Cat MD6640 Blast Hole Drill Operation & Maintenance Manual – PDF DOWNLOAD

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Operation and Maintenance Manual MD6640 Blast Hole Drill Serial Number 2U70X58/141369

SAFETY.CAT.COM

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MD6640 Blast Hole Drill Operation and Maintenance Manual SN: 2U70X58/141369 –Table of Contents– This manual is divided into major sections covering the various serviceable components and systems of the MD6640Blast Hole Drill. These sections and their contents are organized as shown below.

Section

1

- INTRODUCTION

Section

2

- OPERATION

Section

3

- LUBRICATION

Section

4

- PREVENTIVE MAINTENANCE

Section

5

- SERVICE PROCEDURES

Section

6

- BRAKES AND COUPLINGS

Section

7

- COMPRESSED AIR SYSTEM

Section

8

- HEATING, VENTILATION AND AIR CONDITIONING

Section

9

- ENGINEERING DATA

Section

10-

SCHEMATICS

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

DANGER: DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY. The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

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

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

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1-1 Introduction Section MD6640 Blasthole Drill

BI006893 Section

1

Introduction Always refer to the safety information in this section of this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL INFORMATION ............................................................................................................ 3 SAFETY .................................................................................................................................. 4 SAFETY PRECAUTIONS ........................................................................................................ 5 FIRE PREVENTION CONSIDERATIONS ..................................................................................... 8 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS .............................. 9 WARNING SIGNS AND DECALS ................................................................................................ 12 Stored Energy Signs .................................................................................................................. 13

MACHINE OVERVIEW ................................................................................................................ 14 PROPEL MACHINERY .......................................................................................................... 15 MAIN FRAME AND DECKS ................................................................................................... 16 MACHINERY HOUSE ............................................................................................................ 17 MAIN AIR SYSTEMS .............................................................................................................. 18 Air Compressor .......................................................................................................................... 18

HYDRAULIC SYSTEM ........................................................................................................... 19 OPERATOR’S CAB .............................................................................................................. 20 MAST ..................................................................................................................................... 20 Mast/Machinery .......................................................................................................................... 21

ROTARY GEARCASE ........................................................................................................... 22 PULLDOWN GEARCASE ..................................................................................................... 23 DRILL TOOL STRING ASSEMBLY ........................................................................................ 24 BREAKOUT WRENCH ......................................................................................................... 25 CABLE REEL ........................................................................................................................ 25 65 OR 70 FOOT MAST - TYPICAL MACHINE SPECIFICATIONS .............................................. 26 GENERAL ESTIMATED COMPONENT WEIGHTS .................................................................... 28

DECK PLAN.......................................................................LOCATED AT THE END OF THE MANUAL

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1-2 Introduction Section MD6640 Blasthole Drill

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1-3 Introduction Section MD6640 Blasthole Drill

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1

Introduction

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

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed by the parts representative. Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance contact your regional service representative or:

Caterpillar Global Mining, LLC Mining Products Division 3501 S FM 1417 Denison, TX 75020 903-786-9621 The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously. Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.

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1-4 Introduction Section MD6640 Blasthole Drill

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SAFETY The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions.

If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Caterpillar service representative or the factory.

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

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION:

This signal word serves as a reminder of safety practices or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER:

This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER:

This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

CAUTION:

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

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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1-5 Introduction Section MD6640 Blasthole Drill

SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

• Check limit switches for proper operation.

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

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

• Use proper interior and exterior lighting.

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

• Perform functional tests of all safety circuits.

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

• Use extreme caution when working around drilled holes.

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1-6 Introduction Section MD6640 Blasthole Drill

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

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

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

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

• Never utilize the machine air or hydraulic systems for support when working on the machine.

Deactivate or isolate the entire system prior to performing maintenance.

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

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

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

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

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

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

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

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

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

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

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

• Protective eye goggles should be worn at all times when working on the air conditioning system.

Work on the air conditioning system only in a well ventilated area.

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

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

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1-7 Introduction Section MD6640 Blasthole Drill

BI006893 Operating Precautions:

• Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa • When in doubt about the noise level, wear approved hearing protection.

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

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

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

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

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

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

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

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

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

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1-8 Introduction Section MD6640 Blasthole Drill

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FIRE PREVENTION CONSIDERATIONS Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

DO NOT smoke while handling flammables or when near batteries.

Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 of this manual for the Scheduled Maintenance recommendations and the Walk Around Inspection procedure.

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

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

DO NOT carry flammable fluids such as gasoline or solvents on board themachine.

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

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

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

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

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

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1-9 Introduction Section MD6640 Blasthole Drill

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

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

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

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

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

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1-10 Introduction Section MD6640 Blasthole Drill

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RAISE BOOM Extend arm fully with fingers closed and thumb pointing upward.

STOP Extend arm fully with fingers extended and palm facing down.

EMERGENCY STOP With arm fully extended, fingers fully extended and palm facing down, move arm rapidly along a horizontal plane.

TRAVEL With arm extended forward, hand open and raised at wrist, make a pushing motion in the desired direction of movement.

DOG EVERYTHING Clasp hands together in front of body.

TRAVEL (both tracks) With both fists clenched in front of body, make a circular motion with the desired direction of motion (forward or reverse) duplicated with fists.

LOWER BOOM Extend arm fully with fingers closed and thumb pointing down.

MOVE SLOWLY While giving any motion signal, hold other hand motionless in front of desired signal hand. (Hoist slowly is example provided.)

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1-11 Introduction Section MD6640 Blasthole Drill

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RAISE BOOM AND LOWER LOAD Extend arm horizontally with fingers extended and thumb pointing upward, alternately open and close fingers for the duration of the desired movement.

LOWER BOOM AND RAISE LOAD Extend arm horizontally with fingers extended and thumb pointing downward, alternately open and close fingers for the duration of the desired movement.

SWING Extend arm horizontally with index finger extended in desired direction of swing.

TRAVEL (Single Track) Use a raised fist on the side that remains locked and make a vertical circular motion in front of chest for the direction and side of desired movement.

EXTEND BOOM (Telescoping Booms) Place both hands in front of body with palms upward, fingers clenched, and thumbs extending outward.

RETRACT BOOM (Telescoping Booms) Place both hands in front of body with palms upward, fingers clenched, and thumbs extending inward.

EXTEND BOOM (Telescoping Booms) With fingers clenched and thumb extended toward body, use a single hand motion to tap on chest with thumb of hand.

RETRACT BOOM (Telescoping Booms) With fingers clenched and thumb extended away from body, use a single hand motion to tap on chest with heel of hand.

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1-12 Introduction Section MD6640 Blasthole Drill

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WARNING SIGNS AND DECALS The placards depicted below are mounted on the machine as delivered. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.

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1-13 Introduction Section MD6640 Blasthole Drill

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Stored Energy Signs

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1-14 Introduction Section MD6640 Blasthole Drill

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MACHINE OVERVIEW This machine is designed and constructed to provide efficient service under the most severe conditions. It is built to the highest possible standards and will provide trouble free operation if properly maintained.

Winch, Auxiliary

Mast Ladder Mast Assembly

Mast Rack

Mast Safety Restraint Device

Pipe Rack

Front of Machine

Mast Machinery Guide Frame

Pulldown Gearcase

Mast Machinery

Breakout Wrench

Machinery House

Main Air Hose

Air Conditioner

Rear Leveling Jack Dust Collector

Mast Brace

House Filter Assembly

Hydraulic Cylinder, Mast Hoist

Operator’s Cab

Mast Hinge A-Frame

Rotary Gearcase Shock Coupling Main Frame Pad, Leveling Jack

Pad, Leveling Jack Walkways, House

Crawler Assembly

Front Leveling Jack Boarding Stairs

Crawler Drive Sprocket

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1-15 Introduction Section MD6640 Blasthole Drill

PROPEL MACHINERY The propel system of this machine is a chainless hydraulic drive system which will allow the separate tracks to counter-rotate. This capability provides the machine with the capacity to turn completely around within its own length. Each track is driven by a hydraulic motor and a planetary gearbox equipped with a hydraulically released, spring activated brake. The machine is capable of 2 different propel speed ranges. The lower speed range is used for maneuvering in close spaces while the high speed range is used for tramming in open areas, over long distances.

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1-16 Introduction Section MD6640 Blasthole Drill

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MAIN FRAME AND DECKS The main frame is of welded box type construction with integrally placed mast supports and jack towers.

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BI006893 MACHINERY HOUSE

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1-18 Introduction Section MD6640 Blasthole Drill

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MAIN AIR SYSTEMS The screw compressor is located within the machinery house just forward of the hydraulic pump gearbox. The rotary screw compressor is an oil flooded, single stage twin screw type compressor which has a nominal rating of 3,000 cfm (84.9m3/min), @ 65 psi and a maximum operating pressure of 65 psi.

Air Compressor

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1-19 Introduction Section MD6640 Blasthole Drill

HYDRAULIC SYSTEM Hydraulic pressure for operation of this machine is provided by four separate pumps. These pumps are driven by the electric motor located in main machinery house, forward of the hydraulic filters and reservoir.

The machine has 2 separate, though not completely independent hydraulic systems, the OPEN and CLOSED circuits. Both draw fluid from a common reservoir.

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1-20 Introduction Section MD6640 Blasthole Drill

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OPERATOR’S CAB The sound insulated operator’s cab of the MD6640 provides a sealed, comfortable enclosure from which the operator can perform the tasks involved with the operation of the machine. The location and design of this compartment have been structured to provide the optimum viewing angles with immediate accessibility. The operator’s seat is a self-contained unit that includes the seat, seat suspension and swivel base assembly, the primary operator’s controls and the JLT display monitor.

The auxiliary control console is within reach to provide access to additional functions of the machine.

The cab is provided with dual doorways to the main deck.

MAST The mast is a fabricated structure of steel tubes and formed plates. The major structure is composed of vertical tubes welded together with back bracing. The mast functions to provide the mounting and guide for the equipment required to operate the drilling function of the machine. The mast is capable of being positioned at any 5o increment within it’s operating range from 65 degrees through 90 degrees (vertical). The mast can be raised and lowered by 2 (two) 9.00 inch (228mm) hydraulic cylinders.

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Mast/Machinery

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1-22 Introduction Section MD6640 Blasthole Drill

ROTARY GEARCASE

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1-24 Introduction Section MD6640 Blasthole Drill

DRILL TOOL STRING ASSEMBLY

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BI006893 BREAKOUT WRENCH

CABLE REEL

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1-26 Introduction Section MD6640 Blasthole Drill

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65 OR 70 FOOT MAST - TYPICAL MACHINE SPECIFICATIONS Refer to the images on the following page.

Hole Diameter

to 16”

406mm

Hole Depth (single pass - 65 Ft. mast)

65 Ft.

19.81m

Hole Depth (single pass - 70 Ft. mast)

70 Ft.

21.34m

A

Overall Height with 65 Ft. (19.81m) mast

102' 5”

31.22m

A

Overall Height with 70 Ft. (21.34m) mast

104' 5”

31.85m

B

Height to Top of handrails on Operator’s Cab

18' 6"

5.64m

C

Ground to Top of Deck

6' 4"

1.93m

D

Ground to Bottom of Rear Jack

2' 0"

0.61m

E

Ground to Top of Machinery House Roof

14’ 10”

4.52m

F

Overall Width of machine

23' 9"

7.24m

F1

Machine C/L to Left side

11' 10"

3.61m

F2

Machine C/L to Right side

11' 11"

3.63m

G

Machine C/L to Left Outside Edge of Tracks (36 inch/914mm)

10' 5"

3.17m

G1

Machine C/L to Right Outside Edge of Tracks (36 inch/914mm)

9' 7"

2.92m

H

Machine C/L to Left Rear Leveling Jack C/L

7' 6"

2.29m

H1

Machine C/L to Right Rear Leveling Jack C/L

7' 3”

2.21m

I

Centerline of Hole to Centerline of Equalizer Axle

0’ 5”

0.12m

J

Height to Top of Machinery House Pressurization Unit

16’ 6”

5.03m

K

Height to Top of Cable Reel

10’ 1”

3.07m

L

Ground to Bottom of Front Jack

2’ 1”

0.63m

M

Diameter of Jack Pads

3' 8"

1.12m

N

Centerline of Hole to Centerline of Rear Jacks

15 3/4”

4.59m

O

Overall Crawler Length

23' 9”

7.24m

P

Hole C/L to Rear of Operator’s Cab

10' 2”

3.1m

Q

Distance between Front and Rear Jack Centerlines

36' 2”

11.02m

R

Overall Machine Length

48' 4"

14.73m

S

Overall Machine Length with Cable Reel

55’ 8"

16.97m

T

Overall Machine Length with 65’ Mast at Rest (19.81m)

121’3"

36.95m

T

Overall Machine Length with70’ Mast at Rest (21.34m)

123’ 4"

37.64m

U

Overall Machine Height with 65’ Mast at Rest (19.81m)

32’ 3"

9.52m

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A

B J C

D

K

N M L

O

I H

H

G

G F2

F1 F

Q

1 1

R S T

mdim49HR

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1-28 Introduction Section MD6640 Blasthole Drill

BI006893 GENERAL ESTIMATED COMPONENT WEIGHTS

CAUTION:

These are estimated weights only. Contact your Caterpillar service representative for the exact weight of components on your specific machine before rigging and lifting.

Quantity

Weight Each (U.S. Pounds)

Lower Works Frame, R.H. Crawler ................................................................ 1 ................ 8,480 Frame, L.H. Crawler ................................................................. 1 ................ 8,480 Axle, Crawler Front Equalizer ................................................... 1 ................ 3,370 Axle, Crawler Rear ................................................................... 1 ................ 6,480 Tumbler, Crawler Drive ............................................................ 2 ................ 1,160 Propel Gearcase ...................................................................... 2 ................ 2,750 Link, Crawler .......................................................................... 110 ................. 240 Propel Motor ............................................................................. 2 ................... 198 A-Frame Leg, Front A-Frame ..................................................................

Leg, Rear A-Frame ...................................................................

Cylinder, Mast Latch .................................................................

Pin, A-Frame Lock ....................................................................

Pin, Mast Latch Lock ................................................................

Pin, A-Frame ............................................................................

Ladder, A-Frame .......................................................................

2 ................... 800 1 ................ 2,900 2 ..................... 15 2 ..................... 15 2 ..................... 15 2 ..................... 40 1 ..................... 80

Main Frame Main frame ................................................................................ 1 ...............45,130 Casing Assembly, Left Rear Jack ............................................ 1 ................ 2,260 Casing Assembly, Right Rear Jack .......................................... 1 ................ 5,680 Cylinder, Leveling Jack Hydraulic ......................................... 4 ................... 845 Spud, Jack ............................................................................ 4 ................... 660 Shoe, Spud ........................................................................... 4 ................... 505 Power Module ........................................................................... 1 ...............13,600 Base, Power Module ................................................................ 1 ................ 1,550 Motor ..................................................................................... 1 ................ 6,100 Pump Drive Assembly .......................................................... 1 ................... 805 Bracket, RH, Hydraulic Pump Drive ................................. 1 ................... 155 Bracket, LH, Hydraulic Pump Drive .................................. 1 ................... 150 Pump, Gear, Tandem, ...................................................... 1 ..................... 45 Pump Drive ...................................................................... 1 ................... 175 Filter, Assembly, Air Inlet ....................................................... 1 ................... 605 Air End Assembly ................................................................. 1 ................ 4,070 Separator Assembly ............................................................. 1 ................ 4,275 Reservoir, Hydraulic ................................................................. 1 ................... 705 Reservoir, Lube ........................................................................ 1 ................... 460

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Quantity

Weight Each (U.S. Pounds)

Oil Cooler, Air Cooled ...............................................................

Guard, Oil Cooler .................................................................

Cooler, Compressor Assembly ................................................

Cooler, Compressor .................................................................

1 ................... 570 1 ................... 185 1 ................ 4,200 1 ................ 3,000

MCC. Low Voltage ....................................................................

MCC, Main Compressor...........................................................

Cabinet, ZHC ............................................................................

Control Panel, Static DC Drive .................................................

Cabinet .....................................................................................

Cabinet, PLC ............................................................................

Cabinet, Rotary-ZROC .............................................................

1 ................... 900 1 ................ 1,080 1 ................ 1,030 1 ................... 210 1 ................... 600 1 ................... 800 1 ................ 1,035

Leveling Jack Stand .................................................................. 1 ................... 470 Control Valve ............................................................................ 1 ................... 160 Operator Cab Assembly ........................................................... 1 ................ 8,400 Air Conditioner .......................................................................... 1 ................... 930 Hatch, Bit View .........................................................................

Cylinder, Bit Viewing Hatch ...................................................

Retainer, Plate ..........................................................................

Cylinder, Dust Seal ...................................................................

Carrier, Dust Seal .....................................................................

Gate, Front ...............................................................................

Gate, Rear ................................................................................

Frame, Dust Enclosure ............................................................

Stairway, Boarding ....................................................................

Cable Reel ................................................................................

1 ................... 225 1 .................... 115 1 ..................... 40 1 ..................... 90 1 ................... 300 1 ................... 380 1 ................... 630 1 ................... 700 1 ................... 210 1 ................ 8,000

Machinery House Wall, Machinery House R.H. .....................................................

Wall, Machinery House Front ...................................................

Wall, Machinery House L.H. .....................................................

Door Cove, L.H. ........................................................................

Cove, Hydraulic ........................................................................

Panel, Center Roof ...................................................................

Panel, Rear Roof ......................................................................

Extension, Left Hand ................................................................

Panel, Roof, L.H. Extension .....................................................

Roof Section, Machinery House ...............................................

Hatch, Pressurization Unit Roof ...............................................

Enclosure, Dynavane Bleed Fan ..............................................

1 ................ 1,745 1 ................ 1,040 1 ................ 1,180 1 ................... 135 1 ................ 1,250 1 ................... 575 1 ................... 600 1 ................ 8,925 1 ................... 430 1 ................ 2,030 1 ................... 345 1 ................... 375

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1-30 Introduction Section MD6640 Blasthole Drill

BI006893 Quantity

Weight Each (U.S. Pounds)

Duct, Pressurization Unit Transition ......................................... 1 ................... 275 Duct, Upper Bleed Fan Discharge ........................................... 1 ..................... 90 Duct, Lower Bleed Fan Discharge ........................................... 1 ................... 100 Shroud, Pressurization Unit Rain ............................................. 1 ................... 120 Filter, Air/Bleed Air Duct ............................................................ 1 ................ 1,000 Support, Blower Fan ................................................................ 2 ................... 145 Hatch, Roof .............................................................................. 1 ................... 350 Oil Cooler Blower and Blower Motor ........................................ 1 ................... 220 Mast Braces Brace, Mast ..............................................................................

Sleeve, L.H. Brace ...................................................................

Sleeve, R.H. Brace ...................................................................

Support, R.H. Mast Brace ........................................................

Support, L.H. Mast Brace .........................................................

Support Arm, R.H. Safety Sling (lower) ....................................

Eyebolt ......................................................................................

Pin, Lock ...................................................................................

Cylinder, Brace Lock ................................................................

Pin, Pivot ..................................................................................

Cylinder, Mast Hoist Hydraulic ..................................................

2 ................ 1,555 1 ................... 705 1 ................... 710 1 ................... 865 1 ................... 860 1 ................... 105 2 ................... 145 2 ..................... 20 2 ..................... 20 8 ..................... 40 2 ................ 1,350

Mast Assembly Mast Structure .......................................................................... 1 ...............26,000 Rack, Pulldown Pinion ............................................................ 42 .................. 100 Plate, Mast Bottom ................................................................... 1 ................ 1,995 Gearcase, Pulldown .................................................................

Shaft, Input ...........................................................................

Coupling, Pulldown Input ......................................................

Shaft, 2nd Intermediate Pulldown .........................................

Gear, 2nd Intermediate Pulldown .........................................

Housing, Encoder .................................................................

Pinion, First Intermediate ......................................................

Gear, First Intermediate ........................................................

Gear, Output .........................................................................

Shaft, 1st Intermediate & Shipper, Pulldown ........................

Brake, Pulldown ...................................................................

Motor, Hoist and Pulldown ....................................................

Support, Pulldown Gearcase ...............................................

1 ................ 1,170 1 ..................... 72 1 ..................... 50 1 ................... 145 1 ................... 390 1 ..................... 30 1 ................... 155 1 ................... 465 1 ................... 690 1 ................... 710 1 ................... 100 1 ................ 1,900 1 ................ 1,015

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1-31 Introduction Section MD6640 Blasthole Drill

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Quantity

Weight Each (U.S. Pounds)

Gearcase, Rotary .....................................................................

Shaft, Intermediate Rotary ....................................................

Gear, Intermediate Rotary ....................................................

Gear, Rotary Drive ................................................................

Shaft, Rotary Drive ...............................................................

Bearing, Shaft Center ...........................................................

Carrier, Lower Bearing .........................................................

Retainer, Bearing ..................................................................

Housing, Upper Seal ............................................................

Carrier, Upper Bearing..........................................................

Bearing, Shaft Lower ............................................................

Pinion, Rotary Motor .............................................................

Motor, Rotary ........................................................................

1 ................ 2,950 1 ..................... 75 1 ................... 100 1 ................... 590 1 ................... 355 1 ................... 130 1 ................... 215 1 ................... 210 1 ..................... 35 1 ..................... 30 1 ..................... 35 1 ..................... 55 1 ................ 2,550

Coupling, Shock ....................................................................... 1 ................ 2,500 Guide Frame (LH) ....................................................................

Guide Frame (RH) ....................................................................

Housing, L.H. Mast Guide Roller ..........................................

Guide Roller Assembly, Upper ..................................................

Guide Roller, Upper ..............................................................

Guide Roller, Lower (Front) ..................................................

1 ................ 1,130 1 ................ 1,130 1 ................... 415 2 ................... 150 4 ..................... 40 2 ..................... 45

Extender, Drill Pipe ...................................................................

Bushing, Drill Pipe Guide ..........................................................

Wrench, Bit, 12.25 ...................................................................

Wrench, Bit, 10.625 .................................................................

Tool Wrench Assembly ............................................................

Winch, Hydraulic Driven ...........................................................

Hydraulic Cylinder, Rack Position ............................................

Ladder, Mast .............................................................................

Ladder, Mast Lower ..................................................................

1 ................... 620 1 ................... 310 1 ................... 125 1 ................... 140 2 ................ 2,100 1 ................... 415 2 ..................... 90 5 ................... 100 1 ..................... 85

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1-32 Introduction Section MD6640 Blasthole Drill

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2-1 Operation Section MD6640 Blasthole Drill

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Section

2

Operation Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL INFORMATION ............................................................................................................ 5 OPERATION NEAR ELECTRICAL TRANSMISSION LINES ................................................... 5 CONTROLS - LOCATION AND FUNCTION ................................................................................ 6 OPERATOR’S CONTROL CONSOLES ...................................................................................... 7 OPERATOR’S CONTROL CONSOLE - OVERVIEW ................................................................... 7

LEFT CONTROL CONSOLE .................................................................................................. 8 LEFT CONTROL CONSOLE - OVERVIEW ................................................................................ 8

PROGRAMMED DRILL CONTROL PUSHBUTTON — OPTION ...................................... 9 OPERATING MODE SELECTOR SWITCH ...................................................................... 9 PULLDOWN / HOIST SPEED RANGE SELECTOR SWITCH ......................................... 9 HOIST BRAKE SWITCH ................................................................................................. 10 MAIN AIR VALVE SWITCH ............................................................................................... 10 DEPTH INDICATOR RESET PUSH-BUTTON ................................................................ 10 EMERGENCY STOP PUSH-BUTTON ............................................................................ 11 BIT VIEW HATCH SWITCH ............................................................................................. 11 LEFT JOYSTICK (DUAL FUNCTION) - PROPEL TRACK / WINCH ............................... 11 ROTARY DRIVE SPEED SELECTOR SWITCH ............................................................ 12 HOIST/PULLDOWN RHEOSTAT .................................................................................... 12 DUST CONTROL ON/OFF SWITCH — OPTION .......................................................... 12 DUST CURTAIN SWITCH — OPTION ............................................................................ 12 DUST CONTROL FLOW CONTROL — OPTION .......................................................... 13 UNDER DECK SPRAYERS — OPTION ........................................................................ 13 RIGHT CONTROL CONSOLE .............................................................................................. 14 RIGHT CONTROL CONSOLE - OVERVIEW ............................................................................. 14

PIPE POSITIONER SWITCH .......................................................................................... 15 RIGHT JOYSTICK (TRIPLE FUNCTION) - PROPEL TRACK / PIPE RACK / MAST ...... 15 ROTARY SPEED POTENTIOMETER ............................................................................ 16 DUST SEAL SLIDER SWITCH ....................................................................................... 16 PROPEL SPEED RANGE SELECTOR SWITCH .......................................................... 16 HORN PUSH-BUTTON ................................................................................................... 16 TOOL WRENCH SWITCH .............................................................................................. 17 BREAKOUT WRENCH SWITCH .................................................................................... 17 PIPE RACK SELECTOR SWITCH ................................................................................. 17 BIT CAROUSEL SWITCH ............................................................................................... 17 LEVELING JACK CONTROL SWITCHES ...................................................................... 18

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2-2 Operation Section MD6640 Blasthole Drill

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AUTO LEVEL SWITCH ................................................................................................... 18 AUXILIARY CONTROL CONSOLE ....................................................................................... 19 AUXILIARY CONTROL CONSOLE ............................................................................................ 19

EXTERIOR LIGHTS ........................................................................................................ 19 TRAIL CABLE TRIP PUSH-BUTTON .............................................................................. 19 FLOOR DEFROST SWITCH .......................................................................................... 20 HEATER / VENT / AIR CONDITIONER CONTROLS ...................................................... 20 BOARDING STAIRS SWITCH ......................................................................................... 20 RADIO / CASSETTE PLAYER ........................................................................................ 20 OPERATOR’S DISPLAY ............................................................................................................. 21 OPERATOR’S DISPLAY MONITOR ........................................................................................... 21

DISPLAY AREA & INDICATORS ............................................................................................ 21 DISPLAY SCREENS ............................................................................................................. 22 TITLE SCREEN ......................................................................................................................... 22 LEVELING SCREEN ................................................................................................................. 23 STATUS SCREEN ..................................................................................................................... 23 ACTIVE ALARM ........................................................................................................................ 24 STATUS SCREEN with Pop-up Ribbon ...................................................................................... 24 ALARM HISTORY ...................................................................................................................... 25 HELP NAVIGATION ................................................................................................................... 25 PLC DIAGNOSTICS .................................................................................................................. 26 CALIBRATION and LIMITS ....................................................................................................... 26 OPERATING HOURS ................................................................................................................ 27 FIELD TESTS ............................................................................................................................ 27

MACHINERY HOUSE CONTROLS ...................................................................................... 28 LIGHTING LOAD CENTER .............................................................................................. 28 LIGHTING LOAD CENTER ........................................................................................................ 28

CONTROLS LOCATED ON LOW VOLTAGE START CABINET .................................... 29 CONTROLS LOCATED ON LOW VOLTAGE CABINET ................................................. 29 CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET ..................... 30 TYPICAL PROGRAMMABLE CONTROL CABINET ................................................................... 30

HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ............................... 30 TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ........................... 30

MISCELLANEOUS CONTROLS ..................................................................................... 31 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................................... 31 Hydraulic Reservoir Remote Fill Control Panel ............................................................................ 31

PORTABLE REMOTE PROPEL STATION (OPTIONAL) ................................................ 31 PORTABLE REMOTE PROPEL STATION ................................................................................. 31

RADIO REMOTE PROPEL STATION (OPTIONAL) ........................................................ 32 PRESTART CHECKS ................................................................................................................. 34 EXTERNAL INSPECTION ..................................................................................................... 34 ONBOARD INSPECTION ..................................................................................................... 36 PRESTART LUBRICATION ......................................................................................................... 38 START-UP ................................................................................................................................... 39 MACHINE START UP ............................................................................................................ 39 MACHINERY CHECK ...................................................................................................... 40 BREAK-IN OF NEW COMPONENTS ............................................................................. 40 ROTARY DRIVE UNIT BREAK-IN ............................................................................. 40

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2-3 Operation Section MD6640 Blasthole Drill

HOIST/PULLDOWN GEARCASE BREAK-IN ........................................................... 40 ELECTRIC MOTOR BREAK-IN ................................................................................ 40 OPERATION ............................................................................................................................... 41 PROPELLING ....................................................................................................................... 41 DEFINITIONS .................................................................................................................. 41 PROPEL PROCEDURE ................................................................................................. 42 STRAIGHT PROPEL - FORWARD OR REVERSE .................................................................... 43 GRADUAL RIGHT HAND TURN ................................................................................................. 44 GRADUAL LEFT HAND TURN ................................................................................................... 44 COUNTER-ROTATION LEFT HAND TURN ................................................................................ 45 ENSURE GRADUAL TURNS ARE MADE - 15° INCREMENTS ................................................. 45

TOWING PROCEDURE ................................................................................................. 47 TOWING PROCEDURE ............................................................................................................. 47

CABLE REEL OPERATION .................................................................................................. 49 LEVELING ............................................................................................................................. 50 MAST RAISING AND LOWERING ......................................................................................... 51 MAST RAISING ................................................................................................................ 52 MAST STATUS SCREEN .......................................................................................................... 53

MAST LOWERING .......................................................................................................... 54 PULLDOWN MACHINERY OPERATION .............................................................................. 55 AUXILIARY WINCH OPERATION .......................................................................................... 56 PIPE RACK OPERATION ............................................................................................... 57 PIPE RACK OPERATION .......................................................................................................... 58

TOOL HANDLING .................................................................................................................. 60 PIPE LOADING AND UNLOADING .................................................................................. 60 DRILL TOOL STRING ASSEMBLY .................................................................................. 62 TOOL STRING .......................................................................................................................... 62 STABILIZER INSTALLATION ..................................................................................................... 63

BREAKOUT WRENCH OPERATION ................................................................................... 67 DRILL TOOL STRING DISASSEMBLY .................................................................................. 68 ADDING ADDITIONAL DRILL PIPE .................................................................................. 70 REMOVAL OF MULTIPLE SECTION DRILL PIPE ........................................................... 71 ANGLE DRILLING ................................................................................................................. 72 ANGLE DRILLING EQUIPMENT ................................................................................................ 72 PIPE POSITIONER ................................................................................................................... 73 JIB CRANE ................................................................................................................................ 74

DUST SUPPRESSION SYSTEM OPERATION .................................................................... 75 WATER INJECTION SYSTEM .................................................................................................. 76

DRILLING .............................................................................................................................. 77 VERTICAL DRILLING ...................................................................................................... 77 STARTING THE HOLE (COLLARING) ...................................................................... 78 NORMAL DRILLING ................................................................................................... 79 ENDING THE HOLE .................................................................................................. 81 ENDING THE HOLE (MULTIPLE PIPE SECTIONS) ................................................. 82 DRILLING DIFFICULT FORMATIONS ............................................................................. 82 UNCONSOLIDATED MATERIALS ................................................................................... 83 WET OR STICKY FORMATIONS ......................................................................................... 85 ANGLE DRILLING ................................................................................................................. 86

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2-4 Operation Section MD6640 Blasthole Drill

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PROGRAMMED DRILL CONTROL DRILLING ..................................................................... 87 PREPARING TO MOVE .................................................................................................. 88 MACHINE SHUTDOWN ........................................................................................................ 89 SHUT DOWN PROCEDURE ................................................................................... 89 SHORT TERM STORAGE ........................................................................................ 90 LONG TERM STORAGE ........................................................................................... 91 ATTENDED LONG TERM STORAGE ...................................................................... 92 UNATTENDED LONG TERM STORAGE .................................................................. 92 TOOL RECOVERY ..................................................................................................................... 93 DRILL STABILITY CHARTS ................................................................................................... 95 Drill Stability Chart - Special Propel Conditions .......................................................................... 95 Drill Stability Chart - Typical Propel Conditions ........................................................................... 96

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2-5 Operation Section MD6640 Blasthole Drill

BI006893 Section

2

Operation

GENERAL INFORMATION This section of the manual will assist in the operation of this machine. It provides the operator with the location and explanation of the controls, instructions for machine operation and certain maneuvering techniques. Throughout this section and the remainder of the manual, the use of the terms “LEFT, RIGHT, FRONT and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

Safe operation of the machine minimizes production delays and costly damage to equipment.

Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel.

Overall safety depends upon the use of good judgment and the alertness of the entire mining crew. Refer to Section 1 in this manual for specific safety precautions.

OPERATION NEAR ELECTRICAL TRANSMISSION LINES DANGER:

HIGH VOLTAGE! The following precautions shall be complied with whenever operating around or near electrical distribution and transmission lines.

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual we are considering the entire machine or its load, in any position, that can reach to within the minimum distance specified by local, state and federal regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.

Before working in the vicinity of power lines, always take the following precautions: •

Always contact the owners of the power lines or the nearest electric utility before beginning work.

•

You and the electrical utility representative must jointly determine what specific precautions must be taken to insure safety.

•

It is the responsibility of the user and the electric utility to see that necessary precautions are taken.

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2-6 Operation Section MD6640 Blasthole Drill

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•

Consider all lines to be power lines and treat all power lines as energized even though it is known that the power is shut off and the line is visibly grounded.

•

Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.

•

Caution all ground personnel to stand clear of the machine at all times.

•

Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.

DANGER:

HIGH VOLTAGE! Death or injury could result should any part of the machine approach the minimum distance of an energized power line specified by local, state and federal regulations.

CONTROLS - LOCATION AND FUNCTION Regardless of previous experience, the new operator of any machine must become familiar with the location and function of all of the operating controls before beginning to operate the machine.

Since this manual covers all possible controls that could be used on this machine, become familiar with both this manual and the particular machine being operated.

CAUTION:

Read and become familiar with this manual before attempting to operate any of the machine controls. Pay particular attention to the caution and warning statements, and any federal, state, local or company safety rules relating to the machine. Failure to be aware of and understand the hazards associated with the operation of the controls may lead to death, personal injury or serious machine damage.

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2-7 Operation Section MD6640 Blasthole Drill

BI006893 OPERATOR’S CONTROL CONSOLES

The operator’s control consoles are mounted on each side of the operator’s seat. The display monitor is mounted on the left console, as shown. An auxiliary control console is located to the right of the operator.

NOTE: The operator controls are all electric. The switches, potentiometers and joysticks operate electric controls, electromechanical controls, or electrohydraulically actuated valves on the machine.

OPERATOR’S CONTROL CONSOLE - OVERVIEW

NOTE:

The panels with controls as shown on the following pages are typical of what could be included on a console.

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2-8 Operation Section MD6640 Blasthole Drill

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LEFT CONTROL CONSOLE

LEFT CONTROL CONSOLE - OVERVIEW

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2-9 Operation Section MD6640 Blasthole Drill

PROGRAMMED DRILL CONTROL PUSHBUTTON — OPTION The programmed drill control pushbutton is used to activate or deactivate the programmed drill control system on the machine.

OPERATING MODE SELECTOR SWITCH This four-position switch is used to select one of three drill operating modes.

PROPEL - Enables all propel functions while disabling the winch, mast and all rotary and pulldown/ hoist functions.

DRILL - Enables all drilling functions while disabling all propel functions.

MAST/WINCH - Enables all mast and winch functions while disabling all propel functions.

REMOTE - Enables all propel functions to be operated from the remote control unit and disables the cab operator controls.

PULLDOWN / HOIST SPEED RANGE SELECTOR SWITCH The pulldown/hoist speed range selector switch controls the operating mode and speed range of the hoist/pulldown drive when in a drilling mode of operation. The operating mode selector switch must be in the DRILL position for this speed selector to function.

The switch is a four-position switch with the following designations: PULLDOWN, HOIST LOW, HOIST HIGH, and PIPE RACK/JOINT. In the PULLDOWN setting, which is used for normal drilling, full pulldown force is available but the speed range for both pulldown and hoisting is limited to about 25 FPM (7.62 MPM).

The HOIST LOW and HOIST HIGH settings are used for pipe raising at high speeds.

In the HOIST LOW position full hoisting and lowering force is allowed, but the speed is allowed to reach a higher level (typically about 25 FPM [7.62 MPM]).

In the HOIST HIGH position maximum head speed capability is allowed for both hoisting and lowering.

Typically about 75 FPM (22.86 MPM).

As a result of obtaining a higher speed, the hoist force capability at full speed is not as large as is obtainable in the HOIST LOW position.

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2-10 Operation Section MD6640 Blasthole Drill

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In the PIPE RACK/JOINT position, the speed limit is reduced to 25 FPM (7.62 MPM) the down force is limited to head and drill steel weight. This is the switch position for any pipe rack operation.

NOTE: Pipe rack operation also requires the rotary head assembly to be above the pipe racks before operation is allowed.

HOIST BRAKE SWITCH The hoist brake switch is a two-position switch used to set or release the hoist brake. This switch must be in the RELEASE position before the hoist/pulldown drive is allowed to move the mast machinery. Placing the switch into the SET position during the machine operation immediately disables hoist/pulldown drive operation.

Under normal operating conditions, the hoist/pulldown speed rheostat should be set to “OFF” before setting the brake.

NOTE: Applying the hoist brake is a spring action. After the HOIST BRAKE switch is turned to the SET position, the brake coil is de-energized allowing the springs in the brake to apply force to the brake discs.

When releasing the hoist brake, the brake coil is energized; compressing the springs, which release pressure on the brake discs.

MAIN AIR VALVE SWITCH This two-position switch is used to control the butterfly valve on the air compressor’s discharge line. The operating mode switch must be in the DRILL position (in other modes it defaults to the closed position).

OPEN - Opens the butterfly valve.

CLOSE - Closes the butterfly valve and causes the air compressor to run unloaded.

DEPTH INDICATOR RESET PUSH-BUTTON The depth indicator reset push-button is used to zero out the depth meter, as shown on the operator’s display monitor, when one hole is completed and another is to be started.

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2-11 Operation Section MD6640 Blasthole Drill

BI006893 EMERGENCY STOP PUSH-BUTTON

The emergency stop push-button on the left control console is a large red mushroom head pushbutton switch. Pressing the emergency stop push-button will shut-down the air compressor, hydraulic systems and shut-off all controls. It will also simultaneously provide immediate mechanical braking.

This button should only be used in emergency situations.

CAUTION:

PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

BIT VIEW HATCH SWITCH This two-position switch is used to move the hatch for viewing the drill bit on the ground. Moving the switch to the CLOSE position will close the hatch. Turning the switch to the OPEN position will open the hatch.

LEFT JOYSTICK (DUAL FUNCTION) - PROPEL TRACK / WINCH NOTE: A neutral lock is provided to prevent accidental movement of the joystick. The joystick automatically returns to neutral and the lock is engaged anytime that the joystick is released. To enable movement of the joystick, lift up on the lock (located below the joystick knob). Speed of operation increases as the joystick’s position is deflected farther away from neutral.

LEFT TRACK PROPEL - Use to control the propel speed and direction for the left track when the OPERATING MODE switch is at the PROPEL position.

NOTE:

The propel brake must be released, the jacks fully retracted, the boarding stairs up.

1.

PUSH the joystick away from you to propel the left track forward.

2.

PULL the joystick toward you to propel the left track in reverse.

WINCH - Use to control the winch hoist/lowering speed, along with the direction of travel when the OPERATING MODE switch is in the MAST/WINCH position.

1.

PUSH the joystick away from you to hoist or raise the winch hook.

2.

PULL the joystick toward you to lower the winch hook.

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2-12 Operation Section MD6640 Blasthole Drill

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ROTARY DRIVE SPEED SELECTOR SWITCH The rotary speed selector switch is a three position switch located above the rotary rheostat. This switch determines the speed/torque range of the rotary motor. In the LOW position, the motor has the highest torque capability but is limited in speed to about 85-100 RPM at the bit. In the HIGH position, the motor has a higher speed capability (110-140 RPM range) but motor torque will be less (typically 68% to 74%). The MEDIUM position provides for operation between the HIGH and LOW positions.

The switch should be set to the range that most closely matches the desired bit speed range. The LOW setting is sufficient for most conditions. If more speed is desired, select the desired range as needed.

HOIST/PULLDOWN RHEOSTAT The hoist/pulldown rheostat controls the speed and direction of the hoist-pulldown motor for hoisting or lowering the rotary drive unit.

Turning the rheostat in the hoist direction from the “0” position will raise the rotary drive unit.

Maximum speed is available at full clockwise position.

Turning the rheostat in the pulldown direction from the “0” position will lower the rotary drive unit.

Maximum speed is available at full counterclockwise position.

NOTE: The rheostat utilizes a reference scale and pointer. When the rheostat is turned, the pointer indicates, on the reference scale, the relative percentage of full speed being set.

The panels with controls as shown on the following pages are typical of what could be included on a console.

DUST CONTROL ON/OFF SWITCH — OPTION The dust collector switch is a two position switch used to start the fan on the dust collector hopper.

When the switch is in the OFF position, it will shut the dust collector fan motor off.

DUST CURTAIN SWITCH — OPTION The dust curtain switch is a two-position switch. Turning the switch to the UP position will raise the dust curtains. Turning it to the LOWER position will lower the dust curtains.

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BI006893 DUST CONTROL FLOW CONTROL — OPTION This switch is not used on this application.

UNDER DECK SPRAYERS — OPTION This switch is not used on this application.

2-13 Operation Section MD6640 Blasthole Drill

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2-14 Operation Section MD6640 Blasthole Drill

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RIGHT CONTROL CONSOLE

RIGHT CONTROL CONSOLE - OVERVIEW

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2-15 Operation Section MD6640 Blasthole Drill

BI006893 PIPE POSITIONER SWITCH

The pipe positioner switch is a three-position spring-return switch. Turning the switch to the OVER HOLE position will retract the positioner alignment cylinders. When fully retracted it will then extend the positioner jaw cylinder to clamp the drill pipe. Turning the switch to the STORE position will retract the jaw cylinder, then extend the positioner alignment cylinders to the stored position.

RIGHT JOYSTICK (TRIPLE FUNCTION) - PROPEL TRACK / PIPE RACK / MAST NOTE: A neutral lock is provided to prevent accidental movement of the joystick. The neutral lock must be released for this joystick control to function. The joystick automatically returns to neutral and the lock is engaged anytime that the joystick is released. To enable movement of the joystick, lift up on the lock located below the joystick knob.

Speed of operation increases as the joystick is displaced farther away from the neutral (center) position.

PROPEL - Use to assign the propel speed and direction for the right track when the OPERATING MODE switch is in the PROPEL position.

NOTE:

The propel brake must be released, the jacks fully retracted, the boarding stairs up.

1.

PUSH the joystick away from you to propel the right track forward.

2.

PULL the joystick toward you to propel the right track in reverse.

PIPE RACK - Use to manually control the pipe rack overhole and stored functions when the OPERATING MODE switch is in the DRILL position.

1.

PUSH the joystick away from you to extend the pipe rack toward the overhole position.

2.

PULL the joystick toward you to retract the pipe rack toward the stored position.

MAST - Use to control the mast raising and lowering functions when the OPERATING MODE switch is in the MAST/WINCH position.

1.

PUSH the joystick away from you to raise the mast.

2.

PULL the joystick toward you to lower the mast.

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2-16 Operation Section MD6640 Blasthole Drill

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ROTARY SPEED POTENTIOMETER The rotary speed potentiometer is used to control the speed and direction of the rotary drive motors.

The OPERATING MODE switch must be in the DRILL position for this control to function.

NOTE: Speed of operation increases as the potentiometer knob is rotated from OFF toward MAXIMUM in either direction. Maximum obtainable speed is determined by the position of the ROTARY DRIVE SPEED RANGE switch.

Rotate the knob clockwise from OFF toward MAXIMUM to rotate the tool string clockwise.

Rotate the knob counterclockwise from OFF toward MAXIMUM to rotate the tool string counterclockwise.

DUST SEAL SLIDER SWITCH This is a three-position spring-return switch which is used to initiate movement of the drill deck dust seal. Turning the switch to the REAR position will cause the dust seal mechanism to move toward the rear of the machine. Turning the switch to the FRONT position will cause the dust seal mechanism to move toward the front of the machine. This switch is functional whenever the hydraulic pumps are running, and is only used on machines with the angle hole drilling package.

PROPEL SPEED RANGE SELECTOR SWITCH This two-position switch is used to set the propel speed. In the LOW position, the propel is in a low speed range (about 35% of maximum). This position is used when maneuvering in tight spots and in drilling patterns. NORMAL position is used when moving from one site to another.

HORN PUSH-BUTTON The horn push-button is used to sound the warning horn of the machine.

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2-17 Operation Section MD6640 Blasthole Drill

TOOL WRENCH SWITCH This three-position, spring-return-to-center-OFF switch is used to control the tool wrench functions.

Turning and holding the switch in the EXTEND position will cause the tool wrench to extend to engage the drill pipe. Turning and holding the switch in the RETRACT position will retract the wrench, releasing the drill pipe.

Allowing the switch to spring-return to the center OFF position stops the motion of the tool wrench from any position in its normal range of motion.

BREAKOUT WRENCH SWITCH This three-position, spring-return-to-center-OFF switch is used to operate the Breakout wrench cylinder. The pipe rack must be in the stored position for this switch to function.

Turning and holding the switch in the EXTEND position will cause the breakout wrench to extend to clamp the drill pipe and break the made up joint. Turning and holding the switch in the RETRACT position will cause the tool to open, release the drill pipe, and retract the wrench.

Allowing the switch to spring return to the center OFF position stops the motion of the breakout wrench cylinder from any position in its normal range or motion.

NOTE: The breakout wrench must be in the fully-retracted position before raising the pipe handling arm.

PIPE RACK SELECTOR SWITCH The pipe rack selector switch is a four-position switch used to determine which pipe rack will be operated. For machines without a pipe rack or with only one pipe rack, this switch is not used.

BIT CAROUSEL SWITCH This switch is not used on this application.

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2-18 Operation Section MD6640 Blasthole Drill

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LEVELING JACK CONTROL SWITCHES The three toggle switches are used to manually raise or lower the leveling jacks.

AUTO LEVEL SWITCH The automatic leveling switch is a three-position spring return switch. Pressing the switch to the EXTEND position will extend the leveling jack cylinders and raise the machine. Pressing the switch to the RETRACT position will retract the cylinders and lower the machine. When this switch is being used, manual leveling toggle switches are not functional.

NOTE: The automatic leveling switch is a spring-return switch. The switch must be held until the desired action of the leveling jacks has been achieved. Releasing the switch will allow it to return to the neutral position but the jacks will remain in the position to which they were moved.

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BI006893 AUXILIARY CONTROL CONSOLE

AUXILIARY CONTROL CONSOLE

EXTERIOR LIGHTS The two position switch is used to turn the exterior lights ON and OFF.

TRAIL CABLE TRIP PUSH-BUTTON The large mushroom head push-button is used to completely cut power to the entire machine.

Pressing the TRAIL CABLE TRIP button will disable power to the drill from its source.

CAUTION:

PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

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FLOOR DEFROST SWITCH The floor defrost switch is a two-position switch used to turn the heater ON or OFF.

HEATER / VENT / AIR CONDITIONER CONTROLS The heater/vent/air conditioner controls consist of three controls.

The HVAC control switch selects the mode being used and has the following positions: OFF, FAN, HEAT, and COOL. A temperature rheostat is used to adjust cab air temperature.

The fan speed switch controls air circulation. The three positions are: OFF, LOW and HIGH.

BOARDING STAIRS SWITCH The boarding stairs switch is a two-position switch. A similar switch is located at the stairs. Depending upon the position of the stairs, the switch must be moved from its present position to the opposite position for the stairs to change position.

RADIO / CASSETTE PLAYER The AM/FM radio receiver includes a stereo cassette player.

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BI006893 OPERATOR’S DISPLAY

The operator’s display provides the operator with an interface to the machine and it’s functional areas. From this informational display, the operator can make inputs that effect machine operation, monitor systems and make system adjustments. Through this display terminal the operator will receive pertinent fault data to identify potential problems and prevent machine damage.

OPERATOR’S DISPLAY MONITOR

Refer to a separate manual for further operational procedures for the Operator’s Display Monitor.

The display monitor is mounted on a tilt-swivel bracket on the left control console. Individual operators can position the screen in any desired position.

DISPLAY AREA & INDICATORS The display area of the monitor screen is the large area in the center of the screen. This area is “touch sensitive.” All information will be displayed on this area either in a text format or in the form of visual icons. The buttons and icons that appear on the screen will respond to touching the screen in the appropriate area of the icon.

These icons and buttons will react by activating the screen, switch activation or display information relevant to the icon. The switches and buttons will be covered in the following pages under the screen topic in which they appear.

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The indicators on the lower portion of the screen area are indicators and sensors, which indicate functionality of the operator display and it’s interface with the machine’s PLC controller. They have no effect on machine operational use.

All of the machine controls can be found on the Operator’s Display Panel touch sensitive screen or the left and right Control Consoles of the operator’s seat.

DISPLAY SCREENS The information provided in the central area of the title screen is machine specific and lists the machine serial number and a copyright notice relating to the control and display software.

TITLE SCREEN

The Main Menu Icons appear at the bottom of all screens allowing quick navigation.

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LEVELING SCREEN

The Leveling Screen provides detail on the machine’s level and jack status.

STATUS SCREEN

The Status Screen is the primary operational information tool visible to the machine operator during daily use of this machine. The controls available on this screen will provide the operator with the information needed to view “at a glance” the status of items required for drilling, and make changes in control settings. The Status Screen is most commonly used during the drilling process.

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ACTIVE ALARM

The Active Alarm screen will provide a list of all active alarms and faults that have been initiated on the machine and have not been RESET. Once an alarm or fault has been sensed, these messages will remain visible and WILL NOT be removed from this screen until it is RESET.

STATUS SCREEN with Pop-up Ribbon

Any new alarms will pop-up automatically any time that a machine sensor detects a newly occurring fault or warning message.

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ALARM HISTORY

The Alarm History screen retains a chronological record of all alarms. This screen provides pertinent information; fault codes, date, time and a brief description for each account.

HELP NAVIGATION

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PLC DIAGNOSTICS

This screen provides access to PLC troubleshooting data screens. The status of all inputs and outputs on each of the primary remote I/O racks can be retrieved from this screen by pressing the node buttons on the left side of the display.

CALIBRATION and LIMITS

The Calibration and Limits screen is used to set most machine limits required to control the movements of the machine.

WARNING: When this screen is active, mast machinery limits are disabled.

Extreme care must be taken to prevent mechanical damage to the drill.

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OPERATING HOURS

The Operating Hours/Fault Counter screen provides the operator with information on the number of faults that have occurred since last RESET. It also provides the total operating hours.

FIELD TESTS

This screen is used for field testing of the electrical, hydraulic, and mechanical subsystems. The tests on this screen allow certain protective circuits to be bypassed for test purposes.

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MACHINERY HOUSE CONTROLS NOTE: The controls shown on the following illustrations are typical of the controls on a machine. Because of the variations of controls that can be supplied for customers needs, be sure to become acquainted with the controls on the cabinets of your machine. All controls will be identified with nameplates.

LIGHTING LOAD CENTER The lighting load center is located on the left side of the front wall of the machinery house.

The lighting load center contains the breakers to control the interior and exterior lights and various auxiliary functions.

LIGHTING LOAD CENTER

Each breaker is labeled as to its particular function on any particular machine.

The controls are three-position lever operated circuit breakers. Moving the lever in one direction (ON) will close the circuit, while moving it in the opposite direction (OFF) will open the circuit. The center position is the tripped position. The breaker may be reset by moving the lever to the OFF position and then back to the ON position.

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BI006893 CONTROLS LOCATED ON LOW VOLTAGE START CABINET

The low voltage start cabinet contains the breaker for the main compressor. Turning the breaker to the ON position will activate the compressor circuits, allowing the compressor to be started.

CONTROLS LOCATED ON LOW VOLTAGE CABINET The low voltage cabinet contains most of the breakers for the auxiliary equipment on the drill.

Because of the variations of equipment supplied on a particular drill, a list of typical controls which might appear on the cabinet is shown in figure.

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CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET The typical programmable controller cabinet contains controls as shown in figure.

TYPICAL PROGRAMMABLE CONTROL CABINET

HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS Typical controls on the Hoist/Pulldown and Rotary Drive Control cabinets are shown in the figure below.

TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS

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BI006893 MISCELLANEOUS CONTROLS

Located about the machine are various miscellaneous controls and monitors which would be used with optional equipment or do not fit in the previously described groups.

HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL The hydraulic reservoir remote fill control panel is used to monitor the reservoir as it is being filled.

The instructions for use of these controls are printed directly below the controls.

Hydraulic Reservoir Remote Fill Control Panel

PORTABLE REMOTE PROPEL STATION (Optional) The portable remote propel station is located in an enclosure under the operator’s cab on the right side of the machine. In addition to storing the portable station the enclosure includes 40 feet of cable and an enabling switch to energize or de-energize the station. Another enabling switch and plug in socket are located at the front right corner of the drill main frame. The station includes two joysticks, one for each crawler frame; an emergency stop push-button; a propel speed selector; and a red indicator which will light up when the station is energized.

PORTABLE REMOTE PROPEL STATION

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2-32 Operation Section MD6640 Blasthole Drill

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RADIO REMOTE PROPEL STATION (Optional)

The radio remote propel station is located in the operator’s cab. To enable the station, position the operating mode switch located on the left control console to Remote Propel. The station includes two joysticks, one for each crawler frame; an emergency stop push-button; function selector switches as described below; and an indicator which will light up when communication is established between the transmitter and the receiver. There is also an indicator light for the status of the e-stop and the battery charge.

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PRESTART CHECKS Before starting the drill, inspect it to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example, an undetected oil leak could result in a dry gear case, which would lead eventually to excessive gear wear or destruction, seized bearings, or other mechanical problems. A few minutes spent inspecting the machine often results in considerable savings in time and machine efficiency. This inspection should be performed before each shift.

EXTERNAL INSPECTION 1.

Check areas around and under the machine for signs of water or lubricant leaks. If single droplets of water or lubricant are noticed, leakage is minimal. Determine the source of the leak and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine the source and take remedial action immediately.

15

12

LH VIEW

RH VIEW

14

FRONT OF MACHINE

FRONT OF MACHINE

9

9 13

11

10

10

16

6

11

8

1 7

3

2

4

8

5

8

4

2

16

3

1 7

8

6 insp6640

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2-35 Operation Section MD6640 Blasthole Drill

2.

Inspect the crawler belts for broken or cracked pads, missing lock pins, loose track pins, and proper crawler belt tension.

3.

Check the drive tumbler gearcase, hydraulic motor and hoses for leaks. Check the lubricant level in the drive tumbler gearcase.

4.

Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and bolts.

5.

Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or covered with cuttings.

6.

Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp rocks. Have an electrician inspect the strain relief device and the condition of the cable where it enters the machine.

CAUTION:

The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with approved rubber gloves and insulated hooks or tongs.

7.

Inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or damage. If loose wires are noted, do not touch them but notify an electrician immediately.

8.

Inspect the leveling jack spuds for proper lubricant covering. Inspect the leveling jack pads for cracks, broken or missing pins, or excessive dirt accumulation.

9.

Inspect the mast braces and locking pins. Replace missing or defective components immediately. Verify that all adjusting bolts are properly adjusted. Check all hoses and cylinders for leaking.

CAUTION:

Use a safety belt and lanyard to protect against falls when climbing on the mast braces or working on the machinery house roof.

10.

Inspect the mast hinge pins for loose or missing keepers or bolts. Replace missing or damaged parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.

11.

Inspect the mast hoist cylinders for loose or missing pins or keepers, oil leaks, damaged hoses or structural damage. Repair or replace any missing or damaged components immediately.

12.

Inspect the mast structure for bent or broken chords or plates, loose or broken parts, proper rack lubrication or excessive rack wear. Inspect ladders, handrails and platforms for broken or missing parts. Repair or replace broken or missing parts immediately.

13.

Check the main air flex hose, lubrication lines, and electric lines running from the mast to the rotary drive/pulldown unit for interference with the mast or excessive wear or leaks.

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14.

Check the safety restraint cables on the mast. Be certain that the cables and supports are in good repair with no cracks, missing or loose hardware or any damage that could affect their effectiveness.

15.

Every 160 hours inspect the upper auxiliary winch sheaves. All pins, keepers and hardware should be secured.

16.

Check the machinery house air filtering fan duct to see that it is clear of obstructions.

17.

Inspect dust collector hoses for integrity.

ONBOARD INSPECTION 1.

Inspect the air compressor lubrication lines for leaks. Correct any leaks found immediately.

2.

Check the condition of the air compressor intake filter. Replace the filter cartridge if the red flag is visible in the service indicator. Empty the dust hopper and clean the pre-cleaner element.

Inspect the housing and ductwork for damage or leaks. Repair or replace leaking components.

3.

Check the oil level in the hydraulic tank. Fill the tank to the proper level as described on the instruction plate on the tank.

4.

Check hydraulic system for leaks. Correct all leaks immediately and clean up all oil spills immediately.

5.

If the machine is equipped with a bit lubricator for the main air system, check that the lubricator is full.

6.

Inspect the automatic lubrication central pumping stations for proper operation. Check the supply of lubricant; refill tank as necessary.

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BI006893 7.

Close and lock all electrical cabinet doors.

CAUTION:

Assume all parts inside of the electrical cabinets are energized. All electrical components should be serviced by qualified electrical personnel only.

8.

Inspect the compressor radiator and fan. Check for signs of deterioration or damage to hoses, valves, fittings, etc. Check for leaks at all joints. Check the radiator core for blockage by dust, dirt, leaves, paper, etc. and clean as necessary

9.

Check the operator’s display terminal for any faults.

10.

Inspect the machinery house for general cleanliness. Clean all dirt and debris from the machinery house.

CAUTION: Do not use compressed air to clean the machinery house.

Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the machine. Failure to clean the inside of the machinery house will cause damage to many of the components located there.

11.

Inspect the auxiliary winch and auxiliary winch line.

12.

Check the oil level in the pump drive gearbox. Fill with recommended oil to the proper level.

13.

Check all controls for free operation. Return all controls to the OFF or SET position.

14.

Inspect the operator’s cab for housekeeping and cleanliness. Clean dirt and debris from the cab. Clean the windows to give full visibility for proper operation.

CAUTION: Do not use compressed air to clean the operator’s cab. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the cab.

15.

Inspect the tool wrenches for free operation, broken or missing parts, proper lubrication, lubricant leaks or dirt accumulation. Repair or replace parts as necessary and clean the drilling platform.

CAUTION:

16.

Before working near or under the rotary drive/pulldown unit, make sure all of the operator’s controls are off and tagged and the hoist brake set to prevent movement of the unit. Serious personal injury or death could result should the rotary drive/pulldown unit fall when personnel are working near or under it.

Inspect the automatic breakout wrench for free operation, broken or missing parts, proper lubrication, lubricant leaks or excessive dirt accumulation. Repair or replace parts as necessary.

Be certain that the breakout wrench is retracted.

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17.

Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or lubricant leaks. Be certain that the upper gate is closed and that the rack is in the stored position.

18.

Inspect the guide bushing for excessive wear or dirt accumulation. Also inspect the retainer lugs to be sure they are intact. Do not operate the machine without both retainer lugs intact and securely welded to the deck.

19.

Inspect the tool string for excessive wear, dirt accumulation, bent pipe and secure joints. The bit cones and bearing should be in good condition. Manually turn the cones to make sure they turn freely.

20.

Inspect the rotary gear case for lubricant leaks, damaged lines, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearbox. Fill to the recommended level with an approved gear lubricant. Check the rotary motor ventilation inlets for leaves, paper, rags, etc. blocking the flow of air.

21.

Inspect the rotary drive unit for excessive wear or dirt accumulation. Inspect the guide rollers for proper adjustment and excessive wear. Check for loose or missing bolts and bent or cracked structural members.

22.

Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper adjustment and excessive wear.

23.

Inspect the pulldown gearcase for lubricant leaks, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearbox. Fill to recommended level with an approved gear lubricant . Check the pulldown motor ventilation inlets for leaves, papers, rags, etc. blocking the flow of air.

24.

Check the hoist brake for proper operation.

25.

Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation.

The deflector should seal around the drill pipe securely.

26.

If the machine is equipped with a fire suppression system, perform any applicable checks or inspection as described in the fire suppression system owner’s manual.

27.

If the machine is equipped with a dust collector system, inspect the filter dessicant color.

Change dessicant if required.

PRESTART LUBRICATION Lubrication is an extremely important job. Most drills come equipped with automatic lubrication systems that lubricate most of the necessary points at regular intervals. These systems, although automatic, are not foolproof. Broken lines, dirty lubricant, faulty feeders, and a whole range of other problems can cause wearing parts to loose lubrication. For this reason, it is important that all lubrication points be inspected every shift to verify that they are receiving lubrication. Also, there are several points for lubrication that either need lubrication very infrequently, or are not possible to pipe into the automatic system. These points will need lubrication applied manually.

The lube charts in Section 3 of this manual provide the location and frequency of lubrication.

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START-UP Start-up of the drill is not a difficult operation, but it is very important. Improper start-up could cause various safety and operating difficulties as well as damage to the machine. Following the step-bystep procedure listed below to start the machine will help reduce the possibility of accidental injury or machine damage.

MACHINE START UP NOTE: THE MACHINE IS TO BE STARTED ONLY AFTER THE PRESTART INSPECTION AND LUBRICATION AS DETAILED EARLIER IN THIS SECTION, HAVE BEEN COMPLETED. 1.

Go into the operator’s cab and verify that all controls on the operator’s console are in the off or neutral position. Be sure that the EMERGENCY STOP push-button is in the pulled-up position.

NOTE:

ON SOME MACHINES THERE ARE TWO OR MORE EMERGENCY STOP PUSHBUTTONS. BE SURE THESE PUSH-BUTTONS ARE IN THE PULLED-UP POSITION.

2.

Go to the machinery house to the low voltage start cabinet. Turn on the main compressor breaker.

3.

On the low voltage cabinet turn all the breakers to the ON position.

4.

On the programmable controller cabinet verify that the lockout control push-button is in the RELEASED position.

5.

Press the air compressor start push-button on the programmable controller cabinet to start the main compressor.

NOTE:

If the ambient temperature is below 32°F (0°C), the machine will normally use special fluids in the hydraulic system and/or heaters for the system.

When the machine is shutdown, temporarily or for an extended time, power should be left on the machine to maintain heater operation. If power is removed at shutdown, the machine fluids should be warmed to at least 32°F (0°C) before attempting to start the machine.

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MACHINERY CHECK The following is a list of points and equipment that should be checked for proper operation immediately following start-up of the drill. If operating difficulties are not found during this procedure, they probably will not be noticed until some point in time at which the system or component will cease to function and cause serious damage to the machine.

1.

Check the main air system for leaks.

2.

Verify that the air compressor radiator fan is operating correctly. Check the coolant system for leaks.

3.

Check for leaks in the hydraulic system.

BREAK-IN OF NEW COMPONENTS When a machine is new, is returned to service after a long period of storage, or is returned to service after major repairs, certain precautions must be taken upon initial start-up and for a time following the start-up. These precautions are necessary to insure that the full service life of the components is realized.

ROTARY DRIVE UNIT BREAK-IN Break-in of the rotary gear case is limited to reduced loading during the first 100 hours of operation and a complete oil change at the end of the break-in period.

This break-in period applies only to new gearcases or gearcases in which a new gear has been installed.

HOIST/PULLDOWN GEARCASE BREAK-IN Break-in for the hoist/pulldown gearcase is limited to reduced loading during the first 100 hours of operation and a complete oil change at the end of the break-in period.

The break-in period applies only to new gearcase or gearcases in which a new gear has been installed.

ELECTRIC MOTOR BREAK-IN Break-in of the rotary and hoist/pulldown motors is limited to reduced loading and inspection for the first 8 hours of operation. This break-in period is intended to spot any problems in the motors before

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2-41 Operation Section MD6640 Blasthole Drill

they lead to serious damage to the motors or the machine. Inspection should include monitoring the motor temperature and listening for unusual noises which might indicate a problem. Inspection should also include verifying that all blower vents and intake openings are open.

OPERATION Operation of this machine is the same as the operation of any other drill. But just because the machines operate the same in principle does not mean they operate the same in all respects. For this reason it is important that the operator becomes familiar with the particular machine that is being operated.

The purpose of this section of the operator’s manual is to detail the procedures involved in operating many of the major components and preparing to drill a hole. The actual drilling procedure is detailed later within this section.

Become familiar with the controls and learn to operate at reduced speeds. As the machine and drilling cycle become more familiar, increase speeds gradually to the full operating capability of the machine.

The most important reason to operate slowly at first is safety. Operating at full speed means that things happen quickly, perhaps more quickly than expected. This unexpected operation of equipment can very easily lead to an accident.

For the purpose of this manual, we will assume that the drill has been left in the proper condition for operating. If this is not the case, complete the prestart checks and start the machine using the procedures as outlined.

PROPELLING

DEFINITIONS “Listing” is a machine geometry condition which can occur on vehicles which have a pivotal axle and a fixed axle. It is that condition when the upper works is tilting over onto the pivotal axle, lifting one side of the fixed axle.

“Tipping” is defined as the point of impending overturning. A machine can tip to the rear without listing first. Under all other conditions, the machine will “list” before tipping.

“Maneuvering slope” is the grade on which the machine can be propelled in any direction without listing or tipping.

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PROPEL PROCEDURE Before beginning the propel operation, the operator should first inspect the travel route for large rocks, deep ruts, or uneven contours. When working on a grade, verify the slope and compare to the allowable maneuvering slope limits at the end of this section.

CAUTION:

Do not attempt to maneuver or steer the machine on grades which exceed the allowable maneuvering slopes without consulting the special propel section. Failure to follow these instructions could result in a machine tip-over, damaging the equipment and resulting in possible serious injury or death.

The operator’s display terminal leveling/propel screen should be monitored during propel to make sure the allowable machine stability limits are not exceeded.

Once it has been verified that the travel route is in good condition, the machine is now ready to propel.

NOTE: This machine should only be propelled long distances with the mast fully lowered, fully raised and locked, or locked at an ANGLE HOLE setting.

For long propels of 1,000 feet (304.8 meters) or more, or if the machine is to be propelled over grades which approach the allowable stability limits, the tool string should be disassembled, the rotary drive unit lowered, and the mast lowered. This achieves the most STABLE condition for a machine against tipping and also reduces stresses in the mast structure.

For long propels of 1,000 feet (304.8 meters) or more, the temperature of the undercarriage components should be monitored. The lower rollers, take-up tumblers and propel planetaries should operate below 95 degrees C. The propel motor should operate below 90 degrees C. If these temperature limits are reached, stop the machine and allow the track components to cool down.

Note that propelling in low speed reduces the heat build up in these components.

If while propelling with the MAST-DOWN and the HEAD-DOWN the drill starts to list, it will continue to list until the upper works contacts the pivotal axle. The machine will reach equilibrium when the upper works contacts the pivotal axle and WILL NOT TIP OVER. With the mast-down and the head-down, full listing will NOT cause the machine to tip over. The operator should attempt to propel toward a more level area on the bench to correct this condition.

All of the stability values shown are based on a fully loaded machine (i.e. full water tank, cable on cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by the Customer and shipped by manufacturer.

This machine is propelled using the controls on the operator’s console in the operator’s cab or radio controlled from the remote propel station outside the machine.

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BI006893 1.

Verify that the hoist brake is set. Verify that the tool string is clamped with the tool wrenches to prevent the tools from moving during the propel operation. Also, verify that the tool string is hoisted to a position to avoid striking the ground when the machine is propelled. Verify that the leveling jacks are fully retracted and that the dust curtains are fully raised. Verify that the boarding stair is raised.

2.

Move the operating mode selector switch to PROPEL or REMOTE PROPEL. The remote propel is radio controlled.

3.

Press the drill/propel control ON push-button. The automatic leveling/propel screen will appear on the operator’s display terminal. If the propelling is being done from the remote propel station, turn the enabling key switch to the ENABLE position.

4.

At the control console or remote propel station, turn the propel selector switch to the SLOW SPEED position.

NOTE: There are two propel speeds available to the operator, SLOW SPEED (MAX = 0.27 MPH; 0.44 KM/H) and NORMAL (MAX = 0.9 MPH; 1.45 KM/H). For the inexperienced operator or for maneuvering in tight spots and in drill patterns, the SLOW SPEED setting allows for a more relaxed control operation.

When the operator becomes more proficient or when moving from one site to another, the increased speed of normal propel is used.

5.

To propel straight forward lift up on both joysticks to unlatch them and release the propel brakes, then move both joysticks slowly forward. Speed is increased as the levers are moved forward. To propel straight in reverse pull both joysticks slowly to the rear. Speed is increased as the levers are pulled.

STRAIGHT PROPEL - FORWARD OR REVERSE

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6.

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To make a gradual forward right turn, leave the right joystick in neutral and operate the left joystick forward.

GRADUAL RIGHT HAND TURN

GRADUAL LEFT HAND TURN

7.

To make a gradual forward left turn, leave the left joystick in neutral and operate the right joystick forward.

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BI006893 8.

Gradual turns should be done in steps of 15 degrees each. After turning the machine a maximum of 15 degrees, the machine should be propelled straight for about one-half of the length of the machine to clear the crawler belts of dirt and rocks. Turning the drill in more than 15 degree increments will subject the crawler belts to severe strain.

COUNTER-ROTATION LEFT HAND TURN

9.

To make a sharp counter-rotation turn, push the left joystick forward and pull the right joystick to the rear. To make a turn to the left, push the right joystick forward and pull the left joystick to the rear.

ENSURE GRADUAL TURNS ARE MADE - 15° INCREMENTS

CAUTION:

ENSURE THAT THE TURN IS STOPPED EVERY 15 DEGREES AND THAT THE MACHINE IS PROPELLED FORWARD, OR REARWARD, AT LEAST TEN FEET PRIOR TO RESUMING THE TURN. MAKING GRADUAL TURNS WILL GREATLY EXTEND THE SERVICE LIFE OF THE TRACKS.

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NOTE: When using the counter-rotation method for turning, have a helper available who can watch that the trail cable does not get fouled and/or torn from the main junction box or cable reel.

NOTE: The ability of the machine to counter rotate is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig in and machine to bog down.

NOTE: The propel brakes are released whenever either joystick is lifted from its mechanical neutral detent. The propel brakes are set when both joysticks are returned to their neutral detent and released.

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BI006893 TOWING PROCEDURE CAUTION:

Be sure crawlers are securely blocked before disengaging gearbox clutch for towing.

1.

Secure the machine by blocking crawlers.

2.

Secure the tow bar to the towing vehicle.

TOWING PROCEDURE

3.

Fasten a lanyard to the towing safety valve lever. The valve is mounted to the left front jack casing. Run the lanyard down the casing, along the tow bar and secure it to the towing vehicle. If during towing the tow bar should come loose from either the drill or the towing vehicle, the lanyard will trip the safety valve and set the drill propel brakes.

4.

Disconnect the drive tumbler gearbox from the propel motor as follows: a.

Ensure that the propel pump controls are in neutral position

b.

Loosen shifter lever lock screw

c.

Pull out shifter lever to disengage clutch

d.

Tighten shifter lever lock screw

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2-48 Operation Section MD6640 Blasthole Drill

5.

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Use the hand pump mounted to the right front jack casing. Pump the jack until 650 PSI (4,482 kPa) shows on the gauge near the pump.

NOTE: Anytime pressure drops below 500 PSI (3,450 kPa), brakes could drag resulting in premature brake failure.

NOTE: Do not tow at speeds greater than 0.9 mph (1.45 kph) Excessive planetary gearbox heating can occur.

6.

When towing is completed, reverse the above procedure. The hand pump pressure can be released by turning the release valve on the pump.

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2-49 Operation Section MD6640 Blasthole Drill

CABLE REEL OPERATION When the cable reel switch is in the AUTO position, is designed to pick up trail cable as the drill moves toward its power source. It is not designed to drag the trail cable over the ground.

The line pull is proportional to operating pressure. The correct line pull is when there is sufficient pull on the cable to wind it on the reel, but not too great to put unnecessary strain on the trail cable.

The line speed is dependent on the volume of hydraulic oil flowing through the system. The correct line speed is slightly faster than the travel speed of the drill.

To manually operate the cable reel, proceed as follows:

1.

Start the main air compressor motor.

2.

To spool the trail cable onto the reel, turn the cable reel switch to the REEL IN position.

3.

To spool the trail cable off of the reel, turn the cable reel switch to the REEL OUT position.

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2-50 Operation Section MD6640 Blasthole Drill

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LEVELING To level the drill, proceed as follows: 1.

Place the machine in the proper location to drill the required hole. Verify that the leveling jack pads will rest on solid footing. Cut or fill or reposition as necessary to achieve solid footing. Maximum angle for jack pad is 17°.

2.

The operating mode selector switch must be in the DRILL position and the main air compressor motor must be energized.

NOTE: Normally the machine will be leveled using the automatic leveling switch, Step 3. For manual leveling use Step 4 through 7.

3. To level the machine automatically verify that the operating mode selector switch is in the drill mode, then turn the automatic leveling switch to the EXTEND position and hold the switch in that position. The Automatic Leveling/ Propel screen will come on automatically on the operator’s display terminal. Use the screen to monitor the drill as it is being leveled. The jack cylinders will extend and raise and level the machine. When the machine is raised and leveled, release the switch and it will spring return to the CENTER or OFF position. This procedure can be performed by the operator while he is seated at the main operator’s console.

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To level the machine manually, use the three jack switches and the automatic leveling screen on the operator’s display terminal. The operator uses control switches on the right-hand console and observes the operator’s display screen.

5.

Lower all four leveling jacks until they are resting on the ground. Then, starting with the low side (left or right) of the drill, slowly lower the jacks until the weight of the machine is resting on them. The leveling jack controls should be operated in pairs while doing this operation. This reduces the twisting of the drill frame. Once the weight of the machine is resting on the downhill side leveling jacks, slowly lower the uphill side leveling jacks until the machine weight is resting on them. The machine need not be raised a great deal during this operation, since the purpose is only to get the weight of the machine resting on the leveling jacks.

CAUTION:

During this and subsequent leveling procedures, it is important that the drill stays as close to level as possible. Care should be taken especially when working on steep grades.

6.

Once the machine weight is resting on the leveling jacks, the machine may be leveled. Starting with the downhill side of the machine, lower the two side leveling jacks to bring the machine into side-to-side level as observed on the operator’s display terminal screen. Then, once the machine is level from side-to-side, operate the leveling jack controls for the downhill end of the machine to bring the machine into level end-to-end as observed on the operator’s display terminal screen.

7.

Once the machine is level, make sure that the weight of the machine is off of the crawlers.

The preferred method of doing this is to raise the machine until the closest point of the lower rollers to the crawler belts is 2" to 7" (5.1 to 17.8 cm). This assures that the machine is resting on the leveling jacks while maintaining a low center of gravity.

MAST RAISING AND LOWERING The mast on this machine is normally left in the raised position for most situations including propelling from hole to hole on a blast pattern. Lowering the mast is necessary under three conditions: 1.

Maintenance work is not possible or too dangerous to perform with the mast up.

2.

Long moves over 1,000 feet (304 m) where the drill will be towed into position, propelled at high speed, or be loaded onto a trailer.

3.

Any situation when steep slopes are encountered. Contact Caterpillar Global Mining Service Department if unsure of slope limitation for propelling.

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2-52 Operation Section MD6640 Blasthole Drill

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MAST RAISING

CAUTION:

Raising or lowering the mast is a two-person job. Do not attempt to raise or lower the mast without the assistance of a helper familiar with the procedures involved.

CAUTION:

During the mast raising procedure personnel should be kept clear of the machine and the area immediately surrounding the machine, especially the front of the machine. No one is to be allowed on the mast, operator’s cab roof, or machinery house roof while the mast is in the air. Failure to heed this caution may result in the death or serious injury of personnel struck by the mast should it fall for some reason.

CAUTION:

Limitations exist as to the length, diameter, wall thickness and number of drill pipes that may be stored in the pipe racks when raising or lowering the mast. Refer to the pipe size limitation chart in the appendix before attempting to raise or lower the mast. Failure to comply with these limitations will overload the mast, mast support and hydraulic system possibly causing loss of control of the mast.

1.

Inspect the mast and machine exterior to ensure that all wires, hoses, cables, etc. are clear of the machine to prevent damage to the machine or equipment during the raising procedure.

Check that the mast cylinder pins, mast hinge pins, and mast brace pins are in place and secured. Verify on the operator’s display terminal operator’s display screen that no reference to A-frame pins is shown. Verify that the operating mode selector switch is in the DRILL mode.

2.

The main air compressor motor must be energized. Move the operation selector switch to the MAST/WINCH position. Slowly raise the mast by lifting and then slowly pushing the mast joystick, located on the right control console, forward. As the mast reaches an angle of 70 degrees it will begin to go over center and tend to come into the vertical position by itself.

Care should be used once the mast has gone over center since the speed of the mast will increase sharply.

CAUTION:

The mast joystick should be moved away from and returned to the neutral position very slowly. Sudden starts and stops can be damaging to the mast and hydraulic system. Be extremely cautious as the mast approaches 70 degrees as once the mast goes over center only a very slight movement of the joystick is necessary to cause motion in the mast.

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NOTE: Pay close attention to the hoses, wires and cables that run between the mast support and the mast to prevent damage to the machine as the mast is being raised. Have a helper watch from a safe position on the left side of the machine as the mast is going up.

3.

Once the mast is vertical, move the mast lock switch located on the mast screen on the operator’s display to the LOCK position to lock the mast in the vertical position. Mast Pins Locked light on operator’s display screen will illuminate when mast is locked in position. Turn the mast brace lock switch to the LOCKED position to secure the mast and brace in the vertical position.

NOTE: When moving the mast for angle hole drilling, on machines with mast lengths of 65 ft (19.8 m) or more, the drill pipe must be stored in the racks and the rotary head lowered to its lowest position.

4.

If the mast is to be set up for angle drilling move the A-frame lock switch and the mast brace lock switch to the UNLOCK position to release the A-frame front leg lock pin and mast brace lock pins. The readout (A-Frame Pins Unlocked and Mast Brace Pin Unlocked) will show up on the mast status screen on operator’s display screen.

MAST STATUS SCREEN

5.

Verify that the operation mode selector switch is still in the mast/winch position, then lift and pull the mast joystick slowly to the rear. Slowly lower the mast to the desired drilling angle, then turn the mast brace lock switch to the LOCKED position to secure the mast and brace in the desired position.

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MAST LOWERING NOTE: Refer to cautions at beginning of mast raising.

To lower the mast:

1.

Level the machine.

2.

Remove the drill pipe from the rotary drive unit and store it in the pipe racks. Remove the bit and stabilizer from the machine. Clear the drill deck of all tools and materials which could fall off during the lowering procedure. Secure the auxiliary winch hook. Be sure the auxiliary winch line is secured to the mast. Raise the dust curtains. Lower the rotary/pulldown unit to its lowest position.

3.

Check the condition of the mast hinge pins, lugs and cylinder pins.

4.

If the machine is set up for angle drilling and the mast is at an angle proceed to step 4. If the machine is set up for vertical drilling proceed to step 5.

5.

Turn the mast brace lock switch to the UNLOCK position to release the mast lock pins, then raise the mast to the vertical position. Turn the A-frame lock switch to the LOCK position to lock the A-frame front leg. The readout (A-Frame Pins Locked) on the operator’s display will appear when the A-frame pins are in the LOCKED position. Now proceed to step 5 to lower the mast.

6.

If the mast lock pins and/or mast brace lock switch have not been released, turn the switches to the UNLOCK position to release the pins. The readout (Mast Pins Unlocked and Mast Brace Pins Unlocked) will be shown on the operator’s display when the pins are released.

7.

Slowly lower the mast by lifting and then pulling the joystick to the rear. As the mast moves away from the vertical position, its speed will increase. Gently reduce the lowering speed by moving the joystick toward neutral.

CAUTION:

The joystick should be moved away from and returned to the neutral position very slowly. Sudden starts and stops can be damaging to the mast hydraulic system. Be extremely cautious as the mast approaches the mast rests, as only a slight movement of the control is necessary to cause motion in the mast. Lay the mast in the mast rests gently to prevent damage to the mast or machine house.

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2-55 Operation Section MD6640 Blasthole Drill

NOTE: Pay close attention to the hoses, wires and cables that run between the mast support and the mast to prevent damage to the machine as the mast is being lowered. Have the helper observe the machine from a safe position on the left side of the machine as the mast is coming down.

NOTE: Do not allow the mast, especially if near horizontal to lower too quickly. Damage may result from the mast hitting the mast rests too hard.

8.

Once the mast is resting in the mast rests, inspect the mast and the mast support to verify that no hoses, wires or cables are kinked or damaged. Repair any damages found immediately.

PULLDOWN MACHINERY OPERATION Use of the pulldown machinery is necessary during the tool handling and the drilling procedures.

The pulldown machinery supplies power to either raise or lower the rotary/pulldown unit. Power is supplied to the pulldown gearbox by an electric motor.

To operate the hoist/pulldown machinery proceed as follows;

1.

Move the operating mode selector switch to the DRILL position.

2.

Turn the hoist/pulldown selector switch to either PULLDOWN, HOIST HIGH, HOIST LOW, or PIPE RACK/JOINT.

For this procedure, turn the switch to the PULLDOWN position.

For a review of each switch position, refer to HOIST/PULLDOWN SPEED SELECTOR SWITCH. 3.

Press the drill/propel control ON push-button. The Control Enable indicator will show on the operator’s display screen.

4.

Turn the hoist brake switch to the RELEASE position. The Head Brake Released indicator will appear on operator’s display screen.

5.

Rotate the hoist/pulldown rheostat in the hoist direction to hoist the rotary/pulldown unit. The farther the rheostat is turned to the right the faster the unit will be raised.

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6.

Rotate the pulldown force rheostat in the pulldown direction to lower the rotary/pulldown unit.

The farther the rheostat is turned to the left the faster the unit will be lowered.

7.

When the hoist/pulldown operations are complete, set the hoist/pulldown speed rheostat to the OFF position and then turn the hoist brake switch to the SET position.

CAUTION:

Whenever the hoist/pulldown speed rheostat is in the OFF position, the hoist brake switch must be in the SET position to prevent the rotary/pulldown unit from creeping downward due to the weight of the unit.

AUXILIARY WINCH OPERATION To operate the auxiliary winch proceed as follows: 1.

Place the operation mode selector switch in the MAST/WINCH position.

2.

To hoist the auxiliary winch line, lift and move the winch joystick, located on the right console, forward. To stop the line, return the joystick to the NEUTRAL position.

3.

To lower the winch line, lift and move the joystick rearward. To stop the line, return the joystick to the NEUTRAL position.

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PIPE RACK OPERATION

The machine can be equipped with 1 to 4 pipe racks and depending upon the number of pipe racks the pipe rack configuration and operation will be different.

On a machines with one pipe rack, the rack will be on a swing out arm and will be in #1 position .

On a machine with two pipe racks, the racks will be on swing out arms and will be in #1 and #4 positions.

On a machine with three pipe racks, two pipe racks will be located on a carousel that swings out and then is rotated. This carousel houses pipe racks in #1 and #2 positions as shown. The third pipe rack is a swing out rack that will be in #4 position.

On a machine with four pipe racks, there are two swing out carousels with two racks in each carousel. The carousels rotate to make each rack available for use. The left carousel houses racks #1 and #2 and the right carousel racks #3 and #4.

The general method of operating the pipe racks is as follows:

1.

Place the operating mode selector switch in the DRILL position. The main air compressor must be energized.

2.

Verify that the operating mode selector switch is in the DRILL position and that the hoist/ pulldown speed selector switch is in the PIPE RACK/JOINT position.

3.

Select the desired pipe rack.

4.

Lift and move the pipe rack joystick, located on the left console, out of neutral to perform the desired operation.

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PIPE RACK OPERATION

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The following special sequence is required for each pipe rack configuration.

1.

2.

One pipe rack configuration.

Turn the pipe rack selector switch to the #1 position.

b.

Operate the rack as described under general procedure.

Two pipe rack configuration.

NOTE:

3.

a.

a.

If the first pipe rack is to be operated place the selector switch #1 position and operate the rack as described under general procedure.

b.

If the second pipe rack is to be operated place the selector switch in the #4 position and operate the rack as described under general procedure.

Take extra care to insure that one pipe rack is out of the way and locked in place before operating the second pipe rack.

Three pipe rack configuration. a.

The first and second pipe racks are part of a carousel and require a special operating sequence. The third pipe rack is a standard swing out rack.

To operate the third pipe rack place the selector switch in the #4 position and operate the rack as described under general procedure. b.

The carousel configuration of pipe racks one and two requires a special sequence.

Position #1 of the selector switch will allow, when the joystick is pulled to the rear, the carousel with pipe racks to be swung out over the guide bushing hole.

One of the pipe racks will be over the hole. Position #2 of the selector switch will allow, when the joystick is pulled to the rear or pushed forward, the carousel to rotate to move the other pipe rack over the hole. Returning the selector switch to position #1 and moving the joystick forward will return the carousel to the stored position. c.

Because of the sequence of operation pipes must be removed from pipe rack #1 first and then pipe rack #2. When returning the pipes to the racks return pipe to #2 pipe rack, then #1 pipe rack.

NOTE: Take care to insure that one pipe rack is out of the way and locked in place before operating the other pipe rack.

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4.

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Four pipe rack configuration. a.

The four pipe rack configuration consists of two swing out carousels with two pipe racks to each carousel. Pipe racks #1 and #2 in the left carousel and pipe racks #3 and #4 in the right carousel work and are sequenced the same as the carousel in the three pipe rack configuration. For pipe rack #3 and #4, the #4 position of the selector switch controls the swing out of the right carousel and the #3 position controls the rotation of the carousel.

b.

Because of the sequence of operation, pipe must be removed from pipe rack #4 first, then pipe rack #3. When returning the pipes to the racks, return pipe to #3 pipe rack, then #4 pipe rack.

TOOL HANDLING This section describes the procedures necessary to load, unload, handle, assemble and disassemble the drill tools.

The procedures detailed in this section are intended to be as universally applicable as possible. It is, however, impossible to prepare a procedure that will take into account every possible machine option or tool vendors’ products. For this reason it is important that the operator not only become familiar with these procedures, but with the machine and the particular tools being handled.

PIPE LOADING AND UNLOADING Loading pipe onto the drill is necessary when the drill is new and has not yet had the pipe installed or when the pipe has been removed for changeout or for maintenance to the mast. The procedure in this manual, unlike some more commonly used procedures, requires that the mast be in the horizontal or lowered position to load the drill pipe. This is necessary for safety.

This procedure, while not the most expedient for machines requiring pipe changeout while the mast is in the drilling position, is quite efficient while the mast is in the stored position. Proper scheduling of maintenance and production requirements against pipe life will allow using this procedure while reducing the downtime of the machine.

To load drill pipe onto the drill, proceed as follows: 1.

If the mast is in the vertical or drilling position, lower the mast and store it in the mast rests.

Refer to the appropriate topic in this manual for the exact operating procedures.

2.

Obtain a crane with suitable capacity and reach to place the drill pipe into the pipe racks with the mast in the stored position. Normal placement of the crane is on the left side of the drill since this allows the shortest reach and greatest boom angle.

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BI006893 CAUTION:

3.

Follow all applicable safety measures when working with cranes and rigging. Failure to follow safe working procedures can cause an accident, leading to the possible death or injury of personnel.

Position the pipe to be installed in such a position so as to be accessible to the crane. Normal placement of the drill pipe is on the left side of the machine, laying at right angles to the machine. This allows the crane to lift the pipe and swing without excessive boom hoisting and lowering. The pipe may be stored on suitable blocking on the ground, or on a truck or trailer.

CAUTION:

Make sure the drill pipe is secured against unwanted or unexpected movement. Failure to secure the pipe properly may result in the pipe shifting and causing death or serious injury to personnel in the area.

4.

The upper gate is open when the pipe rack is empty. This function is controlled by a limit switch in the lower pocket of the pipe rack.

5.

Using suitable rigging, attach the crane to the drill pipe. The pipe should be rigged so that it will remain horizontal while being lifted. Attach suitable tag lines to the pipe. Remove the thread protectors and clean and lubricate the threads and shoulders on each end of the pipe. Install an approved lifting bell to the pin (upper) end of the pipe. Lift the pipe into position over the mast.

6.

Using a tag line guide the pipe into the desired pipe rack. Place suitable blocking beneath the pipe to allow the sling to be removed from the pipe.

CAUTION:

Block the pipe securely to prevent it from moving unexpectedly.

7.

Remove the slings from the pipe. Attach a sling to the lifting bell on the pin end of the pipe and lift the pipe sufficiently to remove the blocking.

8.

Slide the pipe down the pipe rack until it rests on the bottom of the pocket. Lay the pipe in the pipe rack and remove the sling and lifting bell.

9.

When the pipe rest in the bottom of the pocket it will trigger the limit switch and close the upper gate.

10.

Repeat the procedure for additional lengths of pipe.

11.

Unloading the pipe is the reverse of the procedure used for loading the pipe.

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DRILL TOOL STRING ASSEMBLY The tool string consists of one or more sections of drill pipe, a stabilizer (drill collar) and a bit. In assembling the tool string, the stabilizer is the first item installed, then comes a section of drill pipe and finally the bit.

To install the stabilizer proceed as follows:

1.

Place the stabilizer to be installed in a position so as to be accessible to the auxiliary winch line. Clean and lubricate the threads and shoulders on each end of the stabilizer. Install a lifting bell on the pin (upper) end of the stabilizer and lift it onto the drilling deck with the auxiliary winch line. Securely block the stabilizer horizontally on blocking sufficient enough to place the stabilizer 8-10 inches above the drill deck. Remove the auxiliary winch line.

2.

Remove the guide bushing from the hole in the drill deck.

Place the guide bushing on the upper end of the stabilizer with the tapered end of the bushing toward the lower (box) end of the stabilizer. Reattach the auxiliary winch line to the lifting bell.

3.

Install the stabilizer and drill bushing in the hole in the drill deck. Make sure the drill bushing is seated properly.

Lower the stabilizer until the slots in the stabilizer are aligned with the tool wrenches. Extend the tool wrenches to hold the stabilizer in place.

4.

Remove the auxiliary winch line from the stabilizer and secure it out of the way. Remove the lifting bell from the stabilizer and store it.

TOOL STRING

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NOTE: The use of stabilizers that have been modified or that do not allow this procedure to be used should be avoided. The use of nonstandard stabilizers will make assembly and disassembly of the tool string difficult and dangerous.

STABILIZER INSTALLATION

To install a single section of drill pipe proceed as follows: 1.

Lower the rotary/pulldown unit until the pipe coupling on the unit can be reached from the drill deck. Set the hoist brake and press the drill/propel control OFF push-button. Clean the inside threads on the coupling to remove any dirt or old lubricant. Apply a coat of drill thread compound to the threads and shoulder of the coupling.

NOTE:

Use only drill pipe thread compound on the pipe threads. Drill pipe thread compound contains material that will prevent the threads from seizing and galling under the severe pressure encountered on the pipe threads.

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2.

Press the control ENABLE button and release the hoist brake. Raise the rotary/pulldown unit to a position mast so as to clear the pipe rack as it comes in to place. Set the hoist brake.

3.

Verify that the main compressor/hydraulic pump motor is running, the hoist/pulldown speed selector switch is in PIPE RACK/JOINTS position, the operating mode selector switch is in DRILL position, and on the operator’s display terminal that the head is clear of pipe rack. Place the pipe rack selector switch in #1 position. The pipe rack joystick will now control only the #l pipe rack.

4.

Lift and move the joystick forward (OVER HOLE position) to move the pipe rack over the hole. Once the rack is over the hole return the joystick to the NEUTRAL position.

5.

Release the hoist brake and lower the rotary/pulldown unit until it is approximately 1 foot above the upper end of the drill pipe. Reset the hoist brake.

6.

Turn the rotary rheostat clockwise until the rotary drive unit coupling begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen.

Release the hoist brake and carefully lower the rotary drive unit until the coupling contacts the drill pipe. Allow the rotary/pulldown unit to lower under gravity while the coupling is threading onto the pipe.

7.

When the drill pipe begins to turn with the rotary coupling, stop the rotary motion and check the joint between the coupling and the pipe. The shoulders on the pipe and coupling must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the pipe is removed from the rack. If the shoulders of the pipe and coupling are contacting, the joint is made up.

CAUTION:

The threads on the drill pipe are tapered to make assembly and disassembly of the pipe easier. The threads are designed to disengage after only a few revolutions of the pipe. Failure to have the pipe shoulders contacting may result in the pipe joint uncoupling and the pipe falling from the rotary/pulldown unit.

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There is no provision made for holding the pipe stationary in the rack while the joint is tightened. If the joint does not tighten using the above procedure it may be necessary to apply a small amount of hoist power to the rotary/pulldown unit to lift it slightly to remove the pressure from the drill threads.

CAUTION:

Do not lift the drill pipe. Lift the rotary/pulldown unit only enough to relieve the pressure on the threads. Lifting the unit enough to lift the pipe will not only put pressure on the other side of the threads, but may also allow the pipe rack upper gate to open. Should the joint uncouple at this point, the drill pipe may fall out of the rack, causing death, serious injury or serious machine damage.

If the pipe joint does not make up by relieving the weight of the drive unit from the threads it will be necessary to inspect and/or repair the threads on the rotary coupling and the drill pipe. Inspect the threads for rough surfaces and burrs and apply a liberal coat of thread compound to them. The threads should have a smooth finish and no burrs or dirt that will hinder joint make-up. The joint shoulders should also be clean and smooth and should have compound applied.

After cleaning and repairing the threads, try making the joint again. If the joint cannot be made, either the drill pipe or the coupling is defective. Replace the pipe or coupling as necessary.

8.

Once the joint is made up between the coupling and the pipe, the pipe is now ready to be lifted out of the pipe rack pocket. Lift the pipe approximately a foot above the top of the pocket to allow the pipe rack to swing out of the way. Set the hoist brake.

9.

Once the pipe has been lifted clear of the pipe rack, swing the pipe rack to the STORED position by lifting and pushing the joystick rearward to the STORED position.

NOTE:

10.

Verify that the upper gate on the pipe rack is open before retracting the pipe rack.

Retracting the pipe rack with the gate closed will cause damage to the pipe rack.

Once the pipe rack has been stored the pipe should be cleaned out using the bailing air.

Remove all personnel from the area and turn on the bailing air for a moment. After cleaning the pipe, clean and lubricate the threads and shoulder on the lower end of the pipe and the upper end of the stabilizer.

CAUTION:

Before working around the tool string set the hoist brake. Press the control ENABLE button.

11.

Release the hoist brake and lower the rotary/pulldown unit until the drill pipe is approximately 1 foot above the upper end of the stabilizer. Reset the hoist brake.

12.

Turn the rotary rheostat clockwise until the drill pipe begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and carefully lower the rotary drive unit until the drill pipe contacts the stabilizer. Allow the rotary drive unit to continue to lower under gravity while the drill pipe is threading onto the stabilizer.

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13.

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When the stabilizer begins to turn with the drill pipe, check the joint between the stabilizer and the pipe. The shoulders on the pipe and stabilizer must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the stabilizer is released. If the shoulders of the pipe and stabilizer are contacting, the joint is made up.

Installation of the drill bit is the last step in preparing the tool string.

To install the bit, proceed as follows: 1.

Hoist the completed drill pipe/stabilizer assembly 2 to 3 ft (0.6 to 0.9 m) off the drill deck. Place the bit basket (furnished with machine) into the hole left by the guide bushing in the drill deck.

Remove all personnel from the drilling deck and the immediate area. Turn on the main air stream to blow any contaminants from the drill pipe and stabilizer.

2.

Place the bit into the bit basket. Coat the threads and shoulders of the bit and stabilizer with drill pipe thread compound.

3.

Turn the rotary rheostat clockwise until the tool string begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and slowly lower the rotary/pulldown unit and tool string onto the bit. Lower the drive unit in small increments until the threads catch and the stabilizer starts to thread itself onto the bit.

As soon as the threads start to catch, set the hoist brake and let the stabilizer screw itself onto the bit.

4.

When the joint is tight the rotary unit will slow down and the rotary load meter will show an increased load. At this point return the rotary rheostat to the neutral position.

5.

After making the bit to stabilizer joint, hoist the rotary drive unit to allow the bit basket to be removed. Remove the bit basket and store it in a safe place.

6.

Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck.

Set the hoist brake and press the control ENABLE button. The tool string is now complete for single pass drilling or for the first pass of multiple pass drilling.

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BI006893 BREAKOUT WRENCH OPERATION CAUTION:

When working with the breakout wrench it is important that the hoist brake be set, the control ENABLE button is off to prevent operation of the hoist or rotary controls. Failure to follow this caution may lead to the controls being energized while personnel are in the area, leading to the death or serious injury of those personnel.

Operation of the breakout wrench is necessary anytime a pipe joint, except the joint at the rotary coupling, must be broken. This includes removing the bit or stabilizer, or separating two sections of pipe.

To break a joint with the breakout wrench, proceed as follows: 1.

If a pipe joint between pipe sections or between the stabilizer and the pipe is to be broken, align the slots in the lower pipe to be broken with the tool wrench jaws. Close the tool wrench by turning the tool wrench control switch to the ENGAGE position. Make sure the lower tool is held securely by the tool wrench and that the slots or flats in the tool are aligned with the tool wrench.

CAUTION:

All personnel should be removed from the drill deck when operating the breakout wrench.

2.

To break the joint, turn and hold the breakout wrench switch to the EXTEND position. The jaws of the breakout wrench should grip the upper tool and turn it while the lower tool is held stationary by the tool wrench. Release the breakout wrench switch.

3.

Once the joint has broken, repeat the cycle 2-3 times to loosen the joint sufficiently to allow the rotary unit to finish disassembly.

4.

Turn and hold the breakout wrench switch in the RETRACT position until the breakout wrench releases the upper section of pipe and moves away from the pipe.

5.

Using the rotary unit, continue disassembly of the joint. Refer to the appropriate topic for exact operating procedures.

CAUTION:

6.

The joint must uncouple freely while using the rotary unit. If the joint does not uncouple freely, repeat the procedure using the breakout wrench until it does. Constantly observe the joint between the rotary coupling and the first section of pipe when running the rotary motion in reverse. If this joint begins to uncouple, stop the rotary motion immediately and retighten the joint. If this joint uncouples the pipe will fall, possibly causing death or serious injury to personnel.

If the lower tool is the bit, secure the bit with the bit basket as described in the topic BIT REMOVAL. Operate the breakout wrench as described above, except that the lower tool (bit) is secured by the bit basket, not the tool wrench.

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2-68 Operation Section MD6640 Blasthole Drill

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DRILL TOOL STRING DISASSEMBLY The tool string is disassembled in reverse of assembly, that is the bit is removed first, then the drill pipe and lastly the stabilizer.

To remove the bit from the tool string, proceed as follows: 1.

Raise the tool string 2 to 3 ft (0.6 to 0.9 m) above the drill deck. Install the bit basket in the hole in the drill deck.

2.

Using the breakout wrench, break the joint between the stabilizer and the bit. After breaking the joint, use rotary power to disassemble the joint. Use a slight amount of hoist power to lift the tool string off of the bit to facilitate the disassembly.

3.

Hoist the tool string 2 to 3 ft (0.6 to 0.9 m) off of the drill deck. Secure the rotary/pulldown unit and controls. Attach a lifting bell to the bit. Attach the auxiliary winch line to the lifting bell and lift the bit out of the bit basket.

4.

After removing the bit, a new bit may be installed or the bit basket may be removed, allowing removal of the drill pipe.

To remove the drill pipe from the rotary drive unit, proceed as follows: 1.

Lower the tool string until the slots or flats on the upper end of the stabilizer are aligned with the tool wrench. Clamp the stabilizer in the tool wrench. Using the breakout wrench to break the joint between the stabilizer and the drill pipe. After breaking the joint, use the rotary unit to disassemble that joint completely. Raise the rotary/pulldown unit and drill pipe 2 to 3 ft (0.6 to 0.9 m).

2.

Press the control ENABLE button to the OFF position and set hoist brake. Go to the drill deck and clean the pocket of the pipe rack to be used of dirt, cuttings or any material that will interfere with the entrance of the pipe or the operation of the pipe rack gate controls. Verify that the gate controls are intact.

3.

Clean and lubricate the threads and shoulder on the lower end of the pipe. This is to prevent rusting while stored in the pipe rack. After performing this function, return the controls to operating condition.

4.

After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4, swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.

5.

Slowly lower the rotary/pulldown unit and place the lower end of the pipe into the pipe rack pocket. Make sure that the pipe is seated firmly on the bottom of the pocket.

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BI006893 6.

2-69 Operation Section MD6640 Blasthole Drill

Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full speed. The joint should break at the rotary coupling.

NOTE: IF THE JOINT DOES NOT BREAK IMMEDIATELY, RETURN THE ROTARY RHEOSTAT TO THE ZERO POSITION TO REDUCE THE CHANCE OF DAMAGING THE MOTOR BY STALLING IT. 7.

If the joint does not break, it will be necessary to index the slots on the drill pipe so as to allow the rotary drive unit to build up speed before stopping the drill pipe. This is done by rotating the drill pipe in the forward direction until the slots in the pipe are almost aligned with the pawls in the sockets. This allows the drill pipe to rotate almost one-half turn before being stopped by the pawls.

If the joint does not break in a second attempt, the drill string will need to be reassembled, a hole drilled down and then use the breakout wrench to break the joint.

8.

When the joint breaks, gently raise the rotary/pulldown unit as the joint is unthreading.

9.

When the joint completely unscrews, the pipe will drop to the bottom of the pipe rack pocket.

The upper gate will automatically close around the drill pipe. When the joint is completely unscrewed, raise the rotary/pulldown unit until it is in a position so as not to be struck by the pipe rack when it is moved. Set the hoist brake.

10.

Swing the pipe rack into the stored position.

To remove the stabilizer, proceed as follows; 1.

With the stabilizer still clamped in the tool wrenches, attach a lifting bell to the upper end of the stabilizer. Attach the auxiliary winch line to the lifting bell and lift the stabilizer and guide bushing from the hole in the drill deck. Block the assembly in a horizontal position.

2.

Remove the auxiliary winch line from the stabilizer. Remove the guide bushing from the stabilizer and replace the auxiliary winch line.

3.

Using the auxiliary winch line, remove the stabilizer from the drill. Replace the guide bushing in the hole in the deck.

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2-70 Operation Section MD6640 Blasthole Drill

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ADDING ADDITIONAL DRILL PIPE Installation of additional sections of drill pipe is necessary when the depth of the hole is to be greater than the total length of one section of pipe. Installation of the second and third sections of pipe is essentially the same procedure as installation of the first. The rotary/pulldown unit is raised above the pipe racks, a pipe rack with pipe moved over the hole, the rotary coupling threaded to the pipe, and the pipe removed from the rack and the rack stored.

To add an additional section of drill pipe, proceed as follows: 1.

The first part of the hole should be drilled as deep as possible with the first section of pipe.

The hole should be drilled deep enough to place the joint between the rotary drive unit and the top of the first section of the pipe even with the top of the tool wrench. After completing this section of the hole, turn the main air stream off.

2.

Raise the tool string until the slots or flats in the top of the first section of pipe are aligned with the tool wrench. Clamp the tool wrench firmly around the drill pipe.

3.

Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full speed. The rotary coupling should turn, breaking the joint between the pipe and the coupling.

NOTE: If the joint does not break immediately, return the rotary rheostat to the zero position to reduce the chance of damaging the motor by stalling it.

4.

If the joint does not break, use the breakout wrench to break the joint.

5.

When the joint breaks, apply enough hoist power to raise the rotary/pulldown unit as the joint is unthreading. Do not apply enough power to lift the tool wrench and cause it to lose its grip on the pipe. Once the joint is completely disassembled, raise the rotary/pulldown unit to a position to make the coupling accessible from the drill deck. Set the hoist brake, press the drill/propel control OFF push-button to prevent operation. Clean and lubricate the threads and shoulder of the rotary coupling. Use an approved drill thread compound on the threads and shoulder. After cleaning and lubricating the coupling, raise the rotary drive unit to a position above the pipe racks so as not to be struck by the pipe or rack as the rack swings into position over the guide bushing.

6.

Position the pipe rack and install the new section of pipe to the rotary unit.

7.

Once the new section of pipe is attached to the rotary unit and the pipe rack stored, lower the pipe until it is approximately 3 feet above the drilling deck. Set the hoist brake. Place a cover over the threads on the pipe held by the tool wrench. Clear all personnel from the area and turn the main air stream on to blow away any dirt from inside of the pipe attached to the rotary unit. After turning off the main air stream, remove the cover from the lower pipe and clean and lube both the pin threads on the lower pipe and the box threads on the upper pipe.

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BI006893 8.

2-71 Operation Section MD6640 Blasthole Drill

After cleaning and lubricating the threads, turn the rotary rheostat until the drill pipe is rotating at approximately 5 RPM as shown on the operator’s display terminal operator’s display screen.

Lower the rotary/pulldown unit slowly by gravity until the threads begin to contact. Once the threads begin to join the two pipes, attempt to minimize the pressure on the threads by allowing the joint to close slightly while holding the upper pipe in position with the hoist brake, then allowing the upper pipe to descend slightly to keep the tool wrench from losing its grip on the lower pipe. Once the joint is tight, stop the rotary motion.

NOTE: Be sure that the joint is made properly before attempting to unclamp the lower pipe.

Should the joint not be made properly and fail, the lower pipe will fall into the hole and be difficult to recover.

9.

Disengage the tool wrench and retract it fully. The second section of pipe is now installed.

To install the third section of pipe, follow the procedure for installation of the second section of pipe, except that the third section of pipe is now installed between the rotary unit and the second section of pipe.

REMOVAL OF MULTIPLE SECTION DRILL PIPE Disassembly of multisection pipe strings is essentially the same as disassembly of a single section of pipe. The difference is that instead of the stabilizer being held by the tool wrench, it is the first or second section of pipe.

The tool string is disassembled to reverse order of assembly. First, the last section of pipe to be installed is removed, followed by the second section of pipe installed, and then the first. In each case the lower section of pipe is held by the tool wrench while the joint is broken by the breakout wrench. The joint is then disassembled by the rotary motion and the pipe stored in the pipe rack.

The procedure is then repeated as necessary to remove all, or part of the tool string.

NOTE: For normal operation it is not necessary to completely disassemble the tool string to move from hole-to-hole within the drill pattern as long as the stability limitations are not exceeded. Do not disassemble the tool string more than necessary.

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2-72 Operation Section MD6640 Blasthole Drill

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ANGLE DRILLING

ANGLE DRILLING EQUIPMENT

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2-73 Operation Section MD6640 Blasthole Drill

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All tool handling procedures are carried out the same way either in angle drilling or in standard vertical drilling. The only addition to the procedures is the use of the pipe positioner to hold the drill pipe to be threaded together in position and a mast A-frame with adjustable front legs. It also includes an adjustable pipe seal which can be moved to align with the drill pipe.

PIPE POSITIONER

During angle drilling the deck remains horizontal providing a horizontal surface to work from. The drill pipe, however, is laying at the angle of the mast. In order to make a joint at the drilling deck, such as when adding the stabilizer, bit or drill pipe or when removing these components, it is necessary to hold the drill pipe in position so as to line up with the drill pipe or component being held on the drill deck. This is the function of the pipe positioner.

The pipe positioner is moved into position by hydraulic cylinders. The pipe positioner jaws are opened by a single hydraulic cylinder.

NOTE: Do not operate the rotary machinery except at low speeds to make and break joints while the jaws are closed around the pipe. Operating the rotary machinery at high speeds or drilling while the pipe positioner jaws are closed around the pipe will damage the jaws and positioner structures.

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2-74 Operation Section MD6640 Blasthole Drill

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To make a joint with the pipe positioner, proceed as with normal joint assembly. When the pipe rack has been moved into position, retract the positioner into place and lock the jaws around the pipe.

Proceed as normal to make the joint. Once the joint is made, open the positioner jaws and extend the positioner to the stored position.

To break a joint both the pipe positioner and the breakout wrench are utilized. The pipe positioner is used to hold the pipe in position to be loaded into the pipe rack. The breakout wrench is used to break the joint.

To break a joint, proceed as normal with joint disassembly. Proceed as normal with joint disassembly.

Before breaking the joint completely, clamp the pipe with the pipe positioner. After breaking the joint, hoist the drill pipe and lower the pipe rack, release the jaws and extend the positioner.

Proceed as normal with the pipe joint disassembly procedure.

NOTE: IN CASES WHERE THE MACHINE IS EQUIPPED WITH A DRILL PIPE TONG INSTEAD OF THE BREAKOUT WRENCH, THE DRILL PIPE TONG JIB CRANE IS DESIGNED SO THAT IT CAN BE EXTENDED FROM 4 TO 7 FEET. FOR VERTICAL DRILLING, THE CRANE SHOULD BE EXTENDED TO THE 5 FOOT POSITION. FOR ANGLE DRILLING OF 25 DEGREES THE CRANE SHOULD BE EXTENDED TO THE 6.5 FOOT POSITION.

JIB CRANE

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2-75 Operation Section MD6640 Blasthole Drill

DUST SUPPRESSION SYSTEM OPERATION Most drills are equipped with some sort of dust control system. This system may be either a dry type filter or a water injection system. Dust control is necessary to contain the dust generated by drilling from escaping to the environment. All machines are equipped with dust control curtains and dust seal to contain the dust around the drill hole as standard equipment. The dust seal must be adjusted to the pipe angle when angle hole drilling.

There are two ways to suppress dust generation or prevent the escape of the dust to the atmosphere.

The two methods cannot be used at the same time as they are not compatible. One method to suppress the generation of dust is to inject water into the main air stream as it passes to the bit.

The water serves to conglomerate the dust particles into larger particles that may be treated as cuttings. The other method to suppress the dust is to contain the dust in the dust curtain enclosure then draw off the lighter particles and filter them out of the air before returning the air to the atmosphere. The filtering is done by a filter unit, which forces the dust laden air through filters where the dust is removed. In the filter system, the dust must remain dry as wet material will plug the filters.

NOTE: When the machine is equipped with a dry-type dust filter system, the air for cleaning the filters is drawn from the bailing air system. Air pressure to the dry-type dust filter must be maintained at 40 PSI (276 kPa) to ensure proper cleaning of the filter elements.

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2-76 Operation Section MD6640 Blasthole Drill

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WATER INJECTION SYSTEM

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2-77 Operation Section MD6640 Blasthole Drill

BI006893 DRILLING

VERTICAL DRILLING Once the drill has been inspected and started, positioned, leveled, and the tool string assembled, it is now ready to begin drilling. There are two methods of drilling, vertical drilling and angle drilling.

Vertical drilling is, as the name implies, drilling a vertical hole. Angle drilling is drilling the hole at some angle from vertical (up to 25 degrees). This section of the Operator’s Manual details the procedures involved in the drilling of vertical holes.

The actual drilling procedure involves three main sections: 1.

Starting the hole (collaring)

2.

Drilling the hole

3.

Cleaning or reaming the hole

Many types of formations are found in mining areas. Formations that are drilled may range from a wet clay to solid taconite. Each formation, and the parts of the hole within each formation, requires drilling techniques, expressly for that formation. A hole drilled through fragmented limestone is not drilled the same way that a hole is drilled through consolidated taconite. For this reason it is important that the operator not only become familiar with the basic drilling procedures and the specific machine being operated, but that he also become familiar with the formation being drilled.

For the purpose of this section of the Operator’s Manual it is assumed that the hole will be drilled in a consolidated rock formation. This is probably the simplest formation to drill in. Special circumstances will be taken into account in the DRILLING IN DIFFICULT FORMATIONS section of this manual. It is also assumed that the operator is familiar with the location and operation of all of the controls on the machine and that the machine is in good repair.

During the actual drilling the operator’s display terminal should be turned on and the operator display screen shown on the monitor. All of the drilling parameters noted in the following paragraphs will appear on the operator’s display screen.

NOTE: The bar graphs on the operator’s screen on the operator display terminal shows the condition of each of each functions. If a function operates beyond its normal operating range, especially for rotary current and hoist/pulldown force, the bar graph color will change from green to yellow or red when the graph valve raises into that particular range. For details, refer to the Operator Display Manual.

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2-78 Operation Section MD6640 Blasthole Drill

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STARTING THE HOLE (COLLARING) Since the first few feet of a hole are usually in unconsolidated material, the procedure for drilling through this material will be different than for the remainder of the hole. This procedure is commonly referred to as collaring the hole.

To begin, or collar the hole, proceed as follows: 1.

Verify that the tool wrench and breakout wrench are retracted fully. Clear the drill deck of personnel and material which is not necessary for the drilling procedure (i.e. oil drums, tools, spare bits, etc.).

2.

Place the operating mode selector switch in the DRILL position. Place the hoist/pulldown speed selector switch in the PULLDOWN position. Press the control ENABLE button to the ON position. Release the hoist brake and allow the tool string to lower so that the guide bushing is firmly seated in the hole in the drill deck. Make sure that the slots in the bushing align with the lugs on the drill deck. Reset the hoist brake.

3.

Turn the rotary speed selector switch to LOW position. Turn the rotary rheostat clockwise until the rotary speed bar graph on the operator’s display terminal screen indicates that the tool string is turning at approximately 25 RPM.

4.

Lower the dust curtains and turn on the dust control system. Place the main air valve switch in the OPEN position to supply bailing air to the bit.

NOTE: While the bit is passing through the unconsolidated material laying on the top of the formation, the pulldown speed sufficient to cause penetration of the bit is provided by turning the hoist/pulldown rheostat slightly in the pulldown direction.

5.

Release the hoist brake and allow the drill bit to contact the ground. Monitor the vibration coming from the tool string. To reduce vibration slow the rotary speed with the rotary rheostat.

Keep the vibration to a minimum. As the vibration lessens, increase the rotary speed and the pulldown speed while monitoring the rotary current bar graph and the air pressure bar graph on the operator’s display terminal screen.

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2-79 Operation Section MD6640 Blasthole Drill

The objective is to penetrate the formation as fast as possible without damaging the machine or plugging the hole with cuttings. Monitoring the rotary current, and keeping the load in the lower portion of the bar graph (green) will eliminate damage to the rotary motor. Reducing the load on the motor is accomplished by reducing the pulldown force on the bit. Reducing the pulldown force will, in most instances, accomplish this. In some cases it may even be necessary to hoist the tool string slightly to reduce the loading. Monitoring the air pressure graph will indicate the condition of the hole. If penetration is too fast and the bailing air cannot remove the cuttings as fast as they are generated, the hole will plug and the air pressure will rise. Varying the penetration rate will vary the air pressure. Keep the air pressure in the normal working range by increasing or reducing the penetration rate. Keep the vibration levels to a minimum by varying the rotary speed and the pulldown force.

6.

When the bit passes through the fragmented material (approximately 3-5 ft [0.9-1.5 m]) and into the consolidated material underneath, the vibration and loading will reduce drastically.

When this occurs, the hole has been collared and normal drilling may commence.

NORMAL DRILLING After the bit has passed through the unconsolidated material at the top of the hole, it is no longer necessary to reduce the load on the bit to reduce vibration and rotary motor loading. More rapid penetration and increased pulldown force may now be used to complete the hole as fast as possible with minimum vibration. This is the normal drilling condition for the machine.

Normal drilling follows the same guidelines as collaring the hole. Penetration is increased to the maximum determined by the rotary motor load, the vibration of the tool string, and the air pressure.

By keeping the penetration at or slightly below the optimum, the hole can be completed in the shortest possible time.

To begin normal drilling proceed as follows: 1.

When normal drilling is desired it is necessary to add pressure to the bit in addition to the deadweight of the tool string and rotary/pulldown unit. This pressure is furnished with the electric motor and pulldown gearbox. To activate the pulldown motor, turn the hoist/pulldown rheostat in the pulldown direction as required for maximum drill rate and pulldown force.

Turning the control in the pulldown direction will increase the pressure on the bit by calling for a desired pulldown speed.

Apply enough pulldown force to allow the bit inserts to chip the material being drilled, rather than pulverizing it. If the pulldown force is not sufficient enough, the bit will ride over the top of the material being drilled and will not create chips. This condition can be observed by monitoring the cuttings. If the cuttings are finely pulverized material, the pulldown force is not enough. Another cause of poor cutting is a worn bit. If pulldown force is high, but the cuttings are fine and penetration is slow, change the bit.

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2-80 Operation Section MD6640 Blasthole Drill

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2.

Monitor the rotary motor load (current) and adjust the pulldown force to keep the bar graph in the lower (green) portion of the graph. It is permissible for the load to increase momentarily into the yellow, but continuous running in the yellow or red portions will cause rotary motor damage.

3.

Monitor the vibration of the tool string and the machine. Keep the vibration to a minimum by varying the pulldown speed and the rotary speed. If vibration increases, reduce the rotary speed first. If this does not reduce the vibration to an acceptable level, reduce the pulldown speed until the vibration is acceptable.

NOTE: Excessive or prolonged vibration of the tool string and machine will cause eventual damage to the machine.

Monitor the air pressure. Keep the pressure in normal working range to eliminate compressor overheating. Pressures above normal working range indicate that the hole is starting to plug with cuttings. Stop the pulldown by returning the hoist/pulldown rheostat to the OFF position. Set the hoist brake. Wait a moment and if the pressure starts to decrease, let the hole clear before returning to drilling. If the pressure does not start to decrease it will be necessary to hoist the tool string to clear the hole. To do this release the hoist brake and turn the hoist/pulldown selector switch to the LOW position and the hoist/pulldown rheostat in the hoist direction. Hoist the tool string until the hole is cleared. Leave the rotary motion activated since this will help clear the hole. If the pressure is noticed slowly rising during drilling, reducing the penetration rate momentarily may eliminate the need to cease pulldown and hoist the tool string.

4.

Continue normal drilling until the hole is at the desired depth. It may be necessary to add drill pipe to complete the hole. Refer to the appropriate sections in this manual for the procedures necessary for adding drill pipe.

The operator’s display screen will show the hole depth in feet.

5.

Once the finished hole depth is reached it is necessary to clean or ream the hole before it is completed.

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2-81 Operation Section MD6640 Blasthole Drill

ENDING THE HOLE Once the finished hole depth is reached normal drilling ceases. It is now necessary to ream the hole before preparing the drill to move to the next hole. Reaming the hole removes cuttings that have fallen to the bottom of the hole and also straightens and increases the diameter of the hole.

As the bit and tool string are cutting through the formation, the bit may tend to wander slightly. This wandering is due to the fact that the stabilizer cannot be exactly the same diameter of the bit or it would wear out quickly and create operation problems. The stabilizer tends to keep the bit on course, but it cannot keep the hole exactly straight. Reaming the hole straightens the hole and therefore increases the diameter of the hole slightly. Reaming the hole also removes any cuttings that are lodged in the hole. These cuttings must be removed or they will eventually fall to the bottom of the hole, reducing the drilling depth.

To complete the drilling procedure the hole is reamed as follows: 1.

When the hole is drilled to the finished depth, leave the main air stream on and the rotary rheostat to the MINIMUM position and the motion activated. Return the hoist/pulldown rheostat to the “0” position and set the hoist brake. Allow the tool string to rotate and the air to bail the hole for a moment. This removes all of the cuttings in suspension from the hole.

2.

Turn the hoist/pulldown speed selector switch to the LOW HOIST position and the hoist/ pulldown rheostat in the HOIST direction while simultaneously releasing the hoist brake. Slowly hoist the tool string out of the hole. If resistance is met, or if vibration increases, return the hoist/pulldown rheostat to OFF position and set the hoist brake. Allow the obstruction to be removed by the bit before continuing. If the hole is very crooked (indicating a worn stabilizer) it may be necessary to repeat this procedure of hoisting, then stopping and allowing the bit to clear, many times before reaching the top of the hole. This procedure straightens the hole and allows the tool string to be removed.

3.

Once the tool string has been removed and the hole reamed, it must now be cleaned out.

Reaming the hole loosens cuttings that have become lodged in the side of the hole. These cuttings, and most of the cuttings generated during reaming will fall to the bottom of the hole.

This filling of the hole may reduce the actual depth of the hole significantly, so it is necessary to remove these cuttings from the hole. To do this, release the hoist brake and turn the hoist/ pulldown rheostat slowly in the pulldown mode.

Leave the air on and the tool string turning at 25-30 RPM. When the bit reaches the point where the cuttings have accumulated on the bottom of the hole, these cuttings will be forced out of the hole.

When the cuttings have been cleaned out of the bottom of the hole, the bit will contact the undrilled formation at the bottom of the hole and stop penetrating. Once the flow of cuttings out of the hole stops and the tool string stops penetrating, the hole is clean.

4.

After cleaning the hole the tool string may be raised to the top. Turning the hoist/pulldown rheostat control in the HOIST direction and the hoist/pulldown speed selector switch in the HOIST HIGH position will hoist the tool string.

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2-82 Operation Section MD6640 Blasthole Drill

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ENDING THE HOLE (MULTIPLE PIPE SECTIONS) Reaming the hole with multi-section tool strings is the same as reaming with single pipe section strings. The reaming procedure must be done in stages as the pipe sections are removed.

While removing the drill pipe the cuttings dislodged from the sides of the hole and the cuttings generated by reaming will fall to the bottom of the hole. To effectively clean the hole, it would be necessary to reassemble the tool string and lower it to the bottom of the hole. This is not desirable as it is time consuming. One method to eliminate the need to clean the hole is to overdrill the depth and allow cuttings to fill the hole to the desired finishing depth. Experience in this area will show how much to overdrill the hole. A good practice is to overdrill the hole by 1 to 2 feet (0.3 to 0.6 m) over the estimated finished hole depth. This way, if the estimate is wrong, the hole will be 1 to 2 feet (0.3 to 0.6 m) too deep. This can easily be corrected by a few shovels full of cutting thrown into the hole. Underestimating, on the other hand will require that the tool string be reassembled and the hole cleaned.

DRILLING DIFFICULT FORMATIONS For the purpose of explanation, the drilling procedure given in the DRILLING section of the manual assumes that drilling takes place in consistent, consolidated rock formation. Unfortunately, not all drilling is in this type of formation. This section of the Operator’s Manual will detail, in general, some typical drilling difficulties encountered.

The main cause of difficult drilling are unconsolidated material or wet sticky material. Unconsolidated material causes vibration far greater than experienced in consolidated formation, and if severe enough, may also decrease the bailing velocity of the main air stream. Wet, sticky material causes problems with cleaning the hole since the material may coat the hole and the drill pipe, increasing the air pressure above the working range. Wet material may also plug the bit orifices, freeze the bit cones, or compact into balls that refuse to be bailed out of the hole. The general procedure for drilling in difficult formations is the same as the procedure for drilling in good formations. The hole is collared, drilled, reamed, and cleaned using the standard operating procedures. Monitoring of the machine is, however, critical while drilling in difficult formations.

NOTE:

Failure to closely monitor the machine and its bar graphs as shown on the operator’s display terminal operator’s display screen will result in damage to the machine or a stuck drill pipe.

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2-83 Operation Section MD6640 Blasthole Drill

UNCONSOLIDATED MATERIALS Drilling unconsolidated materials may present two problems. The first, and most severe, is the vibration encountered if the penetration rate is too fast. As the bit rotates the cones pass over the material and the teeth or inserts chip away at the material being drilled. Unconsolidated material, however, has voids in it. When the bit passes over a void in the material it only contacts part of the bottom of the hole. As each roller passes through the void, the tool string moves down, as the roller falls into the void, and then back up as the roller climbs out. This continual up and down motion results in shock loads being transmitted from the bit, through the tool string, to the machine.

To drill through an unconsolidated formation it is necessary to reduce the load on the bit as it is passing over the voids. It is also helpful to isolate the shock loading to the tool string. This is accomplished by first reducing the pulldown speed. If reducing the pulldown speed does not reduce the vibration to the machine to an acceptable limit, it may even be necessary to hoist the bit above the void and then lower the bit a small amount at a time so as to chip away at the sides of the void a little at a time. Reduction of the rotary speed will also help reduce the vibration of the tool string.

This is the last procedure that should be tried since if the pulldown speed is left high and the rotary speed diminished, the vibration will be just as severe, only at a different frequency.

Unconsolidated material presents another problem due to the fact that the voids in the material may allow the bailing air to escape through the sides of the hole, rather than passing along the drill pipe and exiting through the top of the hole. This loss of air reduces the volume of air available to bail the hole, causing the cuttings to fall to the bottom of the hole and be reground by the bit. This further reduces the penetration rate since these cuttings must be ground up by the bit and bailed out of the hole or they will plug the hole. Unconsolidated material may also cause the hole to cave in. This creates problems due to the sudden addition of material into the hole and the resultant loss of bailing velocity due to the increased diameter of the hole.

If unconsolidated material is causing the loss of bailing air volume or caving of the hole it is necessary to continually clean the hole as the recycled cuttings or the caved material will plug the hole. Closely monitor both the bailing air pressure and the flow of cuttings from the hole. If the air is being lost the air pressure will remain constant but the flow of cuttings will stop or drastically decrease while penetration does not decrease. Continue drilling for a few feet to try and get past the leak. If the bailing air pressure starts to rise, the hole is plugging. Immediately hoist the tool string until the pressure drops and allow the drill string to rotate for a few moments to clear itself. Then lower the tool string to the bottom of the hole and clean it out. It may be necessary to regrind the cuttings to make them small enough to seal the leak and be bailed out of the hole by reduced air volume. Once the hole is clean, repeat the hoisting and lowering procedure every 2 to 3 feet (0.3 to 0.6 m) to keep it so.

If the material tends to cave in from the sides of the hole, the tool string can become stuck in the hole quickly. If the caved material is small, it will fit between the cones of the roller and fall to the bottom of the hole. The hole can then be cleaned out using the same procedure as for a leaky hole. If the caved material is large it will be necessary to pull the tool string out of the hole and then redrill the caved material.

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NOTE: Be very cautious when drilling in formations which tend to cave in easily, especially if the material caves in large blocks. Should the material that caves into the hole be too large to lift with the rotary drive unit or too hard to break with the top of the bit, the tool string will have to be abandoned in the hole.

Experience will dictate what procedure to follow when encountering material which tends to cave in. When the formation is unfamiliar always be cautious. Caution may result in lower production, but it could save a great amount of work and a complete tool string should the tool string become stuck. Always clean the hole often and monitor the air pressure constantly. If the air pressure starts to climb, hoist the tool string immediately — do not wait to see if the pressure will level off or not.

By the time it is determined what the air pressure will be, the hole is plugged. Cleaning the hole often accomplishes two things.

First, it removes the caved in materials from the hole. Second, it loosens any potentially hazardous material and causes it to cave in while the stool string is being hoisted. If the hole caves in while in the hoist mode there is a better chance of recovering from the cave in.

If the hole should become plugged there are two ways to recover the tool string. Each method depends upon what type of material has plugged the hole. If the material that is plugging the hole is small (less than 6 inches [15.2 cm] square), it is possible to grind the material sufficiently to allow it to pass between the lobes of the bit and fall to the bottom of the hole. This condition can be observed if the bailing air pressure increases over normal working range. Large, chunky material will let the bailing air through, while fine material won’t. Also, when attempting to hoist out of the hole the tool string will not vibrate greatly, due to the small size of the material. Large material will cause the tool string to be shocked every time a lobe on the bit strikes the block.

To recover the tool string from a hole plugged with smaller material hoist the bit until it runs into the plug and stops hoisting. With rotary motion turning at approximately 50-60 RPM keep high hoist loading on the bit and allow the bit to work its way through the plug. Monitor the rotary motor loading (current) and reduce the hoist loading (force) to keep the load in the lower portion of the bar graph.

Once the plug is passed, clean the hole and return to drilling. The main air pressure may or may not exceed the safety valve setting and cause the main air compressor to overheat. If the safety valve opens when the hole is plugged, continue to attempt to free the tool string. The safety valve will close when the plug has been removed. If the compressor overheats and shuts down continue to attempt to free the tool string without the compressor. Allow the compressor to cool for a few minutes and restart it. Continue this procedure until the tool string is free.

If the material plugging the hole is large it will be necessary to try and force the material back into position enough to let the bit go past, and then try and redrill through the plug. Large material is indicated when the tool string experiences severe vibration when being hoisted. To free the tool string apply maximum hoist power. If the plug does not clear itself within a few moments lower the tool string a few feet if possible and try again.

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If the plug does not clear itself after repeated attempts at clearing it, there are two options available.

The tool string can be abandoned immediately without further trial or an attempt to drill through the plug using the top of the bit can be made. In either case the hole being drilled will have to be abandoned. In the first case the cost of the abandoned tool string is known, while in the second case a gamble is being taken as the bit and stabilizer will almost certainly have to be scrapped and there is no guarantee that the rest of the drill pipe will be recovered. If it is decided to abandon the tool string, attempt to unscrew a section of pipe to recover some of the tool string. If this cannot be done, lower the tool string to the bottom of the hole and then, using a suitable burning torch, cut the drill pipe at ground level. It will be necessary to move over an existing hole to remove the stub of pipe from the rotary drive unit.

CAUTION:

Before cutting the drill pipe verify that the main air compressor is shut down. Burning the pipe with the main air compressor running may cause a fire or explosion as hot slag is introduced to the main air stream or may cause hot material to be blown back onto the torch operator.

If an attempt is to be made to free the drill string by drilling with the top of the bit, apply only enough hoist pressure to keep the vibration and rotary motor load levels in an acceptable range. Vary the hoist pressure by alternately placing the hoist/pulldown selector in the hoist and neutral positions.

Vary the rotary speed to help reduce vibration. Drilling through a large block with the top of the bit can be a lengthy procedure and it is important to prevent damage to the rest of the machine. Once the tool string is free, check the bit and stabilizer as well as the drill pipe for damage. Replace components and move to a new location for the hole. Do not try and drill the same hole again as this will almost certainly cause the tool string to become stuck again.

WET OR STICKY FORMATIONS Drilling in wet or sticky formations presents three possible problem areas. The three problems that may be encountered are coating of the hole and pipe with material, conglomeration of the material into pieces too large to remove with the bailing air stream and caving of the hole. Either of these problems may be present, or any combination of the three may be present at the same time.

Drilling in wet formations follows the same practices as drilling any other formation. Drilling wet formations, however, requires that particular attention be paid to the bailing air pressure and penetration rates. Wet formations are more susceptible to plugging the hole, but recovering the tool string from the plugged hole is easier than with unconsolidated material.

In the case where the material is adhering to the drill pipe and coating the sides of the hole it is necessary to ream and clean the hole every 5 to 10 feet (1.5 to 3.0 m) to remove the offending material. It is also necessary to clean the drill periodically to remove the caked on material. This can be accomplished by removing the tool string from the hole and allowing the material to be scraped off by the guide bushing. It is important then, if the guide bushing is to be used to clean the tool string, that the bushing be kept in good repair.

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In the case where the material is conglomerating into large pieces, these pieces fall back down to the bottom of the hole and are recycled through the bit to be broken up. If the amount of recycled material is too great it will accumulate at the bottom of the hole and restrict the main air stream. To keep this material at a minimum, clean the hole periodically. When hoisting the tool string, allow the material to be ground by the bit and fall to the bottom of the hole before cleaning the hole.

In the case where the material is caving from the sides of the hole, treat the formation as unconsolidated and drill according to the procedure detailed in this manual for unconsolidated material.

It is important when drilling through difficult formations to constantly monitor the machine and tool string. Allowing the tool string to become stuck is an expensive mistake and can be avoided by cautious drilling practices. Reaming and cleaning the hole may only take a few moments, but it could be the difference between an abandoned hole and tool string and a successfully completed hole.

ANGLE DRILLING NOTE: When moving the mast for angle hole drilling on machines with mast lengths of 65 ft. or more, the drill pipe must be stored in the racks and the rotary head lowered to its lowest position.

Angle drilling follows the same general drilling procedures as vertical drilling. The main difference in the drilling procedures, besides the fact that the hole is at an angle, is the need to monitor the condition of the different systems more closely while angle drilling. The differences in the operating procedures for the different systems on the machine are limited to handling the tool string and raising and lowering the mast to the proper drilling angle.

When drilling an angle hole, monitoring of the system indicators such as the drilling air pressure, the rotary load and the machine vibration, becomes more critical than when drilling a vertical hole.

The reason these monitors become more important is the fact that an angle hole will tend to wander downward as the hole is being drilled. This wandering is due to the drill steel assuming a natural camber as it is being extended past the guide bushing. This camber is unavoidable and becomes worse as the angle of the hole approaches 25 degrees.

The force of gravity continually acts upon the tool string causing it to bend downward. This downward bending is known as the camber of the drill pipe. This camber causes the hole to be drilled with a gradual bend in it. This causes the drill pipe to contact the side of the hole, increasing the load on the rotary motor. This also tends to inhibit the bailing of the hole since the cuttings are not flowing vertically. The flow of the bailing air (and suspended cuttings) must be diverted around the points that the drill pipe is resting on the side of the hole. This contributes to the increased air pressures needed to drill an angle hole. The vibration of the tool string will be increased while drilling at an angle, due to the tool string resting on the side of the hole, rather than on the bottom.

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2-87 Operation Section MD6640 Blasthole Drill

PROGRAMMED DRILL CONTROL DRILLING P.D.C. Drilling is similar to normal drilling in that the machine must be positioned, leveled and setup manually by the operator. The actual drilling operation will be controlled by the automated system. To start the automated system use the following start-up sequence.

1.

Make sure the hoist/pulldown rheostat and the rotary rheostat are in the OFF position.

2.

Verify that the desired drilling depths, collaring depth, and wet hole depth have been set per P.D.C. operating parameters screen on operator’s display terminal.

3.

Place hoist/pulldown speed selector switch in the PULLDOWN position.

4.

Place the operating mode selector switch in the DRILL position.

5.

Press the drill/propel control ON push-button.

6.

Place the Main Air Valve switch in the OPEN position.

7.

Verify on the operator’s display terminal that no PDC faults exist. If a fault exits, it must be cleared before the PDC control can be activated.

8.

With the operator’s display screen shown in the operator’s display terminal, press the depth indicator reset push-button to reset the hole depth and bit depth indicators to zero.

9.

Place hoist brake control in the RELEASE position.

10.

On the operator’s display terminal with operator’s display showing, press keypad button F5 to turn on P.D.C. The readout above the F5 key will then read “PDC on.”

After the above start-up procedure has been initiated the automatic controls will take over the actual drilling of the hole. Water injection (if so equipped) will be shut off at preset depth. When the total depth of the hole is reached, as preset, the tool string will be automatically hoisted and when the bit approaches the top of the hole, the control will stop the bit, shut off the air and set the hoist brake.

If problems arise in the P.D.C. functions, the system will have to be corrected by a qualified electrician.

In most cases, if a malfunction occurs in the automated system, the automated system can be turned off and the drilling completed manually.

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PREPARING TO MOVE Once the hole has been completed and the tool string removed from the hole it is necessary to move the drill to the next hole location to prepare to drill the next hole. Preparing to move the drill consists of proper storage of the tool string, lowering the machine to the ground, and inspection of the machine and travel route prior to propelling.

To prepare the drill to move, proceed as follows: 1.

Upon completion of the current hole, hoist the tool string from the hole. If using multiple pipe sections, remove and store all pipe necessary to remove the entire tool string from the hole.

Turn off the dust control system and raise the dust curtains.

2.

Clamp the stabilizer with the tool wrench to prevent movement of the tool string during propel.

CAUTION:

3.

Do not propel with the tool string in a position where it will be struck against the ground while propelling. Should the tool string hit the ground while propelling, damage to the machine and tool string will result.

Press the automatic leveling switch to the RETRACT position to raise the jacks and lower the machine. Hold the switch in the RETRACT position until the jacks are fully retracted. Refer to the auto leveling screen on the operator’s display terminal to verify all four jacks are fully retracted.

NOTE: If the machine is to be lowered manually, refer to steps 4, 5 and 6 and operator’s display terminal screen auto leveling.

4.

Using the manual leveling jack controls, lower the machine so that it remains level, but is touching the ground. Use the leveling jack controls in pairs (i.e. either both side controls, or both end controls simultaneously) to reduce the twisting loads on the drill frame.

5.

Once the machine is touching the ground, it may be lowered completely. To lower the machine completely, first lower the uphill side or end of the machine to the ground, then lower the downhill side or end to the ground. It is important that the machine be lowered in stages to minimize both the angle of the machine and the bending stresses placed on the machine.

CAUTION:

6.

While manually lowering the machine to the ground it is imperative that the machine be kept as level as possible. It may be necessary to lower the machine in stages to keep it as level as possible.

Once the machine is completely lowered, retract the leveling jacks to the maximum retracted position.

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2-89 Operation Section MD6640 Blasthole Drill

NOTE: When manually lowering the machine be sure that the leveling jacks are fully retracted before propelling the machine. Propelling the machine with a leveling jack not fully retracted will result in serious damage to the jack and machine structures.

7.

Inspect the machine, travel route as outlined in the PROPELLING topic in this manual. After completing the inspections the machine is ready to propel.

MACHINE SHUTDOWN Shutting down the machine is necessary any time that the operator must leave the machine, either at the end of the shift, or for a period of time during the shift. Machine shut down is also necessary for most maintenance work to be performed.

Shutting down the machine is essentially the reverse of starting it up. The degree of storage work to be done is determined by the length of time the machine will be shut down. Shut down for a short period involves little extra work, while shutting the machine down for a lengthy period will involve considerable effort.

SHUT DOWN PROCEDURE To shut down the machine, proceed as follows: 1.

Complete the hole, if any, currently being drilled. If the hole is not completed before the machine is shut down, it will be necessary to abandon the hole and drill another in its place. Do not try and redrill a hole that has been left unfinished as releveling and placing the drill in the exact same position is extremely difficult.

2.

Remove the tool string from the hole. If multiple pipe sections are used, remove and store pipe sections as necessary to remove the entire tool string from the hole.

NOTE: Do not shut the machine down with the tool string in the hole. To do so may cause damage to the drill pipe and may lead to the abandonment of the tool string and the hole.

3.

Determine the length of time the drill is to be idle. Refer to the appropriate storage topic in this manual for the degree to which the tool string must be disassembled. If necessary, disassemble and store the tool string at this time.

4.

If possible lower the rotary drive unit to its lowest position and set the hoist brake. If the tool string is not to be removed, clamp the stabilizer with the tool wrench and set the hoist brake.

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5.

Following the procedures in the PREPARING TO MOVE topic in this manual, lower the drill to the ground. Place the leveling jack pads on the ground, but do not place any weight on them.

6.

Shut off the main air compressor. Place all controls in the off or neutral position.

7.

Go to the machinery house and turn off all breakers. If the machine is to be shut down for a short period of time and it is necessary to leave the lights on, it is permissible to leave the lighting breaker and lights on.

8.

Inspect the machine for obvious damage or wear. Make note of any operating difficulties discovered while drilling and any problems discovered during this inspection. Report the difficulties to the appropriate personnel.

9.

Close all doors and windows tightly.

SHORT TERM STORAGE If the machine is to be shut down for more that 3 eight hour shifts, but less than 3 weeks, short term storage precautions are necessary. These precautions are necessary to insure that the machine is not damaged or does not deteriorate during the storage period.

Short term storage is primarily concerned with placing all components in a safe position and providing additional protective lubrication to normally lubricated components.

To store the machine for a maximum of 3 consecutive weeks, proceed as follows: 1.

If not already done so previously, complete all shut down procedures as detailed in the MACHINE SHUT DOWN topic in this manual. During the shut down procedure it is necessary to remove and store the complete tool string. Remove the bit from the stabilizer and store it in a protected place. Coat the bit with a suitable oil to prevent rusting while stored. As the drill pipe is being disassembled, clean and lubricate the threads on each end of the pipe before storing in the pipe racks.

2.

Lower the rotary/pulldown unit to the lowest position and set the hoist brake. Inspect the rotary/pulldown unit for damage or wear and note any problems discovered. Cover the rotary and pulldown motors with waterproof tarps or covers. Raise the dust curtains. Retract the drill pipe tong cylinder.

3.

Check the oil level in the rotary/pulldown unit. Check the cases to see if there is water in the oil. If there is water in the cases, drain and refill the cases with suitable oil. If no water is present, fill the cases to the proper level.

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2-91 Operation Section MD6640 Blasthole Drill

4.

Manually cycle the lube system and verify that all points on the mast are receiving lubricant. If the auto lube system is not functioning properly, repair or replace components as necessary.

5.

Lower the leveling jacks until the jack pads are resting on the ground, but no machine weight is on them.

6.

Inspect the air compressor for signs of wear or damage. Make note of any damage discovered.

7.

If the air compressor motor is equipped with anti-condensation heaters, turn them on at this time. If the motor is not equipped with heaters, have a qualified electrician install heaters or a suitable substitute. Cover the motor with a waterproof tarp or cover.

8.

Close and lock all electrical cabinet doors.

9.

Fill the radiator to the top with the proper oil on machines equipped with screw compressors.

10.

Manually cycle the auto lube system to verify that all points on the machine are receiving lubricant. Repair the system as necessary to lube all points.

11.

Lube all manual lube points.

12.

Clean the dust hoppers on the dust control system if required.

13.

Close and lock all windows and doors.

LONG TERM STORAGE Long term storage procedures are necessary any time the machine is to be left for a period exceeding 3 weeks. Long term storage includes all procedures necessary for short term storage, and depending on the situation, some additional precautions.

There are two procedures involved in long term storage of the drill, the choice of which depends upon whether the machine can be attended to while in storage. If the machine can be started and the majority of the machinery operated once a month during the storage period, much less protective work is necessary. If the machine must remain unattended, special precautions are necessary to prevent damage to the machine.

NOTE: If the machine is to be unattended during the storage procedure the procedures necessary to store the machine properly will take considerable time and restoring the machine to production will take even longer. Do not utilize the unattended long term storage procedure unless absolutely necessary.

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ATTENDED LONG TERM STORAGE The attended long term storage procedure combines the short term storage procedure with monthly start-up and running periods. To store the machine for a long period of time it is necessary to complete the procedures listed in the SHORT TERM STORAGE topic in this manual. Then, once a month for the duration of the storage period, complete all start-up inspection and lubrication procedures listed in this manual and start the drill. Run all of the gear trains for 10-20 minutes to distribute the oil over the gears and bearings. Hoist and lower the rotary/pulldown unit the full length of the mast 4-6 times to distribute lubrication to the mast and rotary/pulldown unit components.

Cycle the tool racks 2-3 times. Run the air compressor for 1 hour. Propel the drill at least 6 times the length of the machine. After running the machine components, follow the short term storage procedure once again and store the machine for another month. Repeat this procedure every month until the machine is returned to service.

UNATTENDED LONG TERM STORAGE It is not within the scope of this manual to detail the procedures involved in the long term storage of a drill. These procedures will involve disassembly of the major units on the drill, duties that are not usually performed by operating personnel. Refer to the Mechanical Maintenance Manual for details concerning the long term storage of the machine.

The procedure listed here is an outline intended only to give a general idea of the effort involved in proper storage of the machine. To store the unattended machine for an extended period of time, proceed as follows: 1.

Complete all short term storage procedures.

2.

Remove the motors from the drill and store in a heated building.

3.

Completely fill the rotary and pulldown gear cases with an approved oil. Both cases can be filled completely by adding the oil through the breather openings. Remove all water from the cases.

4.

Loosen the guide rollers on the rotary/pulldown unit frame to provide one-half inch clearance between the rollers and the mast.

5.

Remove the auxiliary winch line.

6.

Cover the rotary gear case and hoist/pulldown gear case with a waterproof tarp.

7.

Remove the air compressor from the machine and store in an attended heated building.

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2-93 Operation Section MD6640 Blasthole Drill

8.

Close and completely seal all electrical cabinets.

9.

Close and completely seal the operator’s cab.

10.

Close and completely seal the machinery house. Completely seal the filter fan unit.

11.

Completely drain the compressor coolant system.

12.

Propel the machine onto blocks to prevent the crawler belts from rusting. Coat the entire crawler belts with a rust preventative oil. Coat the propel chains with a rust preventative oil.

13.

Block the leveling jacks in the full retracted position.

14.

Manually grease every lube point (including auto lube points).

TOOL RECOVERY Normally the drill tools are always either connected to the rotary drive unit or are held by the tool wrench. Mistakes, however, do happen and the drill tools may be dropped down the hole. Tool recovery (or tool fishing) is the procedure used to recover these tools.

There are two situations where the tool recovery procedures are necessary and each situation dictates the procedure to be used. The first situation is when the tools have been uncoupled and have fallen below the guide bushing. It is possible in this situation to recover the tool string and, if no damage was done, return to drilling. The other situation is where the drill pipe has broken and has either fallen below the guide bushing or cannot be handled normally.

If the tools have uncoupled and the upper end of the tool string is still above the guide bushing, recouple the tools as would normally be done for tool joint make-up. Clamp the tool string with the tool wrench to aid in making the joint. When the tools are coupled, remove the tool string from the hole, remove the bit and turn the main air on momentarily to clean the inside of the drill pipe. Clean and reinstall the bit and return to drilling.

If the tools have uncoupled and the upper end of the tool string is below the guide bushing but still above ground level, re-couple the tool string as would normally be done to tool joint make-up, except use caution when making the joint. Caution is necessary when making the joint as the tools in the hole will now be at an angle with respect to the tools on the drill. Cross threading of the joint is possible in this situation and should be avoided since it will not only damage the threads but result in an unreliable joint. One method to realign the tools would be to attach a suitable pulling device to the tools in the hole and center the tools with blocking (make sure it doesn’t fall down the hole). This would allow normal joint make-up without abandoning the hole. If this is not possible, the leveling jacks may be adjusted to align the tools. Be sure that the stability limits of the machine are not exceeded. It will be necessary to abandon the hole since the drill cannot be repositioned in the exact same orientation as before losing the tools. When the tools are recovered, clean the pipe and bit as detailed in the first procedure of this section and return to drilling.

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If the tool string has uncoupled and the upper end of the lost tool string is below ground level, there are two methods of recovering the lost tools. One method is to attempt to make the joint using the drill pipe still connect to the rotary drive unit. The other method is to use special equipment (not supplied) to recover the tools.

If the top of the lost tool string is not reachable from ground level, very gently lower the remaining tool string until it contacts the tools in the hole. Using very slow rotary speed and low torque, attempt to re-make the joint. If the joint can be made, very gently raise the tools to a position where the top of the recovered tools can be clamped in the tool wrench. Rebreak the joint and inspect the threads on both sections of pipe. Repair the threads if necessary before continuing. When the tool string is repaired, remove the bit and clean both it and the drill pipe to remove any dirt that may have entered while the joint was uncoupled.

If the joint cannot be made using the above procedures, or if the pipe has been broken or been damaged to an extent that it cannot be handled normally, it will be necessary to use special equipment and techniques to continue drilling or recover the lost tools. It is not within the scope of this manual to detail the procedures necessary to handle broken or lost tools, and the use of these tools should be described by the manufacturer.

CAUTION:

WHEN PERFORMING SPECIAL PROCEDURES NOT DETAILED IN THIS MANUAL, ALWAYS FOLLOW THE RECOMMENDATIONS OF THE TOOL MANUFACTURER AND PRUDENT SAFETY GUIDELINES. FAILURE TO FOLLOW SAFE PROCEDURES MAY RESULT IN THE DEATH OR SERIOUS INJURY OF PERSONNEL OR SERIOUS DAMAGE TO THE MACHINE.

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Drill Stability Chart - Special Propel Conditions

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Drill Stability Chart - Typical Propel Conditions

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3-1 Lubrication Section MD6640 Blasthole Drill

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3

Lubrication Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents LUBRICATION PRINCIPLES ......................................................................................................... 3 Auto Lube Reservoir & Control Panel ..........................................................................................

Auto Lube Piping ~Mainframe (View #1) ......................................................................................

Auto Lube Piping ~Mainframe (View #2) ......................................................................................

Auto Lube Piping ~Crawlers ........................................................................................................

Auto Lube Piping ~Mast (View #1) ..............................................................................................

Auto Lube Piping ~Mast (View #2) ..............................................................................................

4 5 6 7 8 9

LINCOLN TYPE SL-1 LUBRICANT INJECTORS .................................................................. 10 LUBRICANT INJECTOR OPERATION ............................................................................ 11 INJECTOR ADVANTAGES .............................................................................................. 12 TROUBLESHOOTING .......................................................................................................... 13 BIT LUBRICATOR ................................................................................................................. 14 FLOWMASTER PUMP SERVICING ..................................................................................... 15 PRESSURE CONTROL VALVE ADJUSTMENT .............................................................. 15 FLOW CONTROL VALVE ADJUSTMENT ............................................................................. 16 FlowMaster Rotary Driven Hydraulic Pump Schematic ................................................................ 16

CRANK CASE OIL ................................................................................................................ 16 PUMP DISASSEMBLY PROCEDURE .................................................................................. 17 FlowMaster Rotory Driven Hydraulic Pump Assembly ................................................................. 18

PUMP ASSEMBLY PROCEDURE ........................................................................................ 19 FlowMaster Rotary Driven Hydraulic Pump Components ............................................................. 20

TROUBLESHOOTING .......................................................................................................... 21 Lube Pump Hydraulic Schematic ............................................................................................... 22

LUBRICATION POINTS ............................................................................................................... 23 GEARCASE AND RESERVOIR CAPACITIES ...................................................................... 23 LOWER WORKS LUBRICATION ......................................................................................... 24 MAIN FRAME LUBRICATION ................................................................................................. 25 MAST LUBRICATION ~PART 1 ............................................................................................. 26 MAST LUBRICATION ~PART 2 ............................................................................................. 27 MAST LUBRICATION ~PART 3 ............................................................................................. 28 LUBRICANT CLEANLINESS ................................................................................................. 29 LUBRICANT SELECTION ........................................................................................................... 30 ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT ................................................ 31 MPO - MULTIPURPOSE OIL................................................................................................. 32 RWRL - RUNNING WIRE ROPE LUBRICANT ..................................................................... 33

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HYDO – HYDRAULIC OIL ..................................................................................................... 35 PAO SYNTHETIC HYDRAULIC FLUID ............................................................................ 36 Recommended Viscosity vs. OAT Chart .................................................................................... 36

PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID .................................................. 36 Recommended Viscosity vs. OAT Chart .................................................................................... 37

ADDITIONAL LUBRICATION BENCHMARKS: EGL - ENCLOSED GEARCASE LUBRICANT ................................................................... (insert) MPG - MULTIPURPOSE GREASE .................................................................................... (insert) OGL - OPEN GEAR LUBRICANT ...................................................................................... (insert) CERTIFIED LISTING FOR OGL, MPG, AND EGL LUBRICANTS ...................................... (insert)

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3-3 Lubrication Section MD6640 Blasthole Drill

BI006893 Section

3

Lubrication LUBRICATION PRINCIPLES The proper lubrication of this machine is vital to its successful, continued operation. Application of the CORRECT lubricant in the CORRECT amount at the CORRECT place as part of a PROVEN maintenance program is required to keep the machine operating at a level of productivity. Proper lubrication will provide better component service life with a reduction of repairs and downtime.

When not properly lubricated, moving parts wear quicker and fail sooner.

The primary wear items of this machine are lubricated by an automatic system that dispenses lube to selected points at pre-selected, timed intervals during machine operation. This system is covered in more detail further on in this section. It is important to the operation of this automatic lube system that you become familiar with it and understand its operation in order to properly maintain and service it, thus keeping it operable. It is also necessary that you inspect on a regular basis the points for automatic lubricant application to insure the system is performing its job adequately.

Some components, due to their location and function, can not be readily covered by the automatic lube system. You should become familiar with these points so you can service them properly at the intervals listed. A listing of the parts covered by the automatic lubrication system is included later in this section. The standard lubrication fittings used for manual service are the hydraulic type, push-on fittings having 1/8 inch or 1/4 inch NPT threads.

Bushings and bearings operating in a highly contaminated atmosphere (dust, grit, etc.) should be lubricated until clean grease seeps out around the journal or seal, or comes out the purge fitting, if one is provided.

Overfilling an anti-friction bearing can cause it to run excessively warm. After lubricating anti-friction bearings (those that are sealed such as in electric motors must use electric motor grease) remove the pressure fitting, or the relief plug when provided, allowing the bearing to purge itself of any excess lube during the first 10-15 minutes of operation. Replace the fitting or plug after that time.

Grease in a bearing generally deteriorates gradually, not suddenly. Only a small amount needs to be added to it at regular intervals to maintain the proper lubricant level. Adding a small quantity of grease to the bearing every 600 operating hours, unless otherwise specified, is adequate.

Open gears and pinions require a constant coating of high grade lubricant which is specified for operation. Inspect all open gear sets at least once daily (every 24 hours) to ensure they are coated with OGL. CAUTION:

Contact with or ingestion of petroleum products can be harmful.

Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

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3-4 Lubrication Section MD6640 Blasthole Drill

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Auto Lube Reservoir & Control Panel

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3-5 Lubrication Section MD6640 Blasthole Drill

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Auto Lube Piping ~Mainframe (View #1)

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3-6 Lubrication Section MD6640 Blasthole Drill

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Auto Lube Piping ~Mainframe (View #2)

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3-7 Lubrication Section MD6640 Blasthole Drill

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Auto Lube Piping ~Crawlers

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3-8 Lubrication Section MD6640 Blasthole Drill

BI006893

Auto Lube Piping ~Mast (View #1)

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3-9 Lubrication Section MD6640 Blasthole Drill

BI006893

Auto Lube Piping ~Mast (View #2)

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3-10 Lubrication Section MD6640 Blasthole Drill

BI006893

LINCOLN TYPE SL-1 LUBRICANT INJECTORS These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted on manifolds or individually. Each injector expels a maximum of .08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lube to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted; however it is recommended that injectors initially be set and used at their maximum setting.

NOTE:: MAXIMUM Operating Pressure: RECOMMENDED Operating Pressure: MINIMUM Operating Pressure: MAXIMUM Recharge Pressure: CAUTION:

3,500 2,500 1,850 600

PSI PSI PSI PSI

STORED ENERGY! Contact with or ingestion of petroleum products can be harmful. Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

To set an injector for maximum output: 1.

2.

3.

4.

Loosen locknut.

Turn adjusting nut until there is a small gap at the top of the stem.

Orient the adjusting nut so that the opening is toward the front of the injector.

Tighten the locknut.

To reduce an injector’s output: 1.

2.

3.

Loosen locknut.

Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This forces the stem into the body, retarding the stem’s movement.

Set the locknut.

CAUTION: Do not turn adjusting nut down (clockwise) more than 5 full turns from the maximum discharge setting. Check output flow from injector at this time to ensure it is still operating. If not, back off adjusting nut until injector does consistently operate. Inspect the adjusted injector for operation over 3 or 4 cycles after returning machine to work to make sure it is functioning.

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3-11 Lubrication Section MD6640 Blasthole Drill

BI006893 LUBRICANT INJECTOR OPERATION

STAGE 1:

The injector piston is in its normal or reset position. The discharge chamber is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to open the passage leading to the piston.

STAGE 2:

STAGE 3:

When the slide valve uncovers the passage, lubricant is admitted to the top of the piston, forcing the piston down. The piston forces lubricant from the discharge chamber through the outlet port to the bearing.

As the piston completes its stroke, it pushes the slide valve past the passage, cutting off further admission of lubricant to the passage. The piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump.

STAGE 4:

After the pressure is relieved, the compressed spring moves the slide valve to the closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber.

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3-12 Lubrication Section MD6640 Blasthole Drill

BI006893

NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.

INJECTOR ADVANTAGES

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3-13 Lubrication Section MD6640 Blasthole Drill

TROUBLESHOOTING AIR LOCKS: When the system is not primed properly, air is often trapped in the pump, supply line, injectors, or feed lines. Since the air pockets, with their great compressibility, provide a cushion against the normal rapid rise in supply line pressure, they serve to make the cycling of the system sluggish and erratic. In some extreme cases, particularly when the pump is air locked, they may make the system inoperable.

NOTE: If cycling time of a new installation greatly exceeds the cycling time determined from the system planning, it is an indication of an air lock in the system.

When the pump fails to prime and pump due to air locks, the vent plug located on or near the pump outlet on all Lincoln models should be opened while the pump is in operation and all of the air allowed to escape. The use of oil as an aid to priming is recommended. Air in the supply lines is expelled by loosening pipe plugs at the end of each line (main supply lines, etc.) and allowing generous quantities of lubricant to escape carrying with it the entrapped air. Air locks in the injectors are corrected, in the case of the SL-1 injectors, by opening the lube fitting and allowing the lubricant and air to escape. Air locks in the feed line can be corrected by loosening the feed line connection at the bearing inlet and allowing lubricant and air to escape as the system is cycled repeatedly. Do not loosen any connections which are under pressure.

DIRTY SUPPLY LINES: This is a preventive maintenance problem and should be thoroughly checked before the system is installed. However, a malfunction of the injectors or the vent valve can usually be traced, by the disassembly of the unit and examination, to foreign material from the supply line inner surfaces preventing proper operation.

After the trouble has been encountered, only the disassembly and complete cleaning of the affected units will restore the system to its original state. Preventively, the supply lines should be thoroughly cleaned and blown out before installation.

ALL INJECTORS DO NOT WORK PROPERLY: On a newly installed system, the indicator stems on one or more injectors fails to move to the discharge position. As a result, some of the bearings do not receive the measured amount of lubricant.

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3-14 Lubrication Section MD6640 Blasthole Drill

BI006893

Those units equipped with a pressure switch must be adjusted to allow a higher developed pressure, at which level all of the injectors will discharge.

3500 PSI maximum for high pressure systems.

1000 PSI maximum for low pressure systems.

(For long life, keep pressure to a minimum permissible for proper injector operation.)

INDICATOR STEMS DO NOT RETURN TO NORMAL: This condition could be due to the sluggish operation of all new assemblies and after a few operations this stiffness may disappear.

However, it could be an indication that, after venting, the residual supply line pressure is too high to allow the injectors to operate normally. This is due to a restriction in the supply line which hampers the rapid venting pressure. This condition may be the result of many things: notably, lubricants, low temperatures at which lubricants stiffen, or coupled with the above, an extremely short lubrication cycle. This condition is usually encountered when the lubrication cycle is relatively short. In the automatic system, where the cycle can be as low as 3-3/4 minutes, it can be a big problem.

CORRECTIONS: 1.

The lubricant should be checked. The use of the centralized system eliminates the need (in most cases) for the heavy soap additive which only lengthens the effective line of the individual lubricant application.

2.

The lubricant can be made more resistant to physical change by the use of low temperature additives.

3.

The output of lubricant per cycle can be increased and the lubrication interval lengthened.

4.

Be sure lubricant used meets requirements of system.

When hand operated systems are being tested after installation, repeated operations can use short intervals between cycles. Under normal conditions, the cycling of a hand operated system will usually be infrequent (once an hour at the most), allowing plenty of time for proper venting.

BIT LUBRICATOR The Bit Lubricator is located at the right, front of the machine, beneath the house air filter.

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3-15 Lubrication Section MD6640 Blasthole Drill

BI006893 FLOWMASTER PUMP SERVICING CAUTION:

To reduce the risk of serious bodily injury, including fluid injection, injury from moving parts, and splashing in the eyes or on the skin: always follow the following Pressure Relief Procedure whenever you shut off the pump; when checking or servicing any part of the spray system; when installing, cleaning or changing dispense valve nozzles; or whenever you stop dispensing.

PRESSURE RELIEF PROCEDURE 1.

Close the shut-off valve to the material supply line.

2.

Turn power OFF to lube pump at the control panel. Disconnect 24DCV power supply at the solenoid valve.

3.

Relieve pressure unloader.

at

safety

The lube pump is factory set at 350 PSI working inlet hydraulic pressure with a flow rate of 2.5 GPM. Maintain hydraulic pressure between 300-450 PSI. Maximum flow rate is 7 GPM. However, adjusting the lowest pump outlet pressure and hydraulic fluid flow to obtain the desired to results will minimize pump wear.

Pump pressure and flow rate will vary depending on operating temperatures. DO NOT ADJUST THE PUMPS PRESSURE BEFORE THE INITIAL START-UP PROCEDURE. For more information on installation and start-up, refer to the manufacturer’s literature included with this machine.

PRESSURE CONTROL VALVE ADJUSTMENT 1.

Loosen the locknut on the pressure reducing valve by turning the nut COUNTER-CLOCKWISE.

2.

Turn the valve stem COUNTER-CLOCKWISE until it reaches the stop. This adjustment allows the minimum pressure setting which is approximately 170 psi.

3.

With the pump stalled against pressure, turn the pressure control valve stem CLOCKWISE until the desired pressure is attained on the manifold pressure gauge. DO NOT EXCEED 450 PSI.

4.

Tighten (CLOCKWISE) the locknut to 20-25 Ft.Lbs.

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3-16 Lubrication Section MD6640 Blasthole Drill

BI006893

FLOW CONTROL VALVE ADJUSTMENT 1.

Loosen the locknut on the flow control valve by turning the nut COUNTER-CLOCKWISE.

2.

Adjust the flow by turning the valve stem CLOCKWISE to reduce the flow and COUNTERCLOCKWISE to increase it. The flow valve can be turned in until the valve is completely closed, and out a maximum of 2-1/2 turns.

3.

After adjusting the flow to the desired setting, tighten (CLOCKWISE) the locknut to 20-25 Ft.Lbs.

FlowMaster Rotary Driven Hydraulic Pump Schematic

WARNING: Relieve pressure from the pump and supply lines before servicing or repairing the pump, to reduce the risk of an injury from injection, splashing fluid or moving parts.

CRANK CASE OIL Check the crank case oil every 100 hours of operation. Change the crank case oil every 500 hours of operation. Use SAE 10W30 motor oil in all units except Model 85610. In Model 85610, the manufacturer recommends Mobil Arrow HFA Low Temp oil for use at -70°F ambient temperatures.

The crank case should be filled to the center of the drain plug located on the back of the crankcase.

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3-17 Lubrication Section MD6640 Blasthole Drill

PUMP DISASSEMBLY PROCEDURE 1.

Remove and separate manifold (37) from the hydraulic motor (42).

2.

Remove the pipe plug (45) and drain the crank case oil from the pump housing (46).

3.

Remove the housing cover (30) and cover gasket (31).

4.

Remove the retaining ring (57) and pull the shovel plug (56) from the housing tube (55).

5.

Remove and separate the hydraulic motor (42) from the pump housing (46).

6.

Remove the 2 outlet pin nuts (50) from the pump housing (46).

7.

Remove the pump sub-assembly (1-28) from the pump housing (46). Pushing the subassembly up with a wooden or plastic rod .75 inch O.D. against the check seat housing (28) is helpful.

8.

Remove the housing tube (55) from the pump housing (46) by inserting a .75 inch O.D. rod through the inlet holes at the bottom of the housing tube (55) and unscrewing it.

9.

Remove the bronze bearing (51), o-ring (52) and back-up washer (53) from the housing tube (55).

10.

Remove the crankrod assembly (1-8) from the pump by unscrewing the screws (12) and then pulling out the wrist pin bushings (13).

11.

Remove the check seat housing (28) from the reciprocating tube (21).

12.

Unscrew the wrist pin anchor (14) from the reciprocating tube (21) and pull the plunger assembly (9-20) from the tube.

13.

Using a .50 inch O.D. rod, push the cup seal (22) and pump cylinder (24) from the reciprocating tube (21).

14

Remove the pump plunger (20) from the plunger link rod (17). A spanner wrench is required.

15.

Unscrew the plunger link rod (17) from the plunger tube (11) and slide off the cup seal (16), back-up washer (15) and the wrist pin anchor (14).

16

Unscrew the plunger tube (11) from the outlet pin (9).

17.

To dismantle the crankrod assembly (1-8), remove the screws (1) and counter weights (2).

18.

Remove the retaining rings (6) and press the crank eccentric (7) out of the ball bearing (8). Be sure to support the ball bearing (8) on the inner race.

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3-18 Lubrication Section MD6640 Blasthole Drill

BI006893

FlowMaster Rotary Driven Hydraulic Pump Assembly

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3-19 Lubrication Section MD6640 Blasthole Drill

BI006893 PUMP ASSEMBLY PROCEDURE 1.

When the pump is disassembled, it is recommended to replace all seals and gaskets. For replacement parts and service kits, refer to part sheet, “PUMP, HYDRAULIC, ROTARY DRIVEN” in the parts manual for this machine.

2.

In the process of disassembly, examine the following components and replace if excessive wear is indicated: •

Ball Bearing (8)

•

Crank Eccentric (7)

•

Crank Rod (5)

•

Wrist Pin (13)

•

Plunger Tube (11)

•

Pump Plunger, Ball & Spring (18-20)

•

Pump Cylinder (24)

•

Check Seat Housing & Ball (26 & 28)

•

Upper Bronze Bushing (51)

•

Housing Tube (55)

•

Shovel Plug (56)

•

Reciprocating Tube (21)

3.

The assembly procedure is reverse of the disassembly procedure except for the following:

4.

Install parts (22-28) into reciprocating tube (21) after the plunger assembly (9-20) is installed.

5.

Install the pump sub-assembly (1-28) into the pump housing (46) before tightening the housing tube (55) to the pump housing (46). Be sure the reciprocating tube (21) is inserted through both bushings before tightening the housing tube (55).

6.

Use LocTite 242 (or similar product) medium strength thread lock on all torqued threaded connections. Extreme care must be exercised to prevent excess compound from flowing into critical areas such as clearance fits and ball check. Allow a minimum of 30 minutes cure time before operating the pump.

7.

Torque Specifications: A.

Plunger Tube (11) to Outlet Pin (9) ~ Tighten to 100-110 In.Lbs.

B.

Button Head Screws (12) to Wrist Pin Anchor (14) ~ Tighten to 100-110 In.Lbs.

C.

Plunger Tube (11) to Plunger Link Rod (17) ~ Tighten to 100-110 In.Lbs.

D.

Plunger Link Rod (17) to Pump Plunger (20) ~ Tighten to 100-110 In.Lbs.

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3-20 Lubrication Section MD6640 Blasthole Drill

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E.

Flat Head Screws (1) to Counter Weight (2) ~ Tighten to 100-110 In.Lbs.

F.

Wrist Pin Anchor (14) to Reciprocating Tube (21) ~ Tighten to 20-25 Ft.Lbs.

G.

Check Seat Housing (28) to Reciprocating Tube (21) ~ Tighten to 20-25 Ft.Lbs.

H.

Outlet Pin Nut (50) to Pump Housing (46) ~ Tighten to 30-35 Ft.Lbs.

I.

Housing Tube (55) to Pump Housing (46) ~ Tighten to 20-25 Ft.Lbs.

J.

Socket Head Screw (44) to Pump Housing (46) ~ Tighten to 50-55 Ft.Lbs.

K.

Pressure Reducing Valve (38) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs.

L.

Flow Control Valve (39) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs.

M.

Solenoid Valve (34) to Manifold (37) ~ Tighten to 15-20 Ft.Lbs.

N.

Socket Head Screws (33) to Manifold (37) ~ Tighten to 20-25 Ft.Lbs.

FlowMaster Rotary Driven Hydraulic Pump Components

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3-21 Lubrication Section MD6640 Blasthole Drill

BI006893 TROUBLESHOOTING Condition

Possible Cause

Pump does not run.

No pressure on gauge (32): - Closed Supply line shut off valve.

- No power to solenoid valve (34).

- Faulty Solenoid (35).

- Pressure Reducing Valve (38) is Set too low.

- Insufficient Hydraulic Fluid supply.

Pressure is shown on gauge (32): - Closed Fluid outlet line.

- Flow Control valve is fully closed.

- Pump is stalled due to grease backpressure.

Pump is seized or damaged.

Pump speeds up or runs erratically.

Pump runs, but output is low.

Corrective Action

Open shut-off valve.

Correct electrical fault.

Replace solenoid (35).

Reset Pressure Reducing Valve (38).

Check hydraulic supply for proper pressure and flow.

Check outlet line and clear obstructions.

Readjust valve to 3/4 turn open.

Readjust valve to 3/4 turn open.

Dismantle the pump and repair defective or seized component. See disassembly and assembly procedure.

Low level of grease or reservoir is empty.

Follower plate is stuck and separated from grease.

Pump piston or checks are worn.

Refill reservoir.

Insufficient hydraulic fluid supply.

Check hydraulic supply and adjust flow using valve (39).

Increase pressure using valve (38).

Replace faulty components.

Inlet pressure too low.

Faulty inlet (25, 26, 27) or discharge check valve (18, 19, 20).

Check follower plate and container for damage.

Disassemble the pump and repair.

Weepage from housing cover (30).

Cup seal (16) or O-Ring (48) wore out. Check the seals and replace if necessary.

Pump becomes noisy.

No crank case oil.

Worn wrist pin bushing (13).

Pump does not build pressure.

Foreign material holding lower check open.

Add crank case oil. Remove Pipe Plug (45) from Pump Housing (46).

Oil level should be at the bottom of the Pipe Plug opening. For Models 85480, 85481, 85482, 85483 and 85247Add 10W30 motor oil until the crankcase is full.

For Model 85610, add light weight Mobil Arrow HFA Hydraulic Oil until the crankcase is full.

Check the bushings and replace if necessary.

Dismantle & clear check. Consider installing inlet screen (63) before returning pump to service.

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3-22 Lubrication Section MD6640 Blasthole Drill

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Lube Pump Hydraulic Schematic

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3-23 Lubrication Section MD6640 Blasthole Drill

BI006893 LUBRICATION POINTS

The lubrication charts in this section show the principal points on the machine to be lubricated.

Automatic lube systems should be checked daily to see that they are operating properly and that each lube point is receiving the correct amount of lubricant. The types of lubricants are described in LUBRICANT BENCHMARKS in this section of the manual.

GEARCASE AND RESERVOIR CAPACITIES

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3-24 Lubrication Section MD6640 Blasthole Drill

BI006893

The frequency of lubrication given in each chart is intended as a guide. Under unusual operating conditions, some points may require more frequent lubrication or other special attention. Use good judgment in lubricating the machine. If a bearing is showing signs of trouble, such as overheating or unusual noise, it should be given immediate attention. Make sure the lubricant is not dirty or of the wrong grade. Then the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is so that no lubrication point will be missed, and none will be over-lubricated. It is usually best to do this at the beginning of each shift.

LOWER WORKS LUBRICATION LUBE POINT

NO. OF POINTS LUBRICATED

TYPE LUBRICANT

HOURS 8 40 160 1000

AS AUTO REQ.

COMPONENTS

1 2 3 4

22 2 4 2

MPG MPG MPG MPG

X X X X

X X X X

LOWER ROLLER BUSHINGS TAKE-UP TUMBLER BUSHINGS REAR AXLE* EQUALIZER AXLE END PINS

5

2

MPG

X

X

UPPER ROLLER BUSHING

* Pack cavities at crawler frame and bearing block; Check annually.

NOTE: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station.

On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

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3-25 Lubrication Section MD6640 Blasthole Drill

BI006893

MAIN FRAME LUBRICATION LUBE POINT

NO. OF POINTS LUBRICATED

TYPE LUBRICANT

HOURS 8 40 160 1000

AS AUTO REQ.

COMPONENTS

1 2 3

12 1 2

MPG MPG MPG

X X X

X X X

EQUALIZER AXLE CENTER PIN MAST LOCK PINS

4

2

MPG

X

X

A-FRAME LOCK PINS (OPTIONAL)

LEVELING JACK CASING - LOWER

NOTE: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station.

On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

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3-26 Lubrication Section MD6640 Blasthole Drill

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MAST LUBRICATION ~PART 1 LUBE POINT

NO. OF POINTS LUBRICATED

TYPE LUBRICANT

HOURS 8 40 160 1000

AS AUTO REQ.

1 2 3 4 5

2 4 2 6 2

MPG MPG MPG MPG

6 7

1 2

RWRL MPG

X

8

2

MPG

X

X X X X

COMPONENTS

X TOOL WRENCH CYLINDER GUIDES X TOOL WRENCH BEARING BLOCKS TOOL WRENCH CYLINDER PINS DUST CURTAIN LEVER BUSHINGS AUXILIARY WINCH ROPE SHEAVE BEARINGS (SEALED) AUXILIARY WINCH ROPE X MAST BRACE LOCK PINS HOOK BLOCK (OPTIONAL)

NOTE: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station.

On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

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3-27 Lubrication Section MD6640 Blasthole Drill

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MAST LUBRICATION ~PART 2 LUBE POINT

NO. OF POINTS LUBRICATED

TYPE LUBRICANT

HOURS 8 40 160 1000

1 2 3 4 5 6 7

1 1 1 1 2 2 1

MPG MPG MPG MPG MPG MPG MPG

X X X X X X

8 9 10 11

6 2 1 2

MPG MPG MPG MPG

X X

12

4

MPG

X

COMPONENTS

X X X X X X

X

X X

AS AUTO REQ.

AIR SWIVEL SEAL UPPER ROTARY SHAFT BEARING ROTARY SHAFT LOWER SEAL INT. SHAFT UPPER BEARING SHIPPER SHAFT BEARING RACK AND PINIONS SHOCK SUB OR ROTARY COUPLING SEAL X GUIDE ROLLERS X 1ST INT. & SHIPPER SHAFT BEARINGS 1ST INT. GEAR BRGS - SEE NOTE BOGIE FRAME PIVOT PIN BOGIE ROLLER BEARING

NOTES: • Lube Point 10 must be accessed by removing the plug (or cover) on the side of the gearcase cover then carefully aligning the lube fitting in the pulldown gear accordingly.

• The above frequencies are for manual lubrication. For automatic lube systems the frequencies are set at the lube control station.

• On automatic lube systems, the injectors should be set at full opening at initial start-up, then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

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3-28 Lubrication Section MD6640 Blasthole Drill

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MAST LUBRICATION ~PART 3 LUBE POINT

NO. OF POINTS LUBRICATED

TYPE LUBRICANT

1 2 3 4 5 6 7 8 9

1 1 1 1 1 1 1 1 1

MPG MPG MPG MPG MPG MPG MPG MPG MPG

HOURS 8 40 160 1000

X X X X X X X X X

AS AUTO REQ.

COMPONENTS

X X X X

L.H. PIVOT POST UPPER BUSHING L.H. PIVOT POST LOWER BUSHING R.H. PIPE RACK UPPER BUSHING R.H. PIPE RACK LOWER BUSHING L.H. PIVOT POST LOCK PIN R.H. PIVOT POST LOCK PIN X UPPER GATE PIN X MIDDLE PIVOT ASSEMBLY BUSHING X SENSING DEVICE

NOTE: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station.

On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

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3-29 Lubrication Section MD6640 Blasthole Drill

LUBRICANT CLEANLINESS Even the best lubricant is a useless wear preventative if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt gets into the lubricant.

Follow these points of good lubrication practice: • Keep all oil and other lubricants in tightly covered containers.

• Wipe off covers before opening containers.

• Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off before using them.

• Wipe off each fitting before attaching the lubricant gun.

• Wipe off oil filler caps or covers and the surrounding area before removing them

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3-30 Lubrication Section MD6640 Blasthole Drill

BI006893

LUBRICANT SELECTION The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly lubricated bearings, gears, couplings, and other precision parts quickly fail. For this reason, lubricants selected in accordance with the “American Standards Testing Material” (ASTM) standards are recommended. These standards were compiled in cooperation with major petroleum suppliers to ensure the consumer of an exact supply to specific requirements, regardless of source.

We recommend you advise your petroleum supplier of the following information to assist him in selecting the proper product for each application of this machine.

Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory performance in the intended application, and does not relieve the supplier of performance responsibility for brand name products.

Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C) requires special lubrication. Note the temperature ranges on the following lubricant specification sheets. Contact your local supplier, your Caterpillar Global Mining representative, or the Service Department of your local Caterpillar Global Mining office for recommendations if you require additional information or advice.

•

STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE TOP.

•

STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!

•

WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!

•

FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!

•

USE ONLY CLEAN and PROPER LUBRICANTS!

•

DO NOT MIX TYPES or BRANDS of LUBRICANTS!

Even the best lubricants are less useful in preventing wear if they become contaminated by dirt or water due to careless handling or storage.

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3-31 Lubrication Section MD6640 Blasthole Drill

BI006893 ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT SCOPE:

Lubrication performance requirements and recommendations for Air Compressor (Screw-type) Lubricants.

IMPORTANT NOTE

These lubricant performance requirements for screw-type air compressors are only good for A-C Compressor Corporation screw compressors. If the machine is equipped with air compressors manufactured by other than A-C you must refer to the vendor’s maintenance information provided with the machine and Section 7 of this manual.

LUBRICANT RECOMMENDATIONS: The following lubricants are recommended: 1.

If the ambient temperature is expected to always be above -26°C (-15°F), use either: Automatic Transmission Fluid (ATF) - General Motors Dexron III or Ford Type F. or Synthesized Hydrocarbon Fluid - Mobil Rarus SHC 924.

2.

If the ambient temperature is expected to drop to -40°C (-40°F), use Mobil Rarus SHC 1024 or Phillips Philesco ISO32 or equivalent.

NOTE: If the ambient temperature drops below -26°C (-15°F), it may cause the lubricant to thicken in the oil cooler and could result in unit shutdown after a short run. If this happens often and the compressor is being lubricated with ATF, it is recommended that a synthesized hydrocarbon lubricant be used, instead.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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3-32 Lubrication Section MD6640 Blasthole Drill

BI006893

MPO - MULTIPURPOSE OIL SCOPE:

Lubricant performance requirements for Multi-Purpose Oil.

APPLICATION:

The addition of a lubricant to the compressed air system (not for screw-type air compressor systems - see ACSL), hand oil cans, etc.

GENERAL REQUIREMENTS: 1.

Must be fluid at temperature applied.

2.

Should contain rust inhibitor.

3.

Motor oil - API service classification “MS”.

VISCOSITY RECOMMENDATIONS: 1.

Air Line Lubricant AMBIENT TEMPERATURE

2.

SAE NUMBER

Below 10°F

5W

Above 10°F

10W

Hand Oil Can - Viscosity suitable for application and temperature.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

BI006893

3-33 Lubrication Section MD6640 Blasthole Drill

BI006893 RWRL - RUNNING WIRE ROPE LUBRICANT SCOPE:

Lubrication performance requirements for hoist rope lubricant.

APPLICATION:

Primarily for hoist ropes or any other running ropes where fatigue and not wear is of prime concern.

GENERAL REQUIREMENTS: 1.

Penetrate between adjacent wires in order to lubricate and protect them against wear and to keep the rope core from drying out and deteriorating.

2.

Provide a lubricant between sheaves and wire rope.

3.

Resist being washed off.

4.

Protect against rusting or corrosion.

5.

Form a non-sticky film so that dust and dirt will not build up on the wires.

6.

Remain pliable and resist stripping at the lowest temperatures to which the rope will be exposed.

7.

Preferably, it should form a light colored transparent film so that wear, corrosion or broken wires can be readily detected by inspection.

8.

Be capable of easy application, both manually and by devices without being heated.

COMPOUNDING: Suitable for penetrating between the adjacent wires of a rope in order to lubricate them and also to replenish the lubricant in the core.

BI006893

3-34 Lubrication Section MD6640 Blasthole Drill

BI006893

SPECIAL REQUIREMENTS: 1.

Must pass United States Steel Retention Test Using a Timken Tester

2.

Shell Four Ball E.P. - (ASTM D-2596)

3.

Load wear index, kg., min.:

40

Load weld kg., min.:

250

Shell Four Ball Wear - (ASTM D-2266) Wear scar diameter, mm., max.:

0.60

4.

Timken O.K. Load lbs., min. - (ASTM D-2782):

45

5.

Copper Strip Corrosion - (ASTM D-130):

pass

6.

Suggested Application Temperature Ranges

There should be a lubricant for each of the following temperature ranges: 110°F to 30°F 40°F to 9°F 10°F to -50°F NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

BI006893

BI006893

3-35 Lubrication Section MD6640 Blasthole Drill

HYDO – HYDRAULIC OIL Hhydraulic oil suitable for year-round use is recommended, rather than summer or winter only, which can create a mixing of viscosities if a complete draining of oil is not accomplished. This can compromise the intended oil viscosity.

The oil viscosity benchmark for this machine is 3,000 centistokes (CST) maximum on the coldest day for start-up, and 10 centistokes absolute minimum on the hottest day during machine operation.

Optimum oil viscosity at normal operating temperatures is 30 to 60 centistokes.

For climates that rarely see ambient temperatures drop much below freezing (25°F to 32°F), a paraffinic-based petroleum hydraulic oil with little or no viscosity improver (VI) can be acceptable.

For climates where ambient temperatures drop as low as -40°F on their coldest day and are as high as 104°F on their hottest day, a higher VI fluid is required. Paraffinic-based fluids should NOT be used where ambient temperatures reach freezing or slightly below freezing. At freezing or slightly below freezing temperatures, the paraffin wax starts to solidify causing the fluid to have a thicker viscosity than the temperature-viscosity curve actually implies. In addition, the VI additive in petroleumbased oils has the ability to be mechanically sheared, causing the viscosity to drop. This can result in a fluid that can be totally incorrect for use after it has been in service for some time.

For all the above reasons, plus concerns of the oxidation-rate and water-ingestion that leads to sludging, recommended draining intervals of 2,000 hours when using petroleum-based paraffinic or naphthenic-type hydraulic oils should be followed.

The preferred hydraulic oil for this machine is a PAO (poly-alpha-olefin) synthetic fluid with a naturally high VI. Examples being: 198 for Shell® Oil Tellus T 722, a range of 135 to 145 for Mobil® Oil SHC 500 series, 134 for Esso/Exxon® Terrestic SHP 22 Hydraulic Fluid, or 135 for Conoco® SYNCON AW Oil. The 3 to 4 times multiplier in the cost of synthetic fluids, as compared with paraffinic-based petroleum oils, is offset by the fact that the synthetic oil can be left in the system 4 times longer (i.e. 8,000 hours) before a drain interval requirement. The savings with synthetic fluid use results because the frequency of draining intervals is decreased by a factor of 4. This reduces the maintenance time dedicated to changing the system oil and the cost of system oil disposal to 1/4 of what they would otherwise be.

With all of the above in mind, using a SHC-type oil from Shell®, Mobil®, Esso/Exxon® or Conoco® can result in considerable cost savings, whether the mine is located in a cold or warm climate.

BI006893

3-36 Lubrication Section MD6640 Blasthole Drill

BI006893

PAO SYNTHETIC HYDRAULIC FLUID The following bar graph shows recommended viscosity grades for SHC hydraulic oil for various ambient temperatures. For temperatures outside of these ranges, contact the Caterpillar Global Mining Service Department for recommended oil.

Recommended Viscosity vs. OAT Chart

PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID Approved oils will typically have Denison HF-O specification certification. In general, the oils will meet the following minimum requirements: 1.

Maximum Viscosity = 14,000 SUS (3,000 CST) at the minimum expected ambient temperature (for start-up).

CAUTION:

Starting with viscosities greater than 3,000 CST could void warranty.

2.

Minimum Viscosity = 65 SUS at the maximum operating temperature of the hydraulic system.

3.

Ideal Viscosity = 100 SUS at normal operating temperature of the hydraulic system.

4.

Minimum Viscosity Index = 90

5.

Neutralization Number = 10 or less for new oil.

BI006893

3-37 Lubrication Section MD6640 Blasthole Drill

BI006893 6.

Oxidation Hours to 2.0 Neutralization Number per D-943 = 1,500 hours minimum.

7.

Demulsibility (easy separation from water) per D-1401 = 30 ±15 minutes to 3 ml. max. of emulsion.

Recommended Viscosity vs. OAT Chart

CAUTION:

8.

In general, water will not separate from motor oils or automatic transmission fluids, therefore these fluids are NEVER recommended as hydraulic system fluids.

Hydrolytic Stability per D-2619 = Copper wt. loss not to be more than .50 mg/cm2

The oil should contain rust and oxidation (R+O) inhibitors and foam depressants.

CAUTION:

The use of water or glycol base or any other fire resistant fluid is prohibited since serious damage to the hydraulic system will occur which will void the warranty on the machine hydraulic system.

Obtain oil from a reputable supplier. Contact the Caterpillar Global Mining Service Department for specific oil recommendations or approval.

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3-38 Lubrication Section MD6640 Blasthole Drill

BI006893

The lower figure on the previous page illustrates the acceptable temperature range for various viscosity grades (VG) of oil assuming a viscosity index of 125.

1.

The left side of the bars show the absolute minimum ambient temperature for cold startup.

2.

The right side of bars show the absolute maximum oil temperature.

3.

Ideal maximum operating oil temperature is a viscosity of 100 SUS.

NOTE: When determining an oil for the hydraulic system, the system was designed for an allyear oil and for use without heaters. The hydraulic system is tailored to the ambient temperature at the customer’s mine and the correct type of hydraulic fluid is selected.

For extremely cold temperatures, a very light fluid is used with oversize oil coolers to accommodate higher summer temperatures. With this procedure, viscosity limits as little as 30° above ambient can be met.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

SCOPE: This specification covers the requirements for “Enclosed Gearcase Lubricant” used on models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

The materials furnished under this specification are intended to lubricate spur and helical gears as well as anti-friction bearings at the interior of enclosed planetary and non-planetary type gearcases (Propel, Rotary, Pull Down and Pump Drive).

This specification covers “Enclosed Gearcase Lubricants” that may be applied in service at temperatures ranging from –50ºC (-58ºF) to the highest ambient temperature conditions.

GUIDELINES FOR SELECTING AN APPROVED LUBRICANT: Step #1 Using Table 1, determine the recommended oil type (Mineral or Synthetic) based upon the anticipated ambient temperature range.

AMBIENT TEMPERATURE RANGE: Ambient Temperature: The ambient temperature is defined as the air temperature in the immediate vicinity of the gearcase. a. Use atmospheric temperature for gearcases located outside of the machinery house (Rotary, Pull Down and Propel Gearcases). b. Use machinery house temperature for gearcases located inside of the machinery house (Pump Drive Gearcase) for some machines are equipped with machinery house heaters. c. For cold weather applications, the pour point of the lubricant must be at least 5°C (9°F) below the minimum ambient starting temperature. If the ambient starting temperature approaches the lubricant pour point, oil sump heaters may be required to facilitate starting and ensure proper lubrication. Use oil temperature for gearcases having oil sump heaters.

Page 1 of 4

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 1 Ambient Temperature Range 14°F to 100°F (-10°C to 37°C) Less than 14°F to 120°F (Less than -10°C to 50°C)

ISO Viscosity Grade / Oil Type ISO VG 220 / Mineral or Synthetic (poly-α-olefin) Oil ISO VG 220 / Synthetic (poly-α-olefin) Oil

Step #2 Select an approved lubricant for the Propel, Rotary, Pull Down and Pump Drive Gearcases from the Approved Lubricant Tables 2 & 3.

The pour point and flash point of individual brand name gear oils must be observed.

Refer to the oil manufacturers technical data sheets for these properties.

APPROVED LUBRICANTS: Lubricants that have been approved for use by the Gearcase manufacturers are listed in the Approved Lubricant Tables 2 & 3. The use of non-approved lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/regulatory requirements.

Page 2 of 4

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 2 Approved Mineral Oil Lubricants (ISO VG 220) Manufacturer BEL-RAY BP

CASTROL

CHEVRON ESSO FUCHS LE (Lubrication Engineers) MOBIL PETRO CANADA SHELL TEXACO W HITMORE

Product Description Bel-Ray 100 Gear Oil 90 Energol PM 220 Energol GR-XP 220 Energol GR-XF 220 Alpha SP 220 Alpha MAX 220 Optigear BM 220 Tribol 1100/220 Chevron Ultra Gear Lube 220 Gear Compound EP 220 Spartan EP 220 (Only Product Originating from Europe) Renolin CLP 220 Plus Almasol 607 Mobilgear XMP 220 Ultima EP 220 Omala F 220 Auriga EP 220 Meropa 220 Meropa W M 220 Paragon 220

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BI006893

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 3 Approved Synthetic (Poly-α-olefin) Oil Lubricants (ISO VG 220) Manufacturer BEL-RAY BP

CASTROL

CHEVRON FUCHS MOBIL PETRO CANADA SHELL TEXACO WHITMORE

Product Description Synth. Gear Oil 6690 Enersyn EP-XF 220 Enersyn HTX 220 Optigear Synth. A 220 Optigear Synth. X 220 Alphasyn EP 220 Alphasyn T 220 Tribol 1510/220 Tribol 1710/220 Tegra Synth. Gear Lube 220 Renolin Unisyn CLP 220 Mobil SHC 630 Mobilgear SHC 220 Mobilgear SHC XMP 220 Ultima Synth. EP 220 Omala HD 220 Pinnacle EP 220 Decathlon F 220

SPECIFICATION REVISIONS: This specification is subject to change without notice. Please refer to the Bucyrus International, Inc. web site www.bucyrus.com for the latest specification.

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BI006893

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) SCOPE: 1. This specification covers “Multi-Purpose Grease”.

2. Materials furnished under this specification are primarily intended to lubricate heavy duty ball, roller, and plain bearings.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors or metering blocks.

4. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS: 1. Heat Resistance - Shall be thermally stable, should not flow or harden in service.

2. Retention - Shall not exhibit high leakage.

3. Stability - Shall work continuously with a minimum change in consistency.

4. Water Resistance - Shall withstand water washout or leaching.

5. Reversibility - Shall be stable with repeated heating and cooling.

6. Pressure Separation - Shall resist oil-soap separation.

7. Extreme Pressure - Shall withstand heavy shock loading.

8. Compatibility – a. Low temperature greases shall be compatible with mineral oil base greases. b. Grease must be compatible with oil seal lip materials (Nitriles, Viton), and all centralized lubrication system components (i.e. gaskets, o-rings, vent valves, etc.). Reference ASTM D 4289-03.

9. Compounding – a. Suitable for producing the extreme pressure characteristics (without inert fillers) required for heavy duty ball, roller, and plain bearing lubrication.

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BI006893

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) b. Base fluid is to be mineral or synthetics which are compatible with mineral base. c. Thickener types are to be of the following varieties: Aluminum, Lithium, or Calcium.

Page 2 of 5

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY Ambient Temperature (See Note #1) NLGI Consistency # Dropping Point °C(°F) Minimum Timken O.K. load-lbs(kgf) Minimum Shell Four Ball EP Load wear index (LWI) kg Minimum Load Weld kg Minimum Shell Four Ball Wear Wear Scar mm Maximum 40KG for 1 hour @ 75°C @ 1200 RPM Copper Strip Corrosion 24 Hrs @ 100°C (212°F) Rust Test Viscosity of Base Fluid Minimum Motormatic Grease Worker Mechanical Stability 10,000 strokes, Maximum change Roll Stability Test Maximum change in 2 hours Wheel Bearing Test 6 hours @ 104°C(220°F) Maximum loss Water Washout Test Loss @ 38°C(100°F), Maximum Loss @ 80°C(175°F), Maximum

REFERENCE

REQUIREMENT -1°C to +43°C -18°C to +27°C Less than -12°C (+30°F to +110°F) (0°F to +80°F) (Less than +10°F) ASTM D-217 2 1 1, 0, 00 (See Note #2) ASTM D-2265 177(350) 177(350) 177(350)

ASTM D-2509

50(23)

50(23)

50(23)

ASTM D-2596

65

65

65

ASTM D-2596

400

400

400

ASTM D-2266

0.6

0.6

0.6

2e

2e

Pass 220cSt @ 40°C

Pass 130cSt @ 40°C

ASTM D-4048

2e

ASTM D-1743 Pass ASTM D-445 460cSt @ 40°C

ASTM D-217A

10%

10%

10%

ASTM D-1831

15%

15%

15%

ASTM D-1263

10%

10%

10% (NLGI #1 Only)

ASTM D-1264

5%

5%

5% (NLGI #1 Only)

15%

15%

15% (NLGI #1 Only)

Page 3 of 5

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) PROPERTY REFERENCE REQUIREMENT Pressure Oil Separation The Lubrication Engineers U.S. Steel test method - Cake Manual (United States Steel). penetration not less than 25% of grease penetration.

Grease Mobility The Lubrication Engineers U.S. Steel method - not less than 0.10 Manual (United States Steel). grams flow per second at the lowest anticipated ambient temperature.

(Testing temperature not less than -34°C/-30°F).

Pumpability, The Lubrication Engineers To vent from 1800 psi (127 kgf/cm^2) Lincoln Ventmeter Manual (United States Steel). to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Lubricating Solids (Molybdenum Disulfide, Less than or equal to 5% Graphite, Etc.) % by Weight Lubricating Solids (Molybdenum Disulfide, 10 Microns Graphite, Etc.) Particle Size, (Microns, max.)

NOTES: 1. Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

2. Low Temperature Grease - For extended use in low temperature (-12°C to -46°C / +10°F to -50°F) areas, this product should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing.

This product should meet the Mobility and Pump-ability criteria for the lowest anticipated ambient temperature. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

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BI006893

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) CERTIFIED LUBRICANTS: Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Multi-Purpose Grease” (see the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

Page 5 of 5

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) SCOPE: 1. This specification covers “Open Gear Lubricant”.

2. Materials furnished under this specification are primarily intended to lubricate open gears, but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel mechanism components.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles.

4. This specification covers open gear lubricants that may be applied in service at temperatures ranging from -50°C (-58°F) to the highest ambient temperature conditions. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS: 1. Materials furnished under this specification may be asphaltic (bitumen) compounds, or blends of a thickener and mineral oils and/or synthetic fluids. They may be in the form of viscous fluids, semi-fluid greases or pastes.

2. Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed film and boundary conditions.

3. Open gear lubricants supplied under this specification must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between applications under all operating conditions.

4. Various grades or consistencies of open gear lubricants may be required to provide proper lubrication and application properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or exceed the minimum performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

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BI006893

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) 5. Viscosity, a fluid's resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to produce a lubricating film between two interfacing surfaces.

All lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives such as resins or polymers. Some "viscosity enhancers" are shear sensitive, which could result in insufficient protection of the lubricated components under high load, elevated temperatures and/or high shear conditions. The viscosity of the fluids utilized in the open gear lubricants shall be sufficient under operating conditions for the product to meet or exceed the performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

6. Open gear lubricants supplied under this specification must be specifically formulated to protect surfaces, reduce wear, and provide satisfactory service life under all anticipated operating conditions.

7. Open gear lubricants supplied under this specification must have excellent water tolerance and rust preventive qualities, as well as minimal dripping qualities for operation over wide temperature ranges.

8. Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to ensure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip materials (Nitriles, Viton). Reference ASTM D 4289-03.

9. For extended use in low temperature areas, open gear lubricants supplied under this specification should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

Page 2 of 4

BI006893

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY REFERENCE REQUIREMENT Flash point of product as applied, minimum (base product with diluent) ASTM D92 / ISO 2592 Ambient Temperature (See Note #1) -50°C(-58°F) to +10°C(50°F) 61°C (142°F) Above +10°C(50°F) 80°C (176°F) Flash point of base fluid(s), minimum ASTM D92 / ISO 2592 140°C (284°F) Rust protection ASTM D 1743 Pass Copper strip corrosion maximum rating ASTM D 4048 2e 24hr. @ 100°C (212°F) Four ball EP test weld point, minimum kgf ASTM D 2596 800 (base product without diluent) Load wear index (LWI), minimum ASTM D 2596 120 (base product without diluent) Four ball wear test 60 minutes @ 40 kgf.

ASTM D 2266 0.7 Maximum scar, mm (base product without diluent) Adhesive properties Must adhere to surfaces at the lowest anticipated ambient temperature.

Pumpability, Lincoln Ventmeter To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Minimum Base Fluid Viscosity Ambient Temperature ASTM D 445 (See Note #1) °C (°F) -50 to +10 (-58 to +50) 680 cSt at 40°C -20 to +40 (-4 to +104) 1860 cSt at 40°C +10 to +50 (+50 to +122) 3600 cSt at 40°C Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) 15 Microns Particle Size, (Microns, max.)

NOTE: 1. Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

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BI006893

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) CERTIFIED LUBRICANTS: Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Open Gear Lubricant” (see the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000 SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

Page 4 of 4

BI006893

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

SCOPE: Materials furnished under the specifications for “OGL–Open Gear Lubricant (SD4713)”, “MPG-Multi Purpose Grease (SD4711)” and “Dragline Enclosed Gearcase Lubricant” (SD4721 Part A) are intended for use on Bucyrus International, Inc. mining machinery (Electric Mining Shovels, Draglines and Rotary Blasthole Drills).

Lubricants certified by their manufacturers as complying with these Bucyrus International, Inc. specifications are listed in the tables below.

LUBRICANT SELECTION: Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Each lubricant listed in the tables below has a unique operating temperature range. It is the responsibility of the lubricant manufacturer to recommend the appropriate products based upon the applicable Bucyrus lubricant specification (SD4711, SD4713 and SD4721 Part A) and the anticipated ambient temperature range for each application.

CERTIFIED LUBRICANT LISTING FOR “OGL–OPEN GEAR LUBRICANT (SD4713)” Manufacturer Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Castrol Castrol Castrol Castrol Chemtool Inc. Chemtool Inc. Chemtool Inc. Haycock Petroleum

Product Description Molylube SF 100 Sub-Arctic 77070 Molylube SF 100 Arctic 77020 Molylube SF 100 Light 76990 Molylube SF 100 Medium 77010 Molylube SF 100 Heavy 77000 Molylube Unee NS 70550 Molylube Unee 70600 Molylube Unee 70540 Molylube SD-1 70620 Molylube Gear TAC Light 68990 Molylube Gear TAC Regular 68940 Molylube Gear TAC Medium 68950 Molub-Alloy 936 SF Light Molub-Alloy 936 SF Medium Molub-Alloy 936 SF Heavy Molub-Alloy 936 SF Heavy A Alpha OGL-680 Alpha OGL-1860 Alpha OGL-3600 Shovel Lube OGL 1.5 Ultra

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BI006893

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Imperial Oil / Esso Imperial Oil / Esso Lubritene Lubritene Lubritene Lubritene Petro-Canada Petro-Canada Petro-Canada Petron Petron Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Shell Shell Shell Stewart Lubricants & Service Co. (SLS) Talcor Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Dynagear Heavy Dynagear Extra Lubrene Multi Serv OGL Lubrene Multi Serv OGL-H Lubrene OGL-e Lubrene Bio Serv OGL Vulcan Synthetic All Season Vulcan Synthetic 2200 Vulcan Heavy Petrotac EP Premium 30-B Petrotac EP Premium 10-B Silver Streak Quickvent All Season (#196ALL) Silver Streak Quickvent Arctic (#196ARC) Silver Streak BGL 100 Silver Streak BGL 200 Silver Streak BGL 300 Malleus Grease GL 3500 Malleus OGM Heavy Malleus OGM Extra Heavy SLS BI OGL Heavy OGP V Axiom Multiservice Mining Lubricant – Arctic / SurStik 800 – Arctic Axiom Multiservice Mining Lubricant – Medium / SurStik 800 – Medium Axiom Multiservice Mining Lubricant – Heavy / SurStik 800 – Heavy

CERTIFIED LUBRICANT LISTING FOR “MPG-MULTI-PURPOSE GREASE (SD4711)” Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel Bel

Manufacturer Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray Ray

Product Description Molylube AC 1000 40890 Molylube AC 1000 40900 Molylube AC 1000 40922 Molylube LC135 67800 Molylube LC135 67810 Molylube LC135 67820 Molylube LC135 67832 Molylube LC133 67840 Molylube LC133 67850 Molylube LC133 67860 Molylube LC133 67872 Molylube LC131 27660 Molylube LC131 27670 Molylube LC131 27680 Molylube LC131 27692

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BI006893

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Castrol Castrol Castrol Castrol Chemtool Inc. Chemtool Inc. Chemtool Inc. Chemtool Inc. Chemtool Inc. Exxon Exxon Haycock Petroleum Haycock Petroleum Imperial Oil Imperial Oil Lubrication Engineers Lubrication Engineers Lubrication Engineers Lubrication Engineers Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Lubritene Petro-Canada Petro-Canada Petro-Canada Petro-Canada Petro-Canada Petro-Canada Petron Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Shell Shell Shell Shell

Molylube 126 EP 23200 Molylube 126 EP 23220 Molylube 126 EP 23242 Termalene EP 72400 Termalene EP 72420 Molub-Alloy 4086-0 Molub-Alloy 4086/460-1 Molub-Alloy 777-1 ES Molub-Alloy 777-2 ES CSC 174 MGD CSC MP1-220 CSC MP1 CSC MP0 CSC MP00 Ronex Extra Duty 2 Ronex Extra Duty Moly 2 / Mobilgrease XHP 462 Moly Calcuplex M5 NLGI #1 Calcuplex M5 NLGI #2 Epic EP Moly Unirex EP 1 Moly Almagard Vari-Purpose 3750 Almagard Vari-Purpose 3751 Almagard Vari-Purpose 3752 Almaplex Ultra-Synthetic 1299 Lubrene Li 500 EP 2 Lubrene LiM 500 EP 2 Lubrene AXM 1000 EP 1 Lubrene AXM 1000 EP 2 Lubrene AXM 500 EP 1 Lubrene AXM 500 EP 2 Lubrene LXCa 700 EP 2 Lubrene Li 900 WP EP 2 Lubrene EMV-2 Supreme Arctic Supreme EP1 Supreme EP2 Precision XL 3 Moly EP1 Precision XL 3 Moly EP2 Precision XL 5 Moly EP0 Petro-Plate M5/800 NLGI #1 Moly Ultra 800 EP #1 (#221) Moly Ultra Red EP #1 (#229) Moly Supreme #1 (#238) Moly EP Synthetic Blend #1 (#274) Albida Grease HDX2 Albida Grease MDX 1 Albida Grease MDX 2 Alvania Grease SDX2

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BI006893

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Shell Shell Shell Shell Shell Talcor Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Albida SLC 460 Limona LX1 Limona LX2 Albida HLS00 Albida HLS2 Super HD 2-M5 Omnilith 500 Extreme Pressure Grease EP 0 Omnilith 500 Extreme Pressure Grease EP 1 Omnilith 500 Extreme Pressure Grease EP 2 Omnilith 500 M Extreme Pressure Grease EP 0 Omnilith 500 M Extreme Pressure Grease EP 1 Omnilith 500 M Extreme Pressure Grease EP 2 Caliber 3M Extreme Pressure Grease EP 00 Caliber 3M Extreme Pressure Grease EP 0 Caliber 3M Extreme Pressure Grease EP 1 Caliber 3M Extreme Pressure Grease EP 2 Caliber 5M Extreme Pressure Grease EP 00 Caliber 5M Extreme Pressure Grease EP 0 Caliber 5M Extreme Pressure Grease EP 1 Caliber 5M Extreme Pressure Grease EP 2

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BI006893

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

CERTIFIED LUBRICANT LISTING FOR “DRAGLINE ENCLOSED GEARCASE LUBRICANT (SD4721 Part A)” Mineral Oils Manufacturer Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Bel Ray Exxon / Esso Exxon / Esso Lubritene Lubritene Lubritene Mobil Mobil Mobil Mobil Petro-Canada Petro-Canada Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Schaeffer Mfg. Shell Shell Shell Shell Talcor Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Product Description 100 Gear Oil 140 (ISO VG 460) 100 Gear Oil 250 (ISO VG 1000) 100 Gear Oil 350 (ISO VG 1500) 100 Gear Oil 460 SBF (ISO VG 460) 100 Gear Oil 1000 SBF (ISO VG 1000) 100 Gear Oil 1500 SBF (ISO VG 1500) Spartan EP 460 (ISO VG 460) Spartan EP 1000 (ISO VG 1000) Lubrene Syn 1500 (ISO VG 1500) Lubrene Super Series Gear Oil 1500 (ISO VG 1500) Lubrene Super Series Gear Oil 1000 (ISO VG 1000) Mobilgear 600XP 460 (ISO VG 460) Mobilgear 634 (ISO VG 460) Mobilgear XMP 460 (ISO VG 460) Mobilgear 639 (ISO VG 1000) Ultima 460 (ISO VG 460) Ultima 1000 (ISO VG 1000) #209A Universal Gear Lube (ISO VG 460) #209A Universal Gear Lube (ISO VG 1000) #294 Supreme Gear Lube (ISO VG 460) #294A Supreme Gear Lube No Tack (ISO VG 460) Omala 460 (ISO VG 460) Omala 1000 (ISO VG 1000) Omala 1500 (ISO VG 1500) SP Plus Gear Oil (ISO VG 1500) Gear Oil EP (ISO VG 1000) Paragon Heavy Duty Enclosed Gear Oil (ISO VG 460) Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1000) Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1500) Paragon Gold High Performance Gear Oil (ISO VG 1000)

Synthetic (PAO) Oils Manufacturer Bel Ray Bel Ray Lubrication Engineers Lubrication Engineers Mobil

Product Description Synthetic Gear Oil 460 (ISO VG 460) Synthetic Gear Oil 1000 (ISO VG 1000) 9846 Synolec Gear Lubricant (ISO VG 460) 9899 Synolec Gear Lubricant (ISO VG 1000) Mobil SHC 634 (ISO VG 460)

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BI006893

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING (January 22, 2007)

Mobil Mobil Mobil Mobil Mobil Schaeffer Mfg. Schaeffer Mfg. Shell Shell Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co. Whitmore Mfg. Co.

Mobilgear SHC XMP 460 (ISO VG 460) Mobilgear SHC 460 (ISO VG 460) Mobil SHC 639 (ISO VG 1000) Mobilgear SHC 1000 (ISO VG 1000) Mobilgear SHC 1500 (ISO VG 1500) #167 Pure Synthetic Gear Lube (ISO VG 460) #167 Pure Synthetic Gear Lube (ISO VG 1000) Omala HD 460 (ISO VG 460) Omala HD 1000 (ISO VG 1000) GF 365 Synthetic Gear Fluid (ISO VG 460) GF 365 Synthetic Gear Fluid (ISO VG 1000) Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 460) Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 1000)

LUBRICANT CERTIFICATION PROCESS: Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

REVISIONS: This listing is subject to change without notice. Please refer to the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing.

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4-1 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 Section

4

Preventive Maintenance Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents INTRODUCTION ........................................................................................................................... 3 ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM ............................................... 5 SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ..................................................... 5 GENERAL SAFETY CONSIDERATIONS ................................................................................ 6 MAINTENANCE DURING MACHINE OPERATION ........................................................................ 6 MAINTENANCE PRECAUTIONS .................................................................................................. 7 PREVENTIVE MAINTENANCE FOR LUBRICATION..................................................................... 8 LUBRICANT CLEANLINESS ................................................................................................... 9 FREQUENCY OF INSPECTION AND MAINTENANCE ............................................................... 10 MAINTENANCE SCHEDULE & CHECK POINTS ....................................................................... 10 DAILY ..................................................................................................................................... 11 EXTERNAL INSPECTION ............................................................................................... 11 ONBOARD INSPECTION ............................................................................................... 14 AFTER START-UP INSPECTION ................................................................................... 18 EVERY 100 HOURS, OR WEEKLY ...................................................................................... 20 ON-BOARD INSPECTION .............................................................................................. 23 EVERY 500 HOURS, OR MONTHLY .................................................................................... 25 EVERY 2500 HOURS, OR SEMI-ANNUALLY ....................................................................... 27

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4-2 Preventive Maintenance Section MD6640 Blasthole Drill

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BI006893

4-3 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 Section

4

Preventive Maintenance This section of the manual describes those aspects of preventive maintenance on the machine such as inspection, adjustment and routine repetitive tasks. Information related to lubrication techniques, frequency and service points is also partially included. Further detailed information can be found in Sections 3 and 5 of this manual.

At the end of this section are reproducible maintenance schedules that may assist in record keeping and maintenance scheduling.

INTRODUCTION A Preventive Maintenance Programs is a systematic series of operations performed periodically on equipment to prevent breakdowns.

Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only new at one point in time. From that moment, the machinery begins to deteriorate through use and aging. A well organized maintenance program will avoid unexpected high-cost breakdowns and will increase component life.

A systematic approach to the program should be followed and detailed records of all findings kept, to detect potential problem areas. Valuable time and effort can be saved if defects are corrected before they lead to a major breakdown. The records should be reviewed often and kept on file for future reference.

Personnel involved in the program should go through an established training program, to know WHAT to check and HOW to rectify any potential problem area. When personnel are able to do routine maintenance and normal repairs efficiently, downtime is reduced and machine productivity increased. Also, to keep the machine in good running condition, the necessary parts, tools and current information should be kept on hand.

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4-4 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

Equipment maintenance is a science and its practice an art. This art can be divided into 6 types of operations - they are: Inspection is probably the most important operation. Careful observation is required of all parts of the equipment. Slight abnormalities may not interfere with the equipment performance BUT those that are a deviation from the normal should be discovered early. When inspecting, notice placement, state of cleanliness, color, etc. of part(s).

Example: discoloration indicates overheating; all guards, bolts in place and good housekeeping.

Cleaning and keeping clean is essential for good operation. Periodic cleaning should be more frequent on exposed parts than those which are contained within cabinets.

Parts, connections and joints should be free of dust, corrosion and other foreign matter.

A Feeling operation is used more often to check guarded rotating machinery for vibration due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical items should be performed as soon as possible AFTER power has been removed and the circuit grounded. Feeling of excessive heat may indicate an overloaded condition and should be corrected.

A Tightening operation should be done on all connections that have worked loose due to vibration, etc. Loose parts are a definite hazard because they may fall out of place and damage nearby components. The importance of firm mounting and tight connections cannot be overemphasized. Always replace missing or broken bolts with proper size and use the correct tools.

Adjusting should be done when inspection indicates that it is required to maintain normal operating conditions. Specific adjustment is contained in the “Mechanical Adjustment Section” of this manual, the electrical manual or the component manufacturer’s manual.

Lubrication refers primarily to the application of CORRECT LUBRICANT in the CORRECT AMOUNT to bearings and other rotating parts. It also means the application of a light oil to door hinges or other sliding surfaces. Use only clean and proper lubricant.

Planned maintenance, common sense and good judgment is less costly and more effective than panic maintenance. Action taken on recommendations made on the following suggested inspection Check Lists by the maintenance department, should reduce repair and maintenance costs and increase production.

Replacing worn components with genuine oem parts on a scheduled basis will avoid costly down times and emergency repairs. The cost of parts is small when compared to unscheduled breakdowns that result in excessive overtime man-hours and lost machine production.

Whenever a problem is indicated, the inspector should briefly explain it on the maintenance report (a suggested form is at the end of this section) along with his signature. Then, an authorized person should briefly explain a solution to the problem. Finally, CORRECT THE PROBLEM.

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4-5 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM

• Preventive Maintenance Program.

• Well Trained and Motivated Work Force.

• Effective Communications.

• Proper Equipment Selection and Procurement.

• Meaningful Documentation.

• Cooperation with the Operations / Maintenance Department.

• Warehouse Support.

• Good Shop Facilities.

SCHEDULED PREVENTIVE MAINTENANCE PROGRAM Economically maintaining the productivity and performance of this mining drill requires maintenance and inspection activities in a scheduled manner. Manpower requirements and performance of needed maintenance during scheduled downtime dictates a system which recognizes the recommended inspection interval. By staggering the inspection or servicing of these items, labor time and workforce size is balanced.

Maintenance and component inspection should be performed simultaneously during scheduled downtime. History of machine maintenance practices has shown that parts replacement and component rebuild in advance of destructive failure yields the lowest operating costs. Keeping good records is vital to support any preventive maintenance program. Early “change-out” reduces unscheduled downtime and prevents secondary damage. Record keeping should be an “easy to use” format and contain enough detail to isolate the function. Since basic machine life extends over thousands of operating hours, maintenance records can be utilized to forecast budgets for maintenance expenditures. This makes records a very valuable planning tool for mine management.

Use the routine maintenance program that is outlined here to formulate a schedule suited to the work-force and mining environment. Over a period of time, additional inspection or planned work may supplement the activities described in this manual.

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4-6 Preventive Maintenance Section MD6640 Blasthole Drill

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GENERAL SAFETY CONSIDERATIONS The importance of overall safety in the maintenance of a mobile machine should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical components are subject to wear and other deterioration which limits their useful life; thus making them expendable. When new, all such parts have a built in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If however; inspection and adjustment are neglected, these parts eventually reach a condition where they become a potential problem.

Similarly, failure to replace various mechanisms to ensure proper performance of the machine could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the manual periodically to refresh knowledge of these procedures. Supervisors, operators and maintenance men should continuously follow safe practices.

MAINTENANCE DURING MACHINE OPERATION Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. Deficiencies during machine operation should be carefully investigated. It should be determined if a safety problem exists. Maintenance is vital to safe operation! It should be performed systematically by competent personnel.

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the machine is running. Obviously, there are some maintenance procedures, such as gear tooth inspections and replacement which require machine shut down. However; many support duties can be effectively handled at shift change when the machine is still activated.

Automatic lubrication systems function throughout the operational cycles of the machine. These systems release pre-measured lubricant which extends the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

CAUTION:

A repair or maintenance job is not complete until all guards, plates and other safety devices have been replaced before the equipment is restored to operation.

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4-7 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 MAINTENANCE PRECAUTIONS

The operator must be sure that the machine equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a possibly yielding support surface. Before beginning repair or adjustment, the operator shall: 1.

2.

3.

Set all brakes.

De-energize control functions.

Do whatever else is necessary to prevent accidental movement of the machine.

DANGER:

HIGH VOLTAGE! IF POWER IS ESSENTIAL TO THE REPAIR, SUCH AS FOR TESTING, IT SHOULD ONLY BE ENERGIZED WHEN ALL PERSONNEL ARE CLEAR OF ELECTRICAL AND MECHANICAL HAZARDS. The power should only be energized during the testing period and not when repair work is actually being done.

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the OFF position and tagged. The lock and tag should be removed only by the maintenance people who installed them, or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.

Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled.

DANGER:

Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers and switches.

While performing maintenance, the awkward positions assumed and the handling of heavy parts often increases the possibility of injuries. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

DANGER:

Many of the components comprising the machine are heavy, bulky items. EXTREME CAUTION SHOULD BE USED WHEN LIFTING THESE ITEMS. PERSONNEL SHOULD BE CERTAIN OF THE WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT THEM, EITHER MANUALLY OR WITH A LIFTING DEVICE. ALL APPLICABLE SAFETY RULES MUST BE FOLLOWED WHEN USING A CRANE OR OTHER LIFTING DEVICE. Be aware of the load rating, lifting height and swing radius of the lifting device before lifting a load. Failure to follow all applicable safety rules when performing maintenance could result in serious injury, or death.

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4-8 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

PREVENTIVE MAINTENANCE FOR LUBRICATION Lubrication may well be the most important portion of a preventative maintenance program. Do not allow anything to interfere with the lubrication of the machine. Experience will dictate how to adjust the amount of lubricant to use at each servicing. However; the extra effort will result in a smooth running machine with less wear and breakdowns.

It is difficult to predict how much lubricant should be applied to a particular bearing. It varies with how hard the machine is being worked, how much the bearing has previously worn and the grade of lubricant being used. Watch all the bearings closely to insure that the lubricant added at one servicing is enough to last until the next.

Most wearing parts require that lubricant be applied regularly in small quantities as with the automatic lubrication system instead of large amounts applied occasionally. Make regular inspections of the machine and watch for signs of improper lubrication such as the accumulation of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line or lubricant pipe. Normally excess lubricant pumped into a plain bearing is not used. However, certain bearings in locations which may collect dirt should have extra lubricant added to purge all of the old lubricant which may have collected abrasive dirt.

New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant.

Old bushings may overheat because they are so worn that lubricant will not stay in until the next time of servicing. In the case of the new bushing, it may be necessary to give it more frequent lubrication until it is worked in. It may be necessary to do the same for the old bushing, until it can be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a point which needs it rather than trying to run it to the end of the shift.

The most common cause of overheating an anti-friction bearing is churning of the lubricant. This happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing, it is almost a sure sign that too much lubricant was added to the bearing. Continue to lubricate it as often as before, but use less lubricant.

Section 3 of this manual will provide more detailed and specific information on lubricants and their usage.

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4-9 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 LUBRICANT CLEANLINESS

Even the best lubricant is a useless wear preventative if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt gets into the lubricant.

Follow these points of good lubrication practice: •

Keep all oil and other lubricants in tightly covered containers.

•

Wipe off covers before opening containers.

•

Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a clean lint-free cloth before using.

•

Wipe off each fitting before attaching the lubricant gun.

•

Wipe off oil filler caps or covers and the surrounding area before removing them.

Refer to the topic “Lubricant Benchmarks” in Section 3 of this manual for an explanation of each type of lubricant required for servicing this machine. Make sure the lubricant was not dirty or of improper viscosity. When the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is to ensure that no lubrication point will be missed or overlubricated. It is usually best to do this at the beginning of each shift. Reproducible service schedules are provided for recording service information.

NOTE:

Lubrication instructions provided by any vendor for a vendor supplied item have priority over lubrication intervals and procedures indicated here.

CAUTION:

When not possible to work on the machine with a safety harness, use a “cherry picker” or “man basket” when inspecting or servicing elevated areas. A slip or fall can result in severe personal injury or death.

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4-10 Preventive Maintenance Section MD6640 Blasthole Drill

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FREQUENCY OF INSPECTION AND MAINTENANCE The suggested maintenance schedule is developed on a planned usage of 5,000 operating hours per year. This is a planned reference only. The actual conditions within the mine site, operator’s abilities and habits, along with the quality of components and consumables will ultimately drive the inspection schedule used on the machine.

Care should be taken to properly evaluate the maintenance approach during the initial period after machine commissioning.

MAINTENANCE SCHEDULE & CHECK POINTS The following maintenance schedule is based on a typical machine. Certain features or configurations may be different on a specific machine. This maintenance schedule is intended to outline the intervals for the various repetitive maintenance requirements. For any assistance, refer to the appropriate section in this Maintenance and Operation Manual, or contact the Caterpillar Global Mining service representative.

NOTE: This maintenance schedule is not to be substituted for Section 5 ~ SERVICE PROCEDURES in this manual.

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4-11 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 MAINTENANCE INSPECTION CHECK POINTS

MD6640

Blast Hole Drill

DAILY EXTERNAL INSPECTION 1.

Check areas around and under the machine for signs of water or lubricant leaks. If single droplets of water or lubricant are noticed, leakage is minimal.

Determine the source of the leak and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine the source and take remedial action immediately.

2.

Inspect the crawler belts for broken or cracked pads, missing lock pins, loose track pins, and proper crawler belt tension.

3.

Check the drive tumbler gearcase, hydraulic motor and hoses for leaks.

Check the lubricant level in the drive tumbler gearcase.

4.

Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and bolts.

5.

Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or covered with cuttings.

CAUTION:

The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with approved rubber gloves and insulated hooks or tongs.

ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

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4-12 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

DAILY Check Points (cont.)

6.

Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp rocks. Have an electrician inspect the strain relief device and the condition of the cable where it enters the machine.

7.

Inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or damage. If loose wires are noted, do not touch them but notify an electrician immediately.

8.

Inspect the leveling jack spuds for proper lubricant covering. Inspect the leveling jack pads for cracks, broken or missing pins, or excessive dirt accumulation.

9.

Inspect the mast braces and locking pins. Replace missing or defective components immediately. Verify that all adjusting bolts are properly adjusted. Check all hoses and cylinders for leaking.

CAUTION:

Use a safety belt and lanyard to protect against falls when climbing on the mast braces or working on the machinery house roof.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift:

10.

Inspect the mast hinge pins for loose or missing keepers or bolts. Replace missing or damaged parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.

Inspected By: Supervisor:

pmc_6640

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4-13 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 DAILY Check Points (cont.)

11.

Inspect the mast hoist cylinders for loose or missing pins or keepers, oil leaks, damaged hoses or structural damage. Repair or replace any missing or damaged components immediately.

12.

Inspect the mast structure for bent or broken chords or plates, loose or broken parts, proper rack lubrication or excessive rack wear. Inspect ladders, handrails and platforms for broken or missing parts. Repair or replace broken or missing parts immediately.

13.

Check the main air flex hose, lubrication lines, and electric lines running from the mast to the rotary drive/pulldown unit for interference with the mast or excessive wear or leaks.

14.

Check the safety restraint cables on the mast. Be certain that the cables and supports are in good repair with no cracks, missing or loose hardware or any damage that could affect their effectiveness.

15.

Check the machinery house air filtering fan duct to see that it is clear of obstructions.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

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4-14 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

DAILY Check Points (cont.)

MD6640

ONBOARD INSPECTION

1.

Inspect the air compressor lubrication lines for leaks. Correct any leaks found immediately.

2.

Check the condition of the air compressor intake filter. Replace the filter cartridge if the red flag is visible in the service indicator. Empty the dust hopper and clean the pre-cleaner element. Inspect the housing and ducting for damage or leaks. Repair or replace leaking components.

3.

Check the oil level in the hydraulic tank. Fill the tank to the proper level as described on the instruction plate on the tank.

4.

Check hydraulic system for leaks.

Correct all leaks immediately and clean up all oil spills immediately.

5.

If the machine is equipped with a bit lubricator for the main air system, check that the lubricator is full.

6.

Inspect the automatic lubrication central pumping stations for proper operation. Check the supply of lubricant and change or refill drums as necessary.

7.

Close and lock all electrical cabinet doors.

DANGER: HIGH VOLTAGE! Assume all parts inside of the electrical cabinets are energized. All electrical components should be serviced by qualified electrical personnel only.

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-15 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 DAILY Check Points (cont.)

8.

Inspect the compressor radiator and fan. Check for signs of deterioration or damage to hoses, valves, fittings, etc. Check for leaks at all joints. Check the radiator core for blockage by dust, dirt, leaves, paper, etc. and clean as necessary

9.

Check the operator’s display terminal for any faults.

10.

Inspect the machinery house for general cleanliness. Clean all dirt and debris from the machinery house.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

NOTE: Do not use compressed air to clean the machinery house. Compressed air will only move the dirt around.

Use a vacuum cleaner to remove the dirt from the machine. Failure to clean the inside of the machinery house will cause damage to many of the components located there.

11.

Inspect the auxiliary winch and auxiliary winch line.

12.

Check the oil level in the pump drive gearbox. Fill with recommended oil to the proper level.

13.

Check all controls for free operation.

Return all controls to the OFF or SET position.

14.

Inspect the operator’s cab for housekeeping and cleanliness. Clean dirt and debris from the cab. Clean the windows to give full visibility for proper operation.

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-16 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

DAILY Check Points (cont.)

NOTE: Do not use compressed air to clean the operator’s cab. Compressed air will only move the dirt around.

Use a VACUUM CLEANER TO REMOVE DIRT FROM THE OPERATOR’S CAB 15.

17.

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Inspect the tool wrenches for free operation, broken or missing parts, proper lubrication, lubricant leaks or dirt accumulation. Repair or replace parts as necessary and clean the drilling platform.

CAUTION:

16.

MD6640

Before working near or under the rotary drive/pulldown unit, make sure all of the operator’s controls are off and tagged and the hoist brake set to prevent movement of the unit. Serious personal injury or death could result should the rotary drive/ pulldown unit fall when personnel are working near or under it.

Inspect the automatic breakout wrench for free operation, broken or missing parts, proper lubrication, lubricant leaks or excessive dirt accumulation. Repair or replace parts as necessary. Be certain that the breakout wrench is retracted.

Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or lubricant leaks. Be certain that the upper gate is closed and that the rack is in the stored position.

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-17 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 DAILY Check Points (cont.)

18.

Inspect the guide bushing for excessive wear or dirt accumulation.

Also inspect the retainer lugs to be sure they are intact. Do not operate the machine without both retainer lugs intact and securely welded to the deck.

19.

Inspect the tool string for excessive wear, dirt accumulation, bent pipe and secure joints. The bit cones and bearing should be in good condition.

Manually turn the cones to make sure they turn freely.

20.

Inspect the rotary gear case for lubricant leaks, damaged lines, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearbox. Fill to the recommended level with an approved gear lubricant. Check the rotary motor ventilation inlets for leaves, paper, rags, etc. blocking the flow of air.

21.

Inspect the rotary drive unit for excessive wear or dirt accumulation.

Inspect the guide rollers for proper adjustment and excessive wear.

Check for loose or missing bolts and bent or cracked structural members.

22.

Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper adjustment and excessive wear.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-18 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

DAILY Check Points (cont.)

23.

Inspect the pulldown gearcase for lubricant leaks, dirt accumulation and other damaged or missing parts.

Check the lubricant level in the gearbox. Fill to recommended level with an approved gear lubricant.

Check the pulldown motor ventilation inlets for leaves, papers, rags, etc. blocking the flow of air.

24.

Check the hoist brake for proper operation.

25.

Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation. The deflector should seal around the drill pipe securely.

26.

If the machine is equipped with a fire suppression system, perform any applicable checks or inspection as described in the fire suppression system owner’s manual.

27.

Check dust collector supply air filter dessicant color through sight glass. If pink, change dessicant.

28.

Inspect dust collector dropout hose has no holes, rips, or tears.

AFTER START-UP INSPECTION 29.

Check all brakes for proper setting and releasing.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

30.

Listen for unusual noises in the gearcase.

pmc_6640

BI006893

4-19 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 DAILY Check Points (cont.)

31.

Check all bearings for unusual noises and excessive heat.

32.

At the end of any drilling cycle, turn dust collector blower system off, and pulse filter elements.

33.

While operating, observe dust collector blower outlet for dust. If dust appears, inspect and replace dust collector filter elements.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-20 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

MAINTENANCE INSPECTION CHECK POINTS

MD6640

Blast Hole Drill

EVERY 100 HOURS, OR WEEKLY (WHICHEVER OCCURS FIRST) 1.

Check for missing or worn crawler link pins and retaining pins.

2.

Check for cracked or worn crawler links.

3.

Check the tumblers and rollers for cracking, wear and lubrication.

4.

Check for cracking of the crawler frames.

5.

Check for excessive dirt accumulation.

6.

Check for proper belt adjustment (1-3 inch sag between end of upper slide and drive or take-up tumbler).

7.

Check drive tumbler for cracking and wear.

8.

Check the oil level in the propel planetary gearboxes.

CAUTION:

ITEM #

NOTED DISCREPANCY

Be careful when removing the plugs, especially if the unit is hot. Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with great force.

9.

Check the propel gearbox. Hydraulic motor and hydraulic lines for leaks.

10.

Check that rear axle bearing block bolts are tight.

Date:

Check front equalizer axle for wear and cracking.

Inspected By:

11.

Shift: Supervisor:

pmc_6640

BI006893

4-21 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 100 HOURS, OR WEEKLY (cont.)

12.

Check equalizer axle pins for wear and lubrication.

13.

Check dust curtains for wear or damage. Check that the curtains are not frozen to the ground.

14.

Check the curtain raising levers for wear, damage, lubrication.

15.

Check the curtain raising cylinders for wear, damage or leaking.

16.

Check the dust deflector for wear or damage.

17.

Visually check the condition of the trail cable.

18.

Check the cable reel for damage, wear and lubrication. Manually lubricate the drum shaft bearings - 2 points.

19.

Check the cable reel controls for ease of operation and hydraulic leaks.

20.

Check the cable reel drive chains for wear, damage, lubrication and adjustment.

21.

Check the leveling jack frames for cracking.

22.

Check the leveling jack shoes for cracking. Clean off any dirt or rocks.

23.

Check for missing or worn shoe pins and retaining pins.

24.

Check the leveling jack spuds for proper lubrication.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-22 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

100 HOURS, OR WEEKLY (cont.)

25.

Check the leveling jacks for oil leaks.

26.

Check the mainframe for cracking.

27.

Check the retractable stairway for proper operation.

28.

Check the outside of the machinery house and cab for damage or cracking.

29.

Check that all blowers for ventilating and radiators are not obstructed.

30.

Check dry-type dust collection unit duct and hoses for leaks.

31.

Check lube drive shaft bearings on drytype dust collection unit.

32.

Check that water tank is full.

33.

Check the condition of the mast braces and brace pins.

34.

Check the mast brace lock cylinders and hydraulic lines for leaks.

35.

Check that the mast hoist cylinder pins and retaining pins are in place.

36.

Check the mast structure for wear, damage or cracking.

37.

Check the mast’s racking for wear, damage and lubrication.

38.

Check the mast ladder, safety guards and platforms for cracking and missing bolts.

39.

40.

Check the condition of the auxiliary winch line.

Check the condition of the mast head sheaves.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-23 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 100 HOURS, OR WEEKLY (cont.)

41.

42.

Check the condition of the upper portion of the tool racks.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Check the condition of the mast air pipe, bull hose and lube lines. Visually check the condition of the electrical lines.

ON-BOARD INSPECTION 43.

Check oil level in the pump drive gearbox. Add oil if required.

44.

Check the mast hoist cylinder anchor pin and retaining pins.

45.

Check the guidebushing for wear, on the drilling deck.

46.

Check the tool wrenches for wear, lubrication and oil leaks.

47.

Check the lower portion of the tool racks for wear or damage.

48.

Check the pawls in the rack pockets that they work freely.

49.

Check that the rack levers work freely.

50.

Check the cylinders. Lubricate the rack lower arms.

Date: Shift:

51.

52.

Check the rotary coupling for cushion wear and tightness of bolts.

Check the oil level in the rotary gearcase. Add oil if required.

Inspected By: Supervisor:

pmc_6640

BI006893

4-24 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

100 HOURS, OR WEEKLY (cont.)

53.

Check the gearcase and frame for cracking and oil leaks.

54.

Check the guide rollers for proper adjustment.

55.

Check the pulldown gearcase for cracking and oil leaks.

56.

Check the oil level in the pulldown gearcase. Add oil if required.

57.

Check the hoist brake on the pulldown gearcase for proper operation.

58.

Check the oil level, in the machinery house, in the hydraulic reservoir. Add oil if required.

59.

Check all oil filters. Change if required.

60.

Check all belt drives for proper belt tension.

61.

Check the oil level in the screw compressor separator. Add oil if required.

62.

Check all hydraulic, air, lube piping for leaks.

63.

Check dust collector filter elements.

Replace as needed.

64.

Inspect dust collector suction hose for obstructions. Inspect hose joints for integrity.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-25 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 MAINTENANCE INSPECTION CHECK POINTS

EVERY 500 HOURS, OR MONTHLY (WHICHEVER OCCURS FIRST)

1.

Check the crawler belt adjustment and adjust belts if required.

2.

Position the machine so that crawler rollers and take-up tumblers can be checked for excessive movement which indicates bushing wear.

3.

Take sample of propel gearcase oil for testing.

CAUTION:

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Be careful when removing the plugs, especially if the unit is hot. Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with great force.

4.

Remove rotary gearcase inspection cover and inspect gearing.

5.

Take sample of rotary gearcase oil for testing.

6.

Check the rotary gearcase drive shaft bearing adjustment and adjust if required.

7.

Remove pulldown gearcase inspection cover and inspect gearing.

8.

Take sample from the pulldown gearcase oil for testing.

9.

Check the rotary air seal and replace it if required.

10.

Take sample of hydraulic oil from reservoir for testing.

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-26 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

500 HOURS, OR MONTHLY (cont.)

11.

Check and clean or replace all air filters.

12.

Check and clean or replace all oil filters.

13.

Take a close look at all structural units, including crawler frame, axles, mainframe and mast. Check for cracking, stress marks or buckling.

14.

Take care of any deficiencies found during prior inspections which did not require immediate action.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-27 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893 MAINTENANCE INSPECTION CHECK POINTS

EVERY 2500 HOURS, OR SEMIANNUALLY (WHICHEVER OCCURS FIRST) 1.

Position the machine so that one takeup tumbler and lower roller can be removed for inspection of the bushings.

2.

Drain the propel gearcase and fill with new oil.

CAUTION:

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Be careful when removing the plugs, especially if the unit is hot. Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with great force.

3.

While the gearcase is drained, inspect the gears, pinions, bearings and seals.

4.

Drain the pump drive gearbox and fill with new oil.

5.

Drain the rotary gearcase and fill with new oil.

6.

While the gearcase is drained, remove the motor and inspect the gears, pinions, bearings and seals.

7.

Drain the pulldown gearcase and fill with new oil.

8.

While the gearcase is drained, inspect the gears, pinions, bearings and seals.

9.

Re-pack the bearings in the masthead winch sheaves.

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

4-28 Preventive Maintenance Section MD6640 Blasthole Drill

BI006893

2500 HOURS, OR SEMI-ANNUALLY (cont.)

10.

Drain the auxiliary winch and fill with new oil.

11.

Drain the hydraulic reservoir and fill with new oil.

12.

Change all hydraulic oil filters.

13.

Correct any deficiencies found during prior inspections which did not require immediate action.

14.

Clean up around the machine and touch-up paint any parts of the machine where paint is missing and rusting could occur.

MD6640

Blast Hole Drill ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

pmc_6640

BI006893

5-1 Service Procedures Section MD6640 Blasthole Drill

BI006893 Section

5

Service Procedures Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents CRAWLER BELTS ........................................................................................................................ 5 Lower Works - Overview .............................................................................................................. 5

ADJUSTMENT ......................................................................................................................... 6 Crawler Belt Tension - Checking .................................................................................................. 6 Crawler Belt Adjustment - Details ................................................................................................ 7

LINK REPLACEMENT ............................................................................................................. 8 BELT REPLACEMENT ............................................................................................................ 9 Crawler Belt Replacement - Details ............................................................................................. 9

LOWER ROLLERS .............................................................................................................. 10 Lower Roller - Details ................................................................................................................. 10

REPAIR ........................................................................................................................... 11 UPPER ROLLERS ................................................................................................................ 12 Upper Roller - Details ................................................................................................................. 12

REPAIR ........................................................................................................................... 13 TAKE-UP TUMBLERS .......................................................................................................... 14 REPAIR ........................................................................................................................... 14 DRIVE TUMBLER ................................................................................................................. 16 Drive Tumbler and Planetary Gearbox Installation ...................................................................... 16

REPAIR ........................................................................................................................... 16 PLANETARY GEARBOX ....................................................................................................... 17 GEARBOX REMOVAL AND INSTALLATION .................................................................... 17 Planetary Gearbox Mount Bolt Torque Sequence ........................................................................ 18

CHECKING/CHANGING OIL ............................................................................................ 19 Planetary Gearbox Oil Check - Details ....................................................................................... 19

LUBRICANT SPECIFICATIONS ................................................................................ 20 Planetary Gearbox Lubrication Specifications ............................................................................ 20 Oil Change Intervals ................................................................................................................... 20

CRAWLER FRAMES ............................................................................................................ 21 REPAIR ........................................................................................................................... 21 Crawler Frame Removal/Blocking ............................................................................................... 22

AXLES ................................................................................................................................... 23 Equalizer Axle - Details .............................................................................................................. 23

REPAIR ........................................................................................................................... 24 Rear Axle - Details ..................................................................................................................... 24

MAINFRAME ................................................................................................................................ 26 REPAIR ........................................................................................................................... 27 BIT VIEWING HATCH ............................................................................................................ 27 Bit Viewing Hatch - Details ......................................................................................................... 27

MAST A-FRAME .................................................................................................................... 28 REPAIR ........................................................................................................................... 28

BI006893

BI006893

5-2 Service Procedures Section MD6640 Blasthole Drill

LEVELING JACKS ................................................................................................................. 29 Leveling Jack - Details ............................................................................................................... 29

REPAIR ........................................................................................................................... 30 MACHINERY HOUSE ............................................................................................................ 33 REPAIR ........................................................................................................................... 33 HOUSE VENTILATION FAN AND FILTER ............................................................................. 34 Machinery House Ventilation Fan ............................................................................................... 34

WALKWAYS AND LADDERS ................................................................................................ 35 Retractable Boarding Stairway - Details ...................................................................................... 35

OPERATOR’S CAB .............................................................................................................. 36 Operator’s Cab Location Mounting .............................................................................................. 36

OPERATOR’S SEAT ............................................................................................................. 37 OPERATOR’S CONTROLS ................................................................................................. 37 Operator’s Controls .................................................................................................................... 37

AIR CONDITIONING UNIT WITH HEATER ............................................................................ 38 Operator’s Cab Heating/Air Conditioning Unit ............................................................................. 38

HYDRAULIC PUMP DRIVE ................................................................................................... 39 Hydraulic Pump Drive ................................................................................................................. 39 Hydraulic Pump Drive Gearbox - Details ..................................................................................... 40

CABLE REEL .............................................................................................................................. 42 CHAIN TENSIONING ................................................................................................................... 44 HYDRAULIC ADJUSTMENTS ......................................................................................... 45 View A - Hydraulic Adjustment Locations ................................................................................... 45

HYDRAULIC DRIVE START UP INSTRUCTIONS .......................................................... 46 LUBRICATION ................................................................................................................. 48 REPAIR ........................................................................................................................... 48 MAST STRUCTURE ................................................................................................................... 49 REPAIR ................................................................................................................................. 50 MAST SAFETY SLINGS ........................................................................................................ 50 Upper Safety Sling ..................................................................................................................... 50

REPAIR ........................................................................................................................... 51 Lower Safety Sling - Optional ..................................................................................................... 51

ROTARY GEARCASE ........................................................................................................... 52 Rotary Machinery/Gearcase ....................................................................................................... 52

DRIVE SHAFT ADJUSTMENT ......................................................................................... 53 Rotary Machinery Intermediate Shaft .......................................................................................... 54

REPAIR ........................................................................................................................... 55 REMOVE THE UPPER BEARING RETAINER. ......................................................... 55 Rotary Machine Driveshaft - Details ............................................................................................59

ROTARY MOTOR ................................................................................................................. 62 Rotary Drive Motor - Details ........................................................................................................ 62

ROTARY SHOCK COUPLING .............................................................................................. 64 REPAIR ........................................................................................................................... 64 ROTARY/PULLDOWN GUIDE FRAME ................................................................................. 66 Rotary Pulldown Guide Frame - Details ...................................................................................... 66

GUIDE ROLLER ADJUSTMENT ........................................................................................... 67 Rack Pinion and Upper Guide Roller - Details ............................................................................ 67 Lower Guide Rollers - Details ..................................................................................................... 68

REPAIR ........................................................................................................................... 69

BI006893

BI006893

5-3 Service Procedures Section MD6640 Blasthole Drill COUPLING ALIGNMENT ........................................................................................................... 71

PULLDOWN GEARCASE ..................................................................................................... 73 Pulldown Machinery - Overview ................................................................................................... 73

REPAIR ........................................................................................................................... 74 Pulldown/Machinery Gearcase and Base .................................................................................... 74 Pulldown/Machinery First Intermediate and Shipper Shaft .......................................................... 75 Pulldown Machinery Second Intermediate Shaft ......................................................................... 76 Pulldown Machinery Input Shaft .................................................................................................. 78

HOIST BRAKE ...................................................................................................................... 81 INSPECTION ................................................................................................................... 81 Brake Wear Adjustment ............................................................................................................. 81 Hoist Brake - Details .................................................................................................................. 82

BRAKE WEAR ADJUSTMENT ........................................................................................ 83 REPLACEMENT OF FRICTION DISCS .......................................................................... 83 DISASSEMBLY OF MAGNET BODY AND ARMATURE .................................................. 84 RE-ASSEMBLY OF MAGNET BODY AND ARMATURE .................................................. 84 RH Pipe Rack - Details .............................................................................................................. 85 LH Pipe Rack - Details .............................................................................................................. 86

REPAIR ........................................................................................................................... 86 Pipe Rack Variable Equipment .................................................................................................. 88

TOOL WRENCH ................................................................................................................... 89 Tool Wrench - Details ................................................................................................................. 89

REPAIR ........................................................................................................................... 90 BREAKOUT WRENCH ......................................................................................................... 91 REPAIR ........................................................................................................................... 91 GENERAL GUIDELINES FOR DISASSEMBLY ............................................................... 91 AUXILIARY WINCH ................................................................................................................ 92 MAST BRACES ..................................................................................................................... 93 Mast Braces - Details ................................................................................................................. 93

REPAIR ........................................................................................................................... 94 ADJUSTMENT ................................................................................................................. 94 HYDRAULIC SYSTEM................................................................................................................. 95 SYSTEM OPERATION .......................................................................................................... 95 Hydraulic Components Overview ................................................................................................. 95

CYLINDER CIRCUIT HYDRAULIC SYSTEM ........................................................................ 96 PROPEL CIRCUIT HYDRAULIC SYSTEM ............................................................................ 97 GENERAL MAINTENANCE ................................................................................................... 97 HYDRAULIC SYSTEM CLEANLINESS ........................................................................... 97 OIL REQUIREMENTS ............................................................................................... 98 OIL AND FILTER CHANGES ..................................................................................... 98 WEEKLY MAINTENANCE CHECKS ......................................................................... 99 OIL RESERVOIR REPAIRS .................................................................................................. 99 LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING PROCEDURE ... 99 REAR JACKS ................................................................................................................ 100 FRONT JACK ................................................................................................................ 100 PRE-START INSPECTION ................................................................................................. 101 HYDRAULIC SYSTEMS TESTS ......................................................................................... 102 PROPEL PUMP CHARGE PRESSURE CHECK ............................................................... 102 CONTROL PRESSURE CHECK .................................................................................. 103 PROPEL ENABLE VALVE AND LOW SPEED SELECT CHECK ...................................... 103

BI006893

BI006893

5-4 Service Procedures Section MD6640 Blasthole Drill

JACK CYLINDER CHECK IN MANUAL MODE .................................................................... 104 FLOW CONTROL CHECK ................................................................................................. 105 JACK CYLINDER DRIFT TEST .......................................................................................... 107 BRAKE RELEASE PRESSURE CHECK ........................................................................... 107 PROPEL BRAKE EMERGENCY RELEASE CHECK ......................................................... 108 PROPEL PUMP MAIN RELIEF PRESSURE CHECK ......................................................... 108 CRAWLER FUNCTION CHECK ......................................................................................... 109 BIT VIEWING HATCH CHECK ............................................................................................ 110 BOARDING STAIR CHECK ................................................................................................ 110 MAIN FLOW VALVE CHECK ............................................................................................... 110 BREAKOUT WRENCH AND TOOL WRENCH CHECK ..................................................... 110 DUST CURTAIN CYLINDERS ............................................................................................. 110 DUST SEAL SLIDER ........................................................................................................... 111 MAST LOCK ........................................................................................................................ 111 MAST BRACE LOCK CYLINDERS ..................................................................................... 111 A-FRAME LOCK CYLINDERS ............................................................................................ 111 MAST LOCK CONSTANT PRESSURE CHECK ................................................................ 112 MAST BRACE CONSTANT PRESSURE CHECK .............................................................. 112 A-FRAME LOCK CONSTANT PRESSURE CHECK .......................................................... 112 MAST RAISE/LOWER ........................................................................................................ 113 AUXILIARY WINCH .............................................................................................................. 114 HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK .............................................. 115 WINDOW GUARD FUNCTION CHECK - OPTION ............................................................ 115 CHECK JACKS IN AUTO LEVEL MODE ............................................................................. 116 PIPE RACK POSITION CHECK ......................................................................................... 117 PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING ................................ 117 PIPE THREAD LUBRICATOR CHECK ............................................................................... 117 PIPE POSITIONER FUNCTION CHECK ............................................................................ 118 CENTER GUIDE FUNCTION CHECK ................................................................................ 118 AUTOMATIC BREAKOUT WRENCH CHECK .................................................................... 119 DUST CONTROL ..................................................................................................................... 119 GENERAL MAINTENANCE ................................................................................................. 119 DRILLING PLATFORMS AND DUST CURTAINS ................................................................ 120 WATER INJECTION - OPTION ........................................................................................... 120 OPERATION ................................................................................................................. 121 FILLING WATER TANK ................................................................................................. 121 SCHEMATICS, HYDRAULIC .............................. LOCATED AT THE END OF THIS MANUAL

BI006893

5-5 Service Procedures Section MD6640 Blasthole Drill

BI006893 Section

5

Service Procedures

CRAWLER BELTS The crawler belts should be inspected frequently to prevent an unexpected breakdown.

Lower Works - Overview

BI006893

5-6 Service Procedures Section MD6640 Blasthole Drill

BI006893

Check the links for cracks, worn lugs, elongated link pin bores and other damage. Minor cracks in the link do not constitute a major problem. However, cracked links should be repaired by welding or replaced at a convenient time. Links with broken or worn drive lugs should be replaced at the earliest convenient time as they can cause the belt to ride off the rollers or take-up tumblers. Links with elongated pin bores should be checked carefully for cracks at the pin lugs and replaced if badly worn or cracked. Bent, broken, or badly worn link pins should be replaced.

ADJUSTMENT To determine if the crawler belts should be adjusted, raise the machine up on the leveling jacks so that the crawler belts are hanging free and not contacting the ground. At the center of the crawler frame measure the clearance between the bottom of the crawler frame and the roller surface of the crawler links. The minimum clearance is 9" and the maximum clearance is 14". When the maximum clearance is reached, the crawler belts must be adjusted to 9" to 11". Do not operate machine with belt slack in excess of maximum clearance.

Crawler Belt Tension - Checking

Adjustment of the crawler belts is accomplished at the take-up tumbler of the belts. The take-up tumblers are mounted on shafts which are mounted in supports which in turn ride in slots in the crawler frames. Shims place ahead or behind the supports position the tumbler to provide the desired belt tension.

To adjust belt tension: 1.

Using the leveling jacks, raise the machine until the crawlers and belts are suspended above the ground. Block the machine in this position.

2.

Remove the tumbler shim guards from the inside and outside of the crawler frame.

3.

Position suitable hydraulic jacks, (20-ton), behind each of the supports.

BI006893

5-7 Service Procedures Section MD6640 Blasthole Drill

BI006893 4.

Remove several shims from behind the supports.

5.

Actuate the hydraulic jacks to push the supports rearward to provide the desired belt tension.

Make sure the supports slide straight in the crawler frame and do not become cocked.

6.

Insert sufficient shims in front of the supports to maintain the adjustment. Several different thicknesses of shims are provided. Be sure that the shims are the same thickness behind each support.

Crawler Belt Adjustment - Details

7.

Remove the hydraulic jacks.

8.

Reinstall the shim guards on the crawler frame.

9.

Repeat the procedure for the other crawler belt if necessary.

10.

Remove blocking and lower machine.

BI006893

5-8 Service Procedures Section MD6640 Blasthole Drill

BI006893 LINK REPLACEMENT To replace a link in the crawler belts: 1.

Propel the machine to position the defective link in an accessible position near one end of the crawler.

2.

Remove the tension from the belt by removing all of the tensioning shims from behind the take-up tumbler supports. Refer to the Crawler Belt Adjustment for details of this procedure.

SECURE BELT MOVEMENT

FROM

UNWANTED

3.

Attach a suitable lifting device to the defective link. Part the belt at the defective link by removing the two link pins securing the link to one end of the belt.

4.

With the lifting device, lower the end of the crawler belt with the defective link to the ground.

5.

Remove the defective link from the belt.

6.

Install the replacement link on the end of the belt resting on the ground.

SUPPORTING CRAWLER BELT WITH LIFTING DEVICE 7.

Using the lifting device, lift the end of the belt into position to insert the remaining link pins.

8.

Insert the link pins and secure with cotter pins.

9.

Remove any equipment securing the belt against movement.

10.

Readjust belt tension as described in the Crawler Belt Adjustment topic of this manual.

BI006893

5-9 Service Procedures Section MD6640 Blasthole Drill

BI006893 BELT REPLACEMENT

Although belt replacement is required infrequently, there are times when it is necessary. To replace a belt, first propel the machine to firm, flat, level ground.

1.

Remove tension from the belt by removing the shims from behind the take-up tumbler supports as described in the topic Crawler Belt Adjustment.

2.

Part the belt at the midway point of the upper slide by removing the link pins.

Crawler Belt Replacement - Details

3.

Attach a suitable lifting device to the ends of the belt and drag and lift each end of the belt off the crawler frame and lay it on the ground.

4.

Using the machine leveling jacks, raise the machine sufficiently to allow the old belt to be dragged from underneath of the crawler frame. Securely block the machine in this position.

5.

Using a suitable vehicle and rigging, drag the old belt from underneath of the crawler frame.

6.

Assemble the new belt and lay it flat on the ground near the crawler frame.

7.

Using a suitable vehicle and rigging, drag the new belt underneath of the crawler frame so that the roller path in the center of the belt is aligned with the lower rollers, drive tumbler and takeup tumbler.

8.

Remove the blocking and slowly lower the machine until the crawler rollers and tumblers are resting on the belt.

9.

Using a suitable lifting device, lift the ends of the belt into a position to insert the link pins.

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5-10 Service Procedures Section MD6640 Blasthole Drill

BI006893 10.

Insert the link pins and cotter pins to complete the belt.

11.

Readjust the belt tension as described in the topic Crawler Belt Adjustment.

LOWER ROLLERS Inspect the lower rollers for cracks and damage that can impair normal tracking of the crawler belts.

Lower Roller - Details

Once a month raise the machine with the leveling jacks to allow inspection of the rollers. Block the machine in a raised position. Using a suitable lever, check the clearance of the thrust washer by lifting and then lowering the roller. Replace the thrust washers if clearance is excessive.

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5-11 Service Procedures Section MD6640 Blasthole Drill

REPAIR The most common problem encountered with lower rollers is bushing wear. However, over a period of time, the rollers will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Follow the welding instructions in the Appendix.

If bushing replacement is necessary, the roller must be removed from the machine. To accomplish this: 1.

Relieve the crawler belt tension as described in the topic Crawler Belt Replacement.

2.

Using the machine leveling jacks, raise the machine sufficiently to allow removal of the roller.

Block the machine in the raised position. It may be necessary to jack the crawler belt away from the crawler frame and block in position to remove the extreme front or rear rollers.

3.

Remove lubrication guards and lube lines of so equipped to gain access to the roller shaft.

4.

Remove the capscrew and retainer securing the lower roller shaft to the crawler frame.

5.

Support the lower roller with suitable blocking.

6.

Remove the roller shaft.

7.

Remove the blocking and lower the roller out of the crawler frame.

8.

Inspect the roller bushing. Remove, inspect, and replace the bushing if necessary.

9.

Inspect the lower roller shaft. Replace if worn.

10.

Inspect the crawler frame in the area of the lower roller. Repair shaft bore or thrust surfaces if necessary.

11.

Lubricate the roller bushing and shaft.

12.

Install roller in crawler frame and block in line with the shaft bore.

13.

Insert roller shaft.

14.

Install the retainer and capscrew to secure roller shaft to crawler frame. Remove the roller blocking.

15.

Install lubrication guards and lube lines if so equipped.

16.

Adjust lubrication guards and lube lines if so equipped.

17.

Adjust belt tension as described in the topic Crawler Belt Adjustment.

18.

Remove blocking and lower machine. Propel the machine to distribute the lubricant evenly in the roller and check roller operation.

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5-12 Service Procedures Section MD6640 Blasthole Drill

BI006893 UPPER ROLLERS

Inspect the upper roller for cracks and damage that can impair normal tracking of the crawler belt.

Upper Roller - Details

Once a month use a jack to lift the crawler belt off the upper roller. With a suitable lever, check the clearance of the roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.

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5-13 Service Procedures Section MD6640 Blasthole Drill

REPAIR The most common problem encountered with upper rollers is bushing wear. However, over a period of time, the roller will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Contact ylocal our Caterpillar Global Mining l representative for a customized welding repair process.

If bushing replacement is necessary, the roller must be removed from the machine. To accomplish this: 1.

Relieve the crawler belt tension as described in the topic Crawler Belt Adjustment.

2.

Using a jack, raise the crawler belt high enough so that the upper roller can be removed. Block the belt in this position.

3.

Remove the capscrew and retainer securing the roller shaft to the crawler frame.

4.

Support the roller with suitable blocking and remove the roller shaft.

5.

Remove the roller and blocking from the crawler frame.

6.

Inspect the roller bushing. Remove and replace the bushing if necessary.

7.

Inspect the roller shaft. Replace if worn.

8.

Inspect the crawler frame in the area of the upper roller. Repair shaft bore or thrust surfaces if necessary.

9.

Lubricate the roller bushings and shaft.

10.

Install roller into the crawler frame and block in line with the shaft bore.

11.

Install the roller shaft and secure the shaft with the retainer and capscrew. Remove the roller blocking.

12.

Remove the crawler belt blocking.

13.

Adjust belt tension as described in the topic Crawler Belt Adjustment.

14.

Lubricate the roller. Propel the machine to distribute the lubricant evenly and check roller operation.

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5-14 Service Procedures Section MD6640 Blasthole Drill

TAKE-UP TUMBLERS Inspect the take-up tumbler for cracks and damage that can impair normal tracking of the crawler belts.

Every six months raise the machine with the leveling jacks to allow inspection of the tumblers.

Block the machine in a raised position. Using a suitable lever, check the clearance of the tumbler bushing by lifting and then lowering the tumbler. Replace the bushing if the clearance is excessive.

REPAIR The take-up tumblers do not require replacement or repair very often. The most common problem encountered is bushing wear. However, it is possible for the tumbler to develop cracks. When cracks do occur, they can be repaired by gouging out metal on both sides of the crack, and welding the crack. Follow welding instructions in the Appendix.

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5-15 Service Procedures Section MD6640 Blasthole Drill

If bushing replacement is needed, the tumbler must be removed from the machine. To accomplish this: 1.

Position the machine so that the take-up tumbler to be removed is over a slight depression (about 6" deep). This depth will be enough to relieve the weight of the machine from the tumbler.

2.

Relieve crawler belt tension and separate the crawler belt as described in the topic Crawler Belt Replacement. Separation of the belt should take place at a point near the take-up tumbler, and the links laid back out of the way.

3.

Remove the shim guards and lube lines if so equipped.

4.

Using a suitable lifting device to support the take-up tumbler, remove the shaft from the tumbler.

Lift the tumbler from the crawler frame.

5.

Remove the supports and shims from the crawler frame.

6.

Inspect the tumbler bushing. Remove and replace bushing if necessary.

7.

Inspect the tumbler shaft and replace if necessary.

8.

Inspect and clean the shaft supports. Replace if worn.

9.

Inspect the crawler frame in the areas where the supports slide. Rebuild and grind if worn.

10.

Lubricate the tumbler bore and shaft. Install the supports in the crawler frame. Using a suitable lifting device, position the tumbler in the crawler frame.

11.

Install the bearing tumbler shaft and secure with the shaft retainer pin.

12.

Reassemble the crawler belt.

13.

Adjust the crawler belt tension as per topic Crawler Belt Adjustment.

14.

Replace the shim guards and lube lines if so equipped.

15.

Propel the machine to distribute the lubricant evenly in the tumbler bushing and check operation of tumbler.

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5-16 Service Procedures Section MD6640 Blasthole Drill

BI006893 DRIVE TUMBLER

Inspect the drive tumbler for cracked and broken lugs and other defects that can impair normal tumbler function and belt tracking. Check the tumbler retainer bolts for tightness.

Drive Tumbler and Planetary Gearbox Installation

REPAIR Repair of the drive tumbler is limited to repair welding of the lugs or roller area or replacement of the entire unit. Contact your local Caterpillar Global Mining representative for a specific weld repair solution.

To replace the drive tumbler: 1.

Relieve the crawler belt tension and separate the crawler belt as detailed in the Crawler Belt Replacement topic of this manual. Separation of the crawler belt should take place near the drive tumbler and the links laid back out of the way.

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5-17 Service Procedures Section MD6640 Blasthole Drill

BI006893 2.

Using the machine leveling jacks, raise the machine sufficiently to allow the drive tumbler to clear the lugs on the crawler belt. Block the machine in the raised position.

3.

Remove the tumbler retainer bolts and remove the tumbler from the planetary gearbox.

NOTE: The tumbler retainer bolts are metric bolts.

4.

Inspect the drive tumbler. Repair or replace if the lugs or rolling surface are worn or damaged.

5.

Install the drive tumbler on the planetary gearbox. Torque the bolts item 2, (fig. Drive Tumbler and Planetary Gearbox Installation), to 2,600 ft. lbs. (lubed) and item 4 to 1,100 ft. lbs. (lubed).

6.

Remove blocking and lower machine. Verify that all of the rollers and the drive tumbler are resting on the roller path of the belt.

7.

Assemble and adjust the tension of the crawler belts as described in Crawler Belt Adjustment.

8.

Propel the machine to check the operation of the drive tumbler.

PLANETARY GEARBOX The planetary gearbox should be checked daily for oil leaks. The oil level should be checked weekly by removing the oil level plug.

CAUTION:

Be careful when removing the plugs, especially if the unit is hot.

Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with some force.

Monthly, the external bolts of the gearbox should be randomly inspected for tightness. Bolt torques are shown in figure on the previous page.

GEARBOX REMOVAL AND INSTALLATION To remove the gearbox from the crawler frame proceed as follows: 1.

Remove the drive tumbler as described under the topic Drive Tumblers.

2.

Unbolt and remove the hydraulic motor from the gearbox. If necessary, disconnect the hydraulic lines from the motor. Tag and plug the lines. Plug the motor ports. The motor coupling sleeve will be removed with the motor.

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5-18 Service Procedures Section MD6640 Blasthole Drill

BI006893 CAUTION:

Failure to thoroughly clean dirt from joints before opening hydraulic lines could lead to component failure if dirt gets into the system.

3.

Remove the hydraulic line from the gearbox brake port. Tag and plug the line. Plug the brake port.

4.

The gearbox is mounted in the crawler frame so that the hydraulic motor mounting is 15° from horizontal. Before removing gearbox match mark the gearbox and crawler frame so that at reassembly the gearbox will be at the desired angle.

5.

Secure a crane to the gearbox and remove the mounting bolts. Remove the gearbox from the crawler frame.

6.

Installation of the gearbox is accomplished by performing the removal procedure in reverse, tightening the mounting bolts to the torque listed in figure.

NOTE: The gearbox mounting bolts are metric bolts.

Planetary Gearbox Mount Bolt Torque Sequence

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5-19 Service Procedures Section MD6640 Blasthole Drill

BI006893 CHECKING/CHANGING OIL 1.

Check the level of the oil in the gearbox every day by removing the level plug. The oil should be up to the bottom of the hole. Fill as necessary.

Planetary Gearbox Oil Check - Details

2.

Examine the (magnetic) level plug. The oil should be its normal color possibly with some fine metal particles. Clean the plug and install it in the gearbox cover.

If the oil is not its normal color, it should be replaced. If the oil is black the gearbox has been running above 300° F for extended amounts of time. If the oil is a milky yellow color, it has been contaminated with water.

When in doubt, submit an oil sample to any laboratory that performs contamination analysis services. The oil should be changed when the contaminants exceed 10,000 particles per million.

Change the oil every 2000 hours, (1) year or if found to be contaminated:

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5-20 Service Procedures Section MD6640 Blasthole Drill

BI006893 LUBRICANT SPECIFICATIONS

Planetary Gearbox Lubrication Specifications

1.

The oils shown in figure above contain phosphorous type extreme pressure additives. Other oils of equivalent quality and properties may be used, provided they contain phosphorous type extreme pressure additives.

Oil Change Intervals

2.

Contamination depends on operating conditions and operating temperatures. Operating at temperatures of 180° F or above for continuous service will require more frequent oil changes.

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5-21 Service Procedures Section MD6640 Blasthole Drill

CRAWLER FRAMES Inspect the crawler frames for cracks or damage. Pay particular attention to the axle attachment points and the bottom flange plate. Any cracks, wear or damage should be repaired immediately

REPAIR Repair of the crawler frames may be accomplished while the crawler frames are attached to the drill or the crawler frames may be removed to facilitate repair.

To remove the crawler frames from the machine proceed as follows: 1.

Disconnect all hydraulic and lubrication lines connected to the crawler frame. Be sure all joints are clean and all lines and ports are plugged.

2.

Using the machine leveling jacks, raise the machine sufficiently to allow blocking to be placed under the crawler belts and extending 6 to 8 feet from the crawler frame. Blocking material should be selected to facilitate the sliding of the crawler frame away from the machine.

3.

Slowly lower the machine until there is no weight on the rear axle or equalizer axle. Securely block the machine in this position.

4.

From this point either one or both crawler frames may be removed from the machine.

NOTE: Steps 5 through 14 describe the procedure for removing and reinstalling one crawler frame. If both frames are to be removed, Repeat steps 5 through 14 for the other crawler frame.

5.

Remove rear axle retainer and shims or clamp collar.

6.

Remove the equalizer axle pin retaining pin cotter pins, retaining pins and pin.

7.

Using suitable rigging and suitable vehicle(s), pull the crawler frame straight away from the machine. Pull the crawler frame to a position to be repaired or handled with lifting equipment.

8.

Repair the crawler frame and components as necessary.

9.

To replace the crawler frame, first position the crawler in-line with the rear equalizer axle.

10.

Lubricate the rear axle, axle bore, equalizer axle pin and bores.

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5-22 Service Procedures Section MD6640 Blasthole Drill

BI006893 11.

Using suitable rigging and vehicle(s), pull the crawler frame toward the machine. Proceed slowly when attaching the crawler to the rear axle. Make sure the crawler is straight as it is being pulled onto the axle.

12.

When the crawler is in position, insert the equalizer axle pin and retaining pins. Insert the retainer pin cotter pins.

13.

Install the rear axle retainer or clamp collar.

Crawler Frame Removal/Blocking

14.

Connect the hydraulic and lubrication lines.

15.

Raise the machine with the leveling jacks just enough to remove the blocking, then lower the machine.

16.

Propel the machine to check the operation of the crawler components.

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5-23 Service Procedures Section MD6640 Blasthole Drill

BI006893 AXLES

The crawler frames are attached to the machine by two axles. The front axle (equalizer axle) allows the front of the crawlers to pivot, equalizing the load of the machine between the two crawlers. Each end of the axle is pinned to the crawler frames while the middle of the axle is pinned to the bottom of the drill mainframe.

The rear axle is the pivot axle in that as the front of the crawlers move up and down to equalize the loads when propelling over rough terrain, the rear of the crawler pivots about the rear axle. This axle is solidly attached to both sides of the mainframe and does not move during operation.

Inspect the axles and the attachment points frequently for loose bolts or hardware. Inspect the axles for cracks or damage. Repair or replace the axles if worn or damaged. Inspect the pivot pins and retainers for wear or damage and replace as necessary.

Equalizer Axle - Details

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5-24 Service Procedures Section MD6640 Blasthole Drill

BI006893 REPAIR

Normally the axles will not need repair during the life of the machine. Accidents or abnormal wear situations do occur, however, that may make repair of the axles necessary.

Due to the inaccessibility of the axles, removal of the axles from the machine will most probably be necessary.

To remove the axles from the machine, use the following the procedure listed under Crawler Frame Repair.

Remove One Crawler From The Machine.

1.

Position the crawler to allow removal of the axles from the machine. Be sure the machine and the opposite crawler are solidly blocked.

Rear Axle - Details

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5-25 Service Procedures Section MD6640 Blasthole Drill

2.

To remove the equalizer axle, first remove the remaining equalizer axle pin, then securely block the axle to allow removal of the pivot pin.

3.

Remove the axle pivot pin. The pivot bearing block may be removed to facilitate removal of the pin.

4.

Remove the axle from beneath the drill and repair or replace as necessary.

5.

Reinstall the axle by first positioning the axle to allow installation of the pivot bearing block and/or pivot pin. Install the bearing block and/or pivot pin.

6.

Install the equalizer axle pin and retaining pins. Install the crawler frame if only the equalizer is to be repaired.

7.

To remove the rear axle, remove the remaining axle retainer or clamp collar.

8.

Securely block the axle to allow it so slide out of the crawler frame.

9.

Remove the bearing block bolts attaching the axle to the mainframe.

10.

Slide the axle from the crawler frame and remove from beneath the drill.

11.

Repair or replace the axle as necessary.

12.

Position the axle to allow it to slide into the crawler frame.

13.

Lubricate the axle bearing bores in the crawler frame.

14.

Slide the axle into the crawler frame.

15.

Align the axle with the mainframe.

16.

Install the bearing block and bolts to attach the axle to the mainframe.

17.

Install the crawler frame per topic Crawler Frame Repair.

18.

Raise the machine slightly with the leveling jacks and remove the remaining blocking. Lower the machine to the ground.

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5-26 Service Procedures Section MD6640 Blasthole Drill

BI006893 MAINFRAME

The mainframe consists basically of two I-beams tied together with bracing and covered on the top surface with deck plates.

Inspect the drill mainframe for wear, damage or cracks. Pay particular attention to the following critical areas:

Main Frame - Details 1.

Cross bracing which ties the bottom flanges of the I-beams together.

2.

Cross bracing and deck plates which tie the top flanges of the I-beams together.

3.

Mast lock pin attachment areas.

4.

Leveling jack attachment areas.

5.

Areas where the mast A-frame is pinned to the mainframe.

6.

Mast hoist cylinder attachment lugs and the immediate area surrounding these lugs on the mainframe.

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5-27 Service Procedures Section MD6640 Blasthole Drill

BI006893 REPAIR

Cracking, wear or damage to the critical areas listed above require immediate repair. The urgency of repair to other areas of the mainframe is dictated by the area in which the repair must be done and the severity of the damage. Minor damage may not require immediate attention but all damage to the mainframe should be repaired at the first available opportunity.

Repair to the mainframe is limited to repair welding. Follow the recommended procedures detailed in the Appendix to complete welding repairs. If damage is severe or unusual circumstances arise, contact the Caterpillar Global Mining Service Department for specific recommendations.

BIT VIEWING HATCH The bit viewing hatch is mounted in the mainframe in line with the drill pipe and the operator’s station. When the hatch cover is lowered, the operator can view the bit as a new hole is started.

Bit Viewing Hatch - Details

The structure should be checked monthly for weld cracks. The cylinder and hydraulic lines should be checked daily for leaks.

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5-28 Service Procedures Section MD6640 Blasthole Drill

MAST A-FRAME The mast A-frame is a welded structure that is pinned to the mast and the mainframe and helps support the mast at it’s lower end. The rear leg anchor pins are hydraulically operated.

The structure should be checked monthly for weld cracks, structural bending and wear. The cylinders and hydraulic lines should be checked daily.

REPAIR Any cracking, wear, or damage to the A-frame must be repaired immediately. Repair to the Aframe is limited to repair welding. Contact your local Caterpillar Global Mining representative for a specific weld repair solution.

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5-29 Service Procedures Section MD6640 Blasthole Drill

BI006893 LEVELING JACKS

Inspect the leveling jacks for structural damage, proper lubricant coating and proper operation.

Verify that all bolts are tight and all pins are in place.

Check the jack pads for cracks or damage. Clean excess material from the jack pads. Check the jack spuds for wear or damage. Verify that the spuds are coated with lubricant.

Leveling Jack - Details

Proper operation of the jack dictates that the jacks do not settle either while the machine weight is resting on the jacks or when the jacks are in the stored position. To check the jacks, raise the machine on the leveling jacks until the machine is completely off of the ground. Scribe a line on the jack spuds 1 foot below the jack housing. Allow the machine to remain idle for 1 hour. Measure the distance between the scribe lines and the jack housings. If the jacks have drifted more than 1/4", the jack(s) and/or other hydraulic components are leaking and should be repaired.

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5-30 Service Procedures Section MD6640 Blasthole Drill

REPAIR Repair of the leveling jacks is limited to repair welding of selected components and clean-out of others. Repair welding of structural damage is allowable on the jack casing and jack pad. Follow the recommended repair welding practices detailed in the Appendix to repair these items. Repair welding of the jack spud is not recommended if the damage has caused the spud to be bent or become out-of-round. The spud should be replaced if it is bent or no longer round.

Repair of the hydraulic cylinder is limited in this manual to clean-out of the cylinder. Repair of the cylinder itself follows the basic procedures for repair of any hydraulic cylinder.

Repair of the jack casing is limited in this manual to repair of minor cracks or damages. Should any serious damage occur, consult the Caterpillar Global Mining Service Department for repair details.

Note that bolts securing the rear jack casing to the mainframe are torqued to 390 ft. lbs. (snugtight) then turned an additional 1/2 turn. Refer to turn-of-the-nut torquing method later within this section. There should be hardened washers under bolt heads and nuts.

To remove and replace a hydraulic cylinder and jack spud proceed as follows: 1.

If the rear jack is to be worked on, lower that jack until the pad is 1 or 2 inches from the ground.

Raise the other three jacks not being worked on, to the full retracted position. If a front jack is to be worked on, both front jacks should be lowered to 1 or 2 inches from the ground. Raise the rear jacks to the full retracted position.

2.

Stop the hydraulic pump and relieve any pressure in the system by loosening the reservoir breather. When trapped air in the reservoir is relieved, immediately replace the breather.

3.

Carefully disconnect the main hydraulic lines attached to the counterbalance valve at the jack cylinder.

NOTE: Do not disturb the lines going from the counterbalance valve to the electric junction box.

4.

With appropriate plugs, seal open holes in the main hoses that were removed in step 3.

CAUTION:

If working on a rear jack, refer to steps 5 through 8 and 15 through 31. If working on the front jacks, refer to steps 9 through 31.

5.

For rear jack repair, with an open-end wrench, remove the female half of the quick disconnect from the male half that is attached to port PR of the counterbalance valve. Leave the 1/4" hose attached to the female half of the quick disconnect.

6.

When step 5 has been completed, disconnect the 1/4" hose at the electric junction box.

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5-31 Service Procedures Section MD6640 Blasthole Drill

BI006893

CAUTION: Always maintain a firm grip on the hose while the oil is flowing from it.

Do not allow the stream of oil to contact your skin as injury can occur.

7.

Point the open end of the 1/4" hose into an empty 5 gallon pail and reattach the female half of the quick-disconnect to the male half that is still attached to port PR. When the quick disconnect opens, a stream of oil from the rod side of the cylinder will exhaust from the 1/4" hose into the pail. This will allow the jack pad to lower by gravity to the ground at which time the oil will stop flowing.

8.

Again remove the female quick-disconnect half with 1/4" hose as in step 5 and reconnect the 1/4" hose onto port of electric junction box.

9.

For front jack repair, uncouple the quick-disconnect at both front jacks, using a 1 1/4" openend wrench. The male half of the quick-disconnect will remain attached to the valve.

10.

At one front jack only, remove the other end of the quick-disconnect hose from the electrical junction box on the jack.

11.

Place the hose end, removed from the electrical junction box, into a clean five gallon container.

(Two additional 5 gallons will be required to handle the oil from both front jacks.)

CAUTION:

Always maintain a firm grip on the hose while the oil is flowing from it.

Do not allow the stream of oil to contact your skin as injury can occur.

12.

Re-couple the quick-disconnect. As the connection nears completion, oil will run out of the hose-end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing-end of the cylinder.

13.

To remove the oil from the other front jack, a helper will be required. Have the helper continue to hold the disconnected hose into a empty 5 gallon container while you re-couple the quickdisconnect on the other front jack. The oil from this jack will now flow from the hose being held by the helper.

14.

When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

15.

Remove male half of quick-disconnect from port PR and thread it loosely into female half.

Cover open end with protection cap.

16.

Remove 3/8" hose at counterbalance valve and plug open end of hose.

17.

Insert SAE-6 steel O-ring boss plug into ports PR and PH.

18.

Remove the casing cover bolts.

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5-32 Service Procedures Section MD6640 Blasthole Drill

NOTE: If one of the front jacks is to be repaired, the mast brace support must be removed and an eyebolt installed in the cover for removal purposes.

19.

Remove the capscrew securing the shoe retainer to the spud. Separate the shoe from the spud and remove the retainer and split retainer from the shoe.

20.

Attach a suitable lifting device to the lifting lug or eyebolt on the casing cover and carefully lift the spud and cylinder from the casing.

21.

To remove the cylinder from the spud, remove the pipe plugs securing the spud foot pin and remove the pin.

22.

Slide the cylinder from the spud. Remove the casing cover from the cylinder.

23.

Repair or replace components as necessary.

24.

Install the casing cover on the cylinder.

NOTE: The cylinder rod should be retracted fully into the cylinder body. If not, using hydraulic pressure, retract the hydraulic cylinder to the fully retracted position. Note that hydraulic pressure must be used and pressure be exerted at port VR before the counterbalance valves will allow the cylinder to move. Use oil similar to what is used in the hydraulic system.

25.

Using a suitable lifting device, slide the cylinder, body end first, into the spud.

26.

Align the foot pin holes and insert the foot pin. Secure with the square head pipe plugs.

27.

Using a suitable lifting device, lower the spud and cylinder assembly into the jack casing.

28.

Attach the casing cover to the casing. Note that the rear jack casing cover bolts must be torqued to 480 ft. lbs. There should be no plating or lubrication on the bolts.

29.

Install the fittings into the hydraulic cylinder and attach the hydraulic hoses.

30.

Position the pad under the jack and slowly lower the spud end into the pad. Attach the jack pad to the spud using the split retainer and solid retainer. Torque the retainer capscrews to 280 ft. lbs. (dry threads).

31.

Cycle the jack 2-3 times to check the operation of the unit and to remove any air pockets created during the repair procedures. The jack should be extended and retracted to the maximum without lifting the machine.

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BI006893 MACHINERY HOUSE

Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures and bracing. Always restore defective structural members to their original state by repair welding.

Periodically inspect the hinges and latches on all doors and windows to insure they will remain closed during machine operation. Verify the sealing of all doors and windows to prevent the entrance of dust. Search thoroughly for all loose or missing bolts. The absence of these fasteners can result in excessive vibration and wear of house components. Inspect the condition of the paint on both the interior and exterior surfaces of the house. Prepare any paint any areas where the paint has been damaged or any areas where repairs have been made.

REPAIR Repair of the machinery house is usually limited to repair of individual structures within the house.

Repair welding should follow the guidelines detailed in the APPENDIX. Any repair procedure should be undertaken with the object being to prevent the entrance of dust, dirt, or moisture into the house. All joints in the house structure should be adequately sealed and openings in the machinery house should be kept to a minimum.

The machinery house roof is removable, as well as the cross members over the main air compressor.

Verify that the cross members are securely fastened. Verify that the roof is sealed properly and that the clamps are secured.

Machinery House - Exploded View

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5-34 Service Procedures Section MD6640 Blasthole Drill

BI006893 HOUSE VENTILATION FAN AND FILTER

The machinery house is equipped with a ventilation fan and inertial filter which provides clean ventilation air to the main air compressor and machinery house. The machinery house is pressurized slightly above the atmospheric pressure by the fan. This serves to keep dust and moisture from entering the machinery house. The ventilation fan should be operating any time the machine is being operated. Keep all machinery house doors closed at all times to prevent the entrance of dust. Inspection of the ventilation fan itself is not required except as necessary to repair some malfunction.

Machinery House Ventilation Fan

The inertial filter cleans the air entering the machinery house. This filter is self-cleaning and does not require routing service typical of other filters. Proper operation of the filter, however, is dependent upon proper air flow. Restriction of the intake by leaves, rags and paper will lessen the effectiveness of the filter and ventilation fan. A light coating of dust on the blades of the filter is normal and will not impair the efficiency of the filter. To remove material which has accumulated on the blade surfaces, it is necessary to remove the filter cell and steam clean the blades.

BI006893

5-35 Service Procedures Section MD6640 Blasthole Drill

BI006893 WALKWAYS AND LADDERS

Inspect all handrails, walkways, platforms, stairs and ladders on the machine daily. Verify that all structural members are in good repair and that all fasteners and welds are intact. Repair or replace components immediately to insure the integrity of the structures and ensure compliance with safety regulations.

Retractable Boarding Stairway - Details

Keep all walkways, stairways and ladders clear of materials which could present slipping or tripping hazards. Keep walkways clear of tools, supplies or other obstructions. Clean up all grease or oil spills immediately.

BI006893

5-36 Service Procedures Section MD6640 Blasthole Drill

BI006893 OPERATOR’S CAB

Inspect the operator’s cab daily for cracks or structural damage to all side, roof and floor panels.

Check the doors and windows for proper operation and correct sealing. Keep the cab clear of all oil, grease or water spills to help prevent slipping.

Operator’s Cab Location Mounting

BI006893

5-37 Service Procedures Section MD6640 Blasthole Drill

BI006893 OPERATOR’S SEAT The individual operator may adjust the operator’s seat as desired with respect to height, tilt and travel. Periodically lubricate all bearings and pivot points to maintain smooth movement.

OPERATOR’S CONTROLS Inspect all of the operator’s controls daily for wear or damage. Verify the correct operation of all controls daily. Repair or replace malfunctioning controls immediately. Clean all nameplates and markers and maintain all markers and signs in a legible condition including warning signs.

Operator’s Controls

BI006893

5-38 Service Procedures Section MD6640 Blasthole Drill

BI006893 AIR CONDITIONING UNIT WITH HEATER

Inspect the HVAC unit on the operator’s cab roof for proper operation, structural integrity and sealing.

All permanent side panels should be in place and adequately sealed and secured.

Operator’s Cab Heating/Air Conditioning Unit

BI006893

5-39 Service Procedures Section MD6640 Blasthole Drill

BI006893 HYDRAULIC PUMP DRIVE

The hydraulic system pumps are driven by the main air compressor motor through a gearbox. The gearbox is mounted to the compressor base.

The oil level in the gearbox should be checked weekly and oil added if required. Daily check the gearbox for oil leaks and repair as required.

Hydraulic Pump Drive

To remove and disassemble the pump drive gearbox, proceed as follows: 1.

Place the machine in a secure area to perform the repair. Shut off and tag the controls.

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5-40 Service Procedures Section MD6640 Blasthole Drill

BI006893 2.

Drain the oil from the gearbox. There is approximately 7.75 qts. of oil in the gearbox.

3.

Remove the pump mounting capscrews and remove the pumps and gaskets.

4.

Separate the gearbox drive coupling. Remove the gearbox mounting bolts. Remove the gearbox from the mounting pads. Note the thickness of shims.

5.

On a clean surface, position the gearbox so that the hydraulic pump adapter plates are facing up. Remove the plate mounting bolts and lift the adapter plates from the gearbox.

Hydraulic Pump Drive Gearbox - Details

6.

Lift the driven gears and their bearings from the gearbox. This can be done by hand since the bearings are slip fit to the gearbox and adapter pad bores. The bearings are press fit to the gear hubs. It may be necessary to tip the gear slightly to clear the drive gear bearing pocket.

7.

After the driven gears have been removed, turn the gearbox over so that the drive shaft and gear can be removed.

8.

Remove the shaft adapter mounting bolts and remove the adapter assembly and gasket from the gearbox.

BI006893

5-41 Service Procedures Section MD6640 Blasthole Drill

BI006893 9.

10.

Separate the drive shaft adapter assembly as follows: a.

Remove the large snap ring from the bore of the adapter.

b.

Remove the small snap ring from the drive shaft and pull the shaft from the adapter.

Take care not to damage to oil seal.

c.

Remove the bearing from the adapter. Remove the oil seal from the adapter.

Clean and inspect all parts. Repair or replace all damaged or worn parts and reassemble in reverse of disassembly, noting the following: a.

When reassembling the gearbox, use new seals, gaskets and bolts.

b.

Use Loctite® 262 on all bolts and torque all bolts to 200 ft. lbs.

c.

When installing gearbox coupling, proceed as follows: (1.

Verify that the motor shaft is centered.

(2.

Mount the coupling hubs on the motor and gearbox.

(3.

Mount the gearbox so that a 0.63 inch gap exists between the ends of the shafts.

(4.

Check the coupling for angular and offset misalignment. Maximum misalignment should not exceed 0.002 inch. Use shims under the gearbox feet to correct misalignment.

(5.

Torque coupling capscrews (dry threads) to 30 ft. lbs.

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5-42 Service Procedures Section MD6640 Blasthole Drill

BI006893 CABLE REEL CAUTION:

The cable reel handles the trail cable during propelling. The trail cable carries a high voltage which can cause serious or fatal injury.

Whenever work is to be done on the cable reel the trail cable must be disconnected from its power source.

A routine inspection of the cable reel should be performed every 3 months to assure that it is working properly and that the trail cable is being spooled on and off the reel correctly. Check that the level wind mechanism works freely. Check that all drive chains are properly tensioned and well lubricated. Lubricate every six months.

Check all structural components for cracking.

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5-43 Service Procedures Section MD6640 Blasthole Drill

The cable reel should only be lifted using the provided lift points shown below.

The sprocket that drives the guide head unit is interchangeable to allow for reeling of a wide range of cables. Before installing any cable make sure the correct sprocket is installed and the chain is properly tensioned, use of the incorrect sprocket will lead to incorrect cable spacing and potential damage to the cable or reel. Refer to the manufacturer’s documentation for more information.

BI006893

5-44 Service Procedures Section MD6640 Blasthole Drill

BI006893 CHAIN TENSIONING

All chains must be properly tensioned to ensure smooth operation and prevent excessive wear of chain and sprockets. All sprockets must be properly aligned to prevent excessive wear on chain.

The Motor-Spool chain should have 0.50-0.75 in.

(1.3-1.9 cm) of slack when tensioned.

The Spool-Encoder chain should have 0.313-0.625 in. (0.8-1.6 cm) of slack when tensioned.

The Spool-Reducer chain should have 1.75-2.25 in.

(4.5-5.7 cm) of slack when tensioned.

The Reducer-Guide chain should have 0.563-1.13 in. (1.4-2.9 cm) of slack when tensioned.

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5-45 Service Procedures Section MD6640 Blasthole Drill

BI006893

The Guide chain should have 0.50-1.0 in. (1.3-2.5 cm) of slack when tensioned.

HYDRAULIC ADJUSTMENTS When properly adjusted, the cable reel will pick up cable when the drill moves toward its power source. The reel will stall when the drill is stationary and the reel drive will be overpowered when the drill moves away from the power source, allowing the cable to be unwound from the reel.

DANGER:

The cable reel should not be used to pull the trail cable onto the reel.

Wind the cable onto the reel only as the drill moves toward the cable.

Attempting to pull 50 feet or more cable, laid in a straight line onto the reel without moving the machine toward the cable, will damage or possibly break the cable.

View A - Hydraulic Adjustment Locations

Line pull is proportional to operating pressure. The correct line pull occurs when there is sufficient pull on the cable to wind it on the reel, but not too great to put unnecessary strain on the cable.

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5-46 Service Procedures Section MD6640 Blasthole Drill

Line speed is dependent on the volume of hydraulic oil flowing through the system. The correct line speed is slightly faster than the travel speed of the drill.

Line pull when propelling away from the cable reel is set by the counter-balance valve. The cable pull on the cable reel and builds pressure against the counter-balance valve. If cable is being dragged, lower the counter-balance setting.

HYDRAULIC DRIVE START UP INSTRUCTIONS 1.

Start the main compressor motor and allow the hydraulics system to run for 5 minutes to ensure proper operating temperature.

2.

Place a 3000 PSI gauges on test port 49 and 50; both located on station 3 manifold - VB4.

PRESSURE SETTING - REEL FORCE 1.

With the trail cable installed on the cable reel, move the cable reel switch to the reel in position.

2.

Set the pressure relief valve (refer to View A) to 800 PSI. Test port 49; located on station 3 manifold - VB4.

3.

Return the cable reel switch to the neutral position.

4.

Have the operator move the machine toward the cable allowing the cable reel to pick up cable.

5.

If the machine drags the cable, lower the pressure on the pressure relief valve.

6.

If the machine can not reel on the cable, raise the pressure on the pressure relief valve.

7.

Repeat Steps 4 to 6 until proper tension on the cable reel is achieved.

FLOW SETTING - REEL SPEED 1.

With the trail cable installed on the cable reel and the pressure set.

2.

Have the operator move the machine toward the cable allowing the cable reel to pick up cable.

3.

The cable reel should pick up cable slightly faster than the machine propel speed.

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5-47 Service Procedures Section MD6640 Blasthole Drill

4.

If the cable reel does not pick up cable fast enough, adjust the flow control shown in View A.

5.

Once the cable reel speed seems to be set, have the operator stop propelling the machine.

6.

Place the cable reel switch to the unwind position, reel out cable and verify the speed is not excessive.

7.

Adjust the flow control as required and verify wind in speed with the machine propelling in Step 2.

COUNTERBALANCE SETTING - PULL-OUT FORCE 1.

With the trail cable installed on the cable reel, the pressure set, and the flow set.

2.

Have the operator drive away from the cable.

3.

The cable is set properly will pull off the cable reel with out dragging the cable.

4.

If the cable is dragging, lower the counter balance setting. Refer to View A for location.

5.

If the cable spool out cable under the weight of the cable, increase the counterbalance pressure setting.

Now that the cable reel is set, operate the machine and observe the machine to ensure the cable is being layed out and reeled up properly.

• If cable drags when machine propels toward the cable, lower the pressure setting.

• If cable drags when machine propels away from cable, lower the counter balance setting.

• If cable does not pick up the cable off the ground, raise the pressure setting.

• If cable spools out on the ground when machine is at rest, raise the counter pressure setting.

• If cable reel pick ups cable too slow, increase flow setting.

• If cable reel operates too fast, lower the flow setting.

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5-48 Service Procedures Section MD6640 Blasthole Drill

LUBRICATION Lubricate the guide rollers monthly using MPG lubricant. Ensure the rollers turn freely and all mounting hardware is tight.

The chains should be lubricated every six months using a good chain lube. Diamond Chain Company’s Chain Lube, which is a foam-type aerosol lube, is recommended. Check chain for corrosion and tension. Re-adjust chain tension as needed.

Grease the main spool bearings and encoder jack-shaft bearings semi-annually.

The recommended lubricant for the gear reducer is Mobil Delvac Synthetic Gear Oil 75W-90 or equivalent.

REPAIR Repairs of cable reel will consist mainly of replacing worn or damaged parts

BI006893

BI006893 MAST STRUCTURE The mast is a fabricated structure made of steel tubes and formed plates. The structure is formed by four vertical tubes tied together on three sides with tubular lacing. The fourth side is open to allow the rotary drive unit to be raised and lowered the length of the mast.

Inspect the structure daily for wear or damage.

Inspect all mast ladders and platforms for loose hardware and structural integrity. Inspect the racking on the outside of the rear mast tubes for proper lubrication and any wear or damage.

Inspect the mast hinge pins and the structure surrounding the pins for wear or damage. Verify that the hinge pin keepers are in place and tight. Inspect the mast hoist cylinder attachments for wear or damage. Lubricate the pins weekly with the appropriate lubricant.

Inspect the mast lock pins for wear and damage. Verify that the lock pin hydraulic cylinders and hydraulic line are not leaking.

Every 80 operating shifts lower the mast and inspect all welds thoroughly for cracks or damage. Clean the racking on the outside of the two rear mast tubes and check the welds securing the racking to the tubes.

5-49 Service Procedures Section MD6640 Blasthole Drill

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5-50 Service Procedures Section MD6640 Blasthole Drill

BI006893 REPAIR

Repair of the mast structure is limited to repair welding of cracked or broken welds or components or replacement of severely damaged structures. Contact your local Caterpillar Global Mining representative for a specific weld repair solution.

When repairing mast structures by welding it is important to keep in mind that the repair should return the structure to its original condition. All welds should be smooth and any notches or undercuts should be welded and ground. Do not add reinforcing material or change the geometry of the structure. Replace any damaged components with material of the same strength and cross section.

For mast lock pins see Mast A-Frame.

MAST SAFETY SLINGS The mast safety slings are used to help prevent drill pipe coming loose from the rotary unit and falling off the machine or onto the operator’s cab. The slings should be checked weekly to verify that all pipe supports are properly adjusted and all yoke end pins are secured in place.

Upper Safety Sling

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5-51 Service Procedures Section MD6640 Blasthole Drill

BI006893 REPAIR

Lower Safety Sling - Optional

Repair of the safety slings consists mainly of replacing worn or damaged components. Repair welding may be used to repair cracks. Contact your local Caterpillar Global Mining representative for a specific weld repair solution.

BI006893

5-52 Service Procedures Section MD6640 Blasthole Drill

BI006893 ROTARY GEARCASE CAUTION:

Unexpected operation or movement of the pulldown unit and/or rotary gearcase during service or inspection procedures can cause severe personal injury or death. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Inspect the rotary gearcase every shift for loose or missing hardware. Check the gearcase for lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper lubricant to the required level. If water has accumulated in the gearcase remove the drain plug and completely drain the case. Refill the gearcase to the required level with an approved lubricant. Check the air swivel for leaks and repair as necessary.

Rotary Machinery/Gearcase

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5-53 Service Procedures Section MD6640 Blasthole Drill

BI006893

Every 80 operating shifts partially drain the gearcase and remove the inspection cover. Inspect the gear teeth for wear or damage. Check the rotary drive shaft bearing pre-load. If any clearance exists in the drive shaft bearings it will be necessary to adjust the pre-load by removing shims from the lower retainer.

DRIVE SHAFT ADJUSTMENT The drive shaft must be adjusted to give 0.003" - 0.005" pre-load on the bearings. To adjust the bearing preload proceed as follows: 1.

Remove the capscrews which secure the lower bearing retainer to the gearcase. Remove the retainer shims.

NOTE: Cut shims in half for ease of removal and installation.

2.

With the shims removed, reinstall the capscrews and torque to 60 ft.-lbs. to insure proper bearing seating.

3.

Remove all the capscrews except two 180° apart. Re-torque the remaining two capscrews to 50 ft.-lbs., in 10 ft.-lb., increments so that the retainer remains square to the case. Turn the shaft and recheck the capscrew torque.

4.

Measure the gap between the retainer and gearcase at both capscrews. Obtain the average gap by dividing the sum of the measurement by 2.

1.

2.

3.

4.

5.

6.

Lower Bearing Carrier 7. Bearing Retainer Center Bearing 8. Retainer Bolt Rotary Drive Shaft 9. Oil Seal Lower Bearing 10. Spacer Retainer O Ring 11. Seal Retainer Shims 12. Retainer Bolt

BI006893

5-54 Service Procedures Section MD6640 Blasthole Drill

BI006893

Rotary Machinery Intermediate Shaft

1.

2.

3.

4.

5.

6.

7.

8.

9.

Upper Bearing Cover Cover Bolt O Ring Retainer Retainer Bolt Upper Bearing Oil Seal Seal Sleeve Intermediate Gear

10. Intermediate Shaft 11. Lower Bearing 12. Retainer 13. Retainer Bolt 14. Lower Cover 15. Cover Bolt 16. O Ring 17. Gearcase

5.

The average gap minus 0.003" to 0.005" is the total shim pack thickness required to provide 0.003" to 0.005" pre-load on the bearings.

6.

Remove the two remaining capscrews and install the required shim pack and capscrews.

Torque the capscrews to 200 ft.-lbs.

BI006893

BI006893

5-55 Service Procedures Section MD6640 Blasthole Drill

REPAIR There are three areas on the rotary gearcase where repair is possible. This topic deals only with the repair of the internal components of the unit. Repairs of the rotary motor and the rotary coupling are covered under separate topics.

Repair of the rotary gearcase is limited to replacement of worn or damaged components. The unit may be repaired in place on the machine or may be removed from the machine and repaired elsewhere. Refer to the Rotary/Pulldown Guide Frame topic for the procedure necessary to remove the assembly from the machine.

To repair the gearcase either on or off of the machine use the following procedure: 1.

Securely block the gearcase in the upright position. Remove the rotary motor form the gearcase.

Refer to the topic Rotary Motor. Drain the oil from the gearcase. Remove the motor adapter ring. Remove the motor O-ring from the gearcase.

NOTE: If the drive unit is left in the machine, lower it to the bottom of the mast and rest it on the lower stops. Shut off and tag the controls.

2.

Remove the air pipe and gasket from the swivel housing.

3.

Remove the gearcase front cover and gasket.

4.

Remove the intermediate shaft upper bearing cover and cover O-ring.

REMOVE THE UPPER BEARING RETAINER. 5.

Screw an eyebolt into one of the tapped holes in the top of the intermediate shaft. Support the shaft with rigging and a crane.

6.

Support the intermediate gear with blocking so that when the shaft is removed the gear will not fall.

7.

Remove the capscrews securing the lower bearing retainer to the gearcase. Remove the bearing retainer. Remove the O-ring from the retainer.

8.

Slowly lower the intermediate shaft out of the gearcase. Remove the lower bearing, retainer, and spacer from the shaft. The lower bearing has an interference fit of 0.0005" - 0.0025" to the shaft.

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5-56 Service Procedures Section MD6640 Blasthole Drill

NOTE: The inner race of the upper bearing has an interference fit of 0.0006" - 0.0017" to the shaft and may require a slight force to separate it from the shaft.

9.

Position the intermediate gear to be removed through the front opening of the gearcase.

Remove the gear and upper bearing inner race and seal sleeve.

10.

Remove the upper bearing cage and oil seal from the upper bore in the gearcase.

11.

Support the drive shaft with blocking under the rotary coupling.

12.

Remove the lockwire and capscrews securing the swivel housing to the gearcase. Remove the housing.

13.

Remove the seals, spacers and wave spring from the housing.

14.

Remove the locknut, lockwasher and spacer at the top of the drive shaft.

NOTE: The locknut has left hand threads.

15.

Remove the capscrews attaching the lower bearing retainer to the gearcase.

16.

Slowly lift the gearcase until the vertical shaft gear is resting on the bottom of the gearcase. If the weight of the vertical shaft will not free itself from the upper bearing inner race, additional force will have to be placed on the top of the shaft to force the race off the shaft as the gearcase is raised. The race has an interference fit of 0.0001"-0.0021" to the shaft.

17.

When the upper race is removed from the shaft, continue raising the gearcase until it clears the shaft. Remove the shaft and lower the gearcase back onto its blocking.

18.

Remove the upper bearing inner race, seal sleeve, gear spacer and gear from the gearcase through the front opening.

19.

Remove the upper bearing cage, oil seal and O-ring from the upper bearing carrier. Remove the upper lower bearing cup from the lower bearing carrier. The cup has an interference fit of 0.0004"-0.0050" to the carrier.

NOTE: The upper and lower bearing carriers are press fit to the gearcase and should be removed only if damaged or worn.

20.

Unbolt and remove the drive shaft clamp collars.

21.

Unbolt and remove the rotary coupling lower half from the upper half of the coupling.

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5-57 Service Procedures Section MD6640 Blasthole Drill

BI006893 CAUTION:

In the following step a torch is used to heat the upper coupling half.

When using the torch be sure to take all safety precautions. Also use suitable protective equipment when handling the heated item.

22.

Use a torch to heat the upper coupling half and separate the two sections of the drive shaft.

Remove the O-ring from the drive shaft.

23.

Slide the lower bearing retainer assembly from the shaft upper section and disassemble as follows:

24.

Remove the O-ring and shims.

b.

Remove the seal retainer capscrews and retainer.

c.

Remove the seals and spacer.

d.

Remove the lower bearing cup from the retainer. The cup has an interference fit of 0.0010"-0.0050" to the retainer.

With a bearing puller, remove the lower bearing cage and the upper lower bearing cage from the shaft.

NOTE:

25.

a.

The lower bearing cage has an interference fit of 0.0005" - 0.0025" to the shaft. The upper lower bearing cage has an interference fit of 0.0028" - 0.0048" to the shaft.

Inspect all components. Repair of replace all components as necessary.

CAUTION:

There are a number of steps in the following procedure which require heating of certain items prior to assembly. Use suitable protective equipment when handling the heated items.

26.

To reassemble the gearcase first clean all components thoroughly. Inspect all bores and shaft surfaces, and remove any nicks or burrs. Lightly oil all parts. Apply LocTite® #271 to all clean threads at assembly. Be sure to follow manufacturer’s instructions when using Loctite.

27.

Install the upper lower bearing cup in the bearing carrier. This cup is interference fit to the carrier and will have to be pressed in. Be sure the cup is tight against the shoulder in the carrier.

28.

Install the lower bearing cages on the drive shaft upper section. These cages are interference fit and will require heating in an oil bath to 250° F prior to assembly. Be sure the cages are tight against the shoulders of the shaft.

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5-58 Service Procedures Section MD6640 Blasthole Drill

BI006893 29.

Assemble the lower bearing retainer assembly as follows: a.

Install the lower bearing cup in the retainer. This cup is interference fit and will have to be pressed in. Be sure the cup is tight against the should of the retainer.

b.

Install the oil seals and spacer in the retainer. Be sure the lips of the seals face toward the bearing cup.

c.

Install the seal retainer and capscrews. Tighten and lockwire the capscrews.

d.

Install the O-ring on the retainer.

30.

Install the retainer assembly on the drive shaft upper section. Do not install the shims on the retainer.

31.

Install the O-ring in the bottom of the shaft upper section.

32.

Heat the upper shock coupling half in an oven or oil bath to 250° - 300° F maximum. Install the rotary drive collar on the coupling. Insert coupling half on the half drive shaft and install clamp collars and bolts. Allow shaft to cool to ambient temperature.

33.

Remove the clamp collars and install the rotary coupling upper cushion seal strip. Re-install the shaft clamp collars, tighten bolts and lockwire. The splits in the collars should be offset 90° from each other.

34.

Re-install remaining parts of shock coupling per topic, Shock Coupling.

35.

Install the drive gear in the gearcase. Make sure the gear is aligned to the shaft bore. Slowly raise the gearcase so that the shaft can be positioned for installation.

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5-59 Service Procedures Section MD6640 Blasthole Drill

BI006893

Rotary Machine Driveshaft - Details

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5-60 Service Procedures Section MD6640 Blasthole Drill

BI006893 36.

Securely block the drive shaft in an upright position. Slowly lower the gearcase down onto the shaft being careful not to damage the shaft threads. It may be necessary to rotate the gear slightly to align the splines of the gear and shaft.

37.

Insert and snug up the lower bearing retainer capscrews.

38.

Install the gear spacer, seal sleeve and upper bearing oil seal. Be sure the lip of the seal faces upward. Heat the upper bearing inner race in an oil bath to 250° F maximum and install on the shaft tight against the sleeve, Install the bearing spacer, lockwasher and locknut, then tighten the locknut firmly. Allow the race to cool to ambient temperature.

39.

When the race has cooled remove the locknut and lockwasher, and install the upper bearing cage. Re-install and tighten the lockwasher and locknut.

40.

Preload the lower bearings as follows:

NOTE:

a.

Torque the lower bearing retainer capscrews to 60 ft.-lbs. to insure proper bearing seating.

b.

Remove the capscrews except two 180° apart. Re-torque the remaining capscrews to 50 ft.-lbs., in 10 ft.-lb. increments, so that the retainer remains square to the gearcase. Turn the shaft and re-check the capscrew torque.

c.

Measure the gap between the retainer and gearcase at both capscrews. Obtain the average gap by dividing the sum of the measurements by 2.

d.

The average gap minus 0.003" to 0.005" is the total shim pack thickness required to provide 0.003" to 0.005" preload on the lower bearings

e.

Remove the two remaining capscrews and install the required shim pack and capscrews. Torque the capscrews to 200 ft.-lbs. and lockwire.

If the shims are complete circles, cut in half for ease of installation.

41.

Install the seals and spacers in the swivel housing as shown on figure 1-4-6. Be sure the seal lips are facing upward. Install the O-ring in the bearing carrier.

42.

Install the swivel house and secure with the capscrews. Tighten and lockwire the capscrews.

43.

Install the intermediate gear and block in place. Set the seal sleeve on top of the gear. Align the bore of the gear with the bore of the shaft.

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5-61 Service Procedures Section MD6640 Blasthole Drill

44.

Heat the lower bearing in an oil bath to 250° F maximum and install the bearing on the shaft.

Secure the bearing with the retainer and lockwire the capscrews.

45.

Install the O-ring in the lower cover. Insert the shaft assembly into the gearcase. Install the lower cover and secure it with the cover capscrews. Tighten and lockwire the capscrews.

46.

Install the upper oil seal. Heat the inner race of the upper bearing in an oil bath to 250° F maximum and install on the shaft. Be sure the race is tight against the spacer, then secure the race with the bearing retainer. Tighten and lockwire the retainer capscrews. Allow the race to cool to ambient temperature.

47.

Install the upper bearing cage in the gearcase. Install the O-ring on the upper cover and install the cover on the gearcase. Tighten and lockwire the cover capscrews.

48.

Install the motor per topic, Rotary Motor and fill the gearcase with an approved lubricant.

Lubricate all lube points with an approved lubricant.

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5-62 Service Procedures Section MD6640 Blasthole Drill

BI006893 ROTARY MOTOR

Inspection, lubrication and maintenance instructions for the rotary motor are described in the manufacturer’s Motor Manual. To remove the rotary motor proceed as follows: 1.

Lower the rotary drive unit to the bottom of the mast and rest it on the lower stops.

CAUTION:

Open and tag the auxiliary power and control breakers in the machinery house. Do not attempt to disconnect the motor leads with these breakers closed. A voltage hazard is present and electrocution is possible if these breakers are left closed.

Rotary Drive Motor - Details

2.

Have an electrician identify and disconnect the electrical leads to the rotary motor. Remove the cable from the junction box on the motor.

3.

Remove the motor attachment stud nuts and washers.

4.

Using a suitable crane and rigging, lift the motor from the rotary gearcase.

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5-63 Service Procedures Section MD6640 Blasthole Drill

5.

Repair or replace the motor as necessary.

6.

The motor pinion is press fit to the motor shaft. Refer to the Appendix for instructions regarding replacement or installation of the motor pinion.

7.

Prior to installation of the motor clean the mounting surfaces on both the gearcase and the motor.

8.

Install the rotary motor in reverse order of removal. Torque the attachment stud nuts using turn-of-the-nut method. Tighten nuts snug, and then an additional 1/3 turn.

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5-64 Service Procedures Section MD6640 Blasthole Drill

BI006893 ROTARY SHOCK COUPLING

The rotary shock coupling is an optional assembly that replaces the standard lower rotary coupling half. The shock coupling is used to reduce the shock loading transmitted to the rotary drive unit.

NOTE: The procedures detailed in this topic are for a standard oem shock coupling.

Since shock couplings manufactured by differing companies may be furnished with the machine, be sure to verify that the shock coupling being repaired is as described before using the procedure listed below.

Inspect the shock coupling monthly for loose or missing nuts or other wear or damage or air leaks.

When the cushions have worn to a point that the 0.375" pre-load can no longer be obtained, the cushions must be replaced. If the bailing air is escaping from the shock coupling, the seals should be replaced. At this time, also check the seal tube for wear and replace if required.

REPAIR CAUTION:

Unexpected operation or movement of the pulldown unit and/or rotary gearcase during service or inspection procedures can cause severe personal injury or death. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Repair of the shock coupling is limited to replacement of worn or damaged components. Replacement of any of the components will require disassembly of the unit.

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5-65 Service Procedures Section MD6640 Blasthole Drill

To disassemble the shock sub proceed as follows: 1.

Place secure blocking under the shock coupling and lower it onto blocking. Shut off and tag the controls.

2.

Remove the lock wire and slotted nuts from the shock coupling bolts. Remove the bolts and washers.

3.

Be sure the coupling lower half is securely blocked then slowly raise the rotary machinery until the drive shaft lower section clears the shock coupling lower half. Shut off and tag the controls.

4.

Separate the upper cushion, lower cushion, cushion retainer, seal tube and seals from the lower half of the shock coupling.

5.

If the drive shaft lower section is to be removed, use the procedure as outlined in steps 20 and 22 of the topic Rotary Gearcase - Repair.

6.

Clean and inspect all components of the assembly. Replace worn or damaged components as necessary.

7.

If removed, reinstall the drive shaft lower section per steps 31 and 32 under the topic Rotary Gearcase - Repair.

8.

Assemble the upper cushion, lower cushion, cushion retainer, seal tube and seals to the coupling section.

9.

Securely block the assembly in line with the drive shaft lower section. Lower the rotary unit slowly until the shaft is seated in the coupling. Do not compress the cushions. Be careful not to damage seals.

10.

Install the shock sub bolts, apply LocTite to the threads and hand tighten the slotted nuts to establish a free height. Refer to preload chart for nut tightening.

11.

Progressively tighten the nuts no more than 1/2 turn at a time until tightening is completed.

Install lockwire.

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5-66 Service Procedures Section MD6640 Blasthole Drill

BI006893 ROTARY/PULLDOWN GUIDE FRAME

Rotary Pulldown Guide Frame - Details

CAUTION:

Unexpected operation or movement of the pulldown unit and/or rotary gearcase during service or inspection procedures can cause severe personal injury or death. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

The rotary guide frame consists of the two frames that support the rotary machinery and the pulldown machinery. The guide frames also include the guide rollers which are used to align and secure the unit to the mast.

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5-67 Service Procedures Section MD6640 Blasthole Drill

BI006893

Inspect the entire guide frame daily for loose or missing hardware. Inspect the bumper blocks for wear or damage and replace if necessary. Inspect the rack pinions for wear or damage. Check the adjustment of the guide rollers and adjust if necessary. Inspect the alignment of the guide frame in the mast. Check the main air pipe connections for leaks. Verify that the chock bars securing the rotary gearcase are in place and that the welds on the chocks are intact. Check the lubrication of the rack pinion.

GUIDE ROLLER ADJUSTMENT The guide rollers on the rotary/pulldown guide frame keep the assembly aligned to the mast and the rack pinions in contact with the mast rack. As the guide rollers wear, it is necessary to periodically adjust the clearance between the rollers and the mast rack mounting tee. To adjust the guide rollers proceed as follows:

Rack Pinion and Upper Guide Roller - Details

1.

Position the rotary/pulldown unit so that the upper guide rollers and rack pinions are accessible.

Shutdown and tag the controls.

2.

Using a suitable jack or pulling device, pull or push the rack pinion retainer snug against the mast on both sides of the mast. This assures that the backlash of the pinions is correct.

NOTE: Also measure the distance from the face of the mast tee column to the center of the bearing house mounting bolt. This measurement will be used later to determine if the unit is parallel to the mast. This distance should be approximately 16.785 inches.

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5-68 Service Procedures Section MD6640 Blasthole Drill

BI006893

Lower Guide Rollers - Details

3.

Remove the capscrew, nut and washer from the upper front guide roller eccentric pin handle.

Move the handle until a gap of 0.040 inch exists between the roller and the mast tee column.

Secure the handle with the capscrew, nut and washer.

4.

Remove the nut, washer and capscrew that secures the lower rear guide roller eccentric pin handle. Move the handle to position roller against the mast, then measure the distance from face of the mast to the center of the rotary gearcase mounting bolts. This distance should be approximately 16.035 inches. If it is not, continue moving the pin handle until the specified distance is reached. Secure the handle with the capscrew, nut and washer.

5.

With a suitable jack or pull device, pull or push the roller snug against the mast.

6.

Remove the capscrew, nut and washer from the lower front guide roller eccentric pin handle.

Move the handle until 0.06 inch gap exist between the roller and the mast tee column:

7.

Secure the handle with the capscrew, nut and washer.

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5-69 Service Procedures Section MD6640 Blasthole Drill

REPAIR Repair of the rotary/pulldown guide frame is limited to replacement of worn or damaged components.

Repair welding of any of the components is not recommended. Since only limited repairs to the guide frame are possible with the unit installed on the machine, it is assumed for the purposes of this manual that the entire rotary/pulldown unit will be removed from the machine prior to repairs.

Replacement of the rack pinions and guide rollers is possible without removal of the entire guide frame from the machine. The repair procedures for these components are included in the following procedures.

To remove the guide frame assembly complete with the rotary gearcase and pulldown machinery form the machine, proceed as follows: 1.

Lower the rotary drive unit to its lowest position and rest it on the lower mast stops. Open the auxiliary power and control breakers and tag all controls to prevent unauthorized operation.

2.

Remove the upper air pipe from the swivel housing and from the guide angle. Discard the gasket. Use new gaskets at reassembly.

3.

Disconnect the electrical leads to the rotary and pulldown motor and remove the cable from the drive unit.

4.

Disconnect and remove the lubrication hoses leading to rotary drive unit, if so equipped.

5.

Using a suitable crane and rigging, support the entire rotary/pulldown unit.

6.

Remove the upper and lower front guide roller eccentric pin handle anchor bolts and turn handles to back off on the tension on the rollers to the mast.

7.

Remove the capscrews that secure wear plate.

8.

Remove the capscrews that secure bearing to the eccentric pins.

NOTE: To remove the retainer capscrews it may be necessary to rotate the eccentric pin to gain access to the capscrews.

9.

Support the upper bogie rollers and lower front roller, then using the pin handles, pull the upper and lower front eccentric pins from the rollers, bearing housings and guide frames.

10.

With the crane and rigging installed in Step 5, lift the rotary/pulldown unit from the mast and place it on secure blocking.

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5-70 Service Procedures Section MD6640 Blasthole Drill

11.

Completely disassemble the front upper and lower guide rollers and eccentric pins which were removed in Steps 7 and 8. The bearings have an interference fit of 0.0010-0.0030 to the roller and will require a puller to remove them.

12.

Remove the shipper shaft pinion retainers and remove the pinions.

13.

Refer to figure and remove the rear guide roller retainer capscrews and remove retainers, shims, rollers and spacers from pin. Remove the bearings from the rollers. The bearings have an interference fit to the roller and will require a puller for removal.

14.

Using the eccentric pin handles, pull the rear guide roller eccentric pins from the frame.

Separate the handle from the eccentric pins.

15.

Separate the pulldown motor coupling. Remove the motor hold-down bolts, chocks and shims.

With a crane and suitable rigging remove the motor.

16.

Remove the two spreaders at the top of the guide frame. Remove the pulldown unit guard.

17.

Remove the bolts that secure the shipper shaft end bearing housings to the guide frames.

Slide the housings toward the pulldown gearcase.

NOTE: The shipper shaft end bearing outer labyrinth seal is press fit to the bearing housing and will require a certain amount of force to separate it from the bearing housing.

Remove the outer labyrinth seals.

18.

Remove the pulldown gearcase hold-down bolts, chocks and shims. With a crane and suitable rigging maneuver the gearcase out of the guide frame and place it on secure blocking.

19.

Unbolt and remove the pulldown unit base.

20.

Verify that the rotary gearcase is securely blocked and supported.

21.

Using a suitable crane and rigging, support one side of the guide frame.

22.

Remove the bolts securing the guide frame to the rotary gearcase and remove the guide frame from the rotary gearcase.

NOTE: It may be necessary to remove the upper chock bar from the guide frame in order to remove the guide frame from the rotary gearcase.

23.

Repeat Steps 21 and 22 for the opposite guide frame.

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5-71 Service Procedures Section MD6640 Blasthole Drill

BI006893 24.

Clean and inspect all components and replace as necessary.

25.

Reassemble the guide frames and install on the machine in reverse order of disassembly noting the following. a.

Locate and assemble the shipper shaft bearing housings to the guide frames. Bolt and chock complete.

b.

Assemble the upper and lower guide rollers and handles to the guide frames. Shim the rollers to achieve 0.003" roller bearing end play. Torque the retainer capscrews to 55 ft. lbs.

NOTE: The upper and lower front rollers will have to be removed when the rotary/pulldown unit is installed in the mast. c.

Install the R.H. and L.H. guide frames loosely to the rotary gearcase so that the guide frames tip outward to allow the pulldown base to be installed.

d.

Install the pulldown base with dowels and clearance bolts. Install dowels and clearance bolts in rotary gearcase and tighten all bolts.

NOTE: All dowels are to be removed after chock bars are in place and replaced with bolts.

COUPLING ALIGNMENT

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5-72 Service Procedures Section MD6640 Blasthole Drill

BI006893 e.

Install pulldown gearcase and align to center of shipper shaft bearing housings. Shim case as required to center shaft to housings. Insure that inboard retainers are loose on shipper shaft when installing case.

f.

Install bearings to shipper shaft bearingeings and install all retainers and rack pinions.

Chock gearcase in place.

g.

Install pulldown motor and align motor and coupling as follows:

1.

Verify that the motor armature is centered and then position the motor so that there is a gap of .19" between shafts (approx. 1.44" between coupling hub faces).

2.

The coupling should be aligned within 0.002" offset and 0.002" angular misalignment. To find angular misalignment, measure the gap (“L”) between the coupling hubs along the circumference. The point 180° from the minimum measurement should be within 0.002 inch (.0508 mm).

3.

Use shims under motor mounting feet to achieve proper alignment.

4.

When properly aligned tighten motor hold-down bolts and weld chocks to motor base.

CAUTION:

5.

6.

In the following steps when welding chocks, be sure to follow all safety precautions. Also use suitable protection equipment when handling heated items.

Pack coupling with lubricant. a.

Lay rotary/pulldown unit down and install all lower chocks.

b.

Remove front upper and lower guide rollers and install rotary/pulldown unit in mast.

Install front upper and lower guide rollers and adjust per topic Guide Roller Adjustment

c.

Install air pipe and lube line; have an electrician reconnect motors.

Lubricate all points and verify correct operation of the rotary/pulldown unit.

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5-73 Service Procedures Section MD6640 Blasthole Drill

BI006893 PULLDOWN GEARCASE CAUTION:

Unexpected operation or movement of the pulldown unit and/or rotary gearcase during service or inspection procedures can cause severe personal injury or death. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Inspect the pulldown gearcase every shift for loose or missing hardware. Check the gearcase for lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper lubricant to the required level. If water has accumulated in the gearcase, remove the drain plug and completely drain the case. Refill the gearcase to the required level with an approved lubricant.

Pulldown Machinery - Overview

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5-74 Service Procedures Section MD6640 Blasthole Drill

BI006893 REPAIR

Repair of the pulldown gearcase is limited to replacement of worn or damaged components. The unit may be repaired in place on the machine or may be removed from the machine and repaired elsewhere. Refer to the topic Rotary/Pulldown Guide Frame for the procedure necessary to remove the assembly from the machine.

To repair the pulldown gearcase proceed as follows: NOTE: For this procedure we will consider the pulldown gearcase has been removed from the machine per Steps 17 through 20 of the topic Rotary/Pulldown Guide Frame - Repair.

CAUTION:

Be sure the rotary/pulldown guide frame is secured to the mast by cable or other means. Since the rack pinions and upper guide rollers have been removed.

Pulldown/Machinery Gearcase and Base

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5-75 Service Procedures Section MD6640 Blasthole Drill

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Pulldown/Machinery First Intermediate and Shipper Shaft

1. Shipper Shaft 2. Bearing 3. Locknut 4. Lockwasher 5. Seal Retainer 6. O Ring 7. Oil Seal 8. Labyrinth Seal 9. Bearing Spacer 10. Bearing Spacer 11. Bearing Retainer

12. Shims 13. 1st Intermediate Gear 14. Key 15. 1st Intermediate Pinion 16. Pinion Spacer 17. Bearing 18. Spacer 19. Spacer 20. Shipper Shaft Gear 21. Gearcase

1.

Remove bearing spacer from the ends of the shipper shaft. Use a puller to remove the end bearing from the shaft. The bearings have an interference fit to the shaft.

2.

Slide the bearing housing from the shaft and separate the inner labyrinth seal from the housing.

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5-76 Service Procedures Section MD6640 Blasthole Drill

BI006893 3.

If not previously done, drain the gearcase.

4.

Remove bearing cover from the pinion end of the second intermediate shaft. Remove O-ring from the cover.

Pulldown Machinery Second Intermediate Shaft

1. 2nd Intermediate Shaft 2. Bearing 3. Bearing Retainer 4. Cover 5. O Ring 6. 2nd Intermediate Gear 7. Key 8. Gear Spacer 9. Bearing 10. Retainer

11. Seal Retainer 12. Oil Seal 13. O Ring 14. Encoder Coupling 15. Coupling pin 16. Encoder 17. Housing 18. Cover 19. Gasket 20. Gearcase

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5-77 Service Procedures Section MD6640 Blasthole Drill

5.

Remove encoder housing cover, gasket and housing from the opposite end of the second intermediate shaft.

6.

Remove encoder coupling spring pins, then unbolt and remove encoder and coupling. Remove retainer/encoder support from the gearcase. Remove the O-ring and oil seal from the retainer.

7.

Remove the bearing retainer from each end of shipper shaft. Separate O-ring, oil seal and labyrinth seal from each retainer.

8.

Remove the rod bolts, tapered pins and capscrews securing the gearcase cover to the gearcase. With a crane lift the cover from the gearcase.

9.

Lift the shipper shaft from the gearcase. Remove the bearing spacer from the long end of the shipper shaft.

10.

Remove bearing retaining nut, lockwasher, bearing and bearing spacers from each end of the shaft.

11.

Slide shipper shaft gear from the shaft.

12.

Remove first intermediate pinion bearing retainer and shims.

13.

Press the pinion assembly from the shaft. The bearings have an interference fit to the shaft.

Remove pinion spacer from the shaft.

14.

Separate bearings and spacer from pinion. The cup of the brake end bearing has an interference fit to the pinion and will require a puller for removal.

15.

The first intermediate gear is interference fit to the pinion and should only be removed if required. If the pinion and gear are to be separated the lube fittings must first be removed.

16.

Lift the second intermediate shaft from the gearcase. Remove pinion end bearing retainer and bearing. The bearing has an interference fit to the shaft and will require a puller for removal.

17.

Remove encoder end bearing retainer and bearing. The bearing has an interference to the shaft and will require a slight force for removal.

18.

Remove the gear spacer. The gear is interference fit to the shaft and will require a puller for removal. Remove the gear end key.

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5-78 Service Procedures Section MD6640 Blasthole Drill

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Pulldown Machinery Input Shaft

1. Input Shaft 2. Bearing 3. Bearing Carrier 4. Gasket 5. Oil Seal 6. Spacer 7. Retainer 8. O Ring 9. Coupling Spacer 10. Coupling 11. Key 12. Nut 13. Lock Plate

14. Bearing 15. Bearing Spacer 16. Oil seal 17. Seal Retainer 18. Gasket 19. Oil Slinger 20. Hub Spacer 21. Brake Drive Hub 22. Hub Retainer 23. Brake Assembly 24. Bearing Spacer 25. Key 26. Shims

19.

Remove the brake housing and cage mounting capscrews. Slide the brake assembly from the brake drive hub. Disassemble the brake as covered under the topic Hoist Brake.

20.

Remove the brake drive hub retainer capscrew and retainer. Remove hub, hub spacer and oil slinger.

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5-79 Service Procedures Section MD6640 Blasthole Drill

BI006893 21.

At the coupling end of the shaft remove the bearing carrier capscrews. Slide the shaft assembly from the gearcase. Remove the carrier gasket.

22.

Remove spacer and bearing from the brake end of the shaft. The spacer and bearing are interference fit to the shaft and will require a slight force for removal.

23.

Use a puller to remove half coupling from the end of the shaft.

24.

Remove seal retainer from bearing carrier. Remove O-ring, oil seals and seal spacer from the retainer.

25.

Remove bearing spacer and coupling spacer. The coupling and bearing have an interference fit to the shaft and will require a slight force for removal. Remove the carrier and bearing as an assembly, then separate them.

26.

Remove seal retainer from the brake side of the gearcase. Remove gasket and oil seal from the retainer.

27.

Clean and inspect all parts and repair or replace all damaged or worn parts. Reassemble in reverse of disassembly noting the following: CAUTION:

During reassembly of the pulldown gearcase certain items must be heated or cooled for assembly purpose. When heating or cooling the items take all necessary precautions and use suitable protective equipment when handling the heating or cooled items.

a.

The input shaft bearings, bearing spacer and coupling half are interference fit to the shaft and will require heating to install.

b.

Use thread locking compound on the brake hub retainer capscrews, the coupling end bearing oil seal retainer capscrews and the brake drive ring mounting capscrews. Torque drive ring mounting capscrews to 140-150 ft-lbs.

c.

Fill the cavity between seals with lubricant at assembly.

d.

The second intermediate shaft bearing and gear are interference fit to the shaft and will require heating to install.

e.

Use thread locking compound on the encoder end bearing retainer socket head capscrews.

f.

The first intermediate shaft should be assembled as follows:

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5-80 Service Procedures Section MD6640 Blasthole Drill

BI006893 1.

Install pinion inner spacer on the shaft.

2.

If removed during disassembly, reinstall gear on pinion. The gear is interference fit to the pinion and will require heat to install. Be sure key is installed in gear.

3.

Install inner bearing outer race in pinion. Race is interference fit to pinion and will require cooling to install. Slide pinion assembly over shipper shaft as far as it will go.

4.

Heat inner races of pinion bearing and install with spacer between them. Then use special spacer supplied with tools to clamp bearing races. Secure the assembly with the bearing lock nut.

5.

Assemble the remaining outer race and retainer. Install three capscrews equally spaced and torque to 50 ft-lbs. Measure the gap at all three unused holes and calculate average.

Install shim pack equal to average gap and install and tighten all retainer capscrews.

6.

Remove the special spacer and install the remaining material.

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5-81 Service Procedures Section MD6640 Blasthole Drill

BI006893 HOIST BRAKE CAUTION:

Unexpected operation or movement of the pulldown unit and/or rotary gearcase during service or inspection procedures can cause severe personal injury or death. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

The hoist brake is a spring-set electric release brake.

INSPECTION Inspect the brake periodically (every 2000 hours min.) for wear by measuring air gap through slots in cage. One indication of brake wear is a brake release fault signal. When air gap becomes excessive, the brake will not release. When the air gap reaches .065", the gap should be adjusted.

Normal operating gap is .050". When the friction disc pack is worn to 1/2 its original thickness, the disc pack should be replaced.

Brake Wear Adjustment

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5-82 Service Procedures Section MD6640 Blasthole Drill

BI006893

Hoist Brake - Details

1.

2.

3.

4.

5.

6.

7.

8.

9.

Magnet Body Pressure Spring Assembly Cage Cage O Ring Armature Intermediate Disc Friction Disc Wear Adjusting Ring Hub

10. Adjusting Rod 11. Feeler Gauge 12. Nut Plate 13. Manual Release Bolt 14. Limit Switch 15. Switch Bracket 16. Housing 17. Conduit Box 18. Terminal Block

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5-83 Service Procedures Section MD6640 Blasthole Drill

BRAKE WEAR ADJUSTMENT 1.

Make sure the mast machinery is blocked or manually locked in the lowered position as the brake needs to be released to perform the adjustment.

2.

Remove the housing screws and brake housing using care to keep from damaging the switches located on the circumference of the coil housing.

3.

Insert brass feeler gages (0.050 supplied with brake) into air gap at the three slots and release the brake electrically or with the manual release bolts.

4.

Remove the locking screws from the wear adjusting ring in the slots of the cage.

5.

Insert the adjusting rod into one of the holes in the wear adjusting ring and rotate CCW to the end of slot. Repeat until resistance is felt.

6.

Remove gages and turn the adjusting ring to the nearest end of the slot. Remove rod and reinstall locking screws.

7.

Make sure the brake release switches are clean and actuate freely.

8.

Set the brake and re-install the housing. Apply a bead of silicon sealant to all exterior joints.

REPLACEMENT OF FRICTION DISCS 1.

Energize magnet and clamp armature to magnet body with four manual release bolts. Deenergize magnet and remove leads.

2.

Remove cage mounting bolts and magnet body and armature assembly. Back-off wear adjusting ring slightly to allow space for new friction disc pack.

3.

The friction disc pack may now be slid from the hub and cage. Note the order of the pack so that the new parts can be installed correctly.

4.

Re-install new friction disc’s in the correct order with the intermediate discs as shown in figure.

5.

Replace magnet body and armature assembly. (Arrows metal stamped on each part must be in line).

6.

Re-connect lead wires, energize brake and remove four manual release bolts.

7.

Set air gap to 0.050" per Brake Wear Adjustment.

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5-84 Service Procedures Section MD6640 Blasthole Drill

DISASSEMBLY OF MAGNET BODY AND ARMATURE 1.

Place assembly in press with spacer.

2.

Press armature against magnet body and remove manual release bolts from armature. (6500 lbs press force required).

3.

Slowly release pressure from press until spring pressure is relieved. Remove armature.

Pressure spring assemblies may now be removed.

RE-ASSEMBLY OF MAGNET BODY AND ARMATURE 1.

Place magnet body with flange side up on spacer on press base.

2.

Insert pressure spring assemblies and set armature in place being sure to align arrows on armature and magnet body. Insert temporary pins into release bolt holes for aligning.

3.

Press armature against magnet body (6500 lbs press force), remove temporary pins and install four manual release bolts. Tighten bolt to hold armature against magnet body. Remove assembly from press.

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5-85 Service Procedures Section MD6640 Blasthole Drill

BI006893 PIPE RACKS

The pipe racks on the machine are used to store drill pipe in a position from where they can be easily inserted into the drill string. The pipe racks are operated by a hydraulic cylinder which swings the rack into position to accept or deliver drill pipe.

Inspect the pipe racks daily for loose or missing hardware or any wear or damage. Inspect the racks each shift for proper operation. Verify that the pipe is held securely by the upper gate. Check the operating cylinder for proper operation and any oil leaks. Check the bushings on both the pipe racks for wear and replace as necessary. Check the pawls in the pocket on the lower end of the pipe rack for proper operation. Remove any dirt, ice or other debris from the pipe pocket and verify the operation of the gate operating system if no pipe is stored in the rack. Lubricate all points with the required lubricant.

RH Pipe Rack - Details

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5-86 Service Procedures Section MD6640 Blasthole Drill

BI006893

LH Pipe Rack - Details

REPAIR There are no wear items on the pipe racks with the exception of the bushings. All major components of the pipe racks should last through the lifetime of the machine. Repair of the pipe racks is limited to replacement of bushings and thrust washers.

To replace the bushings and thrust washer, proceed as follows: 1.

Raise the rotary drive unit to its highest position and set the hoist brake.

2.

Disconnect, plug and tag all hydraulic lines to the pipe racks.

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5-87 Service Procedures Section MD6640 Blasthole Drill

3.

Secure the pipe rack to prevent movement.

4.

Remove the bolts attaching upper pivot bracket to bracket support. Remove the bracket and then remove bushing from the bracket.

5.

Remove bushing retainer. Remove the half of split bushing from the bushing retainer.

6.

Secure a suitable crane and rigging to the pipe rack. Separate and remove the rack positioning cylinder. With the crane, lift the pipe rack from the mast bottom plate.

7.

Remove bushing and thrust washer from the mast bottom plate and the half of split bushing from bushing retaining block.

8.

Clean and inspect all components. Replace worn or damaged components as necessary.

9.

Reinstall in reverse of disassembly, lubricate all lubrication points and check for proper operation.

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5-88 Service Procedures Section MD6640 Blasthole Drill

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Pipe Rack Variable Equipment

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5-89 Service Procedures Section MD6640 Blasthole Drill

BI006893 TOOL WRENCH

The tool wrenches consist of the Tool Wrench and the Breakout Wrench. They are used to clamp the drill pipe in order to break a pipe joint. The tool wrenches are two specially built hydraulic cylinders operating inside a square casing. A spring loaded pawl engages a pocket in the drill pipe to prevent rotation of the pipe.

Tool Wrench - Details

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5-90 Service Procedures Section MD6640 Blasthole Drill

BI006893

Inspect the tool wrenches daily for loose or missing hardware, or any wear or damage. Inspect the wrenches each shift for proper operation. Check each wrench and associated hydraulic lines for oil leaks and repair any leaks found immediately. Verify that the pawls are fully extended and secured with dowel rod. Verify that the wrenches can pivot about the rear pin. Clean any accumulation of cuttings from beneath the wrenches. Verify that the top blocks are in place and intact. Verify that the rear pin bearing blocks are secured firmly to the drill deck and that the piston rod anchor bolts are secure. Lubricate the assembly with an approved lubricant at the recommended intervals.

REPAIR Repair of the tool wrenches is essentially limited to replacement of the pawl insert. Replacement of the entire tool wrench is accomplished by removing the two hydraulic lines from the piston rod and then removing the four bolts securing the bearing blocks. Repair of the tool wrench itself follows standard procedures for repair of hydraulic cylinders.

To replace the pawl insert, proceed as follows: 1.

Remove the defective tool wrench from the drill deck by removing the hydraulic lines leading to the piston rod and removing the 4 bolts securing the bearing blocks to the drill deck.

2.

Using suitable equipment compress the pawl springs slightly to remove pressure from the pawl retaining pin.

3.

Using suitable equipment remove the pawl retaining pin.

CAUTION:

The pawl is spring loaded. Be sure to adequately restrain the pawl before removing the retaining pin. Failure to restrain the pawl will result in it being forcibly ejected from the cylinder body, possibly causing death or serious injury to personnel in the area.

4.

Completely relax the tension on the pawl springs. When tension is completely removed, remove the pawl and pawl springs from the cylinder body.

5.

Inspect the springs and pawl and replace as required.

6.

Lubricate the springs and pawl with an approved lubricant and reassemble the components in reverse order of disassembly.

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5-91 Service Procedures Section MD6640 Blasthole Drill

BREAKOUT WRENCH The breakout wrench is used to break pipe joints that will not break using the rotary drive.

With the pipe secured by the tool wrenches, the breakout wrench switch is turned to and held in the EXTEND position. The breakout wrench extends, grips the pipe, then turns, breaking the pipe joint.

REPAIR he breakout wrench should be inspected daily for wear or damage, loose or missing hardware, and proper operation. Repair of the breakout wrench is limited to the replacement of worn or damaged components.

GENERAL GUIDELINES FOR DISASSEMBLY 1.

Remove attachment pins to remove hydraulic cylinders.

2.

Remove pin to dismount lever.

3.

Remove pins to dismount jaws.

4.

Remove pins to sidemount arm. Check for excessive wear on brass washers.

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5-92 Service Procedures Section MD6640 Blasthole Drill

5.

If jaw replacement is necessary, teeth or jaw inserts must be removed. Softly strike the tooth to take it out.

6.

Reinstall in reverse order, except for cotter pin.

7.

Check the operation of the wrench. If the inserts contact the pipe, wrench is ready for use. If inserts do not contact the pipe, repeat steps.

AUXILIARY WINCH The auxiliary winch is used to lift tools on and off the drilling deck. The winch consists of a hydraulically driven reel mounted at the bottom of the mast, a cable with hook, and cable guide sheaves at the top of the mast.

The oil level in the winch should be checked monthly. The sheaves at the top of the mast should be checked monthly for wear or damage. Once a year the sheave bearings should be re-packed with lubricant.

For repair of the hydraulic winch refer to the Hydraulic System chapter of this manual.

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BI006893 MAST BRACES

The purpose of the mast braces are to provide support to the mast while angle drilling.

Mast Braces - Details

Inspect the mast braces daily for loose or missing hardware or any wear or damage. Replace any missing hardware and repair any damage immediately. Inspect the upper anchor pins, washers, retainer pins daily, making sure that the retainer pins are in place. Inspect the mast brace structure for cracks and any other damage. Repair the mast brace structure using the repair welding techniques listed in the appendix. Inspect the telescoping lock pins for wear. The telescoping lock pin cylinders and hydraulic lines should be checked daily for leaks. Verify that the adjustment bolt lock nuts are tight and that the mast braces are adjusted properly.

Inspect the mast braces sleeves and supports for wear, damage or loose or missing hardware.

Lubricate all pins with an approved lubricant at the recommended intervals. Lubricate the adjustment bolt with a rust inhibiting oil as required.

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BI006893 REPAIR

The mast braces are not normally considered wear items; therefore any repairs required will have to be handled on an individual basis.

CAUTION:

The mast braces are critical components especially on angle drilling machines. Consult the Caterpillar Global Mining Service Department before attempting major repair or modifications.

ADJUSTMENT Normally the mast braces are adjusted during the machine erection and further adjustment is not necessary. Special circumstances may require the readjustment of the mast braces to original condition. To readjust the mast braces proceed as follows: 1.

Remove the telescoping lock pins form the mast braces.

2.

Accurately level the machine. Be certain that all four corners of the machine are at the same elevation and that the mast is positioned vertically.

3.

Loosen the adjustment bolt lock nut.

4.

Turn the adjustment bolts until the telescoping lock pins can be freely inserted (approx. 14.25" ±2.50" from centerline of adjustment bolt pin to end of brace).

5.

Lock the adjustment bolt in place with the lock nut.

CAUTION:

NOTE:

Once the mast braces are adjusted, it is not necessary to alter the adjustment unless the mast brace is replaced. Difficulty in pinning the mast braces usually results from the machine not being level or the mast not being vertical. Arbitrary adjustment of the mast braces without accurately leveling the machine may cause serious damage to the mast and should be avoided.

Proper adjustment of the mast braces is made with machine leveled and supported on jacks. Difficulty will later be encountered in removal or re-assembly of the telescoping lock pin if the machine is resting on the crawlers.

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BI006893 HYDRAULIC SYSTEM SYSTEM OPERATION

The following description is intended to help field personnel understand hydraulic systems and their operation. The explanation consists of an overview of the systems and the relationship of the schematics to the actual components on the drill.

The two separate though not independent major hydraulic systems: Propel circuit and Cylinder circuit. Both systems draw their oil from a common 108 gal. capacity reservoir. The pumps for the circuits are driven through a gear drive box by the main compressor motor. The gear drive box will increase, decrease or maintain the same speed ratio between the motor speed and the pump speed. The main compressor motor determines the gear ratio of the gear box.

The propel circuit consists of two hydraulic pump/motor drives, one for each crawler. Piggy-backed to the left propel pump is a single gear pump which supplies oil under pressure to leveling jacks and mast raising cylinders and actuators. Piggy-backed to the right propel pump is a two-section gear pump. The cover end pump supplies control pressure for the propel pumps as well as pilot pressure for the mast hoist, auxiliary winch and pipe rack valves. This pump also supplies oil to actuate the bit viewing hatch cylinder, boarding stair cylinder, and the lube system.

Hydraulic Components Overview

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The propel circuit includes brake controls for each crawler. For towing purposes, the system is equipped with a hand pump for manual release of the crawler brakes.

The shaft end pump of the two-section gear pump supplies oil under pressure to the remaining hydraulic cylinders and actuators of the machine.

If the machine is equipped with a cable reel, the complete hydraulic system, including reservoir, pump and motor are part of the cable reel unit.

The systems are totally sealed and filtered so as to keep the oil as clean as possible.

The gear box with pumps is mounted to the rear drive shaft of the main air compressor motor. The reservoir, oil cooler and main frame manifold valves are located at the rear of the machinery house and the various cylinders are mounted at various points around the machine.

CYLINDER CIRCUIT HYDRAULIC SYSTEM Fluid for this system is supplied from the common 108 gallon reservoir. The single gear pump and two-section gear pump supply oil to the actuators at the following rates: 2704 RPM @ 60 HZ Single Pump 65 GPM Shaft end Pump 17 GPM Cover End Pump 18 GPM 2253 RPM @ 50 HZ Single Pump 54 GPM Shaft end Pump 14 GPM Cover End Pump 15 GPM The multiple station manifold valve assemblies contain control valves for the various actuators.

Usually the control valves will be assembled in stacks – one stack for each actuator. A typical valve stack could include a relief valve, a flow control valve, a check valve, a quick disconnect valve for pressure testing and a solenoid valve.

Most hydraulic lines run from the manifold valve to bulkheads, then from the bulkheads to the actuators. All oil returning to the reservoir passes through 10 micron filters before entering the reservoir.

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BI006893 PROPEL CIRCUIT HYDRAULIC SYSTEM

Fluid for the propel system is also supplied from the 108 gallon reservoir. Most hydraulic control valves of the propel circuit are modules bolted directly to the pumps. The pilot pressure valve and brake valves are separate from the pumps. The oil for each pump control circuit is directed through a 10 micron filter equipped with a 25 PSID by-pass valve.

The pilot pressure is controlled to 1000 PSI by the sum of the 850 PSI relief valve and the 150 PSI supercharge relief.

The pumps are equipped with two main relief/pressure override assemblies referred to as a combination valve; one for the forward propel side, and the other for the reverse propel side.

The pressure override portion of the assembly is set at 4500 PSI. The pressure override valve prevents continuous dumping of excessive flow, at load pressure, through the main relief valves. This eliminates unnecessary heating of the oil and protects the pump and motor from damage.

GENERAL MAINTENANCE

HYDRAULIC SYSTEM CLEANLINESS It is extremely important to use the correct oil in the system. It is equally important to keep the oil clean. Whenever a repair procedure requires a connection to be broken or a part to be replaced, first clean the immediate area around the joint and/or part to be replaced. This step is required to assure no contaminates enter the system through the hydraulic lines or replacement parts.

While performing the repair keep everything clean and also keep openings covered or plugged until they are re-connected. Contamination is the most common cause of trouble in a hydraulic system. It causes excessive wear of parts, interferes with the close clearances, and hinders normal operation.

NOTE:

Never add oil to the system by removing the reservoir breather and pouring it in through the funnel. Even new drum oil is dirty and can cause sticking valves.

When hydraulic oil is added to the system, it should always be pumped into the system. The pump discharge line should be attached to the quick-disconnect coupling at the top of the tank. This connection insures that the new oil will pass through the tank return filters before entering the system.

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If the pump used to add the oil is equipped with a filter buggy and the pump has been used for other fluids, the pump system and filter buggy must be purged of the other fluid prior to connecting the pump unit to the quick-disconnect coupling. This purging can be accomplished by flushing the pump unit and filter buggy with at least one gallon of the specified hydraulic oil.

OIL REQUIREMENTS For hydraulic oil benchmarks refer to Section 3 of this manual – (Hydo) Hydraulic Oil.

OIL AND FILTER CHANGES During normal operation change the element when indicated by the filter condition indicator with the oil at normal operating temperature and whenever oil is changed.

NOTE:

Before changing the element, open the circuit breaker for the hydraulic pump motor. Be sure there is no pressure on the system to prevent possible oil leakage.

The change frequency for hydraulic oil depends on the type of oil used in your machine. This cycle can range from 2,000 hrs. for standard grade petroleum base type oil as determined by the lube bench marks, to 8,000 hrs. for certain synthesized hydrocarbon hydraulic oils as noted in the lube bench marks. These change frequencies can be shortened or lengthened depending on the condition of the oils. To determine the condition of the oils, samples should be taken periodically (i.e. 200 hrs.) and analyzed by a reputable manufacturer. When taking oil samples, never take the sample from the tank drain system. If possible, the sample should be taken from a point near the return manifold just before the return filters.

CAUTION:

To minimize fire hazard, no open flames or other ignition sources are allowed when changing oil.

Water should be drained from the bottom of the hydraulic oil reservoir once a day, after a period of shutdown and when the oil is cold.

The hydraulic oil reservoir holds 108 gallons of oil.

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BI006893 WEEKLY MAINTENANCE CHECKS

Check for correct operation of all components of the system. Valves, cylinders, and motors and pumps should operate smoothly, with no jerking or binding. Check the oil level in the reservoir. The reservoir should be almost full (108 gal.) when the mast is horizontal and all other cylinders are retracted. With the mast vertical and all other cylinders retracted, the reservoir should be slightly below 7/8 full.

CAUTION:

Before topping off the fluid in the hydraulic tank, verify that the mast cylinders are extended and all other cylinders are retracted. Failure to comply with the above (i.e. jack cylinders extended) will overfill the tank when the jack cylinders are retracted and will cause the tank to rupture.

CAUTION:

Do not operate with low oil level. Operating with low oil level can cause cavitation and air pockets. This will cause faulty operation and can also cause damage to the system components.

Inspect all components and lines to be sure they are in good operating condition. Check for obstructed or distorted cylinders. Inspect the system for leaks. If a leak is found, tighten the screws or fittings around the leaking area before beginning major repairs. If that does not stop the leak, it may then be necessary to repair or replace the leaking part.

OIL RESERVOIR REPAIRS The hydraulic oil reservoir is epoxy coated on the inside to prevent scale and oxidation.

CAUTION:

DO NOT weld on the reservoir; it will damage the coating.

LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING PROCEDURE If it becomes necessary to work on the leveling jack counterbalance valve for any reason, relieve pressure in the cylinder using the following procedure: 1.

Position the machine with crawlers on the ground and jacks retracted so that the jack pads are approximately one inch off the ground.

2.

Turn off the hydraulic pump and relieve any pressure in the system by loosening the reservoir breather. When trapped air in the reservoir is relieved, immediately replace the breather.

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REAR JACKS 1.

Uncouple the quick disconnect using a 1 1/4" open end wrench. The male half of the quick disconnect will remain attached to the valve.

2.

Remove the other end of the quick disconnect hose from the electrical junction box on the jack.

3.

Place the hose end, removed from the electrical junction box, into a clean five gallon container.

4.

Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

CAUTION:

Always maintain a firm grip on the hose while the oil is flowing from it.

Do not allow the stream of oil to contact your skin as injury can occur.

5.

When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

6.

With the pressure relieved, the counterbalance valve or jack cylinder can now be safely worked on.

FRONT JACK 1.

Uncouple the quick disconnect at both front jacks, using a 1 1/4" open end wrench. The male half of the quick disconnect will remain attached to the valve.

2.

At one front jack only, remove the other end of the quick disconnect hose from the electrical junction box on the jack.

3.

Place the hose end, removed from the electrical junction box, into a clean five gallon container.

(Two additional 5 gallons will be required to handle the oil from both front jacks.)

CAUTION:

4.

Always maintain a firm grip on the hose while the oil is flowing from it.

Do not allow the stream of oil to contact your skin as injury can occur.

Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

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BI006893 5.

To remove the oil from the other front jack, a helper will be required. Have the helper continue to hold the disconnected hose into a empty 5 gallon container while you re-couple the quick disconnect on the other front jack. The oil from this jack will now flow from the hose being held by the helper.

6.

When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

7.

With the pressure relieved, the counterbalance valve or jack cylinder can now be safely worked on.

PRE-START INSPECTION If the machine hydraulic systems have had a major overhaul, the following presort inspection should be completed before start-up of the machine.

CAUTION:

Before starting pumps, establish a safe walking perimeter around machine to reduce possible injury to ground personnel due to automatic operation of boarding stair, dust curtain, or cable reel.

NOTE: Read all instructions before starting any individual test. Initial each step after its completion or record the requested information.

1.

Check all lines and fittings for tightness and plumbing accuracy.

2.

Visually check that no open port exists on any valve.

3.

If the crawlers or mast have been removed from the machine, be sure that all ports have been plugged or capped and all loose lines terminated in a quick disconnect or plugged with a steel fitting.

NOTE: Make note of the oil manufacturer and type of oil being used in this hydraulic system (e.g. Conoco Syncom AW22).

4.

Verify that the hydraulic reservoir is filled to the correct level with the required hydraulic oil.

5.

Check the suction plumbing and the reservoir for external leaks.

6.

From the test kit install 0-1500 PSI gauges to test ports 14 and 15 at the left and right propel pump charge filter outlet, respectively, as shown on the gauge port location table at the end of this section of this manual.

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BI006893 NOTE: All pressure gauges must be calibrated before using.

7.

Verify that pump drive gear box is filled with 7.75 quarts of S.A.E. 80 - 90W oil.

8.

Check the pump drive motor for correct rotation by jogging the main compressor start/stop pushbuttons, or PTO clutch, if diesel driven. Pump drive gearbox input shaft rotation is opposite pump shaft rotation.

9.

When item 8 is complete, continue to jog electric motor until pressure on gauges at test ports 14 and 15 is 100 PSI.

10.

When pressure rise is verified, turn on the hydraulic pumps and visually check all plumbing for leaks.

HYDRAULIC SYSTEMS TESTS The hydraulic systems are equipped with quick disconnect test ports for checking the operation of the systems. The test ports are shown in the figures. The test ports are identified by the circled numbers on the illustrations.

These tests are designed to assure that the specified units are operating correctly and, if they are adjustable, they are adjusted to the correct pressure setting. The results of each of the following tests should be noted in a log book so that on future checks and in case of system failure, pressure readings can be compared to help locate the failure.

NOTE: For location of test points on the machine see the gauge port location table at the end of this section of this manual.

CAUTION:

Before attaching or disconnecting pressure gauges to test ports, be sure that the hydraulic pumps are turned OFF.

PROPEL PUMP CHARGE PRESSURE CHECK NOTE: 1.

Charge pump relief adjustment is on right side of pump.

With pump controls at NEUTRAL and pumps running, check pressure at test port 14 on a 1500 PSI gauge. Set charge pump relief pressure of left propel pump as required to obtain 350 PSI ±10 PSI (use 1-1/16" hex wrench and screwdriver).

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5-103 Service Procedures Section MD6640 Blasthole Drill

2.

With pump controls in neutral and pumps running, check pressure at test port 15 on a 1500 PSI gauge. Set charge pump relief pressure of right propel pump as required to obtain 350 PSI ±10 PSI (use 1-1/16" hex wrench and screwdriver).

3.

Turn off pumps.

CONTROL PRESSURE CHECK 1.

With Pilot Pressure Valve (PPV) disconnected electrically at station 6 of 6 station manifold located immediately above and to the rear of the jack valve stand, and with a 1500 PSI gauge at test ports 7 and 17, turn pumps on. Record pressure at test ports 7 and 17 (approx. 150 PSI). Pressure at test port 17 should be greater than port 7.

NOTE: Before performing step 2, warm-up hydraulic system so that oil cooler motor has cycled ON at least once.

2.

With solenoid wires re-connected to pilot pressure valve (PPV), start pumps and after 10 seconds, with PPV energized, observe pressure at test port 17. Adjust relief valve at station 6 as required to see: 1000 ±10 PSI. Adjustment is facing wall, opposite the electrical solenoid.

3.

Record pressure at test port 7 (approx. 150 PSI).

PROPEL ENABLE VALVE AND LOW SPEED SELECT CHECK 1.

With drill/propel select switch in PROPEL NORMAL, in on-board propel, with a 1500 PSI gauge at test ports 8 and 18, start the pumps and press the drill/propel ON pushbutton.

Record the pressure at test ports 8 and 18. Test port 18 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK. Test port 8 reading should be zero (0)

2.

With pump still running, first lift one propel joystick out of the DETENT position and then release it. Do the same with the other joystick.

NOTE: There is no need to move joysticks out of NEUTRAL. Just lift the joystick clutch straight up to engage solenoid Propel Active Valve (PAV).

Accomplishing step 2 will cause PAV to energize which should cause pressure at test port 18 to go from 650 PSI to 0 and test port 8 should go from 0 to 650 PSI. 3.

With a 1500 PSI gauge at test port 9 and the pumps running, rotate Propel Selector Switch to SLOW speed and record pressure.

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5-104 Service Procedures Section MD6640 Blasthole Drill

4.

Pressure in step 3 should be 1000 ±10 PSI .

5.

With Propel Selector in NORMAL, record pressure at test port 9. (Should read zero.)

JACK CYLINDER CHECK IN MANUAL MODE NOTE: Under no circumstances must either 3-spool valve or relief valve adjustments be allowed to bottom-out. The spool valve is located on the back wall of the machinery house to the left of the hydraulic oil tank and slightly below the top of the tank. The main relief is near the inlet port.

1.

With a 7,500 PSI gauge at test port 16 and pumps running, energize auto level in RETRACT mode. With all cylinders fully retracted, adjust 3-spool valve relief to show exactly 3,300 PSI on the gauge.

2.

Check all jacks for operation versus manual lever movement (i.e. moving the right front jack control to EXTEND, extends the right front jack. Check both directions with all 4 jacks).

NOTE: Re-check hydraulic oil level and add oil as required. Set flow controls per FLOW CONTROL CHECK before continuing with step 3.

3.

Back-out adjustment of relief valve 1/8th of a turn and then tighten the jam nut.

4.

Install a 0-1,500 PSI gauge at test port 70, located at inlet to back pressure valve underneath and slightly to the left (rear) of the 3-spool valve.

5.

With the right front jack manually extending from full RETRACT position, adjust back pressure relief as necessary to see 400 PSI.

6.

With step 5 complete, install a 7,500 PSI gauge at test port 16 and with right front jack extending from full RETRACT towards the ground, adjust relief valve located at inlet of jack spool valve on jack stand. Adjust to see 3,200 PSI.

NOTE: Do not bottom any relief valve adjustments.

7.

Re-check all jacks for operation versus manual lever movement.

8.

Install all four jack pads.

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FLOW CONTROL CHECK 1.

Remove hose nearest wall from 3rd flow control (counting from left to right) on jack valve stand and install a -10 ORS steel plug into the open hose.

2.

Install a 20 GPM Hedland flow meter #700-020 (inlet side) into the open port of flow control.

3.

Disconnect hose coming from the spool valve to the 7th flow control. Install a steel -10 ORS cap onto the flow control’s open port.

4.

Connect the outlet side of the flow meter to the hose just removed from the 7th flow control.

5.

With pumps running and with the aid of a helper, energize left rear jack, in either UP or DOWN mode, to show flow in the meter. Adjust flow regulator, as required. Set all 8 flow controls to 15 GPM for 60 Hz machines as well as for 50 Hz machines running at 3,000 RPM input speed.

All other 50 Hz machines are to be set at 12.5 GPM.

6.

After first flow regulator is tested, substitute the remaining untested regulators into the 3rd position until all eight flow regulators have been checked. All flow regulators MUST end up in their proper position when test is complete.

NOTE: During calibration of flow controls, as well as anytime jacks are being operated in MANUAL or AUTO-LEVEL mode, the flow control should not exhibit any chattering or screaming noise.

7.

With step 6 complete, re-assemble hoses to proper ports.

8.

Now complete Jack Cylinder Check In Manual Mode starting with step 3.

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BI006893 JACK CYLINDER DRIFT TEST NOTE: Read items 1 through 5 of this test before continuing.

1.

Lower all jacks to ground such that the jack pads are firmly on the ground but are not lifting the machine.

NOTE: If in steps 2 and 3 the crawlers are not mounted and the machine is resting on blocks, only lift the machine a few inches.

2.

Manually extend left and right front jacks simultaneously to lift the front of the machine.

3.

Manually extend left and right rear jacks simultaneously to lift the rear of the machine.

4.

Continue to lift the machine by alternating front to rear until the crawler tracks have cleared the ground by 3 or more inches. If crawlers are not mounted, lift the machine approx. 6 inches off the blocks.

5.

With machine approximately level, position all manual jack controls to NEUTRAL and check for jack cylinder drift. Drift should not exceed 1/8" in 30 minutes.

BRAKE RELEASE PRESSURE CHECK NOTE:

Crawlers must be mounted to mainframe for this test.

1.

With 0-1500 PSI gauges at test ports 5 and 6 and with pump running, the pressure should be at or near zero with hands removed from the propel joysticks and drill/propel select switch in PROPEL NORMAL mode.

2.

With pump still running, first lift one propel joystick and then release it and then lift and release the other propel joystick. Anytime either or both joysticks are lifted full up out of the DETENT position, the propel active valve (PAV) will energize and the pressure at test ports 5 and 6 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

3.

With drill/propel select rotated to DRILL mode, pressure at test ports 5 and 6 should be zero regardless of whether the joysticks are in or out of the DETENT position.

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BI006893 PROPEL BRAKE EMERGENCY RELEASE CHECK NOTE: This test must be performed with the pumps OFF. 1.

With 0-1500 PSI gauges at test ports 5 and 6, the bypass valve handle (located on the left side surface of left front jack housing) rotated fully CW, and with hand pump bypass valve CLOSED, manually operate pump handle to raise pressure on the gauge until the operator’s display terminal screen displays: PROPEL BRAKE TOW RELEASE. Record the pressure that causes the operator’s display terminal screen display to appear. (Pressure should be 500 PSI.)

2.

With step 1 complete, continue to operate the pump until the gauge shows 1,000 PSI. Record the amount of pressure drop in 5 minutes (should not be more than 500 PSI).

NOTE: Pressures in step 1 and step 2 should also appear at test ports 5 and 6 on 0-1500 PSI gauges.

PROPEL PUMP MAIN RELIEF PRESSURE CHECK NOTE:

Crawlers must be mounted and there should be no crawler movement during this test.

Main relief valves are on the top of the pump, as mounted on machine.

1.

With machine still raised on jacks and with a 7,500 PSI gauge at test ports 1 and 2 and a 01,500 PSI gauge at test port 59, disconnect the propel brake release line at the brakes and plug the hoses with a -6 O-ring seal plug. Leave the port on the brakes open; do not cap or plug the fittings.

NOTE: Use a 5 mm Allen wrench and a 3/4" open end wrench to adjust main relief valves.

2.

With the pumps running, energize the propel active valve (PAV). Note the presence of 600 PSI at test port 59. Operate the left crawler control in the FORWARD direction by manually pressing coil PLV-FWD. Adjust relief as required to see 4,500 PSI on gauge at test port 1.

3.

Maintain step 1. Place the left crawler control in the REVERSE direction by manually pressing coil PLV-REV. Adjust pressure as required to see 4,500 PSI at test port 2.

4.

With machine still raised on jacks and with a 7,500 PSI gauge at test ports 3 and 4, check main relief pressures on right crawler pump.

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BI006893 5.

With the pumps running, operate the right crawler control in the FORWARD direction by manually pressing coil PRV-FWD. Adjust main relief valve as required to see 4,500 PSI on gauge at test port 4.

6.

Repeat step 5 but place the right crawler control in the REVERSE direction by manually pressing coil PRV-REV. Adjust pressure as required to see 4,500 PSI at test port 3.

7.

Reconnect the propel brake release hoses disconnected in step 1.

8.

De-energize propel active valve (PAV).

CRAWLER FUNCTION CHECK NOTE: 1.

Check that the crawler boxes have each been filled with 7.5 gallons of 80W-90W oil.

With propel selector in SLOW SPEED, check the left crawler function in FORWARD and REVERSE. Record time for 3 revolutions of crawler sprocket: 60 Hz should be 3 revolutions in 56 seconds.

50 Hz should be 3 revolutions in 75 seconds.

2.

Repeat step 1 with propel selector in NORMAL SPEED. Record time for 10 revolutions of crawler sprocket: 60 Hz should be 10 revolutions in 67 seconds.

50 Hz should be 10 revolutions in 80 seconds.

3.

Repeat step 1 for right crawler.

4.

Repeat step 2 for right crawler.

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BIT VIEWING HATCH CHECK Check function of bit viewing hatch with switch in operator’s cab. Hatch should open and close smoothly with no chattering action.

BOARDING STAIR CHECK Check function of boarding stair with switch in operator’s cab. Stairway should raise and lower smoothly with no chattering action.

MAIN FLOW VALVE CHECK 1.

With 0-1,500 PSI gauge at test port 26 and with pumps running, set backpressure relief to see 300 PSI.

2.

With 0-1,500 PSI gauge at test port 23 and with pumps running and all valves de-energized, record pressure observed.

3.

With 0-7,500 PSI gauge at test port 23 and with 0-1,500 PSI gauge at test port 26, start pump and energize main flow valve (MFV) via hydraulic test function. Adjust relief valve of center sandwich valve at station 1 to see 3,000 PSI at test port 23. Record pressure at ports 23 and 26.

BREAKOUT WRENCH AND TOOL WRENCH CHECK Check function of breakout wrench and tool wrench with switches in operator’s cab.

DUST CURTAIN CYLINDERS 1.

Check function versus switch position.

NOTE: After 3 - 5 cycles, operation should be smooth with no jerkiness or chattering.

2.

Adjust door stops.

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BI006893 DUST SEAL SLIDER

Operate in forward and reverse to check function. Record pressure observed at test port 24 on a 0-7,500 PSI gauge.

MAST LOCK 1.

With 0-7,500 PSI gauge at test port 21, energize mast lock latch solenoid and check function.

2.

Adjust relief, as required, to see 1,000 PSI.

NOTE: Adjustment is facing away from left wall.

3.

With gauge still at test port 21, energize mast lock unlatch solenoid. Observed pressure should be 3000 PSI.

4.

Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 21.

MAST BRACE LOCK CYLINDERS 1.

With 0-7,500 PSI gauge at test port 23, energize Mast Brace Lock (MBLV) solenoid and check function.

2.

Adjust relief, as required, to see 1,000 PSI while mast brace lock (MBLV) is energized.

3.

Energize mast brace unlock (MBLV) solenoid. Observed pressure should be 3,000 PSI.

4.

Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 23.

A-FRAME LOCK CYLINDERS NOTE:

1.

This test should not be run unless the mast is fully up or unless the mast is off the machine. Mast lock cylinder pins MUST be extended before conducting this test.

With 0-7,500 PSI gauge at test port 22, energize A-Frame Lock (AFLV) solenoid and check function.

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2.

Adjust relief, as required, to see 1,000 PSI. Adjustment is facing away from left wall.

3.

Energize A-frame unlock (AFLV) solenoid. Observed pressure at port 22 should be 3,000 PSI.

4.

Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 22.

MAST LOCK CONSTANT PRESSURE CHECK 1.

With a 0-1,500 PSI gauge at test port 61, start pump.

2.

Rotate mast lock switch to UNLOCK and then return switch to NEUTRAL.

3.

With switch at NEUTRAL, pressure at test port 61 should be 0.

4.

Rotate mast lock switch to LOCK and then return switch to NEUTRAL.

5.

With switch at NEUTRAL, pressure at test port 61 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

MAST BRACE CONSTANT PRESSURE CHECK 1.

With a 0-1,500 PSI gauge at test port 60, start pump.

2.

Rotate mast brace switch to UNLOCK and then return switch to NEUTRAL.

3.

With switch at NEUTRAL, pressure at test port 60 should be 0.

4.

Rotate mast brace switch to LOCK and then return switch to NEUTRAL.

5.

With switch at NEUTRAL, pressure at test port 60 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

A-FRAME LOCK CONSTANT PRESSURE CHECK 1.

With a 1,500 PSI gauge at test port 65, start pumps.

2.

Rotate A-frame lock switch to UNLOCK and then return switch to NEUTRAL.

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BI006893 3.

With the switch in NEUTRAL, pressure at test port 65 should be 600 PSI.

4.

Rotate A-frame lock switch to LOCK and then return switch to NEUTRAL.

5.

With the switch at NEUTRAL, pressure at test port 65 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

MAST RAISE/LOWER NOTE:

This adjustment limits the maximum lowering speed of the mast.

1.

With the pumps shut down, adjust the Hoist Flow Control located under the deck just forward of the rear torque tube. Loosen the setscrew and turn the adjustment in all the way.

2.

With step 1 complete, back out the adjustment 6 full turns and tighten setscrew.

3.

Install a 0-7,500 PSI gauge at test port 16 and proceed as follows: a.

If mast is not mounted to machine, position mast/winch selector to MAST HOIST and operate master switch in MAST RAISE mode. If cylinders are connected, the cylinder rods should both be extending.

b.

When rods have fully extended, the pressure gauge reading will be 2,500 PSI.

c.

With master switch in LOWER mode, the cylinder rods will retract. The pressure gauge reading should then be 2,500 PSI.

d.

If mast hoist cylinders are not mounted, then pressures at step 3b and step 3c will be seen almost as soon as master switch is moved from NEUTRAL.

NOTE: Step 3e is to be done with jacks FIRMLY on the floor. e.

If mast is mounted, check function carefully by raising mast 6 - 12 inches out of the rack while observing pressure on the 0-7,500 PSI gauge at test port 16. If more than 2,500 PSI is needed to lift mast from rack, adjust port relief on hoist side as necessary.

f.

With step 3e complete, carefully position master switch to LOWER mode and observe “inching” capability of control.

g.

Raise mast to full vertical (with the deck level and on jacks).

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BI006893 h.

With a 0-7,500 PSI gauge at test port 16, observe pressure needed to pull mast out of vertical. Adjust lower mode port relief as necessary to generate enough pressure.

i.

With 0-7,500 PSI gauge still at test port 16, with mast in vertical position and with mast brace and mast lock pins engaged, operate mast hoist in raise and lower to set port relief valves to 200 PSI greater than pressures observed at steps e and h respectively.

NOTE: An alternate way to accomplish step 3i is to disconnect hoses at both mast hoist cylinders and then plug hoses with steel ORS plugs. With hoses plugged, start pumps and operate mast hoist in RAISE and LOWER mode to set port reliefs to 200 PSI greater than observed at 3e and 3h respectively. When reliefs are set, reconnect hoses and check function of mast hoist.

AUXILIARY WINCH With a 7,500 PSI gauge at test port 16, proceed as follows: NOTE:

If the mast is not mounted, skip to step 4.

1.

With the mast mounted and in the rack (fully down), operate the winch with no rope on the drum to check function verses master switch position.

2.

Check the ability to smoothly start in the HOIST and LOWER mode.

3.

Check drum RPM in the HOIST and LOWER mode and record. Drum speed should be: 10 revolutions in 17 seconds (36 RPM).

4.

If mast is not mounted, set port relief so pressure gauge shows 3,000 PSI in the HOIST position when moving the master switch out of NEUTRAL. Moving hoist lever to full LOWER position will show 3,300 PSI on gauge.

NOTE: If mast is mounted, port relief setting may be observed by first disabling WACV electrically and then proceeding per step 4.

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BI006893 HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK

NOTE: Steps 1 through 3 apply to LINCOLN lube system with LINCOLN lube pump only.

1.

With the pumps running, energize Lube Enable Valve (LEV) solenoid.

2.

Adjust pressure reducing valve attached to lube pump manifold, as required, to see 450 PSI on gauge attached to manifold.

3.

With Lube Enable Valve (LEV) energized and the pumps running, observe that the lube pump is functioning.

NOTE: If grease is not pumped during test, then don’t run test step 3 any longer than necessary to see that the pump is cycling.

NOTE: There should be NO external hydraulic oil leakage during test.

WINDOW GUARD FUNCTION CHECK - OPTION

CAUTION:

Before starting test, make sure there is nothing laying on window guard that could fall off to cause injury to personnel or damage to machinery. Keep personnel away from window guard area during test.

1.

With a 0-1500 PSI gauge at test port 75 and with Window Guard Valve (WGV) de-energized, energize Main Flow Increase Valve (MFV) via hydraulic test function on operator’s display terminal screen.

2.

Adjust pressure reducing valve (same valve that test port 75 is attached to) see 900 PSI.

3.

De-energize Main Flow Increase Valve (MFV) and energize Window Guard Valve (WGV) to check function. After 3 or 4 cycles, window guard should operate smoothly, without chatter.

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BI006893 CHECK JACKS IN AUTO LEVEL MODE 1.

Manually position all jacks such that they are midway between the ground and fully up.

2.

Position auto level switch to RETRACT mode and observe that all 4 jacks simultaneously retract.

3.

Maintain step 2 until all 4 jacks are fully up, at which time the operator’s display terminal screen WILL SHOW THE JACKS TO BE FULLY UP and the retract solenoids at the jack valve control manifold have each turned off. Jack Loader Valve (JLV) will stay energized so long as the switch position is maintained in RETRACT. When the auto level switch is returned to NEUTRAL, solenoid JLV should turn off.

4.

With all jacks fully extracted, position the auto level switch to extend and observe that all 4 jacks extend simultaneously. Do not extend jacks all the way to the ground.

NOTE: If the crawlers are not mounted, use extreme care during step 5 through step 8.

5.

With step 3 and step 4 complete, run each jack down individually and manually check that each ground pressure switch activates and is shown on the operator’s display terminal screen.

6.

With step 5 complete, repeat step 2 and step 3.

7.

With step 6 complete, position the auto level switch to EXTEND and observe the following actions of auto level while maintaining switch position: a.

Starting from full retract into extend, all cylinders will extend at once.

b.

As each cylinder pad is lowered enough to generate ground pressure, it will stop moving, until all four cylinder ground pressure indications are shown on the operator’s display terminal.

c.

If the machine is out of level, it will level itself (first side to side and then front to back).

d.

The machine will raise up straight and level on all four jacks.

NOTE: Step 5, step 6, and step 7 must be done with EXTREME care if crawlers are not mounted to machine.

8.

With step 7 complete, position auto level switch to RETRACT to check function.

NOTE: If crawlers are unmounted, step 8 should not be run unless AT LEAST one observer is present outside the machine.

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BI006893 PIPE RACK POSITION CHECK

With 0-7,500 PSI gauge at test port 16, with selector switches in operator’s cab set to DRILL mode, and at PIPE RACK/JOINTS, proceed as follows: 1.

Raise left joystick out of detent, without leaving NEUTRAL, until one second has passed.

NOTE: Step 1 is intended to allow sufficient time for the pipe rack lock pin to unlock the rack, before rack is allowed to be moved.

2.

With step 1 accomplished, move joystick to full stroke, first in one direction and then the other. Pressure should increase smoothly with increasing stick travel. Pressure should be 2,500 PSI at maximum stroke in STORE position. Adjust port relief, as required. Pressure should be 3,200 to 3,300 PSI at maximum stroke in OVER-THE-HOLE position.

3.

Re-check with selector rotated to all four positions.

PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING With the mast in the vertical position, attach a 1,500 PSI gauge to test port 52. With pumps running, set the relief valve at station 3 of 8 station valve located directly above auxiliary winch, as required to see 600 PSI.

PIPE THREAD LUBRICATOR CHECK NOTE: Station 1 of 4-station manifold is located on right side wall of machinery house.

1.

With pumps running and Lubrication Timing Screen showing on the operator’s display terminal, press F7 to energize Pipe Thread Lubricator Valve (PTLV) solenoid.

2.

With step 1 complete, adjust reducing valve on the lube pump assembly to 450 PSI on the gauge located on the grease pump.

3.

With step 2 complete, press F7 again to de-energize (PTLV) solenoid.

CAUTION:

Advise personnel to stay away from grease discharge during testing or adjustment.

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5-118 Service Procedures Section MD6640 Blasthole Drill

With hydraulic pumps running, press F8 on the operator’s display terminal to energize the Pipe Thread Lube Pump and observe that pump runs.

NOTE: Pump will time-out at anywhere between 1 and 10 seconds with initial time-out being set at 2 seconds. Time-out is set on Lubrication Timing Screen on the operator’s display terminal.

PIPE POSITIONER FUNCTION CHECK Check function as follows: 1.

When positioning switch to OVER-THE-HOLE, the clamp stays open until the position cylinders are fully retracted, after which time the clamp should close.

NOTE: The clamp must NOT close until after the position cylinders are fully retracted.

2.

When positioning the switch to STORE (i.e. moving away from Over-The-Hole), the clamp must open first, then the position cylinders will extend the clamp away from the drill steel to the STORED position.

NOTE: The position cylinders must not move until the clamp is fully open.

CENTER GUIDE FUNCTION CHECK 1.

Attach a 7,500 PSI gauge to test port 55.

2.

Activate the center guide switch to OVER-THE-HOLE position.

3.

Observe the pressure at port 55.

4.

The position cylinders should bottom out against the mast and the clamp cylinder should close once 2000 PSI is reached on test port 55. Adjust the sequence valve to obtain about 2000 PSI at test port 55 - the bottom cartridge on station 1.

5.

Activate the center guide switch to the STORE position. The clamp should start to open and the positioning cylinder should only start to retract once the clamp is fully open and 2000 PSI is seen on test port 55. Adjust the sequence valve if required to obtain about 2000 PSI at test port 55 - the second cartridge on station 1.

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6.

5-119 Service Procedures Section MD6640 Blasthole Drill

Repeat operation of the center guide to ensure sequencing operation is correct and repeatable.

Readjust sequence valves in step 4 or 5 as required.

AUTOMATIC BREAKOUT WRENCH CHECK 1.

Attach a 0- 3000 PSI gauge to test port 55 on two station valve located on the side of the mast.

2.

Retract the breakout wrench fully.

3.

Verify 3000 PSI is at test port 55.

Activate the automatic breakout wrench switch to EXTEND and then RETRACT to check proper function.

Refer to OEM documentation for sequence valve setup.

DUST CONTROL

GENERAL MAINTENANCE The dust control system on this drill consists of 1) the drilling platform and 2) dust curtains which trap the cuttings and dust in an area under the machine. Two methods of controlling the trapped dust are available: water injection which dampens the dust before it leaves the drilling hole, and a dry-type system which draws the dust laden air through filter elements which separates the dust from the air.

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5-120 Service Procedures Section MD6640 Blasthole Drill

DRILLING PLATFORMS AND DUST CURTAINS •

Daily inspect the dust curtains for tears and other damage. Replace worn or damaged curtains.

•

Check the curtain raising ropes for broken or frayed ropes. Replace broken or damaged ropes.

•

Check the dust deflector seal which fits around the drill pipe for damage. Replace if damaged.

•

Check the curtain raising lever mechanism for proper operation. Lubricate all pins once a week.

WATER INJECTION - OPTION The maintenance of the water injection system consists mainly of keeping the water tank full of clean water, checking weekly that the pump and valves are operating correctly, and that all hoses and fittings are not leaking.

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5-121 Service Procedures Section MD6640 Blasthole Drill

OPERATION With the operating mode switch in the DRILL position, the main compressor operating, and butterfly valve open, turn switch WIS on the operator’s console to the ON position. Close the air operated drain valve located in the tank.

The water pump is a variable speed pump driven by an AC motor and controlled by a variable frequency drive. The amount of water supplied is governed by the speed of the pump motor. Moving switch WIR on the operator’s console CW will increase the amount of water. Full CW will supply the maximum amount of water.

Because the pump is submerged below the water in the tank, the water will begin pumping immediately. Water will flow from the pump through a flow control valve back to the tank. Once the water pressure increases over 30 PSI [check-valve cracking pressure] and overcomes air pressure from the mast air line, the water will begin to flow to the mast air line. Water will continue to flow until the water injection system is turned OFF or the main butterfly valve starts to close.

When the water injection system shuts down for any reason, the WIC valve will de-energize and the drain valve in the tank will open to drain the system by gravity.

FILLING WATER TANK The fill line of the water tank includes a cam lock style fitting that fills the tank through a stand pipe.

When filling the water tank, connect the water supply hose to the cam lock fitting. Fill the tank until water comes out the vent. When the tank is full, disconnect the water supply hose. Allow the water in the fill line and tank standpipe to drain out.

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6-1 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893 Section

6

Brakes And Couplings Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents BRAKE HUB INSTALLATION ........................................................................................................ 3 Hub Adapter Pre-Heat Advance Requirements Table .................................................................. 4

MOTOR COUPLING INSTALLATION ............................................................................................ 5 Motor Coupling Pre-Heat Advance Requirements Table ............................................................... 6

PARALLEL MISALIGNMENT .................................................................................................... 7 Checking for Parallel Misalignment ............................................................................................. 7

ANGULAR MISALIGNMENT ..................................................................................................... 8 Checking for Angular Misalignment ............................................................................................. 8

MISALIGNMENT EXAMPLES................................................................................................... 9 Parallel Misalignment Example .................................................................................................... 9 Angular Misalignment Example ................................................................................................... 9 Combination Misalignment Example ........................................................................................... 10

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6-2 Brakes and Couplings Section MD6640 Blasthole Drill

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6-3 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893 Section

6

Brakes and Couplings

BRAKE HUB INSTALLATION Brake hubs must be shrunk onto tapered motor shafts in order to achieve the tension and lockup required for the torque values involved. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

Clean and dress the bore and shaft to remove any deformity and foreign matter.

Mount the cold hub onto the shaft and measure the position of the hub on the shaft carefully.

Measure from the end of the shaft to the end of the hub. The dimension derived during this step will be used later.

Remove the hub and pre-heat the item until the “estimated temperature difference” has been reached. Refer to table below.

Example: If the shaft temperature = 25° C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the hub must be heated to 125°C (257°F) for mounting.

CAUTION:

BRAKE HUB TEMPERATURE SHOULD NEVER EXCEED 190°C (374°F) FOR INSTALLATION.

CAUTION:

Pre-heated components temperatures will often be brought to temperatures that can be extremely hazardous to the human body.

USE EXTREME CARE AND ALWAYS WEAR APPROPRIATE SAFETY EQUIPMENT WHEN WORKING WITH PRE-HEATED COMPONENTS AND AROUND THE PROCESSES.

Wipe all oil from both the shaft and the bore of the hub prior to installation.

Replace the heated hub on the shaft once again and take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the hub and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

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6-4 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893

The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact.

Hub Adapter Pre-Heat Advance Requirements Table

NOTE:

This table makes reference to brake hubs only, motor coupling advance data appears in a separate table later within this section.

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6-5 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893 MOTOR COUPLING INSTALLATION

Motor couplings must be shrunk onto tapered motor shafts in order to transmit the torque values involved without slippage. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

Clean and dress the bore and shaft to remove any deformity and foreign matter.

Mount the cold coupling onto the shaft and measure the position of the coupling on the shaft carefully.

Measure the distance from the end of the coupling to the end of the shaft. The dimension derived during this step will be used later.

Remove the coupling and pre-heat the item until the “estimated temperature difference” has been reached. Refer to table below.

Example: If the shaft temperature = 25° C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the coupling must be heated to 125°C (257°F) for mounting.

CAUTION:

PINION OR BRAKE COUPLING TEMPERATURE SHOULD NEVER EXCEED 190°C (374°F) FOR INSTALLATION.

CAUTION:

Pre-heated components temperatures will often be brought to temperatures that can be extremely hazardous to the human body.

USE EXTREME CARE AND ALWAYS WEAR APPROPRIATE SAFETY EQUIPMENT WHEN WORKING WITH PRE-HEATED COMPONENTS AND AROUND THE PROCESSES.

Wipe all oil from both the shaft and the bore of the coupling prior to installation.

Replace the heated coupling hubs on the shaft once again and take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the coupling and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

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6-6 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893

The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact by marking during initial fit-up and comparing to actual fit after assembly.

Motor Coupling Pre-Heat Advance Requirements Table

MOTOR COUPLING ALIGNMENT Final alignment of direct-driven units is made by moving or shimming the unit so that misalignment of the unit and drive shafts is within required tolerance from the general arrangement drawing received with your machine. Misalignment can be either offset, angular, or a combination of both.

Misalignment can occur in both the vertical and the horizontal plane. Refer to the following illustrations to bring couplings within the maximum acceptable misalignment.

The following method of coupling alignment uses a dial indicator. Readings taken 180 degrees apart will measure the runout in one plane. It is important to rotate both shafts to avoid errors due to surface imperfections of the shafts or couplings.

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6-7 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893 PARALLEL MISALIGNMENT

Checking for Parallel Misalignment 1.

Mount the indicator on this coupling hub.

2.

Take readings in the horizontal plane at 90 and 270 degree positions on the hub while turning the shafts.

3.

Correct offset misalignment in the horizontal plane by shifting inboard and outboard feet an equal distance.

4.

Take indicator readings in the vertical plane at 0 and 180 degree positions.

5.

Correct offset misalignment in the vertical plane by adding or removing an equal thickness of shims at each foot.

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6-8 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893

ANGULAR MISALIGNMENT

Checking for Angular Misalignment 1.

Mount the indicator between the coupling hubs.

2.

Measure the gap between the hubs at 90 and 270 degree positions.

3.

Shift the outboard feet until coupling faces are parallel in the horizontal plane.

4.

Take coupling readings at 0 and 180 degree positions.

5.

Raise or lower the outboard feet with shims to parallel coupling faces in the vertical plane.

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6-9 Brakes and Couplings Section MD6640 Blasthole Drill

BI006893 MISALIGNMENT EXAMPLES

Parallel Misalignment Example

Angular Misalignment Example

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6-10 Brakes and Couplings Section MD6640 Blasthole Drill

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The condition shown below is encountered often after major repairs have been made to a machine.

To remedy this condition, perform the alignment for either angular or parallel misalignment, get as closes as possible, then perform the alignment for the other misalignment. Duplication of either, or both processes may be required.

Combination Misalignment Example

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7-1 Compressed Air systems Section MD6640 Blasthole Drill

BI006893 Section

7

Compressed Air System Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents COMPRESSED AIR SYSTEMS .................................................................................................... 3 AIR COMPRESSOR ..................................................................................................................... 4 AIR INTAKE FILTER ................................................................................................................ 5 OIL DRAIN VALVE ................................................................................................................... 6 VARIABLE VOLUME CONTROL — OPTION .......................................................................... 6 SEPARATOR MAINTENANCE ................................................................................................ 8 SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE .................................. 9 ROTARY SCREW COMPRESSOR ..................................................................................... 10 Compressor Air End Assembly .................................................................................................. 10

OIL SYSTEM ......................................................................................................................... 12 START UP AND VENT MODE ............................................................................................... 12 DRILL MODE ......................................................................................................................... 13 VARIABLE VOLUME OPTION ............................................................................................... 13 COMPRESSOR START-UP ................................................................................................. 14 COMPRESSOR SHUTDOWN MODES ............................................................................... 15 COMPRESSOR FAILURE FAULT .................................................................................. 15 COMPRESSOR COOLING FAILURE FAULT ................................................................. 15 COMPRESSOR OVERHEAT WARNING ........................................................................ 15 COMPRESSOR AIR TEMPERATURE FAULT ................................................................ 15 THERMOSTATIC CONTROL VALVE .................................................................................... 15 INLET REGULATING VALVE.................................................................................................. 18 DISCHARGE AIR TEMPERATURE GAUGE ......................................................................... 18 SAFETY RELIEF VALVE ....................................................................................................... 18 SOLENOID BLOWDOWN VALVE ........................................................................................ 18

SCHEMATIC, COMPRESSED AIR .............................. LOCATED AT THE END OF THE MANUAL

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7-2 Compressed Air Systems Section MD6640 Blasthole Drill

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7-3 Compressed Air systems Section MD6640 Blasthole Drill

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Section

7

Compressed Air System COMPRESSED AIR SYSTEMS The main air system supplies compressed air for bailing the hole during drilling. The air also cleans and cools the bearings in the bit. The air is compressed by a rotary oil flooded screw air compressor. Inlet air passes through a filter before entering the compressor.

Inside the air end the air stream will pass through a butterfly valve used to control the amount of air in the compressor. Oil is then injected into the air stream to lubricate, cool and seal the screws of the air end. The compressed air/oil mixture leaves the air end and enters the separator tank. The separator tank removes the oil from the air stream. The separator uses swirling action in combination with 4 filter elements to remove the oil from the air. The air is then passed through a butterfly valve into the mast air pipe.

When the main air valve is activated, a butterfly valve in the mast air pipe is opened and the air flows through the main air piping to the rotary head. A passage in the rotary shaft allows air to flow into the drill pipe, through the bit and out of the hole, carrying out the cuttings.

When the compressor is unloaded by the operator switching into vent mode, the butterfly valve at the inlet of the compressor closes, the main air valve closes in the discharge pipe, the blowdown valve opens allowing the air in the tank to go to atmospheric and the horsepower drawn from the motor will be greatly reduced.

The general maintenance required for the main air system consists mainly of inspection of the components of the system to see that they are working properly and that all liquids are at their proper levels.

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7-4 Compressed Air Systems Section MD6640 Blasthole Drill

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AIR COMPRESSOR The air compressor assembly is composed of the air end, separator tank and associated piping, valves, gauges and filters. The compressor is located on the right side of the machine at the front of the power module.

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7-5 Compressed Air systems Section MD6640 Blasthole Drill

BI006893 AIR INTAKE FILTER CAUTION: Take care to not allow dust, dirt or any foreign objects to fall into the compressor inlet during filter servicing.

This machine uses a manifold type air intake filter assembly, located on the air compressor intake.

Should the air intake assembly require removal, remove the 12 hex head capscrews that fasten the intake to the machine, then lift the intake assembly off the machine. Remove and replace the mounting gasket if required. Reinstallation is the opposite of removal.

An air flow clog indicator is located at the base of the intake filter. Flow through the system will draw the indicator in toward the component during operation. If air flow is indicated while the system is off, push the reset pushbutton to restore the indicator.

Each of the three air cleaners located on top of the manifold consists of 1) a filter precleaner, and 2) the air cleaner. The precleaner filter should be inspected frequently and cleaned whenever necessary. The air cleaner medium should also be inspected at regular intervals (at least every two months), or more often as conditions warrant. The Primary Air Cleaner Medium should be replaced annually, or whenever a tear, hole or rupture is found during inspection.

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7-6 Compressed Air Systems Section MD6640 Blasthole Drill

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OIL DRAIN VALVE

A drain valve is located beneath the main frame immediately below the separator tank. Use this valve to drain oil from the tank. Also a quick fill port with a check valve is located on the outer walkway. The check valve is used in line to prevent oil backflow.

VARIABLE VOLUME CONTROL — OPTION The variable volume feature is used to decrease the bailing velocity to reduce or eliminate sandblasting of the drill pipe and bit. This will result in increased life of these components. To reduce the bailing velocities, reduce the air flow rate or “CFM” of the compressor. Turning the variable volume control switch on the operator’s display will activate the air end spiral valve, reducing in three steps (Level 1, Level 2, Level 3 - Between 100% and 68%) the amount of air produced by the compressor.

With the compressor CFM reduced, the operator can inspect the size of the chips produced from drilling and keep track of the life of the bit and drill tool. From this information, the optimum air volume can be determined.

Many bit manufacturers have instructional literature available with bit pressure tables. These tables will show what the bit pressure should be based on the size of orifices in the bit and the CFM produced by the compressor. Once the desired bailing velocity has been determined, adjust the variable volume switch to obtain the desired bit pressure.

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7-7 Compressed Air systems Section MD6640 Blasthole Drill

NOTE: After adjusting the variable volume control, especially when reducing the compressor CFM by a large amount, make sure the tank pressure while drilling is greater than 30 PSIG. This will avoid excessive oil carryover.

Refer to the figure below for variable volume component locations.

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SEPARATOR MAINTENANCE

The air compressor separator tank contains 4 air filter cartridges. These must be changed at 4000 hours or anytime more than 10 PSI pressure differential exists across the filters, or if the compressor starts to bypass oil. To replace the separator filter cartridges: 1.

Shut down the machine. Ensure that the electric motor and compressor are powered down.

Relieve any residual pressure in the main air line and the separator tank. Check pressure gauge on the tank to verify.

2.

Loosen the hex nuts that attach the separator cover to the tank. Loosen each nut enough to allow the attaching bolt to be pulled away from the tank and lowered.

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7-9 Compressed Air systems Section MD6640 Blasthole Drill

BI006893 3.

With all bolts pulled away, use the installed hydraulic jack at the lower, left hand side of the separator tank to raise the separator cover enough to clear the filter cartridges.

NOTE:

Be sure that the cover seal is not damaged during cover seal removal.

4.

Once lifted, rotate the cover out of the way.

5.

Remove the hex nuts and the filter retainer which covers one of the filter cartridges.

6.

Pull the filter cartridge out of the separator tank. Repeat for the remaining 3 cartridges.

Inspect all parts. Repair or replace as required. Reassembly is the opposite of disassembly. Note the following: SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE Refer to the label on the left side of the separator tank. If the label is not readable, use the following tightening sequence.

Tighten all bolts hand-tight to begin. Then tighten all bolts in order. Start at any bolt and continue in a diametrically opposed (star) pattern. Tighten the bolts incrementally 3 times as follows: 1.

Tighten ALL bolts to 30 Ft. Lbs.

2.

Tighten ALL bolts to 60 Ft.Lbs.

3.

Tighten ALL bolts to 100 Ft.Lbs.

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7-10 Compressed Air Systems Section MD6640 Blasthole Drill

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ROTARY SCREW COMPRESSOR

Compressor Air End Assembly

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The air end of the compressor is an oil flooded, single-stage, twin screw, rotary type. The suction (inlet) port is located on the top, drive shaft (inboard) end of the compressor. The discharge port is located on the bottom (outboard) end. The air end is directly driven through a flexible coupling from the main electric motor. The male rotor of the air end is driven by a gear mounted on an independent input shaft and a mating gear on the male rotor. The female rotor is driven by the male rotor because the rotors are meshed.

Air circulates through the system beginning at the air intake filter, passes through the intake valve and into the air end where it is compressed. As the male rotor is turned counterclockwise (by the clockwise rotation of the gear shaft and gears - not shown), it drives the female rotor counterclockwise. This action causes air to be drawn through the suction port completely filling the uncovered channels or grooves between the spiral (helical) lobes in the male and female rotors.

As the rotors continue to turn, the lobes begin to inter-mesh at the bottom. This inter-meshing causes the spiral grooves to become shorter, thus resulting in the compression of the air entrapped in the grooves. Compression continues until the grooves are uncovered by the discharge port.

From the air end, compressed air is discharged at rated pressure into the air/oil receiver.

During the compression process, cool oil is injected into the entrapped air by a remotely located gear-type oil pump. The oil is injected for the following reasons: Cooling:

The oil removes the heat of compression to maintain discharge air temperatures below 225°F (107ºC).

Sealing:

The oil seals the internal clearances between the rotor, cylinder, and discharge end casing to prevent loss of air volume back to the inlet.

Lubrication: The oil lubricates the rotors, bearings, gears, and mechanical shaft seal.

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Separation of the oil from the air which was injected into the air end during compression begins in the separator. From 90% to 95% of the oil separation from the air is accomplished by a decrease in air velocity, changes in flow direction, adequate baffling and proper location of the inlet port. Final air/oil separation is obtained by forcing the flow through the separator elements to provide practically oil-free air at the outlet. Oil collected by the separator elements is returned to the system by the compressor scavenging line. To prevent tank over-pressurization, an air pressure relief valve is installed downstream or on the dry-side of the separator elements.

OIL SYSTEM The oil system consists of a separate and remote electric pump motor package. The pump suction pulls oil from the bottom of the receiver tank. The relief valve pressure setting for this pump is 180 PSI (to protect the oil cooler) and can be checked at the test port G 9. The pressure from the pump goes to the thermostatic valve, this will either divert the oil to the oil cooler when the oil temperature reaches 140F and on to the compressor filters, or it will be directed to the filters on the compressor if the oil temperature is below 140F. The filters have an internal bypass that opens at a differential pressure of 25 PSID, in case the filters become plugged. Built into each filter is a filter clogged indicator switch that will give a visual and a panel view alert.

Down stream of the filters are devices that provide system feedback; the first is the Main Compressor Oil Temperature Sender - MCOTS and temperature gauge T2 located on the filter assembly, normal operating range for the compressor is 140 F to 190 F. Second is the solenoid operated Air Compressor Oil Stop Valve - ACOSV which when energized, sends oil through the filters to the compressor injectors. Third is the Compressor Oil Pressure Switch COPS which will shut down the compressor if there is a loss of pressure (pressure can be checked at test port G 11). On the outlet of the compressor is the Main Compressor Air Temperature Sender MCATS and temperature gauge T1 which monitor the discharge air temperature from the receiver tank.

START UP AND VENT MODE Start the Air Compressor Oil Circulation Pump, pressure at Test Port G1 on the control manifold should be approximately 100 PSI. Pressure at test port G9, on the pump will be 110 - 180 PSI. Solenoid operated Air Compressor Spiral Valve - ACSV on control manifold will be DE-ENERGIZED. This sends oil to the compressor spiral valve which rotates the valve to MINIMUM. The Variable Volume control valves (if equipped), ACVV1, ACVV2, and ACVV3 are all DE-ENERGIZED. Solenoid operated Air Compressor Intake Valve - ACIV on control manifold will be DE-ENERGIZED. The oil from ACSV communicates with the ACIV and opens both the recirculating valve (sending air to the suction side of the compressor) and holds the compressor inlet butterfly valve shut.

The solenoid operated Drill Air Valve (DAV) will be DE-ENERGIZED. When the DAV is de-energized, the blow down valve will be open resulting in maximum separator tank pressure of 30 to 50 PSI. The Drill Air valve will be shut.

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7-13 Compressed Air systems Section MD6640 Blasthole Drill

DRILL MODE Valve ACSV will be ENERGIZED, the spiral valve will rotate from MINIMUM to MAXIMUM. Valve ACIV will be ENERGIZED; allowing the inlet butterfly valve to open and closes the recirculating valve.

The solenoid operated Drill Air Valve will be ENERGIZED closing the blow down valve and opening the drill air valve sending air to the drill bit.

Maximum tank pressure will be maintained through the Air Pressure Regulating Valve, any operating pressure greater than 80 PSI will modulate the inlet valve to maintain the 80 PSI tank pressure.

VARIABLE VOLUME OPTION The above Drill Mode is for 100% volume, the variable volume option gives the operator control for 3 Different volume outputs between 100% and 68%. The valve positions are as follows: LEVEL 1 ACSV - DE-ENERGIZED ACIV - ENERGIZED Variable Volume manifold ACVV1 - ENERGIZED Variable Volume manifold ACVV2 - DE-ENERGIZED Variable Volume manifold ACVV3 - DE-ENERGIZED LEVEL 2 ACSV - DE-ENERGIZED ACIV - ENERGIZED Variable Volume manifold ACVV1 - DE-ENERGIZED Variable Volume manifold ACVV2 - ENERGIZED Variable Volume manifold ACVV3 - DE-ENERGIZED LEVEL 3 ACSV - DE-ENERGIZED ACIV - ENERGIZED Variable Volume manifold ACVV1 - DE-ENERGIZED Variable Volume manifold ACVV2 - DE-ENERGIZED Variable Volume manifold ACVV3 - ENERGIZED

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COMPRESSOR START-UP NOTE: 1.

For accurate readings, the machine must be level when checking the oil level.

COMPRESSOR OIL - The compressor air end, separator and cooler must be filled with the recommended compressor oil.

NOTE:

After initial start-up, the oil level in the separator will drop due to the oil filling the piping system. Shut down the compressor after approximately 15 minutes of operation. Allow the machine to sit for 10 to 15 minutes to allow air bubbles to settle out of the oil. Check the oil level gauge. If the oil level is below the sight glass, refill to the top of the sight glass.

CAUTION:

The system contains hot oil under pressure. Always check the pressure gauge to make certain the pressure is at zero before opening the fill plug.

2.

DRAIN THE CONDENSATE - Open the drain valve slightly to drain off any condensate into a container. Close the valve securely when oil appears. Dispose of the oil and condensate properly.

3.

START THE UNIT - Start-up the compressor.

4.

OBSERVE THE DISCHARGE AIR PRESSURE - During drilling operations, the main air valve will maintain a minimum pressure of approximately 30 PSIG in the receiver. Pressure higher than this minimum will be regulated by the drill bit orifice size or air pressure control valve setting. The discharge air pressure must not operate above the maximum rating plate pressure during the loaded cycle. However, momentary high pressures up to the 85 PSIG are permitted (e.g. to blow out clogged drill bit orifices).

NOTE:

5.

The tank safety relief valve is set at 150 PSI and should be replaced or serviced anytime it is opened.

OBSERVE THE DISCHARGE AIR TEMPERATURE - The maximum discharge air temperature must not exceed 225°F (107ºC).

NOTE:

The air temperature limit is factory set to shut down the unit at 225°F (107ºC).

6.

OBSERVE THE OIL INJECTION TEMPERATURE - The oil injection temperature must not exceed 185°F (85ºC).

7.

PERFORM MAINTENANCE CHECKS - Refer to the proper area of this manual for recommended maintenance checks.

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7-15 Compressed Air systems Section MD6640 Blasthole Drill

UNLOAD THE COMPRESSOR – To unload the compressor, the air compressor inlet valve (ACIV) is energized, closing the inlet valve, and the drill air solenoid valve (DAV) is de-energized to close the main air valve. The air pressure in the tank is bled down using the blow down valve. Air pressure in the tank will drop to approximately 30 PSI, depending on the quality of the seal on the inlet valve.

NOTE: The discharge air temperature must not exceed 225oF (107ºC). Oil injection temperature must not exceed 185oF (85ºC).

COMPRESSOR SHUTDOWN MODES COMPRESSOR FAILURE FAULT The compressor will shut down if the air temperature is above 212oF (100oC) and oil temperature is more than 72oF (22oC) less than air temperature.

COMPRESSOR COOLING FAILURE FAULT The compressor will shut down if the air temperature is above 212oF (100oC) and oil temperature is within 18oF (-8oC) of air temperature.

COMPRESSOR OVERHEAT WARNING This fault occurs when the air temperature is above 212oF (100oC) COMPRESSOR AIR TEMPERATURE FAULT If the air temperature reaches 225oF (107oC), the compressor will shut down.

THERMOSTATIC CONTROL VALVE The thermostatic (3-way) control valve controls the oil flow to maintain a 140°F (60°C) minimum oil injection temperature.

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On start-up, with the unit cold, the thermal element is open to the bypass line. Oil flows from port B through port A to the compressor, bypassing port C to the cooler. The element is factory set to open at 140°F (60°C). As the receiver oil warms up to this temperature, the thermal element gradually closes port B and opens port C. This allows the cool oil from the radiator cooler to mix with the bypass oil. After the unit is warmed-up, the thermostatic control valve will normally be open to port C. This produces an oil injection temperature above 140°F (60°C). The valve should be fully open at 150°F (66°C) directing full flow to the cooler.

If the compressor shuts down under high air temperature conditions, the thermal element may be stuck in the bypassed position from port B to port A. Let the unit cool down and then restart the compressor. Check the temperature of the hose from the C port to the cooler. If the temperature is above 150°F (66°C) and within 5°F of port A the element is functioning properly. If the oil injection temperature continues to rise past the 150°F (65°C) and the temperature of the hose from port C to the cooler is less than 5°F below port A hose temperature, shutdown the unit immediately. Remove, clean, test, and replace the thermostatic element, if required.

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7-17 Compressed Air systems Section MD6640 Blasthole Drill

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Removal, clean and test the thermostatic control valve as follows: 1.

Shut down the compressor. Lockout and tag the compressor controls. Allow the system to cool if at all possible. Drain the oil. Relieve the oil pressure in the lines to and from the thermostatic valve.

2.

It may be necessary to remove the thermostatic valve from the machine in order to separate the components. However this is not required. At least disconnect the compressor supply hose at valve port A. DANGER:

STORED ENERGY! At operating temperature, the hydraulic fluid is hot and pressurized. Hot hydraulic fluid may cause burns. Hydraulic fluid under pressure may cause injury or death if not released in a controlled manner before the lines are disconnected.

3.

Remove the four bolts and lockwashers attaching the adapter housing at port A.

4.

Remove the adapter housing and O-Ring.

5.

Remove the thermostatic element assembly and seal.

6.

Clean the element and test as follows: CAUTION:

7.

The valve housing and thermostat may be hot. Use suitable protective equipment when handling any hot items.

Place the element in 150°F (65°C) water and stir the water vigorously with the element for 5 minutes. Immediately place the element in the housing. If the element is fully stroked, the seating of the element against the upper housing can be felt. If the element is not fully stroked and seated, replace with a new element, [140°F (60°C) setting].

CAUTION:

Replacement element must be the same as the original. Do not replace with other brands.

8.

Clean the internal surfaces of the adapter housing and the main valve housing.

9.

Lubricate a new O-Ring and slide it over the top of the element assembly and into position on the element.

10.

Place a new housing gasket in the recess of the main valve housing.

11.

Insert the element into the adapter housing. Install the adapter housing over the element.

12.

Install the housing capscrews and lockwashers and tighten. Refill the oil in the system. Remove the compressor lockout and restart the compressor. Test for leaks and for proper operation.

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7-18 Compressed Air Systems Section MD6640 Blasthole Drill

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INLET REGULATING VALVE The intake valve on the compressor is a butterfly valve with an air/oil cylinder operator. The intake valve is closed for the compressor start up. This prevents air from entering the compressor causing the screw to operate in a vacuum. Since the screws are not compressing air, this reduces the horsepower required to drive the compressor.

The intake valve remains in the closed position until the operator want to drill a hole. The operator will place the main air valve switch to the open position; this will cause the air inlet valve control cylinder to retract opening the intake valve. Air will flow into the compressor and start to compress air.

The intake valve is also used to regulate the maximum air pressure in the receiver tank. If the air pressure in the tank becomes too high, the air control regulator will open and extend the air control cylinder closing the intake valve and reducing the air flow into the compressor. Once the hole clears and the air pressure reduced in the tank, the intake valve will return to the full open position.

DISCHARGE AIR TEMPERATURE GAUGE This temperature gauge is a direct reading temperature gauge which indicates the air temperature at the compressor discharge flange.

CAUTION:

This reading must not exceed 225°F (107°C) at any time.

SAFETY RELIEF VALVE The pressure safety relief valve is located on the side of the receiver and is set to relieve the pressure at 150 PSIG. Periodic checks should be made to insure its proper operation.

CAUTION:

Never operate the unit without a proper safety valve setting.

SOLENOID BLOWDOWN VALVE The blowdown valve is installed on the receiver outlet and will automatically open and blowdown the receiver, piping and compressor air end when the compressor is stopped. The blowdown time is approximately five minutes to reduce the pressure down to 0 PSIG. NOTE: Too rapid a blowdown would cause oil foaming and excessive oil carry-over past the oil separator.

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8-1 Heating Ventilation and Air Conditioning Section MD6640 Blasthole Drill Section

8

Heating, Ventilation and Air Conditioning Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents AIR CONDITIONING UNIT WITH HEATER .................................................................................... 3 DESCRIPTION ........................................................................................................................ 3 SPECIFICATIONS ................................................................................................................... 4 HOUSE FANS ............................................................................................................................... 4 INSPECTION ........................................................................................................................... 4 LUBRICATION ......................................................................................................................... 5

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8-3 Heating Ventilation and Air Conditioning Section MD6640 Blasthole Drill

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Section

8

Heating, Ventilation and Air Conditioning

AIR CONDITIONING UNIT WITH HEATER

DESCRIPTION SIGMA climate control units are heavy duty systems designed to be roof mounted on the cabs of industrial and mining equipment.

This unit will provide superior performance in a variety of climate conditions and under the most harsh environment.

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SPECIFICATIONS Nominal Cooling Capacity

25,000 Btu/hr@460V/60Hz 22,500 Btu/hr@380V/50Hz

Refrigerant

HFC 134a

HOUSE FANS

INSPECTION Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate freely without binding.

If vibration is detected, check the following 1. Bearing and drive alignment 2. Shaft straightness 3. Wheel or sheaves loose on shaft 4. Loose or worn bearings 5. Loose mounting bolts 6. Motor out-of-balance 7. Sheaves out-of-balance 8. Nose cap loose on wheel 9. Worn or corroded wheel 10. Accumulation of material on the wheel 11. Cracks on blades and/or at the hub 12. Worn fan blades and hubs

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8-5 Heating Ventilation and Air Conditioning Section MD6640 Blasthole Drill

LUBRICATION All bearings are pre-lubricated and sealed at the factory. Under normal temperature conditions (-20° to +150°F), when the fans are circulating clean air, the bearings are considered lubricated for life and additional lubrication is unnecessary.

If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication is required.

For normal temperatures, a high quality, light neutral mineral grease is used. It is free of abrasive fillers and highly resistant to oxidation.

When fans are operating at elevated temperatures (166°F or higher), silicone or lithium soap base grease should be used. This high temperature grease should have a breakdown point above 350°F. Use a low pressure grease gun for fan bearings. It is preferable that either the gun or the fitting be vented. To prevent overfilling apply only a small amount of grease.

This is especially important when extended lubrication piping is used and the bearing cannot be observed.

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9-1 Engineering Data Section MD6640 Blasthole Drill

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9

Engineering Data Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents CAPSCREW (BOLT) GRADE ...................................................................................................... 3 BOLT TIGHTENING ....................................................................................................................... 4 TORQUE WRENCH METHOD ............................................................................................... 4 Table 1 - Lubricated or Plated Threads or with Hardened Washers .............................................. 4 Table 2 - Dry Threads .................................................................................................................. 4

TURN-OF-NUT METHOD ....................................................................................................... 5 Table of Snug Tight Torque Values ............................................................................................. 5

WIRE LOCKING CAPSCREWS ................................................................................................... 6 Patterns for Wirelocking Capscrews ........................................................................................... 6

MAINTENANCE WELDING ........................................................................................................... 7 WELDING ELECTRODES ..................................................................................................... 8 REPAIR WELDING OF CRACKS ........................................................................................... 9 Joint Preparation for Repair of Cracks ........................................................................................ 9

PREHEAT ........................................................................................................................ 10 WELDING TECHNIQUE .................................................................................................. 10 REPAIR WELDING OF BROKEN PARTS ............................................................................ 11 WELDING AND CUTTING EQUIPMENT ..................................................................................... 12 STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT ....................................... 12 GEAR INSPECTION ................................................................................................................... 14 Gear Tooth Surface Failures ..................................................................................................... 15

AEROQUIP ORS CONNECTIONS ............................................................................................. 16 ORS Connection Assembly ....................................................................................................... 16

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9-3 Engineering Data Section MD6640 Blasthole Drill

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9

Engineering Data

CAPSCREW (BOLT) GRADE The grade classification of a capscrew (bolt) is identified by the marks on the head as shown below:

Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.

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BOLT TIGHTENING TORQUE WRENCH METHOD The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1 lists torque values for lubricated or plated threads and for using hardened washers. Table 2 lists those for dry threads.

The bolts should be tightened to the specified total value in increments, alternating from bolt to bolt to assure gradual, even pull-up of mating parts.

Tightening should progress systematically from the most rigid part of a joint to its free edges.

Circular bolt patterns should be tightened in a diametric crosshatch pattern while applying torque in increasing values to ensure proper pullup of parts.

Table 1 - Lubricated or Plated Threads or with Hardened Washers

Table 2 - Dry Threads

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BI006893 TURN-OF-NUT METHOD CAUTION:

NOTE:

1.

THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC threads, contact the Caterpillar Global Mining Service Department.

When using this procedure the bolt threads and the surfaces under the bolt head and nut must be lubricated. This procedure is applicable only if the joint and under head surfaces for bolt and nut are machined for parallelism.

The bolts should be brought to a “snug tight” condition to insure that the parts of the joint have good contact with each other. “Snug Tight” is defined as the tightness attained by torquing a bolt to the value specified in the table on the following page. Snug tightening should progress systematically from the most rigid part of the joint to its free edges while alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts have been snugged, the first bolts tightened at the most rigid part of the joint should be rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the snug tightening sequence should be repeated for all bolts in the connection. This rechecking and re-torquing procedure should be repeated as many times as is required until the joint is completely pulled up and all bolts are at the specified “snug tight” torque. Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.

Table of Snug Tight Torque Values

2.

The nuts and bolts should then be matched marked by center punching the bolt end and nut.

On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened additionally by the applicable amount of nut rotation as specified in Table 4. It is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

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9-6 Engineering Data Section MD6640 Blasthole Drill

NOTE:

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Nut rotation is read between the punch mark on the bolt and the punch mark on the nut.

For rod bolts, nut rotation is the cumulative total rotational movement between punch marks on both ends of the rod bolt.

WIRE LOCKING CAPSCREWS Wire locking of capscrews is used when maximum lock assurance is required when periodic visual inspection is not possible.

The illustrations below show the recommended wire locking methods for various right hand thread capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd numbered patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock together

Patterns for Wirelocking Capscrews

Use 14 gauge soft annealed lockwire. Thread the wire through the capscrew head so that tightening stress on the wire will exert a tightening torque on the direction of capscrew thread. (The illustrations show lock wire threading for right hand threaded capscrews. Reverse the lock wire patterns shown for left hand capscrews.)

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MAINTENANCE WELDING These recommendations for repair welding apply to the major structural members of the machine.

The high cyclic loading characteristics of the machine are considered in the design and material selected for the construction of the machine. However, due to unusual operational conditions that may be encountered and to the great number of cyclic loadings that may be applied to the machine, fatigue cracks or other abnormalities may occur. Early detection of these conditions through regular machine inspection helps to avoid problems or emergency breakdowns.

Maintenance welding is applied to the repair of cracked or broken structural components.

Reconditioning of broken parts by the application of heating, cutting and welding processes requires attention to a number of details, careful adherence to the repair procedure and observance of federal, state and local safety regulations.

CAUTION:

WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE GENERATION OF TEMPERATURES UP TO THOUSANDS OF DEGREES AT WHICH METALS MELT AND VAPORIZE. When proper precautions are taken to protect personnel and property against the heat, evolved gases and fumes, electric shock and radiation, no harm will result either to personnel or property. In gas heating and cutting, the handling and storage of compressed gases present other hazards that also must be protected against to provide a safe working environment.

Safety precautions should conform to the latest edition of ANSI standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society.

Reconditioning of failed members requires attention to a number of details and careful application of the repair procedure. Only in certain cases is it necessary to strengthen members by added reinforcement.

WARNING: REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY UPON RECOMMENDATION BY THE FACTORY. IMPROPERLY APPLIED REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON THE PERFORMANCE AND LIFE OF THE STRUCTURE. A broken member is best repaired by making a complete penetration weld, preferably by welding from both sides, using the correct welding electrode and observing all precautions such as preheat, back-gouging, etc. The complete penetration groove weld should be ground flush with the base metal on both sides to remove all surface irregularities. An alternate procedure incorporates backup bars to ensure sound, complete penetration welds in the repair area. Be sure to follow all applicable safety measures and federal, state and local regulations.

A complete penetration weld repair conditioned by grinding instead of adding reinforcement is favored to maintain the original pattern of stress flow designed into the structural members. Addition of reinforcement which is not part of the design can reduce fatigue strength because of the change in geometry from the original structure.

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Effective repair welding of cracked, broken or bent structural members of the machine involves knowledge of the types of steel used, proper welding electrodes and recognized good welding practice. The chemical composition, mechanical properties and thickness of the steel determine the welding electrode to be used and the preheat temperature required.

WELDING ELECTRODES With the exception of the boom, weld repairs on the various structures of the machine can be made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both are low hydrogen electrodes which deposit weld metal having excellent properties at strength levels with 70,000 to 80,000 PSI, and impact properties from -20° to -75°F. These are all-position electrodes which produce high quality welds for repairing the structural components of heavy machinery.

NOTE:

Although these electrodes are of superior quality, care must be exercised in their application. Low hydrogen electrodes are highly susceptible to moisture pickup after removal from sealed containers. To maintain low hydrogen, crack-resistant properties, they must be stored in electrode ovens at 250°F up to the time of use. Small portable rod ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes cannot be overemphasized.

Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.

These cracks can propagate in service and lead to ultimate failure of the part. It is necessary to adhere strictly to recognized good welding practice regarding the handling, storage and use of low hydrogen electrodes. To avoid underbead cracks, remove all oil or grease or other contaminates from the surface and be sure the steel is dry.

Preheat to the required temperature. Use only dry electrodes taken from the electrode oven. After exposure to the air, the electrodes must be returned to the oven. Time limit outside the oven is four hours for E7018 and two hours for E8018C1 electrodes.

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BI006893 REPAIR WELDING OF CRACKS

Joint Preparation for Repair of Cracks

Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 4560° included angle for rewelding. If cracked through the full thickness and if it is possible to make the repair from both sides, a double V preparation is preferred. When welding from both sides, back-gouging for complete penetration is always recommended.

When it is not physically possible to back-gouge and weld the second side, an alternate approach must be taken. Sometimes it is possible to gouge through to completely remove the crack, then fit a backup bar on the underside to facilitate making a complete penetration weld.

NOTE: The backup bar must fit tightly to the underside otherwise poor welding conditions conducive to cracking may occur.

When it is not possible to fit a backup due to limited accessibility to the underside, it is advisable to remove a portion of the defective plate and weld in a new piece, using back up bars on all sides to ensure complete penetration welds.

A further alternative is to gouge through, removing the crack, and then weld small stringer beads to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be essentially full penetration, but will be less than perfect on the under side. The other methods are preferred in the order described, that is, welding both sides, welding against a backup bar, or completely replacing a section of plate.

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PREHEAT When preheating, apply heat to a broad, general area surrounding the repair location. A soaking heat which thoroughly penetrates the material through the full thickness is preferred to high surface temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat source can be left operating during welding to maintain the minimum preheat temperature. Preheat temperatures up to 400°F, depending upon the steel analysis, are adequate under most conditions for major repairs. As previously stated, preheat temperatures are determined by the type of steel in the structure. Temperatures should be measured with temperature indicating crayons.

WELDING TECHNIQUE Maximum electrode sizes are 1/4 inch for flat position, 3/16 inch for horizontal position and 5/ 32 inch for vertical and overhead positions. Use a split weave as soon as bead width is large enough to accommodate beads side by side. Throughout all welding be certain thorough fusion with the base metal and adjacent weld beads is obtained on all weld passes. Clean off all slag between passes and all craters before starting the next electrode.

Inspect closely for cracks, undercut or overlap of beads, and gouge out or grind flaws where they occur before continuing. It is very important on highly loaded parts, particularly members subject to cyclic or dynamic stresses, to obtain sound repair welds.

The presence of any stress risers on the surface of a part is detrimental to fatigue life and can result in future cracking. Therefore, it is essential that the finished repair be smooth and well blended into the base metal. Repair weld any undercuts, grind off overlapped weld beads and blend out any notches or gouges. The best condition in a repair weld location is provided by grinding the repair smooth and flush with the surface of the base metal. Final grinding direction is to be identical with the direction of applied load on the structure. Refer to the figure.

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9-11 Engineering Data Section MD6640 Blasthole Drill

REPAIR WELDING OF BROKEN PARTS All recommendations given for repair of cracks apply to repair of broken parts, with additional corrections. Depending on the size and cross-section of the part, a specific sequence of welding procedures may be required in making the repair. These techniques include back-step welding sequence, block welding sequence, alternating from side to side, welding simultaneously on opposite sides, etc. All of these precautionary measures are intended to minimize shrinkage stresses and subsequent distortion or cracking during welding. The method to follow should be determined after a careful analysis of the situation and by approaching the problem with common sense. Generally a procedure which has proven successful in previous experience could logically be applied in most cases.

Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has cracked in service, must be carefully considered before that repair measure is decided upon.

Additional material added for strengthening alters the configuration and geometry of the member, possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts at strengthening by added plates only serves to “chase the crack someplace else.” The stress flow in the part has been altered, creating a location for stress concentration. Attachments requiring fillet welds across a tension member for example, are poor repair methods. A sound repair weld, carefully made and smoothly blended into the base metal on all sides, is preferable to additional reinforcements. Any application of reinforcements requires careful consideration regarding total overall effect on the structure during service, and should be done only after consulting Catepillar Global Mining.

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9-12 Engineering Data Section MD6640 Blasthole Drill

WELDING AND CUTTING EQUIPMENT The welding and cutting equipment needed for general repair welding is listed below.

WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing) OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses HEATING TORCHES, Butane (for Boom Welding) ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines) WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4" C02 - Welding Grade - 45°F Max. Dew Point OXYGEN - Cutting, and Heating ACETYLENE WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts BLOWERS, Ventilating (for Compartment Welding,) GRINDERS, Wheel - Air Powered w/Wheels TARPAULINS - Fireproof (for Boom Welding Shelters) ASBESTOS GLOVES CUTTING GOGGLES, Dark SOAPSTONE MARKERS ANTI-SPATTER COMPOUND TEMPILSTIKS - 200° and 200°

STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT The equipment recommended for stress relieving, after repair welding, is listed below.

TEMPERATURE MEASURING EQUIPMENT SPEEDOMAX, “W” Multipoint, Potentiometer Recorder POWER REQUIREMENT - 120 Volts, 60 or 50 Hz. RANGE - 0 to 1500°F CALIBRATION - Chromel-Alumel Thermocouple Wire ACCURACY RATING - 0.3% of Electrical Span CHART SPEED - 2" per Hour THERMOCOUPLE SELECTION - Six (6) Points FLUORESCENT LIGHTING MANUFACTURER - Leeds & Northrup Company

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9-13 Engineering Data Section MD6640 Blasthole Drill

THERMOCOUPLE EXTENSION WIRE DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500 Ohms or 410 Feet.

WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20°C 66°F, - Chromel - Ohms Alumel - .0683 Ohms.

WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow) OVERALL COLOR - Yellow CATALOG No. 16-59-17 POLARITY DISCONNECT CHROMEL-ALUMEL COMPENSATED CONNECTION JACK Color Code (Yellow) - Catalog No. 040419 PLUG Color Code (Yellow) - Catalog No. 040434 CABLE CLAMP - Catalog No. 072513 ADAPTER - Catalog No. 076794 THERMOCOUPLE ELEMENT CHROMEL-ALUMEL - Type K - Swaged One (1) Inch Stripped CHROMEL POSITIVE WIRE Color Code (None) ALUMEL NEGATIVE WIRE Color Code (Red) CATALOG No. 8784-K-1-3-12"-D 1.

588003 Kaopak Flex Heaters

2.

588004 Kaopak Collector Streamer Type

3.

Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved

Thermocouple Assembly, Complete Catalog No. 8784-K-1-3-12"-Q Temperature Heating Pellets Range: 1050°F, 1100°F, 1200°F, 1250°F Mean Accuracy: +/-1% These Tempil Pellets will begin to melt at the temperature specified.

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9-14 Engineering Data Section MD6640 Blasthole Drill

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GEAR INSPECTION An important part of machine maintenance is regular inspection of gears. This should include the gears and pinions of the pulldown, rotary and propel machinery.

Listen for any unusual noises or vibrations which would indicate excessive wear patterns of gears and pinions. Usually this would necessitate prompt attention before complete failure occurs.

Of primary importance in proper gear operation is correct lubrication. Always check to see that all the gears are adequately lubricated. See the Lubrication Section in this manual for further information on correct lubricants and their application.

A condition of normal wear should result when gears do not operate at excessive loads or temperatures and correct lubricants are used.

Gears are designed to function satisfactorily during the entire life of the machine. Their failure to do this indicates some unusual conditions. Regardless of gear design, size or construction, correct lubrication is essential to assure minimum wear, quiet operation and long service life. Gear tooth shapes are very accurately manufactured, nevertheless there will always be microscopic surface irregularities which cause frictional resistance. With the gears in proper mechanical condition and with correct lubrication, friction is reduced, wear is practically eliminated and gears should operate efficiently. However, even with correct lubricants properly applied, certain mechanical or operating conditions can cause wear and destruction of teeth. Destruction seldom takes the form of tooth breakage, but usually shows up as damage to the contact surfaces.

Such surface failure may rapidly destroy the original tooth contour, preventing smooth, quiet operation.

This failure may be directly attributable to overloading, overheating, shock, abrasives, chips, improper alignment, loose bearings or deflection of shafts or housing.

Many terms are employed to graphically describe the appearance of damaged tooth surfaces. The terms pitting, abrasion, scratching, spalling and galling are the major types of failures under which all of the other failures can be grouped. These five types of failure have different basic causes.

From the lubrication point of view, the cause of the failure is of major interest rather than the appearance of the surfaces. These gear-tooth failure classifications are shown in the figure.

Gears and pinions may show some minor pitting which is usually normal. However, any heavy pitting or spalling or any abnormalities as shown will necessitate replacement.

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9-15 Engineering Data Section MD6640 Blasthole Drill

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Gear Tooth Surface Failures

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9-16 Engineering Data Section MD6640 Blasthole Drill

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AEROQUIP ORS CONNECTIONS The Aeroquip ORS type connection is used throughout the hydraulic system of this machine.

The ORS connection has an O-Ring groove machined into the flat male face. This flat face and ORing mate with the connection’s other machined face to form a virtually leak-free seal.

The face-seal concept allows the components to be installed or replaced without moving mating components or applying strain on tube and hose lines. The swivel nut can be retracted to inspect seal placement and joint fit prior to assembly.

When using this connection, remove the O-Ring from the male face and fill the groove with a high quality multi-purpose grease, then install the O-Ring in the groove. The grease will additionally seal around the O-Ring while helping to retain the O-Ring in the groove. The grease will also lubricate the connection while it is being assembled.

There is no need for special torque of the connection as the installer can “feel” when the fitting is tight.

ORS Connection Assembly

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10-1 Schematics Section MD6640 Blasthole Drill

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10

Schematics Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents SCHEMATICS ............................................................................................................................... 2 SIDE VIEW .............................................................................................................................. 3 DECK PLAN ............................................................................................................................ 4 MAIN FRAME HYDRAULIC SCHEMATIC ................................................................................ 5 MAIN FRAME HYDRAULIC SCHEMATIC (CONT’D) ............................................................... 6 MAIN HYDRAULIC ................................................................................................................... 7 JACK HYDRAULIC SCHEMATIC ............................................................................................. 8 CRAWLER HYDRAULIC SCHEMATIC .................................................................................... 9 MAST HYDRAULIC SCHEMATIC .......................................................................................... 10 HYDRAULIC SOLENOID VALVE & GAGE PORT LOCATION .............................................. 11 AIR SCHEMATIC ................................................................................................................... 12

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10-2 Schematics Section MD6640 Blasthole Drill

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10

Schematics SCHEMATICS The following pages contain a series of block diagrams depicting the schematic layout of the hydraulic systems and air system.

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Schematics Section 10 MD6640 Blasthole Drill

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Winch, Auxiliary

Mast Ladder Mast Assembly

Mast Rack

Mast Safety Restraint Device

Pipe Rack

Front of Machine

Mast Machinery Guide Frame

Pulldown Gearcase

Mast Machinery

Breakout Wrench

Machinery House

Main Air Hose

Air Conditioner

Rear Leveling Jack Dust Collector

Mast Brace

House Filter Assembly

Hydraulic Cylinder, Mast Hoist

Operator’s Cab

Mast Hinge A-Frame

Rotary Gearcase Shock Coupling Main Frame Pad, Leveling Jack

Pad, Leveling Jack Walkways, House

Crawler Assembly

Front Leveling Jack Boarding Stairs

Crawler Drive Sprocket

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Dust Collector

Leveling Jack, Left Rear

Hi-Voltage Disconnect

Main Auxiliary Transformer Transformer

Lightning Arresters

Compressor Oil Cooler and Radiator

Jack Pad

Service Ladder Hydraulic Oil Cooler L.H. Pipe Rack

Hi Voltage Compressor Start Cabinet

Deck Bushing C L Machine and Deck Bushing

Main Air Pipe

Pipe Thread Lubricators

Electro/Hydraulic Valves

Low Voltage Cabinet

Programmable Controller Cabinet

Hydraulic Pumps and Gearcase

Operator’s Cab

Hydraulic Oil Tank

Operator’s Seat

Jack Pad Auxiliary Console

Leveling Jack, Right Rear

Jack Pad Loadcenter

Bit Lubricator

A-Frame

Mast

Hoist/Pulldown Drive Control Cabinet

House Ventilation Filter & Fan Main Air Compressor & Filter Assembly Main Air Butterfly Valve

Tool Wrench R.H. Pipe Rack

Rotary Drive Control Cabinet

Leveling Jack, Left Front

Main Drive Motor

Jack Pad

Separator Leveling Jack, Right Front

Walkway, Right

Boarding Stairs

Auto Lube Reservoir

Front of Machine

C L Deck Bushing

MD6640 Deck Plan sn:2U70X58/ 141369

2U70X58_d

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