit Blocked Up

c.

Incorrect Bit Type

d.

Dull Drill Bit

e.

Incorrect Pulldown Pressure or Rotary Speed

f.

Inadequate Hole Cleaning

High Drill String Torque Excessive drill string torque is also an indicator of a pending problem, some of which might be:

3.

a.

Excessive Pulldown Pressure

b.

Inadequate Hole Cleaning

c.

Crooked Hole

d.

Damaged or Badly Worn Drill Bit

Drill String Vibration This itself often seems like a problem, but the true problem usually lies in the reason for the vibration, some of which are:

4.

a.

Incorrect Rotary Speed

b.

Bent Drill Pipe

c.

Eccentric Drill Pipe Joints

d.

Incorrect Drill Pipe to Hole Size

e.

Crooked Hole

f.

Worn Deck Bushing or Stabilizer

Stuck Drill Pipe a.

Inadequate Hole Cleaning

b.

Crooked Hole

c.

Faulty Formations

Drilling Practices

5-13

Solving Drilling Problems 1.

Recognize the problem. The Operator must be aware of the small problems before they develop into bigger ones.

2.

Analyze the problem. Determine exactly what the problem is, what caused it and what is involved to rectify the problem.

3.

Compare the current problem with others previously encountered to assist in f nding the most likely solution. Decide on a solution.

Experienced operators make decisions almost automatically, they are immediately aware of the signif cance of an indicator. They react spontaneously because their experience tells them the appropriate action to take. By correctly selecting the desirable action in each situation, the Operator will: 1.

Maximize the quality of the products of drilling.

2.

Maximize drilling production.

5-14

Drilling Practices

Section 7

Options and Accessories

Options and Accessories

7-1

Vigilante System IMPORTANT Information General This guide is prepared to assist in the understanding of the fundamental operation of a Drill PLC System only.

It is assumed that personnel using this guide are: 1. Competent to carry out the work being performed.

2. Has completed the required approved Risk Assessments and deemed safe to perform the associated work.

3. Is familiar with the operation of the drill.

4. Has read and understood the relevant operation and maintenance manuals provided with the drill.

No Warranty is given that the information contained herein is free from error or omissions. Accordingly, CAED Pty Ltd and/or Terex Reedrill disclaim liability for any act done or omission made in reliance on the information in the Guide and any consequences of any such act or omission.

Override Features All “OVERRIDE” operations and buttons are operated with the full understanding and acceptance of the system or operation to be overridden.

Overriding any system has the potential for component or machine damage, this procedure must be done only after fault evaluation and with due care.

Further Information See electrical ladder drawings for electrical corcuits.

Documents have been included to provide further information on device specif c components used.

7-2

Options and Accessories

Vigilante System PLC Run / Rem / Program Key-switch RUN Position This position places the processor in the Run mode. The processor scans/executes the ladder program, monitors input devices, energizes output devices, and acts on enabled I/O forces. You can only change the processor mode by changing the key-switch position. You cannot perform online program editing. To change the processor mode to RUN, toggle the key-switch from PROG or REM to RUN. When the keyswitch is left in the RUN position, you cannot use a programmer/operator interface device to change the processor mode.

PROG Position This position places the processor in the Program mode. The processor does not scan/execute the ladder program, and the controller outputs are de-energized. You can perform online program editing. You can only change the processor mode by changing the key-switch position. To change the processor mode to Program, toggle the key-switch from REM or RUN to PROG. When the key-switch is left in the PROG position, you cannot use a programmer/operator interface device to change the processor mode.

REM Position This position places the processor in the Remote mode: either the REMote Run, REMote Program, or REMote Test mode. You can change the processor mode by changing the key-switch position or by changing the mode from a programmer/operator interface device. You can perform online program editing in this position. To change the processor mode to REM, toggle the key-switch from RUN or PROG to REM. When the key-switch is in the REM position, you can use a programmer/operator interface device to change the processor mode.

EEPROM

Options and Accessories

7-3

Vigilante System EEPROM The EEPROM is a backup of the PLC programme.

The PLC has been set up to load from an EEPROM. Loading will occur every time the PLC is powered up and has the EEPROM installed. This has been done to facilitate minor updates via changing the EEPROM. When the PLC is turned on (powered up) it will “look” to see if the EEPROM is installed in the Processor Card. If it is detected, it will then load the programme from the EEPROM into the Processor Card. If it is not detected it will just use the current programme already in the Processor Card.

The EEPROM should never be left in the Processor Card as it will overwrite stored values every time the PLC is turned off and on. E.g. battery isolator turned off for lunch break, during shifts, maintenance work.

This means that the EEPROM should be removed immediately from the card (and kept in a safe location as a backup) after initial loading to prevent a reload and loss of information every time the drill is started.

Procedure to load from a EEPROM 1. Turn off power to PLC 2. Remove the Processor Card (the card with a key in it) 3. Install the EEPROM into the Processor Card 4. Replace Processor Card 5. Ensure key is in the “RUN” position 6. Restore power to PLC 7. LED lights on Processor cards will toggle off-on “FLT”, “DH” and “RUN”.

8. Loading process is ok when the “RUN’ light is ON. 9. After PLC has entered “Run Mode”. Turn power off to PLC. 10. Remove the Processor Card 11. Remove the EEPROM from the Processor Card 12. Replace the Processor Card into the PLC Restore power to the PLC.

Recover from a Processor Fault This procedure will erase all current operating and stored data in the programme i.e. calibration set points.

1. Turn processor key switch from RUN to PROGRAM mode 2. PLC power switched off for 10 seconds and then re-power 3. Key switch to RUN mode 4. If the PLC does not recover then turn power off and remove the processor card.

5. Reload the PLC processor memory with the EEPROM (refer to section “Procedure to load from an EEPROM”) 6. If this does not f x the problem, then call Terex Reedrill for assistance.

7-4

Options and Accessories

Vigilante System Output Card The individual outputs on an Output card are actually miniature relays with a small current carrying capacity of one (1) amp. The contacts of the relays may burn if a faulty f eld device or wiring condition occurs. This condition has occurred if the output indication LED light on the card is ON but no output voltage to operate the f eld device is present on the corresponding output terminal. The LED only indicates that the PLC code is attempting to operate the miniature relay for the corresponding output. If no output voltage is measured on corresponding output terminal then the output relay (within card) is damaged.

Check f eld device and wiring for faults that could cause a high current situation.

Only replace the Output card after f eld fault has been corrected.

Replacing a Faulty Card Turn off power to PLC. Disconnect connector from card (2 screws at each end will jack connector from card).

Remove faulty card and check if it has any Dip Switches that need to be set on new card Set any Dip Switches if required and install new card.

Replace connector & secure with screws.

Turn power back on to PLC.

Analog Card Conf guration When replacing an analog card the dip switches must be set correctly (4 or 8 channel card only)

Options and Accessories

7-5

Vigilante System Touchscreen Setting Date & Time To access the ‘OFF LINE’ mode. Simultaneously touch all four corners of the screen and then select’ OFF LINE’ from the displayed buttons. Now at the ‘MAIN MENU’ select ‘INITIALISE’.

Once the Time and Date are set, return to the ‘MAIN MENU’ and select ‘RUN’ mode

Changing a CF Card PROGRAMME DOWNLOAD PROCEEDURE 1. Gain access to the rear of the touchscreen. Remove the screen and or mounting.

2. Open the CF card cover.

Green LED

3.

4.

5.

6.

7.

8.

9.

10.

11.

Slide the CF card into the slot, label side up, and close the cover.

At the front of the touchscreen. Touch all four corners of the screen simultaneously, select ‘OFF LINE’.

At the MAIN MENU select ‘2’ Screen Data Transfer.

At the Screen Data Transfer menu select ‘3’ Copy From CF Card.

Enter the password 1101 and START. Down load procedure now starts. Takes approx 5 min.

Once complete select the main menu by touching MAIN MENU on the screen.

At the MAIN MENU select ‘4’ RUN to place the touchscreen into ‘run mode’.

Open the CF Card cover – waiting for the green LED to go out indicating it is safe to remove the CF Card.

12. Remove the card, close the cover, and resecure the touchscreen / mounting.

13. Procedure is complete.

Setting Brightness To adjust the brightness of the Touchscreen, Simultaneously touch both bottom corners of the screen and then use the slider to adjust the brightness. Touch anywhere else on the screen to return to the run mode.

7-6

Options and Accessories

Vigilante System Laser Depth System (see also page 8-37) General Info A laser is used to indicate depth on the Drill PLC System. This introduces a reliable method of detecting depth without contact and avoids the use of unreliable encoders and pull wire devices.

The Laser is “only powered up” when the engine is running and the mast is raised.

The added optional functionality incorporated into the Drill PLC Depth system is.... * * * *

Pipe in hole detection Head clear indication Auto retracting of the Pipe Positioner, Centre guide, Hobo Prevent the Pipe Rack from swinging into the Head

Pipe-in-hole override Button

Start Hole button

Functional Description of Operation * When the operator switches from Tram to Drill mode, the Rod counter will equal zero. * The operator must push the START HOLE button on the Touchscreen when f rst starting to drill a hole.

As soon as he does this, the Rod counter display will equal 1 (1 rod on string) and the depth system will be enabled. * The Rod Counter proximity switch is used to detect that a rod has been either added or subtracted. It does this by detecting the pipe rack position. When the Pipe Rack is swung under the Head and then moved back into the parked position, a f ag in the PLC is “set”. * After the Rod counter f ag has been “set”, the Laser then determines the position of the Head. * With the Head above the “midpoint” and the Deck Wrench is operated ....then a rod will be ADDED * If the Head moves down to a set point approx 200mm above “deck wrench” position without the Deck Wrench being operated.......then the rod will be SUBTRACTED

Setting up the Laser * Mount Laser. With head right down measure a distance 400mm away from Laser to Target position on sheave. Move head to its right up position and hold Target on marking. Apply 24V dc to Laser and make sure red dot is in middle of the Target. Mount the Target in this position. * Move head from full down position to full up position and make sure the analog signal is reading over full length of head travel in the PLC/Touch screen. For the Touch screen this can be seen in the general 1057 password protected area - calibration - ‘Laser Actual’ reading. * Laser is now ready to be calibrated for depth reading.

Options and Accessories

7-7

Vigilante System Safety Instructions & Precautions Don’t stare into the laser beam. A prolonged period greater than 0.25ms (normal eye blink speed) can be harmful. Never point the laser beam intentionally at another person.

A warning label indicating the presence of a class 2 laser should be used and placed in a readily visible spot.

Calibration * Measure the full length of head travel. * Enter the password protected Calibration area 1295 for a full calibration set up or 1057 for a partial calibration setup (as for tightening ropes) on the touch screen. * Type in the value on the keypad in millimetres. * Set head right up position. Press touch screen button to accept value. * Set head right down position. Press touch screen button to accept value. * Set head halfway down (midpoint of the rods that are in the rod rack). Press touch screen button to accept value. * Attached bit onto head and move head to position where deck wrench can be engaged and then set deck wrench position. Press touch screen button to accept value. * Break bit off head and move head to position where pipe rack can be swung under head and set head clear position. Press touch screen button to accept value. * With f rst pipe and bit attached to head. Lower steel approx. 100mm below where deck wrench can be engaged and set pipe-in-hole position. Press touch screen button to accept value. * Move the head to a position that allows the Pipe Positioner, Centre guide, Hobo enough time to move out of the way with the head coming down and set the “Kick-out” set point if f tted. Press touch screen button to accept value. * Move the head up and set the “Head up speed slow down” set point so the head will slow down before the hydraulic cylinder “bottoms out.” Press touch screen button to accept value. * Record the new set-point values and forward them to Reedrill for f le updating.

Calibration of the depth system is now complete.

Password protected Calibration screen:

Actual head position from TOP of mast. (mm)

Value indicates feedback from Laser

Touching number ‘Display’ sets the Calibration point

7-8

Options and Accessories

Vigilante System Pipe in Hole Detection This option inhibits the movement of the MAST, JACKS and TRAMMING. All of the following 3 conditions must be met to verify that the pipe is out of the hole......

1. The Rods on string must be 1 or less (the last rod in the string will still be on the head).

2. The depth must equal zero (the actual depth must have counted all the way back to zero).

3. The head must be above the “Pipe in Hole” set point (the head must be at the top of the mast).

Tram Protection The Pipe in Hole is deemed to be clear to Tram only after ALL THREE above conditions are met OR the Override function is operated on the Touchscreen.

The operation of the Tram Override function (on the Tram Screen) is logged on the screen and memory.

The Tram Override function will self reset when the operator switches back to drill mode for the next hole or whenever the drill is f rst started.

Mast and Jack Lowering Protection The Pipe in Hole is deemed to be clear to Tram only after ALL THREE above conditions are met OR the Override function is operated on the Touchscreen.

The operation of the Pipe in Hole Override function (on the Drill Screen) is logged on the screen and memory. The Pipe in Hole Override function will self reset when the operator switches to tram mode for the next hole or whenever the drill is f rst started.

NOTE:

All “OVERRIDE” operations and buttons are operated with the full understanding and acceptance of the system or operation to be overridden.

Overriding any system has the potential for component or machine damage, this procedure must be done only after fault evaluation and with due care.

Pipe Rack Swing Interlock If the Head is below the “Head Clear” set point. The Pipe Rack will not be allowed to swing into the Head.

This interlock prevents collision between the Head and the Pipe Rack carousel.

Distance Meter Setting Up Magnetic Proximity switch is located on the crawler and senses a ring of f ags attached to the track drive.

The distance between each f ag count is approx. 112mm (This may vary slightly on each drill. The actual calibrated f gure can be obtained from the commissioning sheet) The tram direction pressure switch is used to detect a change in direction (Switch must be set to be ON when tram is just moving in one direction only).

It is critical that all f ags are being sensed by the proximity switch when the drill is tramming. If the proximity is too far away from the f ag ring, random sensing will occur, resulting in an incorrect and unrepeatable distance measurement. Initially random sensing can be seen as too many counts being registered and distance displayed incorrect, indicating the proximity switch is ‘f ickering’ on-off over each f ag. Adjustment may be needed to the Proximity, (adjusting it closer to the f ag ring increases detection reliability).

Do not adjust the proximity any closer than 3mm.

Options and Accessories

7-9

Vigilante System A red led on the rear of the proximity operates to indicate the sensing of the f ag.

Incorrect adjustment of the Tram Pressure switch will also cause unreliable distance measurement. If the switching is set to operate too late or system pressure is slow to build then a number of f ags can be missed resulting in an incorrect distance reading.

Errors associated with the distance meter will always be due to faulty or incorrectly adjusted f eld devices.

Start Up and Shut Down Idle Timer The drill will shutdown 5 minutes after the key is turned off.

The drill can be shutdown immediately by turning the key off and then activating the stop button.

NOTE:

If the drill shuts down on any alarm. The key will have to be turned OFF and the stop button pushed to reset the start sequence before the drill can be re-started again.

NOTE:

All “OVERRIDE” operations and buttons are operated with the full understanding and acceptance of the system or operation to be overridden.

Overriding any system has the potential for component or machine damage, this procedure must be done only after fault evaluation and with due care.

Hydraulic Function Enable Drill Tram Enable Function The Drill / Tram functions of the drill will be disabled until the “Hydraulic Function Enable” button is operated on the Touchscreen.

Alarms Shutdown Alarms The following alarms will shut down the drill. They are shown in Orange scrolling across the bottom of the touch screen. * * * * * * * * * * * *

Fire System E/Stops Low Engine Oil Pressure High Engine Coolant Temperature Compressor Air Discharge Temperature Compressor Air Interstage Temperature Low Compressor Oil Pressure, less than 80psi (After 20 second start-up delay) Cummins Engine System Shutdown (via Cummins system or 30 seconds after red light via Drill PLC) Hydraulic Temperature (20 second delay) Low Hydraulic Oil Level (2 second buffer before alarm) Hydraulic Valve Isolated (1 second buffer before alarm) Excessive Incline >45 degrees (3 second buffer before alarm)

NOTE: 7-10

If the drill shuts down on any alarm. The key will have to be turned off and the stop button pushed to reset the start sequence before the drill can be re-started again.

Options and Accessories

Vigilante System Indication Only Alarms The following alarms are display alarms, they can be reset when the fault is rectif ed. They are shown scrolling across the bottom of the Touch screen. * Lube Fault * Alternator * Fuel Level Low (less than 5% for 3 minutes) * Low Engine Coolant Level (5 second buffer before alarm) * Water Tank Level Low (less than 20% for 20 seconds) Note: Water Injection will shut off when water tank level is reduced to 15% * Engine Air Filter is Blocked * Compressor Air Filter Blocked * Hammer Oil System Has Failed (if the pump has failed to stroke 10 times in allotted time) * Hammer Oil Level Low (less than 15%) * Excessive Incline Alarm (Tram mode only) * Fire suppression system pressure low

Filter Bypass Indication Only Alarms Hydraulic Oil temperature must be greater than 550 C before looking at f lter bypass alarms to avoid false triggers. A differential pressure switch must open for 180 seconds to activate alarm. * Right Charge Filter Bypass * Left Charge Filter Bypass * Aux Feed Pump Filter Bypass * Right Tram Port A Filter Bypass * Right Tram Port B Filter Bypass * Rotation / Left Tram Port A Filter Bypass * Rotation / Left Tram Port B Filter Bypass * Main Return 1 Filter Bypass * Main Return 2 Filter Bypass * Case Return Filter Bypass * Compressor Filter Bypass

Solenoid Control Drill / Tram Solenoid (V08) (Off to Tram / On to Drill) Solenoid will energise when....

Key is ON + Drill mode is selected.

Drill / Tram Interlock Solenoid (V07) (On to Tram / On to Drill) Solenoid will energise when....

Key is on + Tram Mode is selected + Tram Conditions are OK + Hydraulic Function is enabled.

OR

Key is on + Drill Mode is selected + Drill Conditions are OK + Hydraulic Function is enabled.

Options and Accessories

7-11

Vigilante System Tram Conditions OK Tram conditions are OK when.......

Tram mode is selected + pipe is out of hole + all steels are racked + head is at top of mast + jacks are raised + ladder is up.

OR Tram mode is selected + Tram Override has been SET. (Tram Override activation will be logged. Tram Override will automatically clear when put into Drill mode.)

NOTE:

All “OVERRIDE” operations and buttons are operated with the full understanding and acceptance of the system or operation to be overridden.

Overriding any system has the potential for component or machine damage, this procedure must be done only after fault evaluation and with due care.

NOTE:

There is a 2.5 second delay when f rst selecting tram mode to allow spool time to port.

Any item in this section f agged with a YELLOW BOX will PREVENT tramming

Tram Override Button

Drill Conditions OK Drill conditions are OK when........

Key is ON + Drill mode is selected + Rod Catcher is Closed + Pipe Rack is Parked.

OR Key is ON + Drill mode is selected + Rod Catcher is Closed + Pipe Rack is Under the Head.

OR Key is ON + Drill mode is selected + Rod Catcher Override is On + Pipe Rack is Parked.

OR Key is ON + Drill mode is selected + Rod Catcher Override is On + Pipe Rack is Under the Head.

Def nitions Pipe Rack Is Parked when the Pipe Rack Parked Prox Switch is activated.

Pipe Rack is Under the Head when the Rod Counter Prox Switch is activated.

7-12

Options and Accessories

Vigilante System Setup Interlock Solenoid (V11) (On to operate Jacks and Mast) Will energise when....

Pipe is Not in hole + Ladder is Up + Hydraulic Function Enable Button (Touchscreen) has been SET. OR Pipe-in-hole override / tram override switch is activated.

NOTE:

All “OVERRIDE” operations and buttons are operated with the full understanding and acceptance of the system or operation to be overridden.

Overriding any system has the potential for component or machine damage, this procedure must be done only after fault evaluation and with due care.

Pipe Rack Pressure Reduce Solenoid (V18) (On to reduce pull-down pressure) Will energise when.....

The pipe rack moves from the parked position (pipe rack Prox switch de-energises).

Aux. Pump Load Solenoid (V03) (On to load Aux pressure) Will energise when.....

Any of the following Aux functions are operated:* * * * * * * * * * * * * *

Mast lock / unlock switch Main air on / off Pipe Rack in / out Carousel Rotate Dust curtain up / down Trapdoor open / closed Deck spanner in / out Pipe positioner in / out Winch up / down Rod Catcher in / out Carousel Lock / unlock Hobo swing in / out Hobo clamp rotate clamp / unclamp Pressure cleaner

Pipe Rack Swing In interlock Will energise for when....

The head is clear of the pipe rack (head is above the depth laser Head Clear set point).

Dust Curtain Raise Solenoid Will energise for 5 seconds when....

Tram mode is selected.

Pipe Positioner Kickout Solenoid Will energise for 5 seconds when....

Head travels past the Kickout set point (depth laser Kickout set point).

Options and Accessories

7-13

Vigilante System Washdown Solenoid Will energise when....

The Washdown Button on the Touchscreen is pressed and the water level in the dust suppression tank is greater than 15%. The washdown pump will turn off when the button is pressed again or will automatically turn off if the Vigilante system detects movement of either Pulldown or Rotation.

Compressor Load solenoid (on to load the compressor) Will energise when...

The engine is started (engine oil pressure is OK), the Drill PLC will wait 30 seconds and load the compressor if the compressor discharge temperature is above 600C. OR The engine is started (engine oil pressure is OK), the Drill PLC will wait 360 seconds and load the compressor if the compressor discharge temperature is below 600C.

Auto Lube Operation The lube cycle time & lube pressure setting can be set from the password protected area.

The time is set in seconds.

If a 1200 second cycle is set. The lube solenoid is activated at the 1080 second mark.

(Lube solenoid will run for 2 minutes).

If the lube pressure switch is not up to pressure within 118 seconds.....a Lube Alarm will occur.

If the manual lube is activated. The lube solenoid will run for 30 seconds. If pressure is not reached in 30 seconds, a Lube Alarm will occur If the Lube alarm continually occurs then inspect for broken grease lines or faulty f eld devices.

Hammer Oiler System Auto Mode The Hammer Oil Lube solenoid will energise and run the pump until the pulse switch counts 10 strokes from the constant delivery distributor block. The Drill PLC system knows that 36cc of oil has now been delivered.

The delivery rate is calculated on how many times the pump must be turned on every hour.

If the Drill PLC fails to count 10 strokes in the correct time (2 seconds less than calculated time), then it will activate a “Hammer Oil Fail” alarm.

If the Hammer Oil Fail alarm continually occurs then inspect for a lazy pump or faulty f eld devices.

Manual Mode The Hammer Oil solenoid will stay energised and run the pump all the time.

NOTE:

7-14

The Hammer Oil system only operates when Bit Air is ON (greater than 20psi), regardless of whether Manual or Auto is selected.

Options and Accessories

Vigilante System Gauges General Info All gauge transducers are 4-20mA signals 4mA = zero on the gauge 20mA = maximum reading of transducer on the gauge (As indicated in the Electrical drawings)

Operation checks Check for blockages in feed line to transducers Verify 4-20mA signal back at PLC with a Multimeter in series on the signal wiring.

Pressure Transducer (see also page 8-69) The Pressure transducers are factory calibrated and preset.

Error code table for error codes as seen on transducer display

Level Transducer (see also page 8-57) The level transmitters under normal operation will display the level of f uid in centimeters. This reading is thedistance from the bottom of the level probe not actual tank depth. The PLC calculates the level read over the probe as a percentage for display on the Drill PLC System.

Level Transducer setup Slide level probe into mounting bung and apply power Select programming mode and select “NED” (this is where the medium type is set) For water select “1c” For fuel select “2o” Select “Cop” this will set the empty detection level (nothing should be touching probe at this point) The calibration is complete and can be de-powered and installed in the tank Error code table for error codes as seen on transmitter display

Hammer Oil Level Transducer (see also page 8-67) This transducer is factory pre-set and no adjustments are necessary.

Options and Accessories

7-15

Vigilante System Temperature Transducer (see also page 8-78) Error code table for error codes as seen on transmitter display

OL UL SC I Err

Above measuring range by more than 3% of the maximum value.

Below measuring range by more than 10% of the minimum value.

Flashing: Short-circuit in the switching output (OUT 1). the output is switched off as long as the short circuit continues.

Flashing: No temperature sensor connected, fault or short circuit in the temperature sensor, wire break, evaluable range (T < -60°C or T > +320°C) exceeded.

When commissioning temperature sensor, complete following procedure ONLY after reading safety instructions supplied with sensor: 1. Press the Mode/Enter button several times until the Mmod (Fig.2) parameter is displayed (Fig.1).

2. Press the Set button (Fig.1) and keep it pressed. The current parameter value (3w, factory default setting, Fig.2) f ashes for 5 seconds. Then the value is increased (incremental by pressing brief y or scrolling by holding pressed).* 3. Press the Mode/Enter button brief y (= acknowledgement, Fig.1) when the 4w setting is displayed (Fig.2). The parameter is displayed again, and becomes effective.

4. To conclude, wait for 15 seconds before continuing. * – To decrease the value move the display of the parameter value to the maximum setting value, after which the cycle repeats from the minimum setting.

5. Using the above steps, repeat for the following parameter settings: a. b. c. d.

7-16

OU2: set to ‘I’ (Fig.3).

ASP: set to (-) 40 (Fig.4).

AEP: set to (+) 150 (Fig.4).

FOU2: set to ‘ON’ (Fig.5).

Options and Accessories

Vigilante System Temperature Transducer (see also page 8-78)

Fig. 1

Programming Procedure

Fig. 2

Mmod Parameter Settings

Fig. 3

OU2 Parameter Settings

Fig. 4

ASP & AEP parameter settings.

Fig. 5

FOU2 parameter settings.

Options and Accessories

7-17

Vigilante System Water Flow Transducer (see also page 8-91) The water f ow transducer must be calibrated whenever it is replaced. The maximum f ow setting must be done f rst and then minimum f ow setting.

7-18

Options and Accessories

Vigilante System Inclinometers (see also page 8-33) Two incline sensors (which are mounted under the dash) are used to detect the machine incline angles when tramming. There are two alarm set points. * Excessive Incline Warning: This warning indication only alarm is preset 2 degrees below machine operating parameters when tramming. The operating parameters vary on type of machine, whether mast is up or down and which direction the drill is facing when tramming up or down an incline. * Excessive Incline - Tip over Imminent: This shutdown alarm is preset set at an angle of 45 degrees. It is obvious that at this point the Machine will be on its side and the Drill PLC system will automatically shutdown the machine.

The incline sensor is a 4-20mA device and feedback can be measured with a multimeter.

4mA

= (-) 80¼ (degrees)

20mA = (+) 80¼ (degrees).

Inclinometer setup To set up newly installed NG4I Inclinometer: * Machine must be jacked and level to correctly perform Inclinometer setting. * Connect Inclinometer wiring as per As built Electrical schematics. * Mount the inclinometer loosely and apply power. * Slowly rotate the inclinometer and check the indicated angle on the relevant touch screen display.

(Buffering in the PLC will cause the Touchscreen incline display to update slowly) * When the zero point is achieved f rmly mount the Inclinometer in that position.

Options and Accessories

7-19

Vigilante System Head Speed Module (see also page 8-31) General info The Head Speed Module picks up a frequency signal from the Head Speed sensor.

The proximity switch sensor is located on the head unit. This frequency signal is then converted to a 4-20mA analog signal and fed to the PLC analog card.

The analog signal from the converter can be checked with a multimeter, in series with the converters output to the PLC.

Calibrating This procedure should be done whenever the head speed module is replaced. It is a set once conf guration as it should not change once set unless by unauthorised tampering has occurred.

With power applied to the module, set in calibration mode (dip switch 4 “ON”) Push Button - Dial 4 - Push Button Dip switch 4 + 6 “ON”

ON

Push Button - Dial 0 - Push Button - Dial 3 -

OFF

Push Button - Dial 5 - Push Button - Dial 0 Push Button - Push Button - Push Button.

Dip switch 4 + 6 + 7 “ON” Push Button - Dial 4 - Push Button Dip switch 4 + 5 “ON” Push Button - Dial 6 - Push Button Turn all dip switches off

7-20

Options and Accessories

Vigilante System Level Switches (see also pages 8-49) When replacing a capacitive level switch, it is necessary to set the “zero point”. The level switch should be screwed into a spare adaptor bung and powered up. The zero point can then be set to ignore detecting the adaptor bung. If a spare adaptor bung is not available, then the tank medium must be below the level switch when setting the zero point.

Dust Suppression Water Injection Operation Water Injection (water) solenoid will energise when...

Drill mode selected + engine oil press sw on + Bit air on (greater than 20psi) + Water Injection switch ON. Water Flow Control will be enabled when...

Water Injection (water) solenoid is ON + Tank water level is NOT Low (greater than 15%).

NOTE: The water f ow control module controls the rate of water delivered.

NOTE: The water f ow control module will not be enabled to activate the Turkey Nest sprays if the water tank level is low (15% or below)

Turkey Spray Operation Tram Spray Solenoid will energise when...

Turkey Spray in Auto + Tram mode selected + engine oil press sw on + Distance meter greater than zero (but less than 4 metres) + maximum run time of 15 seconds when previous conditions are met + Tank water level is above 15%.

OR Turkey spray in manual + Tram mode is selected.

Water Suppression Tank - Top Up Opeation Tank Water Level Top Up Solenoid will energise when...

Bit air is on (greater than 20 psi) + Tank level below 75% Tank Water Level Top Up Solenoid will de-energise when...

Bit air is off OR Bit air is on (greater than 20 psi) + Tank level is 99% or greater Options and Accessories

7-21

Engine Monitor (Murphy PowerView) Description The Cummins QST30 engine operation can be monitored by the optional Murphy PowerView display, located on the engine instrument panel (fig. 7-7). The PowerView is a multifunction gauge, that allows the operator to monitor several engine functions. It also displays fault codes, if there is an engine malfunction. There are four touch sensitive buttons that allows the operator easy access to the displays.

Refer the following PowerView Installation and Operations Manual for complete instructions.

Fig. 7-7 Murphy PowerView Display

7-22

Options and Accessories

Engine Monitor (Murphy PowerView) PV-02124N Revised 05/04 Section 78 00-02-0528

Installation and Operations Manual Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit.

GENERAL INFORMATION

Display Parameters

WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions.

Description The PowerView is a powerful new display in a line of components manufactured

by FWMurphy as part of its J1939 MurphyLink™† Family. The J1939 MurphyLink™ Family of products have been developed to meet the needs for instrumentation and control on electronically controlled engines communicating using the SAE J1939 Controller Area Network (CAN).

The PowerView System is comprised of the PowerView and the Mlink™ PowerView Gages. The PowerView is a multifunction tool that enables equipment operators to view many different engine or transmission parameters and service codes. The system provides a window into modern electronic engines and transmissions. The PowerView includes a graphical backlit LCD screen. It has excellent contrast and viewing from all angles. Back lighting can be controlled via menu or external dimmer potentiometer. The display can show either a single parameter or a quadrant display showing four parameters simultaneously. Diagnostic capabilities include fault codes with text translation for the most common fault conditions.

The PowerView has four buttons using self-calibrating charge transfer activation technology, which eliminates the concern for pushbutton wear and failure. In addition, operators can navigate the display with ease.

The enhanced alarm indication has ultra bright alarm and shutdown LEDs (amber & red). It has a wide operating temperature range of -40 to +85º C (-40 to185º F), display viewing -40 to +75º C (-40 to 167º F), and increased environmental sealing to +/- 5 PSI (± 34kPa). It also features Deutsch DT style connectors molded into the case and fits quickly and easily into existing 2-1/16 in. (52 mm) gage opening with little effort.

Other components in the system are microprocessor-based Mlink™ PowerView Gages for displaying critical engine data broadcast by an electronic engine or transmission’s Engine Control Unit (ECU): engine RPM, oil pressure, coolant temperature, system voltage, etc. and a combination audible alarm and relay unit for warning and shutdown annunciation. Up to 32 components may be linked to the PowerView using a simple daisy chain wire connection scheme using RS485. The PowerView and all connected components can be powered by 12- or 24-volt systems.

Warranty A limited warranty on materials and workmanship is given with this FWMurphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty.html † MurphyLinkTM is a registered trademark of FWMurphy. All other trademarks and service marks used in this document are the property of their respective owners.

The following are some of the engine and transmission parameters displayed by the PowerView in English or Metric units as well as in Spanish, French, or German (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters): ❖ Engine RPM ❖ Engine Hours ❖ Machine Hours ❖ System Voltage ❖ % Engine Load at the current RPM ❖ Coolant Temperature ❖ Oil Pressure ❖ Fuel Economy ❖ Throttle Position ❖ Engine Manifold Air Temperature ❖ Current Fuel Consumption ❖ Transmission Oil Pressure ❖ Transmission Oil Temperature ❖ Transmission Gear Position ❖ Active Service Codes ❖ Stored Service Codes (when supported) ❖ Set Units for display (English or Metric) ❖ Engine Configuration Parameters

Specifications Display: 1.3 x 2.6 in. (33 x 66 mm), 64 x 128 pixels.

Operating Voltage: 8 VDC minimum to 32 VDC max.

Reversed Polarity: Withstands reversed battery terminal polarity indefinitely within operating temperatures.

Operating Temperature: -40 to +85ºC (-40 to185ºF).

Display Viewing Temperature: -40 to +75ºC (-40 to 167ºF).

Storage Temperature: -40 to +85ºC (-40 to185ºF).

Environmental Sealing: IP68, +/- 5 PSI (+/- 34.4 kPa).

Power Supply Operating Current: (@ 14 VDC)= 52 mA minimum; 268 mA maximum (LCD heater on).

CAN BUS: SAE J1939 Compliant.

Case: Polycarbonate / Polyester.

Clamp: Polyester (PBT).

Connectors: 6-Pin Deutsch DTO6 Series.

Maximum Panel Thickness: 3/8 in. (9.6 mm).

Mounting Hole: 2.062 inch (52 mm) in diameter.

Auxiliary Communications: Either: Gages: One (1) RS485 port, MODBUS RTU master.

MODBUS: One (1) RS485 port, MODBUS RTU slave, selectable baud rate; 9600; 19.2K; 38.4K. Potentiometer (External Dimmer)Input: 1K ohm, 1/4 W Shipping Weights (all models): 1/2 lb. (225 g.)

Shipping Dimensions (all models): 6 x 6 x 6 in. (152 x 152 x 152 mm).

PV-02124N page 1 of 18

Options and Accessories

7-23

Engine Monitor (Murphy PowerView) GENERAL INFORMATION continued

Table of Contents

Faceplate Features

General Information page # Description................................................. 1 Display Parameters.................................... 1 Specifications............................................. 1 Key Pad Functions..................................... 2 Mechanical Installation Typical Mounting Dimensions................... 2 Typical Quick-connect Diagram................ 3 Electrical Installation PIN Connectors Nomenclature.................. 3 Typical Wiring Diagrams........................... 4 Operations First Time Start Up................................... 5 Main Menu Navigation............................. 5 Selecting a Language................................. 5 Stored Fault Codes.................................... 6 Engine Configuration Data....................... 6 Faults and Warnings............................... .7 Active Fault Codes................................... 8 Shutdown Codes...................................... 8 Back Light Adjustment............................ 9 Contrast Adjustment.............................. 10 Select Units............................................... 10 Setup 1-Up Display................................... 11 Setup 4-Up Display.................................. 14 Utilities.....................................................15 MODBUS Setup....................................... 15 J1939 Parameters....................................17 Glossary...................................................18

Amber Warning LED

Red Shutdown Derate LED

Display

Bezel

Menu Key

Enter Key

Left Arrow Key (Scroll Up)

Right Arrow Key (Scroll Down)

Keypad Functions The keypad on the PowerView is a capacitive touch sensing system.

There are no mechanical switches to wear or stick, and the technology has been time proven in many applications. It operates in extreme temperatures, with gloves, through ice, snow, mud, grease, etc., and it allows complete sealing of the front of the PowerView. The ‘key is touched’ feedback is provided by flashing the screen. The keys on the keypad perform the following functions: – Menu Key - The Menu Key is touched to either enter or exit the menu screens.

– Left Arrow - The Left Arrow Key is touched to scroll through the screen either moving the parameter selection toward the left or upward.

– Right Arrow - The Right Arrow Key is touched to scroll through the screen either moving the parameter selection toward the right or downward.

– Enter Key - The Enter Key (also known as Enter Button) is touched to select the parameter that is highlighted on the screen.

Typical Mounting Dimensions SIDE 3.489 in.

(89 mm)

HOLE CUTOUT 1.94 in.

(50 mm)

FRONT

2.070 in.

(53 mm) 2.41 in.

(61 mm)

4.25 in.

(108 mm)

0.78 in. (20 mm)

2.062 in.

(52 mm) diameter

0.125 in.

(3 mm)

1.972 in.

(50 mm) .953 in.

(24 mm) R 0.063 in.

(1.6 mm)

3.18 in. (81 mm) PV-02124N page 2 of 18

7-24

Options and Accessories

Engine Monitor (Murphy PowerView) MECHANICAL INSTALLATION

Typical Quick-Connect Diagram Last PVA Gage or PVAA Audible Alarm

To Engine ECU A

To optional external device

To PVAA Audible Alarm

B

Terminating Resistor PVJR

To Battery Power

PVW-CH

POWERVIEW PV100

A

Relay N.O.

B

Relay N.C.

OR

Ext. Sonalert

PVW-PH

Relay Comm.

Optional PVW-A wire harness

Customer provided wire harness or CAN extension harnesses or power extension harnesses.

(includes terminating resistor) A

B

PVA Gage

Next PVA Gage

Wire harness PVW-J

External Dimmer Wire 24 inch.

A

External Dimmer

B

A

B

B+ GRND

CAN–SHLD CAN–LO CAN–HI

Wire harness PVW-P

Wire harness PVW-J

Wire harness PVW-J

ELECTRICAL INSTALLATION

PowerView Unit Back View Deutsch DT06-6S Style Connections Plug A

Plug B

PIN 3 CAN LO –

PIN 4 CAN SHLD –

PIN 2 CAN HI –

PIN 5 Dimmer Potentiometer

PIN 1 V+

PIN 3 RS485+

A

PIN 4 RS485–

B

PIN 6 GRND

PIN 1 V+

PIN 6 GRND

Recommended Connectors: Body: Deustch DT06-6S Wedge Lock: W6S Terminals: 0462-201-16141 Sealing Plug: 114017

PV-02124N page 3 of 18

Options and Accessories

7-25

Engine Monitor (Murphy PowerView) TYPICAL WIRING DIAGRAMS

IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist per inch minimum. CAN–L, CAN–H and CAN Shield should be approved J1939 CAN bus cable (CAN wire for example: RADOX plug and play cable, from Champlain cable). (RS485 wire for example: BELDEN 9841 or 3105A).

PowerView Deutsch DT06-6S Style Unit to PVA Gage NOTE 5

Green-CAN_L Yellow-CAN_H

NOTE 4 RS485 (-) Data

Pin 4

Pin 4

120 ohms See NOTE 6

Pin 3

120 Ω See Note

Pin 2

PVA Gage

Red-V+ Ignition Switch

Pin 5

Pin 1

NOTE 1 Pin 6

ENGINE CONTROL MODULE (SAE J1939 Compliant)

NOTE 2 Gray-CAN_SHLD

RS485 (+) Data

Pin 3

Back View

V+

Pin 1

GRND

Pin 6

Gray-Ground Blue-Back Light NOTE 7

Battery

Illumination Control*(optional) NOTE 3

Note 1: Place Resistor between CAN–H and CAN–L Line near PowerView (included in PVW-P or factory purchased panels).

Note 4: Only use 120 ohm

Note 2: Use SAE J1939 compliant

to PowerView end only.

wiring or equipment.

Note 3: Electronic dimmer switch

recommended with 4A, capacity or heavy duty rheostat switch, 1000 ohm, 0.25 watt.

characteristic impedance cable, ex Belden 9841.

Note 5: RS485 shield connected Note 6: Place Resistor at End of

Line on last PVA gage. (Included for factory purchased panels.)

Note 7: If a backlight dimmer is not

used, connect the blue backlight wire to ground. Do not leave the blue backlight wire unconnected.

PowerView Deutsch DT06-6S Style Unit to MODBUS Output NOTE 5 Pin 3

Green-CAN_L Yellow-CAN_H

120 Ω See Note

NOTE 4 RS485 (-) Data

Pin 3 Pin 2

NOTE 1 Pin 6

Note 4: Only use 120 ohm

characteristic impedance cable, ex Belden 9841.

Pin 5

Red-V+ Ignition Switch

to MODBUS Output See NOTES 6 and 8

Pin 4

Pin 4

Pin 1

ENGINE CONTROL MODULE (SAE J1939 Compliant)

NOTE 2 Gray-CAN_SHLD

RS485 (+) Data

Note 5: RS485 shield connected

Gray-Ground Blue-Back Light NOTE 7 Battery NOTE 3 Illumination Control*(optional)

Note 1: Place Resistor between

to PowerView end only.

CAN–H and CAN–L Line near PowerView (included in PVW-P or factory purchased panels).

Note 6: Place Resistor at End of Line.

Note 2: Use SAE J1939 compliant

Note 7: If a backlight dimmer is not

wiring or equipment.

Note 3: Electronic dimmer switch

For a complete listing of MODBUS Registers visit our website at www.fwmurphy.com

recommended with 4A, capacity or heavy duty rheostat switch, 1000 ohm, 0.25 watt.

(Included for factory purchased panels.) used, connect the blue backlight wire to ground. Do not leave the blue backlight wire unconnected.

Note 8: PVA gages cannot be used

with the MODBUS feature.

PV-02124N page 4 of 18

7-26

Options and Accessories

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION

PowerView Menus (First Time Start Up) 1. When power is first applied to the PowerView, the "Logo" is displayed.

3. Touching the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES

2. The "Wait to Start" message will be displayed for engines with a pre-startup sequence. Once the "Wait to Start" message is no longer displayed the operator may start the engine. Note: Displays only when SAE J1939 message is supported by engine manufacturer.

GO TO 1-UP DISPLAY

LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

WAIT TO START PREHEAT

3. Once the engine has started the single engine parameter is displayed.

0

4. Touch the "Arrows" to scroll to the desired menu item or touch "Menu" to exit the Main menu and return to the engine parameter display.

1500

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

ENG RPM

OIL PRES

BAT VOLT

Selecting a Language 1. Starting at the main menu display use the "Arrows" to scroll to the "Language" menu and once highlighted touch the "Enter" button.

3000

1800 RPM

GO TO 1-UP DISPLAY LANGUAGES LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

ENG RPM COOL TEMP

Main Menu Navigation 1. Starting at the single or four engine parameter display, touch "Menu".

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

2. The language choices will be displayed. Use the "Arrow" buttons to scroll through the selections and touch "Enter" to make a selection.

ENGLISH ESPAÑOL FRANÇAIS DEUTSCH

OIL PRES

❋

2. The first seven items of the “Main Menu” will be displayed.

Touching the "Arrow Buttons" will scroll through the menu selection.

GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

3. Now that you have selected the language, touch the "Menu" button to return to the main menu display.

PV-02124N page 5 of 18

Options and Accessories

7-27

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 5. Touch the "Menu Button" to return to the main menu.

1. Starting at the single or the four engine parameter display touch the "Menu button".

0

1500

ENG RPM

3000

1000 RPM

14.2

57 PSI

LOAD@RPM

SPN110 FMI10 HIGH COOLANT TEMP

ENG RPM

▼

1800 RPM

98%

1 of x

COOL TEMP

BAT VOLT

MORE

HIDE

▼

Stored Fault Codes

OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the Stored Fault Codes is highlighted.

GO TO 1-UP DISPLAY STORED CODES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

Engine Configuration Data 1. Starting at the single or four engine parameter display touch the "Menu Button".

3 Once the "Stored Fault Codes" menu item has been highlighted touch the "Enter Button" to view the "Stored Fault Codes" (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters).

GO TO 1-UP DISPLAY STORED CODES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Engine Configuration" is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

4. If the word "MORE" appears above the "Arrow Buttons" there are more stored fault codes that may be viewed. Use the "Arrow Buttons" to scroll to the next Stored Diagnostic Code.

3. Once the "Engine Configuration" menu item has been highlighted touch the "Enter Button" to view the engine configuration data.

1 of x

GO TO 1-UP DISPLAY STORED CODES ENGINE ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

▼

MORE

▼

SPN110 FMI10 HIGH COOLANT TEMP HIDE

PV-02124N page 6 of 18

7-28

Options and Accessories

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 4. Use the "Arrow Buttons" to scroll through the engine configuration data.

ENGINE SPEED PT 1

or normal operation an auxiliary gage should fail, the single or four parameter screen will be replaced with the "MLink Gage Fault" message.

1000 RPM

ENGINE OIL PRESSURE GAGE NOT RESPONDING

▼

▼

MORE

1 of x

HIDE

5. Touch the "Menu Button" to return to the main menu.

ENGINE SPEED PT 1

3. To acknowledge and "Hide" the fault and return to the single or four parameter display, touch the "Enter Button".

1000 RPM

ENGINE OIL PRESSURE GAGE NOT RESPONDING

▼

▼

MORE

1 of x

HIDE

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

4. The display will return to the single or four parameter screen. !

0

1500

3000

1800 RPM

ENG RPM COOL TEMP !

Faults and Warnings Auxiliary Gage Fault 1. During normal operation the single or four parameter screen will be displayed.

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

98%

1000 RPM

LOAD@RPM

14.2

ENG RPM

!

BAT VOLT

!

Indicates Auxiliary Gage Fault

.!

Indicates Fault Warning

!

Indicates Derate or Shutdown Condition Fault

57 PSI OIL PRES

!

5. Touching the "Enter Button" will redisplay the hidden fault.

Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display. NOTE: The fault can only be cleared by correcting the cause of the fault condition.

ENG RPM

OIL PRES

1 of x

ENGINE OIL PRESSURE GAGE NOT RESPONDING HIDE

2. The PVA Series of auxiliary gages can be attached to the PowerView.

These auxiliary gages communicate with the Modbus master PowerView via a daisy-chained RS-485 port. If at any time during system initialization PV-02124N page 7 of 18

Options and Accessories

7-29

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued

Active Fault Codes 1. During normal operation the single or four parameter screen will be displayed.

0

1500

1800 RPM

ENG RPM

98%

LOAD@RPM

3000

14.2

COOL TEMP

BAT VOLT

1000 RPM

0

ENG RPM

1500

OIL PRES

▼

▼

14.2

!

57 PSI OIL PRES

BAT VOLT

!

WARNING

1 of x

SPN110 FMI0 HIGH COOLANT TEMP MORE

HIDE

HIDE

3. If the word "MORE" appears above the "Arrow Buttons" there are more active fault codes that may be viewed.

Use the "Arrow Buttons" to scroll to the next "Active Fault Code" 1 of x

SPN110 FMI0

HIGH COOLANT TEMP ▼

▼

ENG RPM

!

6. Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display.

SPN110 FMI0 HIGH COOLANT TEMP

MORE

1000 RPM

LOAD@RPM

COOL TEMP

WARNING

MORE

98%

!

3000

1800 RPM

ENG RPM

57 PSI

2. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the "Active Fault Codes" message.

1 of x

5. The display will return to the single or four parameter display, but the display will contain the "Active Fault"warning icon. Touching the "Enter Button" will redisplay the hidden fault.

7. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.

GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM

LOAD@RPM

14.2

BAT VOLT

ENG RPM

!

57 PSI OIL PRES

!

HIDE

Shutdown Codes 1. During normal operation the single or four parameter screen will be displayed.

4. To acknowledge and "Hide" the fault and return to the single or four parameter display touch the "Enter Button".

0

1500

1800 RPM

ENG RPM

3000

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

COOL TEMP

ENG RPM

OIL PRES

BAT VOLT

1 of x

SPN110 FMI0

HIGH COOLANT TEMP ▼

MORE

HIDE

2. When the PowerView receives a severe fault code from an engine control unit the single or four parameter screen will be replaced with the "Shutdown!" message.

1 of x

SHUTDOWN

SPN110 FMI0 HIGH COOLANT TEMP MORE

HIDE

PV-02124N page 8 of 18

7-30

Options and Accessories

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 3. To acknowledge and "Hide" the fault and return to the single or four parameter display touch the "Enter Button".

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Adjust Backlight" is highlighted.

SHUTDOWN

1 of x

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST BACKLIGHT

SPN110 FM10 HIGH COOLANT TEMP MORE

HIDE

4. The display will return to the single or four parameter display, but the display will contain the "Shut Down" icon. Touching the "Enter Button" will redisplay the hidden fault.

98%

!

0

1500

3000

1800 RPM

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM

LOAD & RPM

ENG RPM

!

14.2

ENG RPM COOL TEMP!

3. Once the "Adjust Backlight" menu item has been highlighted touch the "Enter Button" to activate the "Adjust Backlight" function.

57 PSI OIL PRES

BAT VOLT

5. Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display.

1 of x

SHUTDOWN

4. Use the "Arrow Buttons" to select the desired backlight intensity.

SPN110 FM10 HIGH COOLANT TEMP MORE

ADJUST BACKLIGHT HIDE

6. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.

98%

!

0

1500

1800 RPM

ENG RPM

3000

14.2

BAT VOLT

ADJUST BACKLIGHT

1000 RPM

LOAD & RPM

COOL TEMP !

5. Touch the "Menu Button" to return to the main menu.

ENG RPM

!

57 PSI OIL PRES

!

Back Light Adjustment 1. Starting at the single or four engine parameter display touch the "Menu Button".

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

PV-02124N page 9 of 18

Options and Accessories

7-31

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued

Contrast Adjustment 1. Starting at the single or four engine parameter display, touch the "Menu Button".

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM ENG RPM

57 PSI

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until "Adjust Contrast" is highlighted.

Select Units 1. Starting at the single or four engine parameter display touch the "Menu Button".

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

0

1800 RPM

ENG RPM

3. Once the "Adjust Contrast" menu item has been highlighted touch the "Enter Button" to activate the "Adjust Contrast" function.

4. Use the "Arrow Buttons" to select the desired contrast intensity.

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

2. The main menu will pop up on the display. Use the arrow buttons to scroll through the menu until the "Select Units" is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT SELECTUNITSD UNITS ADJUST BACKLIGHT

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

3. Once the "Select Units" menu item has been highlighted touch the "Enter Button" to access the "Select Units" function.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT SELECTUNITSD UNITS ADJUST BACKLIGHT

ADJUST CONTRAST

5. Touch the "Menu Button" to return to the main menu.

1500

4. Use the arrows to highlight the desired units. "English" for Imperial units i.e. PSI, ºF or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, ºC. ENGLISH METRIC KPA METRIC BAR

ADJUST CONTRAST

PV-02124N page 10 of 18

7-32

Options and Accessories

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 5. Touch the "Enter Button" to select the highlighted units.

3. Once the "Setup 1-up Display" menu item has been highlighted touch the "Enter Button" to access the "Setup 1-up Display" function.

ENGLISH METRIC KPA METRIC BAR

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP1-UP 1-UPDISPLAY DISPLAY SETUP SETUP 4-UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT

6. Touch the "Menu Button" to return to the "Main Menu".

ENGLISH METRIC KPA METRIC BAR

❉

7. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

4. Three options are available for modification of the 1-Up display. a). Use Defaults – This option contains a set of engine parameters: Engine Hours, Engine RPM, System Voltage, Battery Voltage, % Engine Load at Current RPM, Coolant Temperature, Oil Pressure. b). Custom Setup – This option allows for the modification of what parameter, the number of parameters, and the order in which the parameters are being displayed. c). Automatic Scan – Selecting the scan function will cause the 1-Up Display to scroll through the selected set of parameters one at a time, momentarily pausing at each.

5. Use Defaults - To select "Use Defaults" use the arrow buttons to scroll to and highlight "Use Defaults" in the menu display.

USE DEFAULTS DEFAULTS USE CUSTOM SETUP AUTOMATIC SCAN OFF

ENG RPM

OIL PRES

6. Touch the "Enter Button" to activate the "Use Defaults" function.

USE USEDEFAULTS DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF

Setup 1-Up Display 1. Starting at the single engine parameter display, touch the "Menu Button".

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 1-up Display" is highlighted.

7. A message indicating the “Single Engine” parameter display parameters are reset to the factory defaults will be displayed, then the display will return to the “Custom Setup” menu.

RESTORED TO DEFAULTS

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP1-UP 1-UPDISPLAY DISPLAY SETUP SETUP 4-UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT

PV-02124N page 11 of 18

Options and Accessories

7-33

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 8. Custom Setup - To perform a custom setup of the 1-Up Display, use the arrow buttons to scroll to and highlight "Custom Setup" on the display.

13. Touch the "Enter button" to select the highlighted parameter for inclusion in the Single Engine Parameter Display.

USE DEFAULTS CUSTOM CUSTOMSETUP SETUP AUTOMATIC SCAN OFF

ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMP 3

9. Touching the "Enter Button" will display a list of engine parameters.

USE DEFAULTS CUSTOM CUSTOMSETUP SETUP AUTOMATIC SCAN OFF

14. Continue to scroll and select additional parameters for the custom 1-Up Display. Touch the "Menu button" at any time to return to the "Custom Setup" menu.

15. Automatic Scan - Selecting the scan function will cause the 1Up Display to scroll through the selected set of parameters one at a time.

Use the "Arrow Buttons" to scroll to the "Automatic Scan" function.

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN OFF

10. Use the "Arrow Buttons" to scroll to and highlight a selected parameter (parameter with a # symbol to right of it).

USE DEFAULTS ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE

This number indicates the order of display for the parameters and that the parameter is selected for display.

16. Touching the "Enter Button" toggles the "Automatic Scan" function on.

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN ON

11. Touch the "Enter Button" to deselect the selected parameter removing it from the list of parameters being displayed on the 1-up display.

USE DEFAULTS ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE

17. Touching the "Enter Button" again toggles the "Automatic Scan" function off.

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN OFF

12. Use the "Arrow Buttons" to scroll and highlight the desired parameter that has not been selected for display.

ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMP

Note that the numbers now indicate the new order of display for the parameters.

PV-02124N page 12 of 18

7-34

Options and Accessories

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set touch the "Menu Button" to return to the main menu.

4. Touch the "Enter Button" to activate the "Use Defaults" function.

This action will reset the unit to the factory default.

USE USE DEFAULTS DEFAULTS CUSTOM SETUP

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN ON

19. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

5. The "Use Defaults"screen will be displayed during the reseting period then will automatically return to the "Setup 4-Up Display" menu.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

0

1500

1800 RPM

ENG RPM

RESTORED TO DEFAULTS

3000

COOL TEMP

6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.

Setup 4-Up Display

USE DEFAULTS CUSTOM CUSTOM SETUP SETUP

1. From the single or four engine parameter display touch the "Menu Button".

0

1500

1800 RPM

ENG RPM

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 4-Up Display" is highlighted.

7. The quadrent with the backlit parameter value is the current selected parameter. Use the "Arrow Buttons" to highlight the parameter value in the quadrant you wish to place a new parameter.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

3. Once the "Setup 4-Up Display" menu item has been highlighted touch the "Enter Button" to activate the "Setup 4-Up Display" menu.

125°F COOL TEMP

1000 RPM ENG RPM

14.2 14.2 BAT VOLT

57 PSI OIL PRESP

8. Touch the "Enter Button" and a list of parameters will appear.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP SETUP 4-UP 4-UP DISPLAY DISPLAY SELECT UNITS ADJUST BACKLIGHT

125°F COOL TEMP

1000 RPM ENG RPM

14.2 14.2 BAT VOLT

57 PSI OIL PRESP

PV-02124N page 13 of 18

Options and Accessories

7-35

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 9. The parameter that is highlighted is the selected parameter for the screen. Use the "Arrow Buttons" to highlight the new parameter to be placed in the quadrent selected in the previous screen.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE ENGINE OIL PRESSURE

3 1 2 4

The number to the right of the parameter indicates the quadrant in which it is displayed.

1. = Upper Left Quadrent 2. = Lower Left Quadrent 3. = Upper Right Quadrent 4.= Lower Right Quadrent

10. Touch the "Enter Button" to change the selected parameter in the quadrant to the new parameter.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE ENGINE OIL PRESSURE

143°F OIL TEMP

143°F OIL TEMP

143°F

57 PSI

OIL TEMP

1500

1800 RPM

ENG RPM

4

ENG RPM

OIL PRES

3000

125%

1000 RPM

143°F

57 PSI

COOL TEMP

COOL TEMP

OIL TEMP

ENG RPM

OIL PRES

2. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

1 Note the number to the right of the selected parameter indicating that the parameter is now assigned to that display location.

3. Once the “Utilities” menu item has been highlighted, touch the “Enter Button” to activate the “Utilities” functions.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

ØRPM 1000 RPM ENG RPM 57 PSI OIL PRESP

13. Repeat the parameter selection process until all spaces are filled.

14. Touch the "Menu Button" to return to the main menu.

125°F COOL TEMP

1000 RPM

COOL TEMP

1. Starting at the single or four engine parameter display, touch the “Menu button”.

3

2 4

125%

Utilities (Information and troubleshooting)

0

1 2

12. The parameter in the selected quadrent has changed to the parameter selected in the previous screen.

125°F COOL TEMP

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY DISPLAY SELECT UNITS ADJUST BACKLIGHT

3

11. Use the "Menu Button" to return to the “4-UP Custom Setup” screen.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE 2 ENGINE OIL PRESSURE

15. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

4. Touch "Select" to enter the “Gage Data” display. When “Gage Data” is selected the PowerView will communicate with the analog gages at a fixed rate of 38.4 k Baud, 8 data bits, no parity check, 1 stop bits, half duplex.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULT CONVERSION DEMO MODE ON

ØRPM 1000 RPM ENG RPM 57 PSI OIL PRESP

PV-02124N page 14 of 18

7-36

Options and Accessories

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 5. Use the “Arrow buttons” to scroll through the items or touch “Menu” to return to the “Utilities” menu.

1 of x

ENGINE OIL PRESSURE ADDRESS: 20 SOFTWARE REVISION #: ERRORS: NONE

11. Use the “Arrows” to scroll and highlight the version then touch “Select” and an asterisks appears to the right of the selection.

NOTE: There are four (4) different methods for converting fault codes. The PowerView always looks for J1939 Version 4 and can be set to use one of the 3 other J1939 versions. Most engine ECU’s use Version 4, therefore in most cases adjustment of this menu option will not be required.

Upon receiving an unrecognizable fault, change to a different J1939 Version. If the fault SPN does not change when the version is changed, the ECU generating the fault is using Fault Conversion method 4. If the SPN number does change but is still unrecognizable, try changing to another J1939 Version not yet used and continue to check the SPN number.

6. Touch “Menu Button” to return to the “Utilities” menu.

J1939 VERSION VERSION 11 J1939 VERSION 2 J1939 VERSION 3 J1939 VERSION 4

1 of x

ENGINE OIL PRESSURE ADDRESS: 20 SOFTWARE REVISION #: ERRORS: NONE

7. Use the “Arrows” to highlight “Remove All Gages”. Touch “Select” to clear gage data from memory. It takes a moment to clear all gages.

12. Touch the “Menu” button to return to “Utilities” menu. Touch the “Menu” button again to to return to the “Main” menu.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

CLEARING GAGES PLEASE WAIT

8. When the gage data has cleared, the display automatically returns to the “Utilities” menu. Scroll to “Software Version”. Touch “Select” to view the software version currently in the PowerView.

SOFTWARE VERSION MURPHY: X.XX

MODBUS Setup 1. Starting at the single or four engine parameter display, touch the “Menu button”.

0

1500

1800 RPM

ENG RPM

9. Touch “Menu” to return to “Utilities”. Highlight “Fault Conversion” using the “Arrows”. Touch “Select” to enter the Fault convertion menu.

*

3000

COOL TEMP

98%

1000 RPM

14.2

57 PSI

LOAD@RPM

BAT VOLT

ENG RPM

OIL PRES

2. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted, then touch “Enter”.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION FAULT FAULTCONVERSION CONVERSION

PV-02124N page 15 of 18

Options and Accessories

7-37

Engine Monitor (Murphy PowerView) POWERVIEW OPERATION continued 3. Once in the “Utilities” menu use the “Arrows” to scroll through the menu until the “Modbus Setup” menu is highlighted, then touch “Enter”.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP MODBUS SETUP FAULT CONVERSION

4. Use the “Arrows” to scroll down to and highlight either the “Slave Active or Master Active” modes. Touch the “Enter” button to toggle between master and slave.

USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE MASTER ACTIVE

5. Use the “Arrows” to scroll to the “Serial Port” menu to highlight it, then touch “Enter”.

USE FACTORY DEFAULT SERIAL PORT SETUP SETUP SERIAL PORT SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE

6. Use the “Arrow” button to scroll to each selection to configure the MODBUS values for your application.

BAUD RATE PARITY PARITY DATA BITS STOP BITS

7. When finished, touch “Menu” to return to the previous screen.

PV-02124N page 16 of 18

7-38

Options and Accessories

Engine Monitor (Murphy PowerView) SAE J1939 MurphyLink System Implementation of J1939 Parameters Source: SAEJ1939-71 Surface Vehicle Recommended Practice SAE J1939 Section

Description

PGN

Parameter

Display Value

5.3.6

Elec Eng Cont #2 - EEC2

61443

Accelerator Pedal Position Percent Load at Current RPM

THROTTLE LOAD@RPM

5.3.7

Elec Eng Cont #1 - EEC1

61444

Actual engine % torque Engine Speed

ENG TORQ ENG RPM

5.3.14

Vehicle Distance

65248

Trip Distance Total Vehicle Distance

TRIP DIST VEH DIST

5.3.19

Engine hours, Revolutions

65253

Total Engine Hours

ENG HRS

5.3.23

Fuel Consumption

65257

Trip Fuel Total Fuel Used

TRIP FUEL FUEL USED

5.3.28

Engine Temperature

65262

Engine Coolant Temp Fuel Temperature Engine Oil Temperature Engine Intercooler Temperature

COOL TEMP FUEL TEMP OIL TEMP INTC TEMP

5.3.29

Engine Fluid Level/Pressure

65263

Fuel Delivery Pressure Engine Oil Level Engine Oil Pressure Coolant Pressure Coolant Level

FUEL PRES OIL LVL OIL PRES COOL PRES COOL LVL

5.3.31

Cruise Control /Vehicle Speed

65265

Wheel Based Vehicle Speed

VEH SPD

5.3.32

Fuel Economy

65266

Fuel Rate Instantaneous Fuel Economy Average Fuel Economy

FUEL RATE FUEL ECON AVG ECON

5.3.35

Ambient Conditions

65269

Barometric Pressure Air Inlet Temperature

BARO PRES AIR IN TP

5.3.36

Inlet/Exhaust Conditions

65270

Boost Pressure Intake Manifold Temp Air Filter Differential Pressure Exhaust Gas Temperature

BST PRES MANI TEMP AIR DIF PR EXH TEMP

5.3.37

Vehicle Electrical Power

65271

Alternator Voltage Electrical Potential (Voltage) Battery Pot. Voltage (Switched)

ALT VOLT SYS VOLT BAT VOLT

5.3.8

Electronic Transmission Controller #2

61445 61445

Selected Gear Current Gear

SLECT GEAR CURNT GEAR

5.3.38

Transmission Fluids

65272

Transmission Oil Pressure

TRAN PRES

Transmission Oil Temperature

TRAN TEMP

5.3.46

Engine Fluid Level/Pressure #2

65243

Injector Metering Rail 1 Pres Injector Metering Rail 2 Pres

INJ PRES1 INJ PRES2 FAN SPD

5.3.58

Fan Drive

65213

5.3.111

Auxiliary Pressures & Temperatures

65164

Auxiliary Temperature

AUX TEMP

Auxiliary Pressure

AUX PRES

Diagnostic Messages

65226 65227 65228

DM1 - Active Diagnostic DM2 - Previously Act Diag Codes DM3 - Diagnostic Clear

SRVCCODE STORCODE

J1939 N/A

Machine Hours (PowerView Calculated)

N/A

Machine Hours

MACH HRS

5.3.17

Engine Conf.

65251

Engine Configuration

ENG CONF

Electronic Transmission Controller #1

61442

Output Shaft Speed

OUT SFT SP

5.3.5

Electronic Transmission Controller #1

61442

Input Shaft Speed

IN SFT SPD

Electronic Transmission Controller #1

61442

Torque Converter Lockup Engaged

TORQ LOCK

PV-02124N page 17 of 18

Options and Accessories

7-39

Engine Monitor (Murphy PowerView) GLOSSARY (Troubleshooting information)

CANBUS FAILURE PowerView has not received any CAN messages for at least 30 seconds.

NO DATA PowerView has not received the particular message being displayed for at least 5 seconds.

NOT SUPPORTED PowerView has received a message from the ECU stating the displayed message is not supperted.

DATA ERROR PowerView has received an error message from the ECU for the displayed message.

EMPTY No parameter selected for this 4-UP quadrant.

WAIT TO START PREHEATING This is a message from the engine indicating it is in a preheating cycle.

Wait until this message clears before starting the engine.

TIMEOUT ECU NOT RESPONDING The ECU did not respond to the PowerView request.

NO GAGE DATA The PowerView has no record of connected gages to the RS485 bus.

MURPHY DE MEXICO, S.A. DE C.V. Blvd. Antonio Rocha Cordero 300, Fracción del Aguaje San Luis Potosí, S.L.P.; México 78384 +52 444 8206264 fax +52 444 8206336 Villahermosa Office +52 993 3162117 e-mail ventas@murphymex.com.mx www.murphymex.com.mx

MURPHY SWITCH OF CALIFORNIA 41343 12th Street West Palmdale, California 93551-1442; USA +1 661 272 4700 fax +1 661 947 7570 e-mail sales@murphyswitch.com www.murphyswitch.com

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RE

P.O. Box 470248 Tulsa, Oklahoma 74147 USA +1 918 317 4100 fax +1 918 317 4266 e-mail sales@fwmurphy.com www.fwmurphy.com

FRANK W. MURPHY, LTD. Church Rd.; Laverstock, Salisbury SP1 1QZ; U.K. +44 1722 410055 fax +44 1722 410088 e-mail sales@fwmurphy.co.uk www.fwmurphy.co.uk

GI

D

FWMurphy

CONTROL SYSTEMS & SERVICES DIVISION P.O. Box 1819; Rosenberg, Texas 77471; USA +1 281 633 4500 fax +1 281 633 4588 e-mail sales@fwmurphy.com

STER

E

®

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In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time.

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PV-02124N page 18 of 18

7-40

Options and Accessories