CAT Rotary Track Drill MD6240 and MD6290 Rotary Blasthole Drill MAINTENANCE & OPERATION MANUAL - PDF

February 2012 BI006752

Operation and Maintenance Manual MD6240 and MD6290 Rotary Blasthole Drill 412450 Rev. 06

SAFETY.CAT.COM

BI006752-06

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

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

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

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

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

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

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

Printed in U.S.A.

BI006752-06

Safety Information This safety alert symbol indicates important safety messages in this manual.

When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

Before Starting Engine, Study Operator’s Manual * Read and understand the warnings and cautions shown in Section 2 * Practice All Safety Precautions * Make Pre-Operations Check * Learn Controls Before Operating It is Owner/Operator’s responsibility to understand and follow manufacturer’s instructions on machine operation and maintenance, and to observe pertinent safety precautions, laws and regulations.

California Proposition 65 Warnings The following warning applies to equipment supplied with lead-acid batteries: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Drill Model : ___________________________________ Drill Serial No. : ________________________________ Date Delivered : ________________________________ Dealer : _______________________________________ Customer : ____________________________________

B1006752

Rev. 06 02/15/2012

Introduction

i

Product Description

BI006752-06

Rotary blasthole drills are designed for blasthole drilling purposes only. DO NOT use these machine for any other purpose than blasthole drilling. Any other use could result in personal injury, property damage and will void the warranty.

These machines are crawler mounted drill rigs, consisting of two (2) major assemblies: 1. Rotary Drill Assembly 2. Excavator Type Undercarriage (Crawlers) The rotary drill assembly is made up of the engine package, compressor package, hydraulic system, rotary drive, pulldown and hoisting system and drill pipe handling mechanism.

The crawlers are powered by two (2) hydrostatic motors. Each crawler has its own independent, variable and reversible speed control, and is equipped with 33.5 inch (85 cm) wide triple cleated grousers.

Manual Contents This manual is furnished to acquaint operators with the machine specifications, safety and operating procedures, machine controls and daily maintenance activites.

NOTE

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

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

Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this manual.

Periodic additions or revisions may be made to this manual. The right is reserved to make changes at any time without notice and without obligation. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to the manufacturer.

ii

Introduction

BI006752-06

Contents

MACHINE SPECIFICATIONS .............................................................SECTION 1

SAFETY ..............................................................................................SECTION 2

OPERATOR CONTROLS ...................................................................SECTION 3

OPERATING INSTRUCTIONS ...........................................................SECTION 4

DRILLING PRACTICES ......................................................................SECTION 5

MACHINE TRANSPORT ..................................................................SECTION 6

OPTIONS AND ACCESSORIES.........................................................SECTION 7

LUBRICATION AND PREVENTATIVE MAINTENANCE ....................SECTION 8

Introduction

iii

Notes

iv

BI006752-06

Introduction

BI006752-06

Section 1

Machine Specifications

\Machine Specifications

1-1

BI006752-06

MD6290 Specifications Pull-down/Hoisting Capacity Rated pull-down capacity

Cooler Assembly

Up to 22,680 kg (50,000 lb); optional 27,216 kg (60,000 lb)

Rated hoist capacity

Up to 21,364 kg (47,100 lb)

Feed rate

0-42.9 m/min (0-141 fpm)

Retract rate

0-44.8 m/min (0-147 fpm)

Pull-down cylinder stroke

513.08 cm (202 in) for 30 ft configuration

Head travel (30 foot config)

1,026.16 cm (404 in)

Pull-down cylinder stroke

589.28 cm (232 in) for 35 ft configuration

Head travel (35 foot config) Pull-down cylinder stroke

1,178.56 cm (464 in) 624.84 cm (246 in) for 11 m configuration

Head travel (11 m config)

1,249.68 cm (492 in)

Type

Radiator-CAC-Oil Cooler Assembly for Cat C15 (Tier III) 540 hp, single, front-end mounted Air-finned, three-core, radiator/aftercooling/hydraulic side-by-side compressor–stacked, CAC-stacked Cooler height

139.70 cm (55 in)

Cooler width

269.24 cm (106 in)

Fan

121.92 cm (48 in) diameter; 10 blades

Fan speed

1,525 rpm

Fan guard

Welded

Engine radiator Top tank

Sealed top tank, pressure cap, overflow tube and sight glass 63.5 mm (2.5 in) top tank; 88.9 mm (3.5 in) bottom tank

Hydraulic

Number of cylinders

1

Cylinder bore

17.78 cm diameter (7 in)

Cylinder rod

12.70 cm diameter (5 in)

Cable type

1 in DYFORM 8

Nominal line tension

5 to 1 factor against working

Cable sheaves (cylinder)

40.64 cm OD (16 in)

Cable sheaves (top and bottom) Sheave pins

Adjustable head guide shoes

Compressor oil core hose connection Hydraulic oil cooler Hose connections Air-to-air cooler Standard ambient rating

63.5 mm (2.5 in) O-ring boss 41.28 mm (1.625 in) O-ring boss 114.30 mm (4.5 in) O.D. 52˚ C (125˚ F)

55.88 cm OD (22 in)

5.08 cm (2 in) diameter with roller bearing

Sheave guards

Coolant connections

Standard at bottom plate Steel with replaceable Nylatron

Radiator-CAC-Oil Cooler Assembly for Cat C27 (Tier II) 800 hp, single, front-end mounted Air-finned, four-core, radiator/hydraulic side-by-side compressor CAC–stacked

Rotary Drive System Rotation speed Torque Horsepower capacity Gearbox

Cooler width 0-220 rpm

12,880 Nm max (0-9,500 ft-lb)

Fan

165.01 cm (65 in) dual fan 116.84 cm (46 in) diameter, two fans, 16 blades

Fan speed

1,700 rpm

Casting design

Fan guard

Welded

Taper roller

Lubrication

Oil flooded

Gearing

Drive motor

Cooler height

138.7 kW (186 hp)

Main thrust bearing

Ratio

289.56 cm (114 in) dual fan

Spur

Engine radiator Top tank Standard ambient rating

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

16:04 to 1 See Hydraulic System

Performance ratings are based on 100% efficiency and on engineering specifications and calculations in accordance with accepted industry standards. These capacities will vary with drilling conditions. All specifications are subject to change without notice.

1-2

Machine Specifications

BI006752-06

MD6290 Specifications Cooler Assembly

Compressor

Radiator-CAC-Oil Cooler Assembly for Cummins QXR-15

Compressor (Standard) Type

Tier III; 485 hp or 535 hp, single, front-end mounted Air-finned, three-core, radiator/aftercooling/hydraulic side-by-side compressor–stacked, CAC-stacked 139.70 cm (55 in)

Cooler width

269.24 cm (106 in) 121.92 cm (48 in) diameter; 10 blades

Fan speed

1,525 rpm

Fan guard

Welded

Engine radiator Top tank

Sealed-top tank, pressure cap, overflow tube and sight glass 63.5 mm (2.5 in) top tank; 88.9 mm (3.5 in) bottom tank 63.5 mm O-ring boss (2.5 in)

Coolant connections Compressor oil core hose connection

41.28 mm O-ring boss (1.625 in) 114.3 mm (4.5 in) O.D. 52˚ C (125˚ F)

Radiator-Coolant-Oil Cooler Assembly for QSK-19

Type

Dry-type with safety element/STG 16

Oil cooling

Air-to-oil cooler, thermostatically controlled

Oil separation

Vertical barrier element, pre-separation in 136 l (36 gal) (T-tank)

Oil filtration

12 micron replaceable element

Drive

Direct coupled to engine flywheel

Controls Air shut-off

Automatic with safety shut-down Hydraulic cylinder-operated from operator’s seat

Compressor (Optional)

Max operating pressure

8.6 bar (125 psi)

Air cleaner Dry type with safety element/STG16

Type

Oil-flooded, single-stage screw

Discharge air flow (sea level)

258.10 cm (101.625 in) single fan 154.94 cm (61 in) single fan 121.92 cm (48 in) diam, 10 blades

Fan speed

1,525 rpm

Fan guard

Welded

Max operating pressure

Standard ambient rating

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

Radiator-CAC-Oil Cooler Assembly for QSK-19

48.1 m 3/min (1,700 cfm) 6.9 bar (100 psi)

Air cleaner Type

Dry-type with safety element/SRG 20

Compressor (Optional) Type (high-pressure)

Oil-flooded, two-stage screw

Discharge air flow (sea level)

Engine radiator Top tank

35.4 m 3/min (1,250 cfm)

Compressor (Optional)

Air-finned, three-core, radiator/hydraulic side-by-side compressorstacked

Cooler height

Oil-flooded, single-stage screw

Discharge air flow (sea level)

Type

Tier I; 750 hp, single, front-end mounted

Fan

8.6 bar (125 psi)

Air cleaner

Type

Hydraulic oil cooler Hose connections Air-to-air cooler Standard ambient rating

Cooler width

29.7 m 3/min (1,050 cfm)

Max operating pressure

Cooler height

Fan

Oil-flooded, single-stage screw

Discharge air flow (sea level)

Max operating pressure

32.6 m 3/min (1,150 cfm) 38.2 m 3/min (1,350 cfm) 42.5 m 3/min (1,500 cfm) 10.3/24.1 bar (150/350 psi)

Air cleaner Type

Dry-type with safety element/SRG 20

Tier II; 760 hp, single, front-end mounted Air-finned, four-core, radiator/hydraulic side-by-side compressor CAC–stacked Cooler width

289.56 cm (114 in) dual fan

Cooler height Fan

165.10 cm (65 in) dual fan 116.84 cm (46 in) diameter, two fans, 16 blades

Fan speed

1,700 rpm

Fan guard

Welded

Engine radiator Top tank Standard ambient rating

\Machine Specifications

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

1-3

BI006752-06

MD6290 Specifications Engine

Engine (cont.)

Engine (Standard) Manufacturer Model Rated horsepower Full load Starting system Safety shut-down system

Engine (Optional) Caterpillar ® C15 electronic (Tier III) 403 kW (540 hp) 2,100 rpm 24 V DC Energized to run

Air cleaner Type Model Batteries Muffler Muffler guard Jacket water cooling/CAC Standard ambient rating

Manufacturer Model Rated horsepower

STG 16 Two (2) 8-D 127 mm (5.0 in) inlet and outlet 10 ga. for personal protection Radiator 52˚ C (125˚ F)

Type

Safety shut-down system

Muffler

Model Batteries Muffler Muffler guard Jacket water cooling/CAC

Caterpillar C27 electronic (Tier II) 597 kW (800 hp) 2,100 rpm 24 V DC Energized to run

Muffler guard

10 ga. for personal protection

Jacket water cooling/CAC

Radiator

Fuel tank

1,382 l (365 gal) optional tank 1,071 l (283 gal) Blankets and/or exhaust wrap

Cummins

Model

QSK-19 (Tier I) electronic

Rated horsepower

559 kW (750 hp)

Full load

2,100 rpm

Starting system

24 V DC

Safety shut-down system

Energized to run

Air cleaner Type

Dry-type with safety element SRG 20 Four (4) 8-D 127 mm (5.0 in) inlet and outlet 10 ga. for personal protection Radiator

Fuel tank

1,382 l (365 gal) (optional tank) 1,071 l (283 gal)

Turbo and manifold covers

Blankets and/or exhaust wrap

1-4

Four (4) 8-D 127 mm (5.0 in) inlet and outlet

Manufacturer

Air cleaner Type

SRG 20

Batteries

Engine (Optional)

Engine (Optional)

Dry type with safety element

Model

Turbo and manifold covers

Full load

Energized to run

Air cleaner Dry-type with safety element

Blankets and/or exhaust wrap

Starting system

24 V DC

Safety shut-down system

Turbo and manifold covers

Rated horsepower

2,100 rpm

Starting system

1,382 l (365 gal) (optional tank) 1,071 l (283 gal)

Model

QSX-15 (Tier III) electronic 362 kW (485 hp) or 399 kW (535 hp)

Full load

Fuel tank

Manufacturer

Cummins

Dry-type with safety element

Model

SRG 20

Batteries Muffler

Four (4) 8-D 127 mm (5.0 in) inlet and outlet

Muffler guard Jacket water cooling (Two pump, two loop) Fuel tank Turbo and manifold covers

10 ga. for personal protection Radiator 1,382 l (365 gal) optional tank 1,071 l (283 gal) Blankets and/or exhaust wrap

Machine Specifications

BI006752-06

MD6290 Specifications Operator’s Cab

Engine (cont.)

Engine (Optional)

Location

Manufacturer

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

Cummins

Model

QSK-19 electronic (Tier II)

Rated horsepower

566 kW (760 hp)

Full load

2,100 rpm

Starting system

24 V DC

Safety shut-down system

Energized to run

Air cleaner

Type

Shock-mounted; two-man, integrated FOPS certified

Length at floor

198.12 cm (78 in)

Width at floor

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

Floor area Height inside

194.51 cm (76.50 in)

Construction

Type

12 ga. steel welded to formed 12 ga. channel and angle supports

Dry-type with safety element

Model

SRG 20

Batteries

Four (4) 8-D

Muffler

127 mm (5 in) inlet and outlet

Muffler guard

10 ga. for personal protection

Jacket water cooling/CAC

1,382 l (365 gal) optional tank 1,071 l (283 gal)

Turbo and manifold covers

.64 cm (0.25 in) tinted safety glass in rubber mounting

Number of windows

10

Number of doors

2 with windows (included in above)

Left door to work deck

Radiator

Fuel tank

Windows

Blankets and/or exhaust wrap

Swing-type HD hinge

Right door

Swing-type HD hinge

Operator’s seat

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

Helper’s seat

Fixed folding jump seat

Insulation, wall and ceiling

Mast Construction

Insulation, floor

ASTM 500 grade B rectangular tubing, welding

Main chord size

Pivot and raising area Hydraulic lines Hose rack Table hole diameter

Front 20.32 cm (8 in) x 10.16 cm (4 in) x 0.64 cm (0.25 in); Rear 10.16 cm (4 in) x 10.16 cm (4 in) x 1.27 cm (0.5 in) Rectangular tubing “A” frame; reinforced in high-stress areas

Location

Sheet steel trough for moving hoses 27.90 cm (11.0 in) diameter deck hole for guide bushing

2

Cylinder rod

8.89 cm (3.5 in) diameter

Cylinder connection pins

\Machine Specifications

Wall-mounted Window wipers and washers

Operator’s Controls

19.78 cm (7.0 in) diameter

Lift capacity each cylinder

82 dB(A) or less

Air conditioner, heater, pressurizer

Pressure-rated steel hydraulic tubing

Cylinder bore

Cylinder stroke

Heavy-duty latches with lockable handles

Sound levels

Other

Mast-Elevating Cylinders Number of cylinders

Door latches

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

96.52 cm (38 in)

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

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

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

47,990 kg (105,800 lb) 45 mm (1.75 in) diameter

1-5

BI006752-06

MD6290 Specifications Operator’s Controls (cont.)

Mainframe

Standard Drilling Controls

Main rails

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

Leveling jack controls (hydraulic)

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

HOBO/Break-out wrench control (electric) Mast elevation control (hydraulic)

Construction

Pull-down control (electric over hydraulic)

Electric welded

Jacks, mast pivot and deck

Pull-down pressure control (pilot hydraulic)

Toolbox

Rotation control (electric over hydraulic)

Welded integrally to mainframe Lockable door, below front deck

Machine deck

Propel controls (electric over hydraulic) Carousel in/out control (electric)

Access both sides

Hand rails

4.80 cm (1.9 in) diameter x 1.22 m (48 in) high

Tow hooks

Welded, two (2) front

Carousel indexing control (electric) Carousel lock (electric)

Leveling Jacks

Mast lock (electric) Dust/water injection (electric) Dust curtain (electric)

4

Location

2 front; 2 rear

Cylinder bore

Deck wrench control (electric)

13.97 cm (5.5 in)

Cylinder rod diameter

Level indicator (bubble)

Cylinder stroke

On/off light switch (electric) Drill hourmeter (gauge)

7.62 cm (3 in) 121.92 cm (48 in) 152.40 cm (60 in) optional front and rear

Lift capacity

Wiper/washer controls (electric)

29,620 kg (65,300 lb) each

Pad connection

Optional

Link pad

Pad diameter

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

Type

Inner extension boot

Triple grouser

Rollers

Sealed, oil-flooded

Number of rollers on each side Upper track chain support Rock guards/chain guides Overall length Width over tracks Final drive Drive horsepower per track Brakes Brake release Tram speed max Gradeability mast down Rear axle Front Track adjustment means Track drive disconnect

21.90 cm (8.625 in) OD 0.81 cm (.322 in) wall

Drill Table & Work Deck 750 mm (29.5 in)

Pad type

Internal at each cylinder

Table height off ground Excavator type

Pad width

60.96 cm (24 in)

Safety check valves

Undercarriage

1-6

Number

10 Two (2) carrier rollers Standard full-length guards

508.00 cm (200 in) (variable with adjustment) 391.16 cm (154 in) Independent hydrostatic, 2-speed motors Maximum 152 kW (204 hp)

Deck floor material

Non-skid sheet metal

Drill deck length

266.06 cm (104.75 in)

Drill deck width

257.81 cm (101.5 in) 6.86 m 2 (73.8 ft 2)

Drill deck area Hand rails

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

Dust Curtain (Optional Hydraulic Lifters, Front and Rear) Material

6.4 mm (0.25 in) rubber nylon reinforced 4.2 m 2 (45.14 ft 2)

Enclosed area Split for excess

Front and rear with 30.50 cm (12 in) overlap

Dust deflector

Natural rubber seal, 1.27 cm (0.5 in) thick, 35.56 cm (14 in) diameter

Spring set, hydraulic release Automatic

132.08 cm (52 in)

Location

Directly below table bushing

3.14 km/h (1.95 mph)

Hydraulic System

66% 20.32 cm (8 in) solid Three-point oscillating type Hydraulic with grease gun Standard (Manual)

Left Track/Rotation Type Max flow Pressure rating

Axial piston, variable volume 283 l/min (75 gpm) 413.7 bar (6,000 psi)

Machine Specifications

BI006752-06

MD6290 Specifications

Hydraulic System (cont.)

Accessories, Tools & Handling Equipment

Right Track Type

Axial piston, variable volume

Max flow

283 l/min (75 gpm)

Pressure rating

413.7 bar (6,000 psi)

Axial piston, variable volume

Max flow

283 l/min (75 gpm)

Pressure rating

344.7 bar (5,000 psi)

Type

9.14 m (30 ft)

12.70 cm (5 in)

1.91 cm (0.75 in)

3.5 Beco

9.14 m (30 ft)

12.70 cm (5 in)

1.91 cm (0.75 in)

3.5 Beco

10.67 m (35 ft)

13.97 cm (5.5 in)

1.91 cm (0.75 in)

4 Beco

9.14 m (30 ft)

13.97 cm (5.5 in)

1.91 cm (0.75 in)

4 Beco

10.67 m (35 ft)

107/125 cc

15.24 cm (6 in)

1.91 cm (0.75 in)

4.5 Beco

9.14 m (30 ft)

Bent axis fixed volume

15.24 cm (6 in)

1.91 cm (0.75 in)

4.5 Beco

10.67 m (35 ft)

16.51 cm (6.5 in)

1.91 cm (0.75 in)

4.5 Beco

9.14 m (30 ft)

16.51 cm (6.5 in)

1.91 cm (0.75 in)

4.5 Beco

10.67 m (35 ft)

17.78 cm (7 in)

1.91 cm (0.75 in)

4.5 Beco

9.14 m (30 ft)

17.78 cm (7 in)

1.91 cm (0.75 in)

4.5 Beco

10.67 m (35 ft)

Axial piston var. 9.76 cubic inch displacement 344.7 bar continuous (5,000 psi); 413.7 bar intermittent (6,000 psi)

Fan Drive Motor(s) Dual fan: 2

Type

Piston

Pressure rating

413.7 bar continuous (6,000 psi)

Depends on pipe diameter

Length

71.12 cm (28 in)

Top thread

13.97 cm (5.5 in) API Reg.

Bottom thread

Depends on pipe diameter

Bit Sub

Pump Drive Gearbox Type Drive

Top Adapter Sub Diameter

Single fan: 1

l3 pad Rubber coupler/drive shaft to front of engine

Diameter

Depends on pipe diameter

Length

76.20 cm (30 in) for 30 and 35 ft mast, 152.40 cm (60 in) for 11 m mast

Filtration Top thread

All filters have indicators and bypass Loop

12 micron 2 per loop (optional)

Charge

3 micron 1 per loop

Main return

12 micron absolute

Case return

12 micron absolute

Oil-Cooling System (Hydraulic Tank) Reservoir

Pipe Length

10.67 m (35 ft)

Rotation Drive Motor Pressure rating

Thread 3 Beco

413.7 bar (6,000 psi)

Type

Wall Thickness

3 Beco

Track Drive Motors

Pressure rating

9.14 m (30 ft); Optional 10.67 m (35 ft)

Diameter

1.91 cm (0.75 in)

206.8 bar (3,000 psi)

(2)–Two-speed

Length

1.91 cm (0.75 in)

216 l/min (57 gpm) single fan; 246 l/min (65 gpm) dual fan

Pressure rating

1.91 cm (0.75 in)

11.43 cm (4.5 in) Gear

Max flow

Customer specification, 11.43-17.78 cm (4.5 in-7.0 in)

Wall thickness

11.43 cm (4.5 in)

Fan Circuit Pump(s) Type

Drill Pipe (optional) Diameter

Accessory Circuit Pump/Hoist/Pull-down Type

Note: 4-pod carousel for 9.14 m (30 ft) and 10.67 m (35 ft) mast, 2-pod carousel for 11 meter mast

644 l (170 gal) with sight and temperature gauge

Reservoir pressure

Atmospheric, filtered breather

Reservoir refill system

871 l (230 gal) through return filter

Lubrication Centralized manual (optional auto lubrication)

Bottom thread

Depends on pipe diameter

Table bushing Optional:

One (1) piece insert standard, roller bushing or two-piece

Deck Wrench Location

Drill deck

Wrench plate

7.62 cm (3 in) T1- Steel

Wrench positioning

Hydraulic cylinder

Impact means

Stationary jaw

HOBO Break-Out Wrench Location Support Wrench type Power

\Machine Specifications

Depends on pipe diameter

Outside mast, under pipe rack Pivot Patented HOBO (Hydraulically Operated Break-Out) Hydraulic Cylinders

1-7

BI006752-06

MD6290 Specifications Accessories, Tools and Handling Equipment (cont.)

Pipe Rack Type

Carousel, with stationary pods and breaker plates

Size of drill pipe/capacity

11.43 cm to 17.78 cm (4.5 in to 7 in)/ 9.14 m (30 ft) and 10.67 m (35 ft) mast 4 pipes

Size of drill pipe/capacity

11.43 cm to 17.78 cm (4.5 in to 7 in)/ 11 m (36 ft 1 in) mast 2 pipes

Length of drill pipe

9.14 m (30 ft); optional 10.67 m (35 ft)

Pipe rack swing Pipe rack index

Hydraulic cylinders (2) Hydraulic motor through chain drive

Location

Outside mast

Winch–Mounted on the mast Rating Cable size Safety hook

3,629 kg (8,000 lb) 12.7 mm (0.5 in) Swivel-type positive lock

Performance ratings are based on 100% efficiency, and on engineering specifications and calculations in accordance with accepted industry standards. These capacities will vary with drilling conditions. All specifications are subject to change without notice or obligation.

1-8

Machine Specifications

BI006752-06

MD6240 Specifications Cooler Assembly

Pull-Down/Hoisting Capacity Rated pull-down capacity

Up to 22,680 kg (50,000 lb)

Rated hoist capacity

Up to 22,680 kg (50,000 lb)

Feed rate

0-38.1 m/min (0-125 fpm)

Retract rate

0-38.1 m/min (0-125 fpm)

Pull-down cylinder stroke (12 meter) Head travel (12 meter)

Head travel (15 meter)

880.11 cm (346.5 in)

Compressor cooler width Fan

187.88 cm (72 in)/162.56 cm (64 in)

121.92 cm (48 in) diam. one fan per cooler, 10 blades Maximum 1,525 rpm

Hydraulic

Fan guard

Welded

Engine radiator, top tank

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

16.51 cm (6.5 in) diameter

Cylinder rod

10.16 cm (4 in) diameter

Cable type

Standard ambient rating

5 to 1 factor against working

Cable sheaves (cylinder)

40.64 cm (16 in) OD

Cable sheaves (top and bottom)

50.80 cm (20 in) OD

Sheave pins

5.10 cm (2 in) diameter with roller bearing

Sheave guards Adjustable head guide shoes Automatic cable tensioning system

Standard at bottom plate Steel with replaceable Nylatron Hydraulic cylinder, powered by fan circuit

Torque Horsepower capacity Gearbox

Compressor (Standard) Type

Oil-flooded, single-stage screw

Discharge air flow (sea level) Max operating pressure

0-220 rpm 12,880 Nm max (0-9,500 ft-lb) 138.7 kW (186 hp) Casting design

Type

Dry-type with safety element SRG 20

Oil cooling

Air-to-oil cooler, thermostatically controlled Vertical barrier element, pre-separation in 189 l (50 gal) horizontal sump (T-tank)

Oil filtration

12 micron replaceable element

Drive

Direct coupled to engine flywheel

Controls

Automatic with safety shut-down

Air shut-off

Hydraulic cylinder-operated from operator’s seat

Main thrust bearing

Taper roller

Lubrication

Oil-flooded

Type (high pressure)

Ratio Drive motor

6.9 bar (100 psi)

Model

Compressor (Optional)

Gearing

Spur

48.1 m 3/min (1,700 cfm)

Air cleaner

Oil separation

Rotary Drive System Rotation speed

52˚ C (125˚ F)

Compressor

1 in DYFORM 8

Nominal line tension

147.32 cm (58 in)/ 147.32 cm (58 in)

Fan speed

1 (stationary rod, moving barrel)

Cylinder bore

Radiator/hydraulic cooler height/width

1,760.22 cm (693.0 in)

Type Number of cylinders

Air-finned, three- or four-core, radiator/hydraulic stacked, compressor separate

726.94 cm (286.2 in) 1,453.89 cm (572.4 in)

Pull-down cylinder stroke (15 meter)

For Cat C27 or Cummins QST-30 ® Engines–Split Coolers

Discharge air flow (sea level)

Oil-flooded, two-stage screw 32.6 m 3/min (1,150 cfm);

16:04 to 1

38.2 m 3/min (1,350 cfm);

See Hydraulic

42.5 m 3/min (1,500 cfm)

Performance ratings are based on 100% efficiency and on engineering specifications and calculations in accordance with accepted industry standards. These capacities will vary with drilling conditions. All specifications are subject to change without notice.

Max operating pressure Air cleaner

10.3/24.1 bar (150/350 psi) Dry-type with safety element/SRG 29

Compressor (Optional) Type (high pressure) Discharge air flow (sea level)

Oil-flooded, two-stage screw 32.6 m 3/min (1,150 cfm); 38.2 m 3/min (1,350 cfm); 42.5 m 3/min (1,500 cfm)

Max operating pressure Air cleaner

\Machine Specifications

10.3/24.1/34.5 bar (150/350/500 psi) Dry-type with safety element/SRG 29

1-9

BI006752-06

MD6240 Specifications Engine (cont.)

Engine

Engine (Optional)

Engine (Standard) Caterpillar ®

Manufacturer Model

C27 Tier II

Rated horsepower

597 kW (800 hp)

Full load

2,100 rpm

Starting system

24 V DC

Safety shut-down system

Energized to run

Cummins

Model

QST-30 (Tier II)

Rated horsepower

671 kW (900 hp) or 783 kW (1,050 hp)

Full load

2,100 rpm

Starting system

24 V DC

Safety shut-down system

Energized to run

Air cleaner

Air cleaner Type

Dry-type with safety element

Model

SRG 20

Batteries

Four (4) 8-D

Muffler

127 mm (5 in) inlet and outlet

Muffler guard

10 ga. for personal protection

Jacket water cooling/CAC Fuel tank

Manufacturer

Radiator 1,325 l (350 gal), optional tank 1,571 l (415 gal)

Turbo and manifold covers

Blankets and/or exhaust wrap

Type

Dry-type with safety element

Model

SRG 29

Batteries

Four (4) 8-D

Muffler

127 mm (5 in) inlet and outlet

Muffler guard

10 ga. for personal protection

Jacket water cooling/CAC Fuel tank

Radiator 1,325 l (350 gal), optional tank 1,571 l (415 gal)

Turbo and manifold covers

Blankets and/or exhaust wrap

Engine (Optional) Manufacturer

QST-30 (Tier I)

Rated horsepower

634 kW (850 hp) or 783 kW (1,050 hp)

Full load

Construction Main cord size

2,100 rpm

Starting system

24 V DC

Safety shut-down system

ASTM 500 grade B rectangular tubing, welding Front 20.3 cm x 10.1 cm x 0.6 cm (8 in x 4 in x 0.25 in); Rear 10.1 cm x 10.1 cm x 1.2 cm (4 in x 4 in x 0.5 in)

Pivot and raising area

Energized to run Hydraulic lines

Air cleaner Type

Dry-type with safety element

Model

SRG 29

Batteries

Hose rack Table hole diameter

127 mm (5 in) inlet and outlet

Muffler guard

10 ga. for personal protection

Jacket water cooling

Radiator 1,325 l (350 gal), optional tank 1,571 l (415 gal)

Turbo and manifold covers

Pressure-rated steel hydraulic tubing Sheet steel trough for moving hoses 27.9 cm (11 in) diameter deck hole for guide bushing

Blankets and/or exhaust wrap

Mast-Elevating Cylinders Number of cylinders

2

Cylinder bore

20.32 cm (8 in) diameter

Cylinder rod

10.16 cm (4 in) diameter

Cylinder stroke

1-10

Rectangular tubing “A” frame; reinforced in high-stress areas

Four (4) 8-D

Muffler

Fuel tank

Mast

Cummins

Model

108.2 cm (42.6 in)

Lift capacity each cylinder

56,728 kg (125,065 lb) at 2,500 psi

Cylinder connections pins

5.71 cm (2.25 in) diameter

Machine Specifications

BI006752-06

MD6240 Specifications Undercarriage

Type

Operator’s Controls Excavator type

Pad width

750 mm (29.5 in)

Pad type

Triple grouser

Rollers

Sealed, oil flooded

Number of lower rollers on each side Upper track chain support

12 Two (2) carrier rollers

Rock guards/chain guides

570.48 cm (224.6 in)

Width over tracks

391.16 cm (154 in)

Final drive

Maximum 152 kW (204 hp)

Brakes

Spring set, hydraulic release

Brake release

Automatic

Tram speed max

2.0 km/h (1.25 mph)

Gradeability mast down

66%

Rear axle

20.32 cm (8 in) solid

Front

Hydraulic with grease gun

Track drive disconnect

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

Standard Compressor Controls

Standard Drilling Controls HOBO/Break-out wrench control (electric) Mast elevation control (hydraulic) Pull-down control (electric over hydraulic) Pull-down pressure control (pilot hydraulic) Rotation control (electric over hydraulic) Propel controls (electric over hydraulic) Carousel in/out control (electric)

Three-point oscillating type

Track adjustment means

Standard Engine Controls

Leveling jacks controls (hydraulic)

Independent hydrostatic motors

Drive horsepower per track

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

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

Standard full-length guards

Overall length

Location

Standard (manual)

Carousel indexing control (electric) Carousel lock (electric) Mast lock (electric) Dust/water injection (electric)

Operator’s Cab

Dust curtain (electric) Location Type

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

198.12 cm (78 in)

Width at floor

151.76 cm (59.75 in) 2

2

3 m (32.4 ft )

Floor area Height inside

194.31 cm (76.5 in)

Construction Windows

Level indicator (bubble)

Shock-mounted; two-man, integrated FOPS certified

Length at floor

12 ga. steel welded to formed 12 ga. channel and angle supports 0.6 cm (0.25 in) tinted safety glass in rubber mounting

Number of windows

Wiper/washer controls (electric)

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

Swing-type HD hinge

Right door

Swing-type HD hinge

Operator’s seat

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

Helper’s seat

Fixed folding jump seat

Insulation, wall and ceiling

2.5 cm (1 in) thermal

Insulation, floor

0.9 cm (0.375 in) closed cell foam with 0.3 cm (0.125 in) pyramid vinyl surface Heavy-duty latches with lockable handles

Sound levels Air conditioner/heater/pressurize

\Machine Specifications

Drill hourmeter (gauge)

2 with windows (included in above)

Left door to work deck

Other

On/off light switch (electric)

10

Number of doors

Door latches

Deck wrench control (electric)

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

1-11

BI006752-06

MD6240 Specifications Mainframe Main rails

Hydraulic System

20.32 cm x 40.64 cm x 1.27 cm (8 in x 16 in x 0.5 in) ASTM 500 grade B Rectangular tubing heavily cross-braced and reinforced at high-stress areas

Construction

Electric welded

Left Track/Rotation Type

Closed-loop, axial piston, variable volume

Max flow

283 l/min (75 gpm)

Pressure rating

413.7 bar (6,000 psi)

Jacks, mast pivot and deck

Welded integrally to main frame

Right Track/Pull-down/Hoist

Toolbox

Lockable door, below front deck

Type

Machine deck

Access both sides

Hand rails

4.80 cm (1.9 in) diameter x 1.22 m (48 in) high

Tow hooks

Welded, two (2) front

Mast rests

Between front jacks, and additional mast rests off front end of frame

Leveling Jacks

283 l/min (75 gpm)

Pressure rating

413.7 bar (6,000 psi)

Fan/Accessory Circuit Type

Open loop, axial piston, variable volume

Max flow

273 l/min (72 gpm) dual fan (one per cooler)

Pressure rating

Number

4

Location

2 front; 2 rear

Cylinder bore

13.97 cm (5.5 in)

Cylinder rod diameter

7.62 cm (3 in)

Cylinder stroke

152.40 cm (60 in)

206.8 bar (3,000 psi

Track Drive Motors (2)-Single Speed 107cc Type

Bent-axis fixed volume

Pressure rating

413.7 bar (6,000 psi)

Rotation Drive Motor Type

Lift capacity

Closed-loop, axial piston, variable volume

Max flow

Axial piston var. 9.76 cubic inch displacement

29,620 kg (65,300 lb) each Pressure rating

Pad connection Pad diameter Safety check valves Inner extension boot

60.96 cm (24 in) Internal at each cylinder 21.90 cm (8.625 in) OD, 0.81 cm (0.322 in) wall

Drill Table & Work Deck Table height off ground

152.08 cm (52 in)

Fan Drive Motor(s)-Single Fan Fan drive motor(s)

Type

Drill deck length

266.06 cm (104.75 in)

Filtration

Drill deck width

257.81 cm (101.5 in)

4.8 cm (1.9 in) diameter x 121.9 cm (48 in) high

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

1-12

413.7 bar continues (6,000 psi)

Pump Drive Gearbox Drive

6.8 m 2 (73.8 ft 2)

Piston

Pressure rating

Non-skid sheet metal

Drill deck area

Single fan: 1

Type

Deck floor material

Hand rails

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

Link pad

3 pad Rubber coupler/drive shaft to front of engine

All filters have indicators and bypass Loop

12 micron 2 per loop (optional)

Charge

3 micron 1 per loop

Main return

12 micron absolute

Case return

12 micron

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

Directly below table bushing

Machine Specifications

BI006752-06

MD6240 Specifications Lubrication

Accessories, Tools & Handling Equipment (cont.)

Centralized manual (optional auto lubrication)

Oil Cooling System (Hydraulic Tank) Reservoir

643 l (170 gal) with sight and temperature gauge

Reservoir pressure

Atmospheric, filtered breather

Reservoir refill system

871 l (230 gal) through return filter

Top Adapter Sub Diameter

Depends on pipe diameter

Length

71.12 cm (28 in)

Top thread

13.97 cm (5.5 in) API Reg.

Bottom thread

Depends on pipe diameter

Bit Sub

Accessories, Tools & Handling Equipment

Diameter

Depends on pipe diameter

Length

Up to 342.90 cm (135 in)

Drill Pipe (Optional, Price-Adder)

Top thread

Depends on pipe diameter

12 meter mast arrangement Diameter Customer specification 11.43-17.78 cm (4.5-7.0 in) Wall thickness 1.91 cm (0.75 in) Length 10.67 m (35 ft) Threads Depends on pipe diameter Diameter Wall Thickness Thread Pipe Length

Bottom thread

Depends on pipe diameter

11.43 cm (4.5 in)

1.91 cm (0.75 in)

3 Beco

10.67 m (35 ft)

Wrench plate

12.70 cm (5 in)

1.91 cm (0.75 in)

3.5 Beco

10.67 m (35 ft)

13.97 cm (5.5 in)

1.91 cm (0.75 in)

4 Beco

10.67 m (35 ft)

15.24 cm (6 in)

1.91 cm (0.75 in)

4.5 Beco

10.67 m (35 ft)

Table bushing

One (1) piece insert, roller deck bushing or two-piece

Deck Wrench Location

Drill deck 7.6 cm (3 in) T1- Steel

Wrench positioning

Hydraulic cylinder

Impact means

Stationary jaw

16.51 cm (6.5 in)

1.91 cm (0.75 in)

4.5 Beco

10.67 m (35 ft)

HOBO Break-Out Wrench

17.78 cm (7 in)

1.91 cm (0.75 in)

4.5 Beco

10.67 m (35 ft)

Location

15 meter mast arrangement Diameter Customer specification 11.43-17.78 cm (4.5-7.7 in) Wall thickness 1.91 cm (0.75 in) Length 7.62 m (25 ft) Threads Depends on pipe diameter Diameter Wall Thickness Thread Pipe Length

Support

11.43 cm (4.5 in)

1.91 cm (0.75 in)

3 Beco

7.62 m (25 ft)

Type

12.70 cm (5 in)

1.91 cm (0.75 in)

3.5 Beco

7.62 m (25 ft)

13.97 cm (5.5 in)

1.91 cm (0.75 in)

4 Beco

7.62 m (25 ft)

15.24 cm (6 in)

1.91 cm (0.75 in)

4.5 Beco

7.62 m (25 ft)

Wrench type

Outside mast, under pipe rack Pivot Patented HOBO (Hydraulically Operated Break-Out)

Power

Hydraulic cylinders

Carousel Carousel, with stationary pods and breaker plates

Size of drill pipe/capacity

11.43-17.78 cm (4.5-7 in)

12 meter mast arrangement (4 pod)

16.51 cm (6.5 in)

1.91 cm (0.75 in)

4.5 Beco

7.62 m (25 ft)

15 meter mast arrangement (2 pod)

17.78 cm (7 in)

1.91 cm (0.75 in)

4.5 Beco

7.62 m (25 ft)

Length of drill pipe

Pipe rack swing Pipe rack index Location Mounting

10.67 m (35 ft) for 12 meter mast, 7.62 m (25 ft) for 15 meter mast Hydraulic cylinders (2 ) Hydraulic motor through chain drive Outside mast Upper, lower pillow-block bearing

Winch Rating Cable size Safety hook

\Machine Specifications

3,629 kg (8,000 lb) 12.70 mm (0.5 in) Swivel-type positive lock

1-13

BI006752-06

MD6290 Component Locator FRONT OF MACHINE COMPRESSOR OIL COOLER HYDRAULIC OIL COOLER

ENGINE RADIATOR

ENGINE AIR FILTER

COMP. AIR CLEANER RH FRONT JACK

LH FRONT JACK

COMPRESSOR AIR/OIL SEPARATOR MAST ACCESS LADDER

AIR COMPRESSOR

FUEL TANK DIESEL ENGINE

MUFFLER

FUEL FILL

DRIVELINE

PUMP DRIVE

RETURN FILTERS DUST COLLECTOR HYDRAULIC OIL RESERVOIR

CHARGE FILTERS (LOOP FILTERS OPTIONAL)

MAIN ELECTRIC CABINENT PRESSURE/VACUUM FILTER

MAST ELEVATING CYLINDERS RH REAR JACK

LH REAR JACK

WINDOW WASHER BOTTLE PIPE CAROUSEL OPERATOR’S CAB IN DECK PLENUM CHAMBER

A/C CONDENSER IN DECK TOOL BOX

CRANE (OPT) DRILLING PLATFORM

CRANE CONTROLS (OPT)

VIEWING HATCH

1-14

Machine Specifications

BI006752-06

MD6290 Component Locator TOP MAST SHEAVE

ROTARY DRIVE

CAROUSEL

BATTERY BOX

TRACK FINAL DRIVE

CRAWLER

HYDRAULIC OIL FILL PUMP

LIGHTS

DUST CURTAINS A/C/ UNIT

\Machine Specifications

1-15

BI006752-06

MD6240 Component Locator FRONT OF MACHINE

MAST REST

WATER TANKS BOLTED UNDER DECK

AIR/OIL RECEIVER TANK

LEFT FRONT JACK COMPRESSOR AIR CLEANER

RIGHT FRONT JACK ENGINE AIR CLEANER

OIL INJECTION TANK AIR COMPRESSOR

FRONT FUEL TANK

ENGINE MUFFLER ENGINE COOLER COMPRESSOR OIL COOLER

ENGINE BATTERY BOX CENTRAL LUBE SYSTEM PUMP FLEX DRIVE COUPLING (COVER REMOVED) PUMP DRIVE GEARBOX

FUEL TANKS BOLTED UNDER DECK

REAR FUEL TANK

HYDRAULIC FILL HAND PUMP MAIN RETURN FILTER CASE DRAIN FILTER

MAIN HYDRAULIC PUMPS

HYDRAULIC TANK

DRILL STEM THREAD LUBRICATOR RIGHT REAR JACK LEFT REAR JACK

DRILLING PLATFORM OPERATOR’S CAB

Due to the variety of drill options and requirements, each drill may vary from the configurations shown.

1-16

Machine Specifications

BI006752-06

MD6240 Component Locator TOP SHEAVES ROTARY DRIVE GEARBOX

TRAVELING SHEAVES FINAL DRIVE

MAST

CARRIER ROLLERS TRACK ROLLERS CRAWLER ASSEMBLY

HYDRAULIC FILL HAND PUMP

TENSIONER IDLER

MAST ELEVATING CYLINDERS

FRONT IDLER

BOTTOM SHEAVES

\Machine Specifications

1-17

SKF ROTARY BLASTHOLE DRILLS 1-18

BI006752-06

Based on MD6290 with 11M mast arrangement

MD6290 Dimensions

Machine Specifications

MD6240 Dimensions Based on MD6240 with 12M and 15M mast arrangement

BI006752-06

\Machine Specifications

1-19

BI006752-06

Transient Stability Limits

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

BE SURE to observe if any overhead power lines arein the area. Contact with overhead high voltage power lines can cause severe injury or death. Follow the maximum safe distance requirements in Section 2 of this manual.

21° 12°

9°

25° 18°

NOTE

18°

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

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

1-20

Machine Specifications

BI006752-06

Line of Sight Limits 17° 30 °

13°

52°

9°

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

10 ° 23°

7°

) 5 2 1 7 2 ) 0 $ & + , 1 (

23°

8°

6°

TRAMMING

25°

31° 14°

30 °

27°

13°

66°

52°

9°

17°

10 ° 8°

23°

6°

23°

7°

DRILLING

\Machine Specifications

1-21

BI006752-06

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

MD6240 AND MD6290 IF DURING MAINTENANCE MACHINE REQUIRES ADDITIONAL SAFETY SUPPORTS, PLACE SUPPORTS (JACK STANDS) AS CLOSE TO LEVELING JACKS AS POSSIBLE. THESE AREAS SUPPORT THE MACHINE DURING DRILLING OPERATIONS.

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

1-22

Machine Specifications

BI006752-06

Section 2

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

Safety

2-1

Hazard Classification

BI006752-06

The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling.

Like all moving objects and reach extending devices, there are potential hazards associated with its use.

These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's must read this manual and have been trained to use the machine in an appropriate and safe manner.

Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer at 1-800-258-0009.

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

Safety Alert Symbol

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

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

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

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

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

Blue 2-2

Safety

Overview of Potential Hazards

BI006752-06

Potential Hazard

Safety

Prevention

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

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

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

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

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

Keep clear of rotating drivelines.

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

Entanglement Hazard. Rotating parts can cause personal injury.

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

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

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

Burn Hazard. Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

2-3

Overview of Potential Hazards Potential Hazard

BI006752-06

Prevention

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

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

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

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

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

2-4

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

Maintain required clearance.

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

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

Flying Object & Spray Hazard.

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

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

Entanglement Hazard. Rotating parts can cause severe injury.

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

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

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

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

Safety

Overview of Potential Hazards

BI006752-06

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

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

READ MANUALS Read all manuals prior to operation.

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

Consult your supervisor, the owner or the manufacturer.

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

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

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

Use the access system provided when servicing the machine.

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

Keep clear of moving stairway.

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

Safety

2-5

Safety Guidelines

BI006752-06

Before Operation •

Do study this manual and fully understand the controls.

•

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

•

Do wear safety helmet, glasses and hearing protection when operating or working on machine.

•

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

•

Do be sure drill area is clear of all obstructions before operating and know the size limitations of the machine.

•

Do attach safety chain when using towbar.

•

Do Not operate machine with: • A hydraulic leak • Broken or damaged electrical wiring • Damaged hydraulic hoses or fittings

Operation •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

After Operation Normal Shut Down 1.

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

2.

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

3.

Allow engine to idle for a minimum of five (5) minutes before stopping.

4.

Turn the ignition key to OFF position.

5.

Check machine for any unusual conditions.

6.

Report any defects to your immediate supervisor.

2-6

Safety

BI006752-06

Safety Guidelines

Maintenance •

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

•

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

•

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

•

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

•

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

•

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

•

Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank.

This will prevent sparks and the possibility of an explosion.

•

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

•

Do Not weld or grind near oil lines.

•

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

•

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

•

Do Not leave tools or other loose objects on the engine, drive mechanisms or drilling platform.

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

Equipment Transfer •

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

Clearances from High Voltage Lines Line Voltage

Minimum Clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv

45 ft (13.7 m) Table 2-1

Safety

2-7

Safety Sign List

BI006752-06

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

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

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

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

(ref. 429469)

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

2-8

Safety

Safety Sign Locator

BI006752-06

Fig. 2-1 Safety

2-9

Safety Sign Locator

BI006752-06

Fig. 2-2 2-10

Safety

Safety Signs

BI006752-06

WARNING

WARNING

Entanglement Hazard Rotating parts can cause personal injury.

3500 lbs/ 1587 kg

Crush Hazard Falling objects can cause severe injury or death.

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

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

(3500 lbs./1587 kg.)

Do not use damaged cable.

429414

428893

428893

429414

WARNING

WARNING

Crush Hazard

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

Place carousel against lower stops before servicing hydraulic circuit.

Purge air from circuit after servicing carousel circuit.

Falling mast can cause severe injury or death.

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

429418

429448

429418

429448

WARNING

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

Keep clear of rotating drivelines.

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

Burn Hazard

429406

429406

Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

429449

429449

Safety

2-11

Safety Signs

BI006752-06

DANGER

WARNING

Maintain required clearance.

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

Fall Hazard

Always contact the electric power line owner.

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

Death or serious injury may result from climbing raised mast.

429437

Line voltage

Required clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv 45 ft (13.7 m)

429437

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

429404

429404 Crush / Fall Hazard Riding rotary head can cause severe injury or death.

Do not ride rotary head.

Lower mast completely to service.

429420

429420

WARNING

WARNING Flying Object & Spray Hazard

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

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

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

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

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

429445

429141

429445 429141

2-12

Safety

Safety Signs

BI006752-06

WARNING

WARNING

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

Entanglement Hazard Rotating parts can cause severe injury.

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

READ MANUALS Read all manuals prior to operation.

Do not operate with guard removed.

Keep all guards in place.

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

Consult your supervisor, the owner or the manufacturer.

429431

429431

429439

429439

WARNING

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

WARNING

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

Explosion Hazard Combustible gas can cause severe injury or death.

429444

429426

429426

Safety

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

429444

2-13

Safety Signs (International)

BI006752-06

429740

Flying Object & Spray Hazard (429740)

429720

Fall Hazard–Mast (429712)

Explosion/Burn Hazard (429720)

T104915

Fall Hazard (T104915)

429713

Explosion Hazard–Ether (429713)

429705

Entanglement Hazard (429705) 2-14

Safety

Safety Signs (International)

BI006752-06

3500 lbs/ 1587 kg 429718

Crush Hazard–Carousel (429718)

429721

Crush Hazard–Winch (429721)

429715

Crush Hazard–Mast (429715)

Safety

429719

Crush Hazard–Rotary Head (429719)

2-15

Safety Signs (International)

BI006752-06

429709

Electrocution Hazard (429719)

429722

Modification or Alter Hazard (429722) 429717

Burn Hazard–Pressurized Fluids (429717)

429714

Crush/Fall Hazard–Rotary Head (429714)

429710

Entanglement Hazard (429710) 429738

Entanglement Hazard (429738) 2-16

Safety

BI006752-06

Section 3

Operator Controls

Operator Controls

3-1

Graphic Symbol Legend

BI006752-06

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

Drill Functions

HOBO Swing

HOBO Lock

Deck Wrench

Auto Pulldown

Holdback

Hoist Pulldown

Winch

Drill Pipe Support

Oil Injection

Pipe Rack Swing

Pipe Rack Rotate

Pipe Rack Lock

Thread Lube

Mast Lock

Dust Curtain/Blower

Main Air

Drill/Propel

Dust/Water

Mast Lower/Raise

Front Jack–UP/DOWN

Left Rear/Right Rear Jack–Up/Down

ON

OFF

3-2

Operator Controls

Graphic Symbol Legend

BI006752-06

Drill Functions

Rotation/Left Track Pressure

Pulldown Pressure

Drilling Air Pressure

Hydraulic System Pressure

Rotation–Forward/Reverse

Pulldown Pressure–Increase/Decrease

Compressor Discharge Temperature

Engine Coolant Temperature

Engine Oil Pressure

Fuel Level

Battery Charge

Engine Hourmeter

Engine Tachometer

Engine Start

Drill Hourmeter

Ether Injection

Engine Stop

Ignition–On/Off

Water Injection–Increase/Decrease

Operator Controls and Indicators

Throttle–Fast/Slow

Operator Controls

3-3

Operator Control Panel (standard)

BI006752-06

Fig. 3-1 Operator Control Panel

NOTE

NOTE

1.

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

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

Level Indicator Indicates when the machine is level.

2.

Throttle Used to control the engine speed. Minimum engine speed is 1300 RPM, Maximum speed is 2100 RPM.

3.

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

Push the levers to raise the jacks.

3a.

Right Rear Jack

3b.

Front Jacks

3c.

Left Rear Jack

3-4

Operator Controls

BI006752-06

4.

Operator Control Panel (standard)

Mast Lever Controls the lowering and raising of the mast.

• Pull lever to raise mast.

• Push lever to lower mast.

DO NOT raise mast close to power lines. See Section 1 for Clearances from High Voltage Lines.

5.

Propel Levers - Hydraulic pilot operated Control the speed and the direction of the tracks.

• •

Push levers to propel forward (radiator end).

Pull levers to propel in reverse (cab end).

5a.

Right Track Lever

5b.

Left Track Lever

6.

Rotation Lever - Hydraulic pilot operated Controls rotary head speed and direction.

• Push lever for forward rotation.

• Pull lever for reverse rotation.

7.

Hoist/Pulldown System Lever - Hydraulic pilot operated Controls the raising and lowering of the rotary head.

• Push lever to raise the rotary head.

• Pull lever to lower the rotary head.

8.

Engine Diagnostic Lamp Light flashes to indicate engine fault.

Refer to engine manual for fault codes and remedy.

9.

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

• Turn control clockwise to increase pressure.

• Turn counterclockwise to decrease pressure.

9a.

Holdback System Pressure Control This valve is used on high pressure machines using down the hole hammers and is used in conjunction with the Holdback System Switch (see switch panel detail) which activates the solenoid valve. Normally this valve is wide open (all the way out, counterclockwise) when drilling begins. As pipe sections are added, the weight on the bit increases. To avoid too much pressure on the bit turn valve IN (clockwise) to increase oil restriction from pulldown cylinder to tank.

• Turn control clockwise to decrease pressure on bit.

• Turn counterclockwise to increase pressure on bit.

10.

Compressor Start-Run Valve–not shown (cold weather option) Low Pressure Machines: When starting machine, valve should be in the "Start" position so compressor is unloaded or in low pressure mode. When machine is warmed up, turn valve to "Run" position.

High Pressure Machines: When starting machine, valve should be in the "Low" position. When machine is warmed up, turn valve to "High" position.

NOTE

Machines without cold weather package do not use this valve.

Operator Controls

3-5

Operator Control Panel (standard)

BI006752-06

Fig. 3-1 Operator Control Panel

Fig. 3-2 Instrument Panel 3-6

Operator Controls

BI006752-06

11.

Operator Control Panel (standard)

Main Circuit Breaker Panel Pull to disconnect, push to reset breakers.

11a. Circuit Breaker Panel For Air Conditioner and Heater.

12.

Light Switches Used to turn on and off outside drill and cab interior lights.

13.

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

14.

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

15.

Ignition The ignition key is used to turn the electrical power ON/OFF. (a) Turn key ON to supply electrical power. (b) Turn key OFF to stop engine.

16.

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

17.

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

18.

Drill Hourmeter Meter records actual drilling hours.

19.

Engine Hourmeter Meter records total engine hours.

20.

Engine Oil Pressure Gauge indicates engine oil pressure.

21.

Engine Tachometer Gauge indicates engine revolutions per minute.

22.

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

23.

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

24.

Fuel Level Gauge indicates fuel level in tank.

25.

Voltage Gauge indicates voltage output of the electrical charging system.

Operator Controls

3-7

Operator Control Panel (optional)

BI006752-06

Fig. 3-3 Optional Control Panel

Fig. 3-4 Water Injection Pump Motor Flow Control Controls hydraulic flow to water pump motor.

Turn clockwise to increase flow.

3-8

Operator Controls

BI006752-06

1.

Operator Control Panel (optional)

Auto Lube Controller Controls auto lube system. Refer to Section 7 of this manual for operator's manual.

2.

Drill Depth Meter Monitors drilling depth. Refer to Section 7 of this manual for operator's manual.

3.

Tram Interlock Light Light ON, indicates drill pipe is still in hole. Machine will not tram until pipe is out of hole.

4.

Test Switch Turn switch ON to check filter indicator lights.

5.

Filter Indicator Lights Light ON, indicates that particular filter needs to be changed. Monitors the following fluid filters: Loop, Charge, Main Return, Case Drain, and Compressor Oil Filter.\

6.

Caterpillar EMS (Engine Monitoring System) Panel An electronic monitoring system that displays various engine parameters. Each time the engine is started, the EMS undergoes an automatic self-test. This panel replaces the engine hour meter, engine oil pressure gauge, engine tachometer, engine coolant temperature gauge and voltage gauge.

7.

Caterpillar EMS Scroll Switch Move switch up or down to scroll through menus on EMS panel.

8.

Horn Button Push button to sound horn.

9.

Jack Retract Light Light ON, indicates jacks are fully retracted.

10.

Oil Injection Light Light ON, indicates oil injection pump is running.

11.

Compressor Low Oil Pressure Light Light ON indicates low oil pressure at compressor bearings.

12.

Rotary Torque Control Turn knob clockwise to increase rotary torque.

13.

Hydraulic Oil Temperature Gauge Monitors temperature of oil in hydraulic tank. Oil temperature in tank should not be above 180o F (82o C) during normal operation.

Operator Controls

3-9

BI006752-06

Cat EMS Panel Engine Monitoring System (EMS) Display Overview

The main gauge module has ten indicators (two rows offi ve) that are used to display the system diagnostics. A digital LCD readout displays the parameters that are monitored. When metric values are displayed, the units of measurement are also displayed. When US values are displayed, the units of measurement are not displayed. For example, if metric values are being displayed, the readout would be “35 kPa”. If US values are being displayed, the readout would be “5”. (The unit of measurement “psi” is NOT displayed.)

The following parameters are monitored:

• Auxiliary pressure • Auxiliary temperature • Battery voltage • Coolant temperature • Engine hours • Engine load (percent) Illustration 53

g00746960

The EMS display is used to display various engine parameters. The EMS display supports backlighting in order to provide excellent visibility in various light conditions.

• Engine oil pressure • Engine speed • Fuel pressure • Fuel rate

The engine ECM processes the operating parameters and diagnostic information before sending this information to the EMS display via the CAT data link. The main gauge module displays the information that is received from the ECM. Only two wires are required from the ECM to the display for communication of all of the engine operating parameters.

The EMS display incorporates three individual gauge modules which can be installed in various locations in order to enhance operation. One main gauge module is required for each desired operator station. The tachometer module and the quad gauge module are optional. These optional modules will NOT operate without being connected to a main gauge module.

The following information describes the function and the requirements for installation of each gauge module:

3-10

• Fuel temperature • Inlet air temperature • Turbocharger outlet pressure (boost) The quad gauge module has graduated warning zones that display information in an analog format.

The quad gauge module displays the following information:

• Battery voltage • Coolant temperature • Engine oil pressure • Fuel pressure The tachometer module displays engine speed (rpm) on an analog gauge.

Operator Controls

BI006752-06

Operator Control Panel (optional)

Fig. 3-5 Instrument Panel with optional Murphy Power View display.

14.

Fig. 3-6 Cummins Engine Panel

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

15.

Ether Injection (optional) Aids in starting cold engine.

16.

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

17.

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

18.

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

19.

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

20.

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

21.

Engine Stop Light (Red) Flashes in a sequence to indicate fault codes. The engine fault codes are listed in the engine operator/maintenance manual. The fault codes can also be accessed using the Power View (14) display.

Operator Controls

3-11

System Pressure Gauge Panel

BI006752-06

Fig. 3-7 System Pressure Gauge Panel

3-12

Operator Controls

System Pressure Gauge Panel

BI006752-06

26.

Rotation / Left Track Pressure Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended periods.

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

27.

Pulldown Pressure Maximum pressure 2600 PSI (179 bar). Higher pressures may cause the machine to tip.

Gauge indicates hydraulic pressure at feed cylinder.

28.

Hydraulic System Pressure Indicates auxiliary pump pressure.

29.

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

When the drilling air is turned OFF, there should be zero pressure on this gauge.

Operator Controls

3-13

Switch Panel (standard)

BI006752-06

HOLD BACK HOBO CLAMP

THREAD LUBE

HOBO SWING

OIL INJECTION

POSITIONER

DUST CURTAIN

DUST/WATER

MAST LOCK

PIPE RACK SWING

PIPE RACK LOCK

AUX. PUMP

MAIN AIR AUTO TOOL

FAST PULLDOWN

DRILL/PROPEL

AUTO PULLDOWN

WINCH

Fig. 3-8

3-14

PIPE RACK INDEX

Switch Panel

Operator Controls

BI006752-06

30.

Switch Panel (standard)

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

31.

•

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

•

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

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

32.

•

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

•

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

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

33.

Drill Stem Thread Lube •

34.

Air Line Lubricator •

35.

Push and hold switch down to activate grease pump to lubricate drill pipe threads.

Push switch down to activate lubricator pump to provide lubrication for "In The Hole Hammers" used on high pressure machines.

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

36.

•

Push switch up to engage water injection system.

•

Push switch down to engage dust collector system.

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

37.

•

Push and hold switch up to engage drill pipe support.

•

Push and hold switch down to disengage drill pipe support.

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

•

Push and hold switch up to lift dust curtain.

•

Push and hold switch down to lower dust curtain.

Operator Controls

3-15

Switch Panel 38.

BI006752-06

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

•

Push and hold switch left to unlock (retract) mast pins.

•

Push and hold switch right to lock (engage) mast pins into mast.

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

39.

Used for Optional Functions

40.

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

41.

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

42.

•

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

•

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

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

• Push and hold switch down to lock pin IN. •

43.

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

• Push switch up to turn drilling air ON. •

44.

Push and hold switch up to move pin OUT.

Push switch down to turn drilling air OFF.

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

•

Push switch up to disengage pulldown.

•

Push switch down to engage pulldown.

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

45.

Fast Down Push switch down to activate "fast down". Use this feature to increase speed of rotary head coming down the mast.

46.

3-16

Winch •

Push and hold switch up to raise winch hook.

•

Push and hold switch down to lower winch hook.

Operator Controls

Switch Panel

BI006752-06

47.

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

48.

•

Push and hold switch up to retract tool wrench.

•

Push and hold switch down to engage tool wrench.

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

•

Push switch up to engage the propel system.

•

Push switch down to engage the drilling controls.

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

49.

50.

TRAM High/Low Switch •

Push switch UP for LOW SPEED tram

•

Push switch DOWN for HIGH SPEED tram.

Holdback System Push switch down to activate the holdback system solenoid valve. This switch is used in conjunction with the Holdback Pressure Control Valve (53).

51.

Auxiliary Pump This switch activates the auxiliary pump, which provides power for the drill set-up and tooling functions, i.e. winch, breakout wrench, deck wrench, pipe positioner and pipe rack.

52.

•

Switch down - Pump loaded

•

Switch up - Pump unloaded

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

53.

•

Turn control clockwise to increase pressure.

•

Turn counterclockwise to decrease pressure.

Holdback System Pressure Control This valve is used on high pressure machines using down the hole hammers and is used in conjunction with the Holdback System Switch (50) which activates the solenoid valve. Normally this valve is wide open (all the way out, counterclockwise) when drilling begins. As pipe sections are added, the weight on the bit increases. To avoid too much pressure on the bit turn valve IN (clockwise) to increase oil restriction from pulldown cylinder to tank.

•

Turn control clockwise to decrease pressure on the bit.

•

Turn counterclockwise to increase pressure on bit.

Operator Controls

3-17

Lights, Circuit Breakers

ADDITIONAL LIGHTS

DRILL LIGHTS

FRONT LIGHTS

ADDITIONAL LIGHTS

CAB LIGHTS

CAB LIGHTS

ECM

BI006752-06

ROTATING BEACON

BEACON

IGN-24V WIPERS

CIRCUIT BREAKERS DRILL LIGHTS

MAIN POWER

CONTROL PANEL

12 VOLT

HEATER & DRILL LIGHTS

PULL TO DISCONNECT

NOTE: Not all switches and circuit breakers are used on every machine. See parts manual for specific switches and breakers.

PUSH TO RESET STARTER

Fig. 3-9 Control Panel - Left Side

Fig. 3-10 Control Panel - Right Side 1. 10 AMP Circuit Breaker - Air Conditioner 2. 15 AMP Circuit Breaker - Heater

3-18

Operator Controls

Remote Mounted Cameras

BI006752-06

There are two remotely mounted cameras on the machine that allow the operator greater visibility while tramming. The cameras are switched on by a toggle switch on the cab circuit breaker panel.

The cameras can be positioned for best view but as a minimum should optimize the operator's visibility to the front and far left side of the machine.

The display is located in the cab so that the operator has full view of the display when the machine is being trammed. Only one camera is able to be viewed at a time.

1

2 3 4 5 6 7

9

8

Fig. 3-11 Camera Display Controls 1. POWER LED–indicates that the monitor has power 2. DAY/NIGHT SENSOR–senses available light and adjusts monitor brightness accordingly 3. MENU BUTTON–initiates display of onscreen user controls for image contrast, brightness and speaker volume 4. + BUTTON– UP button-increases the value for setup menu items, such as volume 5. - BUTTON–DOWN button-decreases the value for setup menu items, such as volume 6. POWER/CAM SELECT BUTTON–when pressed and held for one second, turns the monitor ON or OFF; when pressed briefly, switches image input 7. NORMAL/MIRROR SWITCH–switches image display to Normal or Reverse (as it would appear in a rear-view mirror) 8. MONITOR CABLE–receives power and camera images from the control box 9. BRACKET SLOT–accepts the adjustable mounting bracket Operator Controls

3-19

Heater/AC/Pressurizer

BI006752-06

Fig. 3-12 Heater/Air Conditioner Unit

1.

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

2.

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

3.

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

4.

Vent Control Selects FRESH AIR or RECIRCULATION

Pressurizer w/Air Filter

3-20

Condenser/Dryer

Backpack Combo

Operator Controls

BI006752-06

AC/Heater

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

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

b.

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

c.

If heater fails to heat, check cutoff valves at plumbing connections to engine to be sure they are turned on, then check the heater plumbing.

Fig. 3-13 Heater Connections and Cutoff Valves (Cat. C15) 1. Water Outlet to Heater 2. Water Inlet from Heater

Operator Controls

3-21

Air Conditioner

BI006752-06

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

Daily

Weekly

Monthly

Every 3

Every 6

Yearly

Service

Service

Service

Months

Months

Service

X

X

X

X

X

X

X

X

X

X

X

Check for Cleanliness of Condensing Coil.

X

X

X

X

Clean Condenser Fan Motor With Dry Compressed Air.

X

X

X

X

Check for Correct Setting of Thermostat.

X

X

X

X

Check Refrigeration and Water Lines for Damaged Lines

X

X

X

X

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

X

X

X

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

X

X

X

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

X

X

X

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

X

X

X

Check for Cleanliness of Fresh Air and Return Air Filters.

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

3-22

Operator Controls

Air Conditioner

BI006752-06

Maintenance and Servicing Schedule Daily Service

Every 3 Months

Every 6 Months

Yearly Service

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

X

X

X

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

X

X

X

Check Securing Fasteners on Fresh Air and Return Air Filters

X

X

X

X

X

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

X

X

X

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

X

X

X

X

X

Check Electrical Connections of Thermostat

X

X

X

Check Control Switch 1. Electrical connections 2. Operation

X

X

X

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

X

X

X

Check for Damage and Cleanliness of Louvers

X

X

X

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

Check Against Refrigerant Leakage of the Thermal Expansion Valve

Operator Controls

Weekly Service

Monthly Service

X

X

3-23

Air Conditioner

BI006752-06

Maintenance and Servicing Schedule Daily Service

Every 3 Months

Every 6 Months

Yearly Service

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

X

X

X

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

X

X

X

Check for Leakage of Refrigeration and Water Lines

X

X

X

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

X

X

X

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

x

X

X

x

x

Inspect Motor Brushes for Wear on Evaporator Fan Motor

3-24

Weekly Service

Monthly Service

Operator Controls

BI006752-06

Air Conditioner

DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are bent, use a correct coil fin comb to realign them.

Servicing Condenser Coil - When the cover is removed the condenser coil is exposed, and thus readily available for examination and cleaning. If cleaning is required, wash with low pressure water in the reverse direction to air flow.

Condenser Fan Motor - Inspection of the motor is carried out by lifting the cover and removing the motor from its mounting bracket. The brushes are accessible by removing the brush cover screws.

Inspect brushes for wear and replace if necessary. The motor case should be cleaned using only moisture free compressed air.

Condenser Fan Blade - If any part appears to be damaged or worn excessively, DO NOT REPAIR, but replace the fan blade.

Compressor - The compressor is equipped with either pad type or Rotalock suction and discharge service valves mounted on the cylinder head. The pad type valves and the Rotalock valves are not interchangeable.

Oil Charge - The system is charged with a R-134a compatible oil.

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

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

2.

Whenever the refrigerant has leaked from the system.

3.

Whenever the refrigerant is suddenly released from the cooling cycle.

4.

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

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

Operator Controls

3-25

Air Conditioner

BI006752-06

Servicing (cont.)

Changing Compressor: 1.

Connect pressure gauge to suction gauge port on suction service valve stem one to two turns clockwise. If gauge shows a pressure above zero gauge pressure and compressor can be operated, close suction service valve and operate compressor until compressor suction pressure is reduced to approximately 2 psig.

2.

Stop compressor and immediately close discharge service valve by turning clockwise.

3.

Remove suction and discharge service valves from compressor.

4.

Remove mounting bolts from compressor and remove compressor from engine.

5.

Remove clutch.

6.

Check to see that new replacement compressor: a. Is of the same model and bill of material or an approved replacement for the one being removed. b. Oil level meets compressor manufacturer's specifications.

7.

Install clutch removed from defective compressor with "non-Rok" key in place after checking to see that the clutch has no objectionable imperfections in it. Tighten hexhead bolt in end of shaft.

NOTE

Carefully lower, do not drop, clutch or compressor shaft. In most instances it is a good idea to replace clutch assembly as well.

8.

Mount compressor using specified torque for mounting bolts, making sure that belts are properly aligned and tightened to recommend belt tension (120 pounds for new belts, 100 pounds for used belts).

9.

Securing service valves to compressor: a. If valves are of the flat pad type, check to see that valve mounting surfaces on both valves and cylinder head are clean, free of nicks, gaskets and foreign material. Using new mounting gasket mount valves to compressor and tighten mounting bolts. b. If valves are of the Rotalock type, check to see that valve mounting surfaces on both valves and compressor are clean and that o-ring valve mounting gasket is properly positioned and in good condition. If deformed, broken or split, replace with new gasket. Properly align valve to cylinder head and tighten Rotalock nuts. c. Special care should be used so that no dirt or foreign material enters compressor during installation. The new replacement compressor should not be left unsealed to the atmosphere longer than is absolutely necessary for preparation and actual installation. In no case should compressor be open to atmosphere for more than five minutes.

3-26

Operator Controls

Air Conditioner

BI006752-06

Servicing (cont.)

Changing Compressor (continued): 10.

With service valves in closed position, connect vacuum pump to discharge and suction gauge ports of service valves and evacuate to 500 microns Hg. Stop vacuum pump and close lines to compressor.

11.

Open suction service valve until a minimum pressure of 50 psig in crankshaft is reached. Close service valve, purge pump until a vacuum of 500 microns Hg is again reached. Open and backside discharge service valve by turning counterclockwise, which closes discharge gauge port.

12.

Open suction service valve. Charge system with refrigerant to specified limits through suction service valve gauge port. Operate system for 5 minutes at fast idle, check for leaks. No leaks are permissible.

13.

Seal off discharge and suction connection ports of defective compressor.

Seal Assembly Replacement Procedure (Optional, HG 1000 Only): Parts required: Seal Assembly Kit. This assembly includes front seal plate, seal nose and spring assembly, o-ring for front plate and when required, a seal plate retainer and dust shield.

1.

Remove compressor from engine in accordance with procedure under "Changing Compressor," Items 1 thru 4, inclusive. Place compressor on bench with shaft in up position.

2.

Remove hex nut from end of crankshaft and remove flywheel or clutch by use of a 5/8-11 bolt. Do not tap on shaft or clutch.

3.

Wash or clean seal plate and adjoining surfaces of all dirt and foreign material.

4.

Remove shaft key.

NOTE

If the compressor being repaired has a dust shield, carefully remove it to avoid marring the shaft and discard.

5.

Remove seal plate assembly by removing the six bolts in plate and gently pry plate loose, being careful not to scratch, mar, or nick crankcase mating surface or edges.

6.

Remove carbon nose and spring assembly from shaft by a seal puller. When pulling the seal assembly from the shaft, do not scratch crankshaft. If rubber seal around shaft does not come out with carbon nose and spring assembly, remove same with long nose pliers, pulling on edge of grommet.

7.

Remove all gasket material, dirt and foreign material from crankcase mating surface to seal plate, exposed crankshaft, and adjacent surfaces.

8.

Coat exposed surface of crankshaft with clean refrigeration oil. Dip bellows seal assembly and shaft seal washer in clean refrigeration oil. Place bellows seal assembly over shaft with end for holding shaft seal washer going on last. With hand, push bellows seal assembly on shaft to a position beyond taper of shaft. Do not push into seal cavity.

Operator Controls

3-27

Air Conditioner

BI006752-06

Servicing (cont.)

Seal Assembly Replacement Procedure (continued): 9.

Assemble shaft seal washer in bellows seal assembly, assuring before doing so to see that bellow seal assembly and notches in washer line up with the tabs in bellow seal assembly. Cover exposed surface of shaft seal washer with clean refrigeration oil.

10.

Insert new o-ring in crankcase groove on mating surface for seal plate.

11.

Place new front seal plate or seal plate and retainer over the shaft. Properly line up mounting holes with seal and seal plate. When aligned, place plate and seal assembly up against crankcase. Insert the six capscrews and screw in squarely and evenly. Tighten capscrews in a circular sequence to a torque of 6–7.5 ft-lb.

12.

Rotate shaft by hand 15 to 20 revolutions to seat seal. Clean off excess oil.

13.

Install the key. Replace the clutch and tighten the clutch mounting bolt.

NOTE

In general, it is more cost effective to replace the compressor.

Liquid Receiver/Drier - In the event that the system is contaminated, or has lost all its charge, or is down for extensive maintenance, the receiver/drier should be replaced. It is a low cost item and provides a great deal of protection. If the system has lost its charge completely, replacement should be effected immediately prior to final leak testing and charging. This prevents contaminants being drawn into the desiccant and thereby decreasing its capacity.

NOTE

If the system is charged, the refrigerant MUST be recovered into a refrigerant recovery device.

High Pressure and Low Pressure Controls - Follow Maintenance Schedule. If found faulty, replace completely. Do not attempt to repair any part. Connection is via access ports so minimal refrigerant is lost.

Filters - Clean regularly as per Maintenance Schedule with low pressure water or clean compressed air.

Replace if found that they cannot be cleaned.

3-28

Operator Controls

BI006752-06

Air Conditioner

Servicing (Cont.)

DO NOT brush fins of coil with wire brush or irreparable damage will occur. If fins are bent, use a correct coil fin comb to realign them.

Evaporator Coil - Follow Maintenance Schedule. If found that the coil needs cleaning, wash with low pressure, ambient temperature water. Ensure that a baffle is used to prevent any water from being washed into the cabin through the return air plenum. Some detergent may be misted on to assist cleaning.

Setting of TX Valve Superheat & Evaporator Pressure Regulators - The purpose of these devices in the air conditioning unit are as follows: TX Valve - Thermostatic Expansion (TX) Valve - This device has high pressure liquid refrigerant entering and passing through a very small orifice thereby causing a drop in pressure. This lower pressure refrigerant has some 'flash gas' in it, therefore its volume for a given mass increases, and as the same amount of mass is being fed to the evaporator its velocity through the distributor increases, which causes a further pressure drop and more liquid 'evaporation'. This refrigerant then enters the evaporator coil at a much lower pressure and as heat is taken up through the heat exchange surface, evaporation continues, thereby cooling the air and changing the state of the refrigerant from a high density liquid to a low density gas.

Complete evaporation of the liquid must take place prior to the refrigerant leaving the heat exchange coil, as liquid refrigerant at the compressor will cause damage. Refrigerant is incompressible and flushes out bearings. Refrigerant vapor leaving the evaporator coil should be 'superheated'. At the point where the temperature of the refrigerant corresponds to the saturated pressure, the condition is said to be saturated. If the temperature is higher than saturated pressure, the condition is said to be superheated.

Normally around 10 - 11oF (6oC) is considered favorable.

If it is too high, as is the case in an undercharged system, the system loses capacity as the amount of energy to superheat gas is no where near as much as to change the state of the refrigerant from a liquid to a gas. Suction pressures will be low, suction line warmer than normal.

If it is too low, suction pressures will be higher, but coil temperature will also be high, so heat transfer will not be as effective. If it is 'flooding back', the line will be sweaty all the way back to the compressor and the compressor could be noisy.

Operator Controls

3-29

Air Conditioner

BI006752-06

Servicing (Cont.)

Setting of TX Valve Superheat & Evaporator Pressure Regulators (continued) The following table has been provided for your convenience: SATURATED

10oF

TEMPERATURE

SUPERHEAT

SUCTION PRESSURE

psi

kPa

oF

oC

oF

oC

28.4

196

30

-1

40

5

30.0

207

32

0

42

6

31.7

219

34

1

44

7

33.4

230

36

2

46

8

35.1

242

38

3

48

9

36.9

254

40

5

50

11

How to set - Ensure that coils and filters are clean and system fully charged. Run through normal checks and ensure pressures, etc., are within expected levels and no blockages in supply line to TX valve.

Check that the bulb or coil is securely and cleanly clamped to the suction line.

Fit a thermometer probe to the suction line adjacent to the bulb or coil.

Connect up pressure gauge at the EPR port.

Operate the unit under a stable load and calculate the superheat, then adjust the TX valve slowly.

After adjustment, please allow time for the system to stabilize as 'hunting' will occur for some time.

Evaporator Pressure Regulator - This device modulates according to pressure in the evaporator. Its purpose is to keep pressure, and therefore temperature, above a set figure to prevent ice building-up on the coil, and water in the heating circuit from freezing and possible rupture of the water pipes.

If the pressure falls, it will restrict the flow, therefore the evaporator pressure and temperature rise, but the suction pressure to the compressor falls. Operation is reversed if pressure rises.

In normal air conditioning applications, it should be set at 28-30 psi.

How to Set - Once the TX valve has been adjusted to correct superheat the EPR valve can be adjusted by screwing the adjusting screw beneath the knurled cap. The Lp gauge line is left in position.

3-30

Operator Controls

Air Conditioner

BI006752-06

Troubleshooting I. System Produces No Cooling CAUSE

INDICATIONS

REMEDY

Fuse blown or circuit breaker tripped

Electrical components will not operate.

Replace fuse or reset circuit breaker.

Broken or disconnected electrical wire

Electrical components will not operate.

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

Broken or disconnected ground wire

Electrical components will not operate.

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

Clutch coil burned out or disconnected

Compressor clutch inoperative.

Check current flow to clutch; replace if inoperative.

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

Compressor clutch inoperative.

Replace low pressure or high pressure switches or clutch relay.

Blower motor disconnected or burned out

Blower motor inoperative.

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

Loose or broken drive belt

Visual inspection.

Replace drive belts and/or tighten to specifications.

Compressor partially or completely frozen

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

Remove compressor for service or replacement.

Compressor reed valves inoperative

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

Service or replace compressor reed valves.

Expansion valve stuck in open position

Head pressure normal, suction pressure high evaporator flooding.

Replace expansion valve.

Broken refrigeration line

Complete loss of refrigerant.

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

Safety valve

Complete or partial refrigerant loss.

Examine valve on drier.

Leak in system

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

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

Compressor shaft seal leaking

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

Replace compressor shaft seal.

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

High gauge normal or may read high.

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

Repair as necessary.

Mechanical:

Refrigeration:

Operator Controls

3-31

Air Conditioner

BI006752-06

Troubleshooting II. System Will Not Produce Sufficient Cooling CAUSE

INDICATIONS

REMEDY

Electrical: Blower motor sluggish in operation

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

Remove blower motor for service or replacement.

Compressor clutch slipping

Visual inspection.

Remove clutch assembly for service or replacement.

Obstructed blower discharge passage

Blower operates at high speed but air displacement very small.

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

Clogged air intake filter

Insufficient air displacement by blower.

Replace air filter screens and service, or replace if necessary.

Insufficient air circulation over condenser coils; fins clogged with dirt or bugs.

Insufficient cooling at discharge outlet; excessive high pressure gauge reading.

Clean condenser.

Evaporator clogged

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

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

Evaporator pressure regulator defective or improperly adjusted

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

Repair or adjust as necessary.

Insufficient refrigerant in system

Bubbles in sight glass; high gauge readings excessively low.

Test for leaks. Repair as necessary.

Recharge system until bubbles disappear and gauge readings stabilize to specifications.

Clogged screen in expansion valve

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

Expansion valve thermal bulb has lost charge

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

Clogged screen in receiver

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

Excessive moisture in system

Excessive high and low gauge reading.

Lack of cooling.

Mechanical:

Refrigeration:

NOTE

3-32

Purge system; replace expansion valve.

Inspect system for refrigerant overcharge. Correct.

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

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

Operator Controls

Air Conditioner

BI006752-06

Troubleshooting II. System Will Not Produce Sufficient Cooling (cont.)

CAUSE

INDICATIONS

REMEDY

Refrigeration (cont.): Air in system

Excessive high and low gauge reading.

Sight glass shows bubbles or is cloudy.

System contaminated.

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

Evaporator pressure control valve improperly set

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

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

NOTE

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

III. System Cools Intermittently CAUSE

INDICATIONS

REMEDY

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

Electrical units operate intermittently.

Remove defective part for service or replacement.

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

Clutch disengages prematurely during operation.

Check connections or remove clutch coil for service or replacement.

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

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

Mechanical: Compressor clutch slipping

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

Replace expansion valve if excess moisture present, adjust thermostat.

Purge system, evacuate, recharge.

Thermostat defective

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

Replace thermostat.

Stuck regulator valve

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

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

Operator Controls

3-33

Air Conditioner

BI006752-06

Troubleshooting IV. Excessively Noisy System CAUSE

INDICATIONS

REMEDY

Electrical: Effective winding or improper connection in compressor clutch coil

Visual inspection; clutch vibrates.

Replace or repair as necessary.

Loose or excessively worn drive belts

Belts slip and are noisy.

Tighten or replace as required.

Noisy clutch

May or may not slip; noisy when engaged

Remove clutch for service or replacement as necessary.

Compressor noisy

Loose mounting, worn part inside compressor.

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

Loose panels

Excessive rattles during operations.

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

Compressor oil level low

Compressor noisy and lower portion hot to touch.

If oil level low, determine cause of loss.

If correction made, fill with specified oil.

Blower fan noisy; excessive wear in blower motor.

Blower motor noisy.

Remove blower motor for service or replacement as necessary.

Mechanical:

Refrigeration: Excessive charge in system

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

Low charge in system

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

Check system leaks, charge system.

Excessive moisture in system

Expansion valve noisy; suction pressure low.

Replace dehydrator, purge system, evacuate and charge system.

High pressure service valve closed

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

Open valve immediately.

3-34

Operator Controls

BI006752-06

Operator Controls

Operator's Seat

3-35

Operator's Seat

3-36

BI006752-06

Operator Controls

BI006752-06

Section 4

Operating Instructions

Operating Instructions

4-1

Notes

4-2

BI006752-06

Operating Instructions

Pre-Start Checks

BI006752-06

Commissioning A New Machine The rotary blasthole drill will (in most cases) arrive on two trucks. The mast is shipped separate (in most cases) from the drill rig itself. With the drill rig unloaded from the truck and on level and stable ground, the mast will need to be installed. A manufacturer representative will be on hand to make adjustments and settings on a new machine.

Load drill pipe using a crane whenever possible, this is the best and safest method. If a crane is not available when drill pipe is being loaded, follow the procedure in this section titled "Loading Drill Pipe".

Walk Around Checks: It is the responsibility of the operator to report any damage or service problems to the supervisor.

You may wish to develop your own checklist and standard operating procedure, such as starting point, what to look for, etc. Generally, you should check the following areas before start-up, this applies to new and used machines: •

Check around and under machine for leaks. Determine source of leak and have repairs made.

•

Check crawler belts for broken or cracked pads, missing lock pins or bolts, loose track pins and crawler belt tension. Check track rollers for proper lubrication and wear. Check crawler frames for cracks or damage.

•

Check dust curtains for wear and tear.

•

Check for loose or missing bolts. Report any damage and have repairs made.

•

Check connections to air filters, make sure they are tight. Check to see that filter elements are in place.

•

Check radiator and oil cooler hoses for cracks and loose clamps.

•

Check engine vee belts for cracks or other damage.

•

Check engine fuel/water separator if so equipped and drain water.

•

Check all pivot points to be sure they are receiving adequate lubrication.

•

Check fire suppression equipment to be sure they are adequately charged.

•

Check to see that all alarm systems and EMERGENCY STOPS are functioning properly.

•

Check to be sure all safety guards are in place and not damaged.

•

Check engine/pump driveshaft. Check for loose or missing bolts and adequate lubrication.

•

Check all cables for damage or fraying, loose or missing clamps.

•

Check drill bit for wear, broken or missing carbides.

•

Check that all decals and nameplates are in place and are not damaged.

•

Check wiring for damage and loose connections.

Operating Instructions

4-3

Pre-Start Checks

BI006752-06

Pre-Start Checklist Fluid Levels: A.

Radiator Coolant

B.

Batteries

C.

Engine Oil

D.

Fuel

E.

Pump Drive Gearcase

F.

Water Tank

G.

Hydraulic Tank

H.

Compressor Oil Separator Tank

I.

Rotary Drive Gearcase (check with mast vertical)

J.

Winch Gearcase

K.

Track Drive Gearcases

Operator Controls: •

Safety first! Become familiar with all the controls and their functions.

•

Take it slow at first, as the drilling cycle and controls become more familiar, you can gradually increase your speed to the full operating capability of the machine.

•

Accidents happen quickly, which is why you should operate the machine slowly at first, until you are satisfied that you comfortable with all the control functions.

•

Check that all system gauges are operating properly after start-up.

•

Be alert for any unusual noises or smells.

•

Know the location of EMERGENCY STOP devices and fire extinguishers and how they operate (refer to machine locator drawing in introduction of manual).

Fire Extinguisher Specifications: Fire extinguishers shall comply with EN791:1995 paragraph 5.12.2 and EN 3:1975. Each fire extinguisher shall have an agent with a mass of not less than 13.2 lbs. (6 kg). Fire extinguishers shall be suitable for extinguishing both oil and electrical fires.

4-4

Operating Instructions

BI006752-06

Fire Suppression System (optional)

Description The drill can be equipped with an optional fire suppression system.

The system is manually activated by pushing a remote actuator.

There are two actuators, one located in the operator's cab and one outside the machine. Make yourself familiar with the location of the actuators. Location varies on different machines.

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

Fig. 4-0 Fire Suppression System - 30 lb. Tanks with Actuators (3)

Fig. 4-0a Relief Valve

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

Maintenance Make sure the system is in good operating condition. A fire suppression system does little good if it does not work when you need it. Make it a habit of daily inspection of hoses, fittings, and discharge nozzles.

The nozzles should have plastic caps in place to keep out dirt and debris. Make sure the actuators are not damaged and not covered up with clutter. Take care of your system, and it will take care of you.

NOTE

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

Operating Instructions

4-5

Fire Suppression System (optional)

BI006752-06

In Case of Fire Locate nearest remote actuator.

1.

Turn ignition switch off if possible

2.

Pull Ring Pin on actuator.

3.

Push Red Button on actuator.

4.

Get away from machine and call for help.

Fig. 4-0b Pneumatic Battery Cutoff Valve

Fig. 4-0c Remote Actuator in Operator's Cab

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

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

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

•

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

•

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

4-6

Operating Instructions

BI006752-06

Normal Start-Up Procedure

Before starting the engine, warn nearby members of the work crew that you are starting the machine.

DO NOT USE ETHER on engines equipped with an Air Inlet Heater (electrically or fuel ignited manifold heater).

To Start Engine: 1.

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

2.

Place the compressor Start-Run valve (10) in the start position or low position on high pressure machines.

NOTE

DO NOT start the engine if there is pressure in the compressor receiver tank. If the engine has recently been running, this may require an approximate 10 minute wait to allow complete receiver tank bleed down. Starting the engine while there is residual pressure in the receiver tank will result in a significantly reduced life of the diesel engine starter.

3.

Place throttle lever (2) at about 1/3 speed.

4.

Turn the ignition switch (15) On.

NOTE

The engine diagnostic lamp (8) will flash while the engine is cranking. The lamp should turn off after proper oil pressure is reached. If lamp continues to flash after engine is running, the ECM has detected a problem in the system. Refer to engine manual for diagnostic codes.

5.

Push the engine start button (16) until the engine starts, when engine is started, release start button. Do not crank engine for more than 30 seconds, then allow starter to cool for two minutes before attempting to start again.

6.

If temperature is below 32o F (0o C) use the optional ether injection (17) for starting, use caution not to use too much as engine damage can occur. Press button for 3 seconds and release, then allow 3 seconds before starting engine.

Fig. 4-1 Instrument Panel - Right Side 15. Ignition Switch 16. Engine Start Button 17. Ether Injection (optional) 18. Drill Hourmeter 19. Engine Hourmeter 20. Engine Oil Pressure Operating Instructions

4-7

Normal Start-Up Procedure

BI006752-06

Fig. 4-1a Control Panel - Right Side 1. Level 2. Engine Throttle Lever 8. ECM Diagnostic Lamp 10. Compressor Start-Run Valve* (*not shown)

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

1.

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

2.

Check to ensure compressor air pressure is at least 100 PSI (6.9 bar) for low pressure machines or 300 PSI (20.7 bar) for high pressure machines.

Compressor air pressure must not exceed 125 PSI (8.6 bar) for low pressure machines or 350 PSI (24.1 bar) for high pressure machines.

3.

Check entire machine for oil leaks.

Normal Shut Down: 1.

Allow engine to idle for a minimum of five (5) minutes before stopping.

2.

Turn the ignition key to OFF position.

3.

Check machine for any unusual conditions.

4.

Report any defects to your immediate supervisor.

4-8

Operating Instructions

BI006752-06

Ground Level Engine Stop (optional)

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

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

Be sure you know where the ENGINE STOP device(s) are located. These devices are optional, therefore not all machines will be equipped with them.

In the event of emergency shutdown, the operator should notify the supervisor and be sure corrective action is taken to remedy the fault that caused the emergency shutdown, before restarting the machine.

1.

Take necessary corrective action to correct the fault.

2.

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

3.

Check circuit breakers and reset the engine stop device.

Fig. 4-2 Ground Level Engine Stop Button

P61 PLUG REF CAB JUNCTION BOX TERMINAL

7

E-STOP ENGINE KILL SWITCH BLU 16

NC

+BAT (UNSWITCHED)

56

+BAT (UNSWITCHED)

55

REMOTE SHUTDOWN SW

101

BLU 16

+BAT (SWITCHED)

31 27 26

DIAGNOSTIC LAMP

24

THROTTLE POSITION SENSOR

10

8 71

32

54

+BAT (UNSWITCHED)

1

ELECTRICAL SCHEMATIC Fig. 4-3 Electrical Circuit (ref. 426571)

Operating Instructions

4-9

Cold Weather Operation

BI006752-06

Hydraulic System Warm-Up BE SURE machine does not overheat. Observe hydraulic and water temperature gauges.

When pump drive gearbox is disconnected all hydraulic functions are inoperative, including the cooler fan.

1.

For cold weather start, disengage the pump drive gearbox using the lever on the gearbox (if so equipped). Start the engine and warm up for at least five (5) minutes (refer to "Engine Start-Up Procedure" on preceding page).

2.

Stop the engine, engage the pump drive gearbox and restart the engine.

3.

Level the machine.

NEVER ATTEMPT to commence drilling unless the machine has been leveled and is located on stable ground conditions. Machine can turn over, causing serious injury or death.

DO NOT position jacks on cribbing or timber bridging.

DO NOT position machine close to a highwall.

a. Set the throttle at approximately 1600 RPM and lower all jack pads to the ground by operating the rear and front jack control levers to the down position. b. Operate rear right and rear left jack controls to down position until rear of machine track is clear of the ground and approximately level by watching level indicator (refer to "Leveling Machine"). c. Operate the front jack control to down position, until front of machine track is clear of the ground, approximately level.

4. Raising the Mast. a. Be sure the machine is level and solidly stabilized with the leveling jacks before attempting to raise the mast. b. Be absolutely sure that the mast will not come in contact with power lines, telephone lines or any other obstructions.

LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death. Machine is not insulated.

See Section 2 for Clearances from High Voltage Lines chart.

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

4-10

Operating Instructions

BI006752-06

5.

Cold Weather Operation

Hold Rotation Lever to one-quarter speed and operate rotation in forward position.

DO NOT engage or disengage track drive while engine is running and tracks are in contact with ground. Immediate machine damage could result.

Verify right and left tracks are a minimum of 3 in. (76.2 mm) off the ground.

6.

Set Drill/Propel switch to Propel position.

7.

Hold Propel Levers at 1/4 position and operate tracks alternately in both directions.

8.

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

9.

When hydraulic oil temperature reaches 1000 F (37.80 C) the system is operational.

Compressor Warm-Up (Low Pressure) 1.

Run machine with Compressor Start-Run Valve in the Start position until temperature reaches 160o F (71.1o C). After warm-up, turn selector to Run position.

2.

Gradually load compressor by opening air service valve, using the Drilling Air switch until pressure drops to 70 - 80 PSI (4.8 - 5.5 bar). If temperature rises above 210o F (99o C), close air service valve and continue warm-up.

3.

Partially open air service valve, using the Drilling Air switch. If compressor has stabilized at 160oF (71.1oC) it is now operational.

4.

Gradually increase engine speed to 2100 RPM. Compressor pressure should read 100 PSI (7 bar) and temperature should be 160 - 200o F (71.1 - 93.3o C). Temperature should be monitored and maintained by the air flow direction through the cooler.

Operating Instructions

4-11

Cold Weather Operation

BI006752-06

Compressor Warm-Up (High Pressure) 1.

Run machine with Compressor Start-Run Valve (10) Low until compressor temperature reaches 180oF (82.2oC). After warm-up turn selector valve to High position.

2.

Gradually load compressor by opening air service valve, using the Drilling Air switch (43) until pressure drops to 140 PSI (9.7 bar). If temperature rises above 210oF (98.9oC), close air service valve and continue warm-up.

3.

Partially open air service valve, using the Drilling Air switch (43). If compressor has stabilized at 180oF (82.2oC) it is now operational.

4.

Gradually increase engine speed to 2100 RPM. Compressor pressure should read 350 PSI (24.1 bar) and temperature should be 210oF (99oC). Temperature should be monitored and maintained by the air flow direction through the cooler.

Fig. 4-3a Operator Control Panel - left side 10. Compressor START/RUN (low pressure) or LOW/HIGH (high pressure) Valve 43. Drilling Air ON/OFF Switch

4-12

Operating Instructions

BI006752-06

Propelling Machine

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

DO NOT travel on steep slopes or crosswise to grades.

DO NOT propel machine with mast up other than from hole to hole as this causes machine to become unstable.

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

NOTE

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

Fig. 4-4 Operator Control Panel 5a. Right Track Lever 5b. Left Track Lever 48. Drill/Propel Switch

Operating Instructions

4-13

Propelling Machine

BI006752-06

1.

Select Propel mode with the Drill/Propel switch (48).

2.

Engage right and left track propel levers (5a, 5b) together slowly in the required direction of travel.

Propel speed is varied by the degree of travel, forwards or backwards of the propel levers. To propel in a straight line, the propel levers must be operated equally from the neutral positions.

3.

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

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

4.

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

5.

Select Drill mode with the Drill/Propel switch (48).

ALWAYS select Drill mode once propelling functions are finished as Drill mode engages the brakes. Never leave the machine unattended unless Drill/Propel switch is in the Drill mode. Failure to follow these procedures could result in personal injury or property damage.

Propelling Up, Down and Across Grades: 1.

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

2.

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

3.

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

4.

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

5.

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

4-14

Operating Instructions

BI006752-06

Propelling Machine

Propelling Over Electrical Cables: 1.

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

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

2.

If no approved crossing point exists, then the following procedure should be used to cross electric cables: a. Use a spotter to help guide you. Approach the cable at 90o and stop machine when cable is between the jack pads and the tracks. b. Carefully lower jacks, making sure the jack pads will not rest on the cable. Raise machine upon the jacks until tracks are clear of the ground. c. Move cable under tracks until it is between the opposite end of the tracks and jack pads at the other end of machine. d. Carefully lower machine, making sure cable is not under tracks and retract jacks fully before continuing to propel machine.

Fig. 4-4 Operator Control Panel 5a. Right Track Lever 5b. Left Track Lever 48. Drill/Propel Switch

Operating Instructions

4-15

Leveling Machine

BI006752-06

Leveling Machine NEVER ATTEMPT to commence drilling unless the machine has been leveled and is located on stable ground conditions. Machine can turn over, causing serious injury or death.

DO NOT position jacks on cribbing or timber bridging.

DO NOT position machine close to a highwall.

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

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

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

Refer to leveling procedure on following page.

Lowering Machine (raising jacks) When lowering machine, lower the front (radiator end) of the machine first, keeping jack pads close to the ground. When tracks are on the ground and machine is stable, jacks may be raised fully. Refer to leveling procedure on following page.

Fig. 4-5 Control Console - Right Side 1. Level 3c. Left Rear Jack 3a. Right Rear Jack 4. Mast Lever 3b. Front Jacks

4-16

Operating Instructions

BI006752-06

Re-Leveling Machine

Leveling Procedure 1.

Using the Rear Jack levers (3a & 3c), extend the jacks to contact the ground. Level the rear (cab end) of the machine using the Level Indicator (1) as your guide.

NOTE

Front jacks must be lowered AFTER using rear jacks to level machine. This is to ensure equal hydraulic pressure in both front jacks.

2.

Using the Front Jack Lever (3b), lower the jacks until they contact the ground. Level the front (radiator end) of the machine.

3.

Level machine as near to level as possible.

ALWAYS keep the machine as low to the ground as possible when leveling the machine.

This machine has safety check valves in the leveling system to prevent the jacks from moving in the case of a power failure. Should it be noticed that the jacks are creeping, the machine should not be operated and repairs completed immediately. Failure to follow these instructions could lead to serious personal injury or equipment damage.

4.

To raise the jacks (lower machine), move Jack Lever (3b) to the raise position to lower the front (radiator end) of the machine. Move Jack Levers (3a & 3b) to the raise position to lower the rear (cab end) of the machine. Rear jacks may be raised individually or together.

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

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

Re-Leveling Procedure If machine has been leveled and is up on all four jacks and you need to re-level the machine, use the following procedure (refer to fig. 4-5 for leveling jack controls): 1.

Level the rear (cab end) of the machine first using levers 3a and 3c.

2.

Level the front (radiator end) of the machine using lever 3b even if it appears level. This MUST be done to equalize the hydraulic pressure to the front jacks.

Operating Instructions

4-17

Raising Mast

BI006752-06

LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death. Machine is not insulated.

Refer to Clearances from High Voltage Lines chart below.

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

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

Clearances from High Voltage Lines Voltage Minimum Clearance up to 50 kv 10 ft. (3 m) over 50 to 75 kv 11 ft. (3.4 m) over 75 to 125 kv 13 ft. (4 m) over 125 to 175 kv 15 ft. (4.6 m) over 175 to 250 kv 17 ft. (5.2 m) over 250 to 370 kv 21 ft. (6.4 m) over 370 to 550 kv 27 ft. (8.2 m) over 550 to 1000 kv 42 ft. (12.8 m)

1.

Level the machine.

2.

Check mast for loose drilling tools or parts.

3.

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

4.

Raise mast by engaging the Mast Lever (4) to the raise position. The mast should start to lift; if not, check the auxiliary hydraulic pressure gauge to see if any other functions are engaged.

5.

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

6.

The mast angle may be set from 70 degrees to the vertical depending on drilling applications.

7.

Once the mast has been set at the desired angle, lock the mast into position by pushing the Mast Lock/Unlock Switch to the Lock position. Always visually check to be sure the mast lock pins are fully engaged into the mast lock brackets.

4-18

Operating Instructions

BI006752-06

Lowering Mast

LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death. Machine is not insulated.

Refer to Clearances from High Voltage Lines chart below.

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

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

1.

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

2.

Rotate the drill pipe loader to the stored position and swing the loader into the center of the mast.

3.

Unlock the mast by pushing the Mast Lock/Unlock Switch (fig. 4-6) to the Unlock position.

4.

Lower the mast by engaging the Mast Lever (4) to the Lower position, controlling the lowering speed with the mast lever.

MAST LOCK

Fig. 4-6

Drill Function Panel - Mast Lock Switch

Fig. 4-5 Control Console - Right Side 1. Level 3c. Left Rear Jack 3a. Right Rear Jack 4. Mast Lever 3b. Front Jacks

Operating Instructions

4-19

Loading Drill Pipe

BI006752-06

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

Equipment Required: 1.

Service truck with service winch capable of lifting male end of pipe above the drilling platform of the machine.

2.

Adequate lifting straps.

Procedure: 1.

Be sure machine is on level and solid ground.

2.

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

Switch hoses if necessary. Check fluid level in rotary gearbox.

3.

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

4.

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

5.

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

6.

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

7.

Raise the rotary head up the mast with the pipe, but do not let the pipe go above the deck bushing in the mast base. It is also a good idea to use the pipe support if you have an angle hole machine.

8.

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

9.

Repeat steps 3-8 for the remaining pipe sections.

Installing and Removing Drill Bit Before drilling can commence, you must first install the drill bit sub and the drill bit.

1.

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

2.

Place the drill bit into the bit basket.

3.

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

4.

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

5.

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

6.

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

7.

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

4-20

Operating Instructions

BI006752-06

Drilling Procedures

LOOK UP before raising or lowering mast. Operating near, or coming in contact with electrical power lines will result in serious personal injury or death. Machine is not insulated.

Refer to Clearances from High Voltage Lines chart in Section 2.

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

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

Fig.4-7 Drilling Controls C. Rotary Torque Control 6. Rotation Lever 7. Hoist/Pulldown Lever 9. Pulldown System Pressure Control 9a. Holdback System Pressure Control 14a. Water Injection Flow Control 26. Rotation/Left Track Pressure Gauge

Operating Instructions

27.

28.

29.

35.

43.

44.

Pulldown Pressure Gauge Hydraulic System Pressure Gauge Drilling Air Pressure Gauge Water Injection/Dust Collector Switch Drilling Air Switch Pulldown System (Auto Feed) Switch

4-21

Drilling Procedures

BI006752-06

Drilling with Standard Bit (refer to fig. 4-7) The machine MUST be level and up on all four jacks BEFORE the mast is raised. Once the drill pipe, bit sub, and drill bit have been coupled up, drilling operations are ready to commence.

1.

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

2.

Zero the drill monitor, if equipped.

3.

Turn on the drilling air by switching the Drilling Air switch (43) to the ON position. Note the air pressure on the Drilling Air Pressure Gauge (29).

4.

Start rotating the drill string forward slowly (30-40 RPM) using Rotation Lever (6). Forward rotation is clockwise.

5.

Slowly lower the drill string using Pulldown Lever (7) until the drill bit is firmly collared in the drill hole (about 2 - 3 ft.[0.6 - 0.9 m]). Collaring of the hole should be done slowly and carefully to ensure that the hole will be straight.

6.

Once the hole is collared, engage the Auto Feed (44) by pushing the switch down to the engage position, then start increasing the Pulldown Pressure (9) and rotation speed until a satisfactory rate of penetration is achieved. Pulldown pressure and rotation speed will be dictated by the type of ground being drilled. Refer to Section 5 - Drilling Practices for more information. Adjust Rotary Torque Control (C) as needed.

NOTE

Applying excessive weight or using too fast of rotation speed will result in damage to the drill bit.

7.

Watch the air and rotation pressure gauges while drilling. If a rise in pressure is noted, gently push the Hoist/Pulldown Lever (7) back towards the hoist position just enough to take weight off the bit, then move back to original position. Repeat as necessary until drill string "sounds right" for normal drilling.

8.

If dust suppression is required, either the dust collector or water injection systems may be used.

Switch Water Injection/Dust Collector Switch (35) Down for dust collector, Up for water injection.

Adjust water flow for water injection with Flow Control Valve (14a).

NOTE

9.

Drill down until the desired depth of the hole is reached, then disengage the Auto Feed Switch (44) and start raising the drill string out of the hole using the Hoist/Pulldown Lever (7). As the drill bit approaches the top of the hole, turn off the air and stop rotating the pipe. Lift the drill bit clear of the ground, high enough to allow good clearance when moving to the next hole.

NOTE

4-22

Do not use the dust collector if ground water is encountered. Excessive water injection will reduce drill bit service life.

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

Operating Instructions

BI006752-06

Drilling Procedures

Drilling with a Down-the-Hole Hammer (refer to fig. 4-7) ALWAYS check bit manufacturer's literature for proper bit size, safety, operation and maintenance information.

It is the responsibility of the operator to be sure they understand the proper operating procedures supplied by the bit manufacturer.

The manufacturer will not be responsible for equipment damage due to improper use or misapplication of down-the-hole hammer equipment.

The following is a general guideline for drilling with down-the-hole hammers. Always refer to manufacturer's specifications for correct application and specific drilling procedures.

Preparation 1.

Tighten all joints to recommended torque by bit supplier.

2.

Use proper size choke in the rigid valve (according to manufacturer's specifications) before tool is operated.

3.

Always use the largest diameter bit first, and if necessary, follow with the next smaller diameter bit.

Never use the bit to ream; this will damage the carbides.

4.

Place driver sub over bit, followed by o ring and bit retainer ring. Screw the driver sub/bit assembly into the piston case hand tight before using power make-up. Use slow rotation to tighten to the recommended torque provided by the bit supplier.

Start Up 1.

Be sure the lubricator is working properly and oil has fully coated the drill pipe inside diameter.

2.

Turn on Drilling Air switch (43) and rotate slowly.

3.

Lower the tool slowly into the hole until the bit contacts the bottom and the piston starts operating.

Add just enough pressure to start breaking rock.

ALWAYS apply air and start rotation before putting weight on bit to avoid damage to bit.

4.

As the bit starts breaking rock, apply minimum total weight on bit (refer to manufacturer's specifications).

5.

After drilling a few feet, increase weight on bit until the tool runs smoothly. The air pressure will rise slowly and then stabilize.

NOTE

Additional weight on bit will not increase penetration rate appreciably.

Operating Instructions

4-23

Drilling Procedures

BI006752-06

Drilling with a Down-the-Hole Hammer (cont.)

Total Weight On Bit It is important that the minimum weight on the bit be maintained throughout the hole depth. As the hole gets deeper and pipe sections are added the holdback pressure control (9a) must be turned IN (clockwise) to decrease pressure on the bit to compensate for the added weight of the drill pipe.

NOTE

When reading the pulldown pressure gauge (27), remember this is hydraulic pressure and not weight in actual pounds (see bit manufacturer's specifications for minimum total weight on bit).

Fig. 4-7 Drilling Controls C. Rotary Torque Control 6. Rotation Lever 7. Hoist/Pulldown Lever 9. Pulldown System Pressure Control 9a. Holdback System Pressure Control 14a. Water Injection Flow Control 26. Rotation/Left Track Pressure Gauge

4-24

27.

28.

29.

35.

43.

44.

Pulldown Pressure Gauge Hydraulic System Pressure Gauge Drilling Air Pressure Gauge Water Injection/Dust Collector Switch Drilling Air Switch Pulldown System (Auto Feed) Switch

Operating Instructions

BI006752-06

Drilling Procedures

Back Pressure When a pneumatic tool is operating near the surface, it is exhausting directly to atmosphere and is producing the maximum horsepower for a given inlet pressure. If any positive pressure above atmospheric pressure (back pressure) is encountered at the exhaust, the tool's efficiency will be reduced.

As the hole is drilled deeper, back pressure is constantly increasing, therefore blow energy will be reduced.

To compensate for this reduced efficiency, it is necessary to increase air pressure at the inlet. Increase the inlet pressure until normal drilling rate is obtained.

Rotation Speed •

Proper rotation speed is important for long bit life and good penetration.

•

Refer to manufacturer's bit size vs. rotation speed specifications.

•

Recommended Rotation Speed Range:

•

Use slower rotation for hard abrasive formations.

•

Use faster rotation for softer, less abrasive formations.

•

The bit should penetrate about 3/8 in. (9.7 mm) per tool revolution (except for bits 10 in. (254 mm) diameter and larger).

5–60 RPM

For example: If the rate of penetration is 50 ft. (15.25 m) per hour, the RPM should be about 25. RPM is about one-half of the penetration rate in feet per hour.

•

Adjust the rotation to obtain the best drilling rate and to minimize wear on the bit.

Water or Foam Injection During drilling operations, water or foam injection can be beneficial in some applications.

•

Reduces dust damage to drilling equipment on the surface.

•

Reduces dust inhalation of the drilling personnel.

•

Reduces temperature of the compressed air, preventing close fitting parts from seizing or galling.

•

Helps clean the drilled hole when the formation is producing small amounts water.

The following are helpful hints when using water or foam injection: 1.

Increase the oil injection rate when water or foam is being used.

2.

Test water periodically to assure the proper pH factor. Water with a pH of less than 10 will cause corrosion on steel parts.

3.

Insure that water being used is free from solids contamination.

4.

Upon completion of each hole or any time tool is not being used for three or more hours, clean the tool and the drill pipe by blowing lubricated air through the system.

5.

Water or foam injection will cause the tool to corrode if the tool is not properly maintained. Follow bit manufacturer's maintenance procedures to assure long bit life.

Operating Instructions

4-25

Drilling Procedures

BI006752-06

Drilling with a Down-the-Hole Hammer (cont.)

Suggested Operating Procedures 1.

Maintain good pulldown pressure on the tool and insure that the hole is being cleaned.

2.

Small amounts of water may form mud and partially block the hole. Inject about 1-4 GPM (3.8 - 15 l/min) of water into the air stream during drilling (see manufacturer's specifications for tool size vs. water injection rate).

If the tool starts drilling extremely fast, the pulldown system may not be capable of maintaining the recommended weight required on the bit. The piston will strike the bit when it is not against the rock face, causing severe damage to the bit. Every effort must be made to avoid this condition.

3.

If there is a drop off in the size and volume of cuttings or an air pressure build-up while the tool is operating at a normal rate, raise the tool without turning off the rotation. Work the tool up and down to assure that the tool and pipe are free and the hole is clean before continuing to drill.

4.

Cracks in the formation may cause the tool to bind in the hole. Raise the tool, clear the hole with air and work the tool up and down to assure the tool and pipe are free, before continuing to drill.

Rotate slowly and feed the tool down the hole slowly to resume drilling.

5.

If the top of the hole craters and cuttings and debris fall into the hole, install a short length of casing into the hole. Allow the casing to extend about 6 in. (152.4 mm) above the surface and pack rags, clay or dirt around the outside of the casing.

6.

When rotation stops, the tool will continue hammering until it is raised up off the bottom. If the tool is not raised up off the bottom, the bit carbides will become buried in the formation. Severe damage to the bit can occur if rotation is resumed without first raising the tool up off the rock surface.

7.

Very rough rotation can be caused by a dull bit or in certain rock formations.

8.

If tool fails to function properly, refer to manufacturer's service and troubleshooting information.

4-26

Operating Instructions

BI006752-06

Multiple Pass Drilling

Adding Drill Pipe (refer to fig. 4-7) 1.

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

2.

Disengage the pulldown system by switching Auto Feed Switch OFF. Stop rotation with Rotation Lever (6).

3.

Lift the drill string and align the flats on the drill pipe with the deck wrench. Turn Dust Suppression Switch OFF, engage Deck Wrench with switch onto pipe, and turn Drilling Air Switch OFF.

4.

Using reverse rotation, break the thread joint and undo the threads slowly, simultaneously raising the rotary head clear of the bottom threads.

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

5.

Apply thread grease to the drill pipe threads by pressing Drill Stem Thread Lube Switch.

6.

Raise the rotary head to the top of the mast with Hoist/Pulldown Lever (7).

7.

Swing the drill pipe loader into position using the Pipe Loader Swing Switch. A drill pipe should now be located under the rotary head. If not, you will need to rotate the loader to align the next pipe.

To Rotate Drill Pipe Loader a.

Unlock the pipe loader by switching the Drill Pipe Loader Lock Switch to UNLOCK.

b. Index the pipe loader to the next position by using the Pipe Loader Rotate Switch. Once in position, lock the loader by switching the Drill Pipe Loader Lock Switch to LOCK. 8.

Lower the rotary head slowly onto the drill pipe, once the head engages the drill pipe thread, stop lowering the head. Slowly engage forward rotation, keep rotating until the thread joint becomes tight, which is indicated by an increase in rotation pressure as seen on the Rotation Pressure Gauge (26).

ALWAYS tighten the drill pipe joints in the pipe loader.

9.

Lift the drill pipe clear of the holder on the pipe loader and swing the loader out to the drilling position using the Drill Pipe Loader Swing Switch.

10.

Lower the drill pipe until it engages with the pipe in the deck wrench. Slowly rotate the drill pipe in the forward direction until the joint becomes tight, which is indicated by an increase in rotation pressure as seen on the Rotation Pressure Gauge.

11.

Retract the deck wrench, using the Deck Wrench switch. You are now ready to resume drilling.

Operating Instructions

4-27

Multiple Pass Drilling

BI006752-06

Retracting Drill Pipe (refer to fig. 4-7) 1.

Once the desired hole depth is reached, turn the Auto Feed switch OFF and raise the rotary head with the Hoist/Pulldown lever (7) until the drill pipe thread joint is above the deck wrench.

2.

Turn the Water Injection/Dust Collector Switch and Drilling Air switch OFF.

3.

Align the flats on the lower drill pipe with the deck wrench, the flats should be approximately 2 inches above the deck wrench. Engage the deck wrench on the flats of the drill pipe using Deck Wrench switch.

4.

Slowly place the Rotation lever (6) into reverse and allow the rotation pressure to increase until the drill pipe joint breaks loose.

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

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

5.

Once the pipe joint is broken loose, continue reverse rotation and simultaneously raise the rotary head with the Hoist/Pulldown lever (7) until the threads are disengaged. Stop rotation.

6.

Raise the drill pipe until the bottom of the drill pipe will clear the drill pipe holder when the loader is swung into the center of the mast.

7.

Align the flats on the drill pipe to the same position that would be required to engage the deck wrench.

8.

Swing the pipe loader into the center of the mast with the Drill Pipe Loader Swing switch, ensuring that the drill pipe goes into the pipe loader easily. Do not force the drill pipe into the pipe loader.

9.

Once the loader is in position, lower the drill pipe into the holder, stop the pipe approximately 2 in.

(50.8 mm) from the bottom of the holder.

10.

Slowly place the Rotation lever (6) in reverse, allowing the rotation pressure to increase until the top joint breaks, which can be identified by a decrease in rotation pressure. Once the joint breaks, continue reverse rotation until the drill pipe drops into the holder.

NEVER use excessive force when breaking joints. Make sure loader locking pin is locked before attempting to break joints. Make sure drill pipe is properly secured in loader.

11.

Once the rotary head is disengaged from the drill pipe, raise the rotary head at least 8 in. so it will clear the top of the drill pipe.

12.

Swing pipe loader to the drilling position. Use Drill Pipe Loader Rotate switch to rotate carousel to the next position if required.

13.

Lower rotary head to the drill pipe in the deck wrench using the Hoist/Pulldown lever (7). Use the Fast Down switch to increase the lowering speed of the rotary head. Use forward rotation to engage and tighten to full rotation pressure to ensure joint will remain tight.

14.

Repeat items 3-13 until all pipes have been removed.

4-28

Operating Instructions

BI006752-06

Section 5

Drilling Practices

Drilling Practices

5-1

Drilling Terminology

BI006752-06

A.P.I. Thread American Petroleum Industry Standard type thread. Pulldown The amount of weight that is being applied to the bit.

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

Stabilizers are used to reduce possible hole deflection.

Bit Basket Used to hold the drill bit when adding or removing Substitutes (Subs) the bit.

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

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

T.C.I. Bootleg Tungsten Carbide Inserts, used on Tri-Cone roller The portion of the borehole remaining after the blast. bits.

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

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

Down-The-Hole Hammer A pneumatically operated bottom-hole percussion drill that is rotated mechanically by the drill rig.

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

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

U.H.V. Up Hole Velocity, is the speed at which the drill cuttings are being blown out of the hole, this speed is usually referred to in feet per minute.

Drill Bit Water Injection Drill bits are used to break the rock by a chipping or Used to help with dust suppression and aid hole cutting action cleaning.

Drill Pipe Drill pipe is used as a modem to rotate the drill bit, transfer force to the drill bit and to pass air or water to the bit to aid in hole cleaning.

Dust Collector Used to control dust exiting the drill hole.

Nozzles Orifices in the bit used to control air flow and pressure.

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

5-2

Drilling Practices

BI006752-06

Bit Weight & Rotary Speeds

Many variations in formation characteristics can affect the weight on bit and rotary speed requirements.

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

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

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

PULLDOWN FORCE CALCULATION Bit Diameter = 7- 7/8" 7.875 x 3500 = 27,562.5 Pounds Force 7.875 x 7000 = 55,125 Pounds Force The rotary blasthole drills utilize hydraulic pressure to exert pulldown force on the drill bit; this pressure is indicated on the pulldown system pressure gauge. However, the pressure readings on this gauge indicate hydraulic pressure only and must be converted into actual Weight on Bit (pounds force) per square inch of drill bit diameter.

Check with your bit supplier for optimum drilling efficiency operation.

Laboratory experiments have shown that uniform rock formations, when drilled with rotary drill bits react as follows: 1. Penetration rate is at least directly proportional to the weight on bit.

2. Penetration rate is directly proportional to the rotary speed.

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

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

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

Drilling Practices

5-3

Bit Weight & Rotary Speeds

BI006752-06

(cont.)

In hard formations, it is necessary to use higher pulldown pressures to overcome the compressive strength of the rock formation. The operation of tri-cone roller bits in hard rock is complicated by the sliding and skipping of the bit cutters as the rock breaks away unevenly. Failure to get complete clearing of the drill cuttings becomes a larger problem when high rotation speeds are used.

The use of excessive rotation speeds can cause increased abrasive wear and create shock loads too great for the drill bit, pipe and drill rig. Therefore, there may be little advantage in increasing rotary speeds above recommended levels. Smooth vibration free drilling produces holes most efficiently and possible gains from high rotation speeds may need to be sacrificed to get a constant rate of penetration and economical bit life.

5-4

Drilling Practices

BI006752-06

Rotary Drill Bits

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

Drag or Blade Bits

2.

Tri-Cone Roller Bits

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

Thrust "Weight on Bit"

2.

Torque "Rotation"

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

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

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

Advantages of Drag Bits 1.

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

2.

High penetration rates in soft formations.

3.

Good penetration of difficult formations such as clay.

Disadvantages of Drag Bits 1.

Shorter service life than tri-cone bits.

2.

Not good for drilling hard formations.

3.

Unstabilized drag bits are prone to drill crooked holes.

Drilling Practices

5-5

Rotary Drill Bits

BI006752-06

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

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

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

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

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

Tri-cone bits are fitted with air tubes and nozzles which allow air to pass through the bit. The air tubes are designed to allow air to pass through the bit. The air tubes are designed to allow air to flow through to the bit bearings, the air then aids in cooling and cleaning the bearings.

The bit nozzles allow the main volume of air to flow through the bit for cleaning the cuttings from the hole.

These nozzles are designed so that different sized orifices can be installed for different drilling conditions.

To make sure air gets down to the bearing air tubes, ensure a certain amount of working air pressure at the bit face. Change this pressure by changing the size of the nozzles, which might be needed if the drilling conditions get softer. The orifice size would probably need to be increased to allow more air to pass through the bit for better hole cleaning.

Advantages of Tungsten Carbide, Tri-Cone Roller Bits 1.

Four to Ten times more footage per bit than conventional hard formation steel tooth bits.

2.

The penetration rate will usually equal or exceed that of conventional hard formation bits.

3.

Higher feed pressures can be used in hard formations.

4.

Bits can be used in both soft and hard formations.

Disadvantages of Tungsten Carbide, Tri-Cone Roller Bits 1.

More expensive than conventional bits.

2.

Generally not good for drilling clay formations.

5-6

Drilling Practices

BI006752-06

Rotary Drill Bits

Tri-Cone Roller Bits (cont.)

Tungsten carbide bits may cost more than steel tooth bits and economics must be considered when choosing the correct bits for each application and should enter into your decision when to use them.

All tungsten carbide bit designs incorporated the use of compacts in the gauge surface or the cones, and varying combinations of compacts and hard facing on the gauge surface of the bit leg to provide increased resistance to abrasive wear.

When the formation is relatively uniform, these bits characteristically drill at a constant penetration rate throughout their life.

Sufficient weight must be applied to the bit to produce an effective chipping-crushing action of the formation. However, you should be aware that weights in excess of "sufficient" are not necessarily economical, as they may result in breakage of the compacts as well as reducing the life of the bearings.

Normally the weights used on tri-cone roller bits range from 3,500 to 7,000 pounds per inch of bit diameter with rotary speeds varying up to 200 revolutions per minute.

Drilling Practices

5-7

Rotary Blast Hole Drill Strings

BI006752-06

Drill Pipe Drill pipe is used as a modem to transfer rotation to the drill bit and to convey air to clean the cuttings from the hole.

Blast hole drill pipe is selected to suit the diameter of the hole being drilled, the pulldown and hoisting capacity of the machine, and up-hole velocity requirements to clean the hole.

Standard drill pipe is designed to be run in tension. Drill pipe run in tension is held relatively straight, bending and wear are therefore kept to a minimum. However, Blast Hole rigs apply pressure to the bit through the pull-down system on the machine.

Since blast hole pipe is run in compression it must be made from heavy wall tubing to resist forces which not only may be high, but are also changing rapidly. The pipe must continue to do this in spite of abrasive wear and continual bending stresses. Drilling operations often place great stresses on the drill string, therefore the drill pipe must be manufactured to the highest degree to achieve the ultimate service life.

Periodic inspections should be made of the condition of your drill pipe and should include the following items: 1.

Outside diameter measurement of pipe.

2.

Check welded joints for cracks or excess wear.

3.

Check threads for excessive wear or galling.

4.

Check pipe for bends or eccentric joints.

Fabricated Drill Pipe Blast hole drill pipe design features tool joints made from steels selected specifically for the application and heat treated to obtain optimum strength and toughness.

The tool joints are designed with long tangs that are internally tapered, which enables them to be forced or shrink fitted to the tubing and then welded. Wrench slots or flats are milled to suit the break-out requirements of the drill.

5-8

Drilling Practices

BI006752-06

Rotary Blast Hole Drill Strings

Pipe Threads There are many different types of threads available for drill pipe connections most of which are not acceptable for blast hole drilling because of their vulnerability to damage from excessive forces to the drill string in blast hole drilling.

The two most commonly used threads are: 1.

A.P.I. Regular (American Petroleum Industry Standard)

2.

BECO style thread

With the increase in demand for efficient, economical blast hole drilling, it was observed that several factors caused greater thread wear on blast hole drills.

1.

The drilling of multiple pass holes demands frequent pipe changes. This increased frequency greatly contributes to thread wear.

2.

The coupling of the rotary head to a drill pipe in the pipe loader often occurs at an elevation high in the mast, affording very poor visibility to the operator. This operation is often done by feel and cross threading is not an uncommon result.

3.

Thread loading during joint make-up should be instrument controlled. The rotary head used on blast hole drills can generate very high torque and the skills of the operator usually determines the actual magnitude of the axial forces used. A careless operator can destroy the threads if care is not exercised.

4.

All drill pipe that operates in compression has the tendency to bend and rub on the walls of the hole. These bending forces also act on the threads which increases the possibility of cracks, breaks and tool joint failures.

A.P.I. Regular Threads Field experiences have shown that the normal A.P.I. Regular threads have displayed less than satisfactory life under the above conditions. The majority of drill bits are provided with A.P.I. Regular pins, but since bit changes are less frequent than pipe changes, thread wear is less, making the A.P.I. Regular threads acceptable for bit connections.

BECO Threads The primary feature of the BECO thread series is that 2 threads per inch pitch is utilized. This coarser thread survives much better under adverse conditions. The coarse threads are stronger, less susceptible to damage, more tolerant of wear and easier to loosen from a tight condition. Since the incorporation of the BECO thread system in the early 1960's, the thread has become an unofficial world wide standard for drill pipe used in rotary blast hole drilling operations.

Drilling Practices

5-9

BI006752-06

Rotary Blast Hole Drill Strings

1 API Box Thread

2

API Thread BECO Thread 3 Sub Length Measured Shoulder to Shoulder

4 5

Pipe Length Measured Shoulder to Shoulder

6

Bit Sub Length Measured Shoulder to Shoulder

9

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Rotary Head Spindle Shock Sub Crossover Sub Top Sub Drill Pipe (Rod) Bit Sub Bit Basket Deck Bushing Tri-Cone Drill Bit

7

8

10

Basic Drill–Basic Design Features and Make-up

5-10

Drilling Practices

BI006752-06

Rotary Blast Hole Drill Strings

Thread Grease Precision machined threads and shoulders must be protected from damage. Threads are subjected to a lot of abuse, therefore it is imperative that they are inspected and greased regularly. Prior to each use, clean and visually inspect each pin and box for thread and shoulder damage. Check carefully for galls, burrs, scratches and particularly for cracks. Clean or repair if necessary. Use a zinc, lead or copper based lubricant that is recommended for rotary connections and apply thoroughly to all thread and shoulder surfaces. Ensure grease is clean and free of dust and debris.

Substitutes Substitutes (subs) or adapters are used where threads of one size or type must be coupled with threads of another size or type. They are also used at points of heat wear to provide readily replaceable threads.

Changes in drill pipe diameter must occur gradually. Subs should be gently tapered.

Drill Bit Stabilizers Drill bit stabilizers are used to reduce possible hole deflection and to ensure that the drill bit runs concentrically (evenly in the center of the hole) about its axis and thereby optimizes bit life and penetration rates.

There are two main types of stabilizers available, blade and roller. Blade stabilizers have fixed wings that have been either hard faced or mounted with tungsten carbide inserts. Roller stabilizers are mounted with replaceable rollers which are built up with a special tungsten carbide weld and held in place by long lasting non grease bearings.

Advantages of Blade Type Stabilizers 1.

Generally cheaper.

2.

May use replaceable wear bars for rapid rebuilding.

3.

Can use replaceable sleeves.

Disadvantages of Blade Type Stabilizers 1.

Require rebuilding for each new drill bit.

2.

Have relatively high torque requirements.

3.

In hard ground they may provide little stabilization after the first couple of holes.

Advantages of Roller Type Stabilizers 1.

Lower torque requirements than blades.

2.

Better stabilization.

3.

Generally give more economical life.

4.

Throw away or replaceable rollers.

Disadvantages of Roller Type Stabilizers 1.

High purchase cost.

2.

Expensive replacement of parts

Drilling Practices

5-11

Compressed Air

BI006752-06

Compressed air is the most common method used with blast hole drills for clearing chips from the hole. The advantages of drilling blast holes with compressed air are fast chip removal, and that holes are normally left dry.

In some circumstances a controlled amount of water or foam can be injected into the air stream to aid chip removal, enhance hole stability and control dust problems.

Chips not cleared immediately will be broken into smaller pieces. Secondary breaking wastes energy and increases bit wear.

Air Requirements In rotary blast hole drilling we must always be concerned with delivery of air in sufficient volume and at the proper pressure to assure optimum bit life when drilling with recommended bit weight and RPM. Sufficient air volume should be provided to produce an up-hole velocity of 4,000 to 6,000 feet per minute ( 1220 to 1830 meters per minute).

Up-Hole Velocity Calculations Cubic Feet Per Minute: Velocity =

Free Air CFM x 183.4 (D - d2) .7854 in inches 2

D = Bit Diameter

5-12

d = Drill Pipe Diameter

Drilling Practices

BI006752-06

Drilling Related Problems

The majority of drilling problems originate from errors in judgement or simply from making a bad decision. Drilling problems generally offer several courses or action to overcome the drilling problem, therefore we must make a decision to try another method of operation to rectify the problem. Drilling decisions often avert or accelerate the complex drilling difficulties which we refer to as drilling problems.

EXAMPLE: a.

A decision may be made a long time before the problem is evident, like deciding to use inadequate up hole air velocity. This may lead to slow, inefficient drilling or stuck drill strings.

b.

Or the decision can bring immediate problems, like a decision to increase the pulldown pressure may result in premature failure of the drill bit.

During drilling operations every action taken may have consequences. Operators must recognize that their job involves a continuous sequence of making decisions and the quality of these decisions determines the quality of the operator's performance.

Drilling consists of a continuing sequence of: 1.

Being aware

2.

Interpreting indicators or messages

3.

Making decisions

4.

Monitoring results

Many drilling problems are revealed to the operator by an indicator. This indicator can take almost any form (e.g.: a reduction in the volume of drill cuttings being cleared from the hole). This may not be a problem in itself, but it could be an indicator of a problem developing down the hole, therefore if the operator knows the indicators, they are then made aware of the pending problem.

Human Error Problems These problems have a direct and usually short term connection with a decision (e.g.: The operator decides to try and drill one more hole with a badly worn bit before changing the bit).

Operational Related Problems These problems are connected with the failure of the drilling equipment (e.g.: Engine fails while drill string is in the hole, possibly leading to the drill string becoming stuck while engine is repaired).

Formation Related Problems Some formations present problems that are not readily solved using the available drilling equipment or skills (e.g.: Swelling ground formations due to high levels of ground water). These situations should be viewed as a challenge rather than a problem.

Drilling Practices

5-13

Operating Problems and Indicators 1.

BI006752-06

Drill Bit Penetration Slows or Stops This is a statement of an indicator rather than a problem. The solution depends on the correct diagnosis of the problem, which could be:

2.

a.

Formation Change

b.

Drill Bit Blocked Up

c.

Incorrect Bit Type

d.

Dull Drill Bit

e.

Incorrect Pulldown Pressure or Rotary Speed

f.

Inadequate Hole Cleaning

High Drill String Torque Excessive drill string torque is also an indicator of a pending problem, some of which might be:

3.

a.

Excessive Pulldown Pressure

b.

Inadequate Hole Cleaning

c.

Crooked Hole

d.

Damaged or Badly Worn Drill Bit

Drill String Vibration This itself often seems like a problem, but the true problem usually lies in the reason for the vibration, some of which are:

4.

5-14

a.

Incorrect Rotary Speed

b.

Bent Drill Pipe

c.

Eccentric Drill Pipe Joints

d.

Incorrect Drill Pipe to Hole Size

e.

Crooked Hole

f.

Worn Deck Bushing or Stabilizer

Stuck Drill Pipe a.

Inadequate Hole Cleaning

b.

Crooked Hole

c.

Faulty Formations

Drilling Practices

BI006752-06

Solving Drilling Problems

1.

Recognize the problem. The operator must be aware of the small problems before they develop into bigger ones.

2.

Analyze the problem. Determine exactly what the problem is, what caused it and what is involved to rectify the problem.

3.

Compare the current problem with others previously encountered to assist in finding the most likely solution. Decide on a solution.

Experienced operators make decisions almost automatically, they are immediately aware of the significance of an indicator. They react spontaneously because their experience tells them the appropriate action to take. By correctly selecting the desirable action in each situation, an operator will: 1. Maximize the quality of the products of drilling 2. Maximize drilling production

Drilling Practices

5-15

Notes

5-16

BI006752-06

Drilling Practices

BI006752-06

Section 6

Machine Transport

Machine Transport

6-1

BI006752-06

Machine Specifications–Shipping MD6290 Basic Shipping Weights and Dimensions Quantity

Description of Goods

Approximate Dimensions

Truck one (1)

MD6290 Rotary Blasthole drill c/w 1 each Owner/Operator manual and warranty packet stowed within cab

10.82 m (35 ft 5 in) L x 4.06 m (13 ft 3 in) W x 3.96 m (13 ft) H 41,050 kg (90,500 lb)

Truck two (2)

Mast assembly for MD6290 Rotary Blasthole drill (mast for 35 ft pipe)

14.81 m (48 ft 7 in) L x 1.91 m (6 ft 3 in) W x 1.91 m (6 ft 3 in) H 14,514.96 kg (32,000 lb)

Truck two (1)

Cab half for MD6290 Rotary Blasthole drill c/w 1 ea. Ship out filter kit, 2 ea. tubes superflex, 2 ea. brackets, 1 ea. bag of nuts & bolts, 2 ea. mast bushings, 1 ea. horseshoe bushing, 1 ea. bit basket & 1 ea. lifting bale

2.286 m (7 ft 5 in) L x 0.81 m (2 ft 8 in) W x 2.51 m (8 ft 3 in) H 635 kg (1,400 lb)

Truck two (2)

Walkway for MD6290 Rotary Blasthole drill c/w toolbox stowed within

2.74 m (9 ft) L x 0.86 m (2 ft 9 in) W x 1.30 m (4 ft 3 in) H 589.7 kg (1,300 lb)

Note: final dimensions and GVW and corresponding load-out vary based on options selected and final configuration.

MD6240 Basic Shipping Weights and Dimensions Truck one (1)

(12 m), Rotary Blasthole drill c/w Owner/Operator’s manual stowed in cab

Truck two (2)

Mast assembly for (12 m), Rotary Blasthole drill

Truck three (3)

Cab half assembly for (12 m), Rotary Blasthole drill c/w 1ea. #89044 filter kit, 2 ea. Superflex, 2 ea. brackets, 2 ea. mast bushings, 2 ea. dust chute c/w curtain, 2 ea. clamps, 1 ea. horseshoe bushing, 1 ea. bit basket, 1 ea. lifting bale, 2 ea. portable fire suppression w/brackets, 3 ea. bag of nuts, bolts, 6 ea. handrails, 1 ea. table bushing and cab supports 2 each walkways bundled together with 2 each ladders, toolbox, c/w with accessories stowed within, bit sub, dust chute hose and 2 each chutes for hose for (12 m)

Truck three (3)

Truck three (3)

Mast support rack (mounted off front end) for (12 m)

Truck three (3)

1 each walkway

10.82 m (35 ft 6 in) L x 4.0 m (13 ft 2 in) W x 3.9 m (12 ft 7 in) H 44,678.5 kg (98,500 lb) 17.7 m (58 ft) L x 1.9 m (6 ft 4 in) W x 1.8 m (6 ft 2 in) H 16,329.3 kg (36,000 lb) 2.29 m (7 ft 6 in) L x 0.81 m (32 in) W x 2.51 m (8 ft 2 in) H 635 kg (1,400 lb) 5.1 m (16 ft 7 in) L x 0.9 m (3 ft 2 in) W x 1.5 m (5 ft) H 2,948.3 kg (6,500 lb) 2.9 m (9 ft 6 in) L x 2.2 m (7 ft 2 in) W x 0.4 m (15 in) H 548.8 kg (1,210 lb) 2.87 m (9 ft 4 in) L x 0.61 m (2 ft) W x 1.20 m (4 ft 3 in) H 544.81 kg (1,200 lb)

Note: Final dimensions and GVW and corresponding load-out vary based on options selected and final configuration.

6-2

Machine Transport

BI006752-06

Transporting Machine

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

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

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

Mast Removal: 1.

Remove drill pipe from mast (refer to "loading and unloading drill pipe" in Section 3) and swing carousel all the way in.

2.

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

3.

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

NOTE

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

4.

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

5.

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

6.

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

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

7.

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

8.

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

Machine Transport

6-3

BI006752-06

Transporting Machine

Fig. 6-1 Mast Assembly (lower end) 1. Pivot Lug (2) 2. Capscrew (4), Torque per Note below

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

NOTE

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

1.

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

2.

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

3.

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

4.

Install the pivot lug caps with capscrews and washers and torque per note below.

5.

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

Mast Pivot Bolt Torque NOTE

6-4

MD6290 –

Dry = 1820 Ft. Lbs. (2468 Nm) Lube = 1360 Ft. Lbs. (1844 Nm)

MD6240 –

Dry = 3160 Ft. Lbs. (4284 Nm) Lube = 2360 Ft. Lbs. (3200 Nm)

Machine Transport

BI006752-06

Transporting Machine

Loading and Unloading of Machine

Fig. 6-2 Machine ready for transport 1. Tiedown points (4 per side)

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

1.

Raise dust curtains and secure with rope to prevent interference with trailer wheels (fig. 6-3).

2.

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

3.

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

4.

Remove walkway from cab. Support walkway with forklift or overhead lifting device and remove the four bolts that secure walkway to frame. Load walkway onto trailer with mast. Install the four bolts back on the frame, so they do not get lost.

5.

Cross tape all windows with duct tape.

6.

Be sure jacks are raised all the way up and secure jack pads with chain and nut (provided on each pad). Tram machine onto trailer in reverse for greater visibility.

7.

If lifting machine onto trailer or ship, use the lifting lugs welded to the jack housings. If unit is not equipped with lifting lugs, contact the manufacturer for lifting information for your machine.

8.

Tape exhaust(s) closed, clip all chains on handrail openings, check to see that all doors are closed tight and ignition is turned off. If unit is equipped with a battery disconnect switch, this should be turned off.

9.

Machine should be secured to trailer at four places on each side (fig. 6-2). Secure frame to trailer at front and rear and secure track to trailer at front and rear.

Machine Transport

6-5

BI006752-06

Transporting Machine

Fig. 6-3 Dust Curtain - tied up

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

Operator must read and understand the safety, start-up, shutdown and operation sections of the manual.

1.

Inspect machine for damage before unloading.

2.

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

3.

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

4.

Install cab walkway and mast (refer to mast installation on previous page).

5.

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

6-6

Machine Transport

BI006752-06

Transporting Machine

Loading and Unloading of Mast

Fig. 6-4 Mast ready for transport 1. Tiedown points - mast crown lifting lug, middle and mast base lifting lug

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

NOTE

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

1.

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

2.

Load mast on trailer with mast crown (top) at rear of trailer. Secure mast to trailer using the lifting lugs (two at mast crown and two at mast base) as tiedown points. Secure mast to trailer at midpoint also.

Unloading Mast 1.

For unloading of mast, refer to "Mast Installation" on page 4 of this section.

Fig. 6-5 Mast Tie Down Detail

Machine Transport

6-7

Notes

6-8

BI006752-06

Machine Transport

BI006752-06

Section 7

Options and Accessories

Options and Accessories

7-1

BI006752-06

Cold Weather Operation Description

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

The cold weather option includes the appropriate lubricants (listed in this section) in the compressor, engine, hydraulic system and gearboxes.

An optional diesel fired heater/pump unit, using fuel from the machine's diesel tank, circulates a water/anti-freeze mixture through heat exchanger tubes located in the hydraulic tank, fuel tank, water tank, radiator and engine block ( see fig. 7-5).

The heating system can also be powered by a generator (GenSet) mounted on the machine, or an external power source, to provide 120 or 240 VAC to the system to thermostatically control heating elements and silicone heating pads (see fig. 7-6). A heater/controller (fig. 7-2) supplies power to a distribution breaker box and pumps heated water/anti-freeze through the engine block.

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

Additional measures included for extreme cold protection are: • Thermo-glass cab windows • Additional heater in cab • Spray-on insulating material under the cab, water and fuel tanks • Cold weather wiring for AC/DC systems including low temperature conduit • Ether injection for engine starting, if desired (cat engines only) There are no additional fluid additives required for cold weather operation.

NOTE

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

Heater/Pump Unit The heater/pump unit heats and circulates water and anti-freeze through the engine, radiator, hydraulic tank and fuel tank. Fig. 7-1 shows a typical installation. A 24VDC motor operates the water pump.

Diesel fuel is used to fuel the heating system.

Fig. 7-1 Heater/Pump Installation 1. Heater/Pump Unit 2. Manifold 7-2

Options and Accessories

BI006752-06

Cold Weather Operation

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

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

If the machine is supplied by a GenSet, the GenSet is switched on to provide power for preheating. After the GenSet warms up to operating temperature, the heater/controller is switched on and the Operator can then select which system is to be energized via the distribution breaker box (see fig. 7-6).

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

ON/OFF Switch

Heater

Pump

Fig. 7-3 Heat Exchanger Element in Hydraulic Tank

Fig. 7-2 Heater/Controller Installation

Fig. 7-4 Heating Pad on Auto Lube Grease Container

Options and Accessories

7-3

Cold Weather Operation

BI006752-06

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

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

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

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

Order repair parts from Parts Manual for your specific machine.

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

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

1.

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

2.

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

3.

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

4.

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

5.

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

6.

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

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

NOTE 7-4

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

Options and Accessories

1" HOSE

1" HOSE

1" HOSE

HYD RESERVOIR

1" HOSE

1" HOSE

1" HOSE

WATER TANK

1" HOSE

B

A

1" HOSE

1" HOSE

1" HOSE

1" HOSE

FUEL TANK

FUEL SUPPLY HOSE (5 MM. I.D.) SUPPLIED WITH HEATER (403352)

RETURN

SUPPLY

FUEL FILTER

1 1/2" HOSE

SUPPLY

RETURN

SUPPLY

B

RETURN

A

3/4" HOSE 1 1/2" HOSE

1 1/2" HOSE

REAR VIEW

1 1/2" HOSE

Options and Accessories SUPPLY

ENGINE

SIDE VIEW

BI006752-06

Cold Weather Operation

Fig. 7-5 Cold Weather Plumbing Using Diesel Fired Heater

7-5

1 1/2" HOSE

3/4" HOSE

3/4" HOSE

3/4" HOSE RETURN

7-6

Fig. 7-6 Heater Control Schematic Using 120/240 VAC System

LOAD

LINE

N

W

V

V5 6

100

100

AMP

AMP

380V

220V

380V

12GA

EARTH NEUTRAL

380V

12GA

CUSTOMER SUPPLIED EXTERNAL POWER SOURCE 380V Y3ø/220V 1ø}

CUSTOMER SUPPLIED CIRCUIT PROJECTION

V2 U2

7 W5 U5

W2

THREAD GREASE DRUM HEATER 650W

*

TCR

C1

12GA

12GA

COOLANT PUMP 10GPM

P

HI LIMIT THERMOSTAT

THERMISTOR N/C

OFF

ON

FUEL TANK HEATERS 2@2KW

10GA GND

L1 10GA

L3 10GA

HEATING ELEMENT 2KW

HEATING ELEMENT 9KW

CONTACTOR MAGNETIC

15 AMP

GFI

15 AMP

GFI

50 AMP

15 AMP

GFI

25 AMP

GFI

50 AMP

GFI

15 AMP

GND

HEATING ELEMENT 9KW

12GA

GND

TEMP CONTROL

10GA

HEATING ELEMENT 9KW

10GA

TEMP CONTROL

12GA GND

12GA

12GA

HEATING ELEMENT 2KW

12GA

12GA

HEATING ELEMENT 1.35KW

12GA GND

HEATING ELEMENT 1.35KW

HEATING ELEMENT .338KW

NOTE: 120 VOLTS APPLIED TO STANDARD 240 VOLT HEATER

NOTE: HEATER NEUTRAL WIRE NOT CONNECTED

12GA GND

12GA

ADJ TEMP CONTROL 25F-330F

COMPRESSOR CONTROL BOX HEATER 338W SUCTION MANIFOLD OR HYD TANK COMPRESSOR RECEIVER TANK HEATERS WATER TANK HEATER 2@1.35KW HEATER 9KW 2KW 12GA

10GA

TEMP CONTROL

10GA

10GA

12GA

650W

12GA

GND

750W

12GA

GND

75W

75W GND

HEATER

HEATER

AUTO LUBE GREASE DRUM HEATER 750W

FIXED TEMP CONTR0L 60F

12GA

12GA

TEMP CONTROL

12GA

12GA

GND

TEMP CONTROL

12GA

HEATER

75W

HEATER

ENGINE OIL HEATER (PAN) 500W

GND

75W

HEATER

HEATING ELEMENT 2KW

HEATING ELEMENT 2KW

GND

TEMP CONTROL

HEATING ELEMENT 2KW

HYD. TANK HEATERS 2@2KW

TEMP CONTROL

BATTERY HEATERS 4@75W

GND

WATER TANK HEATER 9KW

AUXILIARY POWER SUPPLY 220VAC 1ø}

GENERATOR

W1

U6

W6

V1

8

12GA GND

H4

N

W

V

BUS BAR

NO BUS BAR

U

GFI

6

H3

H1

2GA

2GA

U1

V6

9KW

TEMP CONTROL

10GA

3

H2

AMP

100

200 AMP RECEPTACLE AND PLUG

AMP

100

U

ENGINE COOLANT FORCED CIRCULATION HEATER

TEMP CONTROL

X4

120V SECONDARY

X3

X2

120V SECONDARY

X1

TRANSFORMER 50KVA

AMP

100

MAIN BREAKER

ON BOARD GENERATOR SET

25 AMP

GFI

50 AMP

DISTRIBUTION BREAKER BOX

4GA

4GA

4GA

ISOLATION SAFETY SWITCH

Cold Weather Operation BI006752-06

Options and Accessories

BI006752-06

Kim Hotstart

CSS Coolant Small System

Installation & Operation Manual

216211-000 rev-2

Options and Accessories

7-7

Notes

7-8

BI006752-06

Options and Accessories

BI006752-06

Kim Hotstart The Kim Hotstart System

System Overview Shown on the next page is the basic layout of the CSS Heating System. This circulating heating system consists of a coolant heating chamber, heating element, adjustable thermostatic control, a centrifugal pump, a control box with electro-mechanical controls and a mounting plate.

Basic System Operation Upon energizing the system, engine coolant which is taken from the coolant drain area in the lower section of the engine is circulated via a centrifugal pump, pulled through the heating chamber and back to a location on the engine furthest from the coolant suction line. The pump stays on and continues this circulation process even when the heating elements are off to provide an accurate, uniform heat to the engine. In the element enclosure is a thermister. This device senses the temperature of the engine coolant and sends a signal to a solid-state temperature controller in the control box that turns the element on and off as needed.

The front panel on/off switch or a 24 VDC input for automatic operation can control system operation manually.

Options and Accessories

7-9

Kim Hotstart

7-10

BI006752-06

Options and Accessories

BI006752-06

Kim Hotstart

Coolant return line to rear of engine.

Engine

Optional Shut-Off Valve Optional Check Valve

Coolant Inlet Coolant Outlet

CSS System engcool.eps

Options and Accessories

7-11

BI006752-06

Kim Hotstart Coolant Requirements

Upon an initial coolant fill and each subsequent replacement, check the quality of the source water. Proper coolant management procedures can eliminate engine and heating system problems. Use these guidelines:

Basic Water Quality Chlorides Sulfates Total Hardness Total Solids pH

50 PPM Max 50 PPM Max 100 PPM Max 250 PPM Max 7,5 to 10.5

To achieve the level of quality required, it may be necessary to use distilled water (not deionized). Distilled water is corrosive without proper inhibitors. Kim Hotstart Manufacturing also recommends use of a well-inhibited ethylene glycol cooling solution at 30% to 60% ratio.

Glycol based inhibitors provide superior corrosion protection, inhibition, a lower freeze point and an increased boiling point.

For heavy duty engines, use a low silicate coolant formula inhibitor composition with a silicate level of no more than 230 PPM. This coolant fill is supplemented with an inhibitor additive package to provide specific inhibition for wet sleeve cylinder liners, cavitation, pitting and erosion.

NOTE: The use of glycol still requires non-corrosive water, periodic reinhibition and inhibitor monitoring.

Kim Hotstart Manufacturing recommends use of "Fleetguard DCA4" (or equivalent), a high quality inhibitor package that provides excellent steel, aluminum, copper and other cooling system metals protection for the pre-heating system and engine. DCA4 formula consists of a balanced combination of phosphate, molybdate and nitrite inhibitor, and is packaged in units for easy calculation of coolant amounts.

7-12

Options and Accessories

BI006752-06

Kim Hotstart

System Start-Up After system installation has been completed, follow these steps for proper Coolant Heating System start-up.

Coolant Heating System Start-Up CAUTION:

DO NOT START THE PUMP BEFORE FILLING THE SYSTEM WITH COOLANT AND NEVER OPERATE THE PUMP DRY.

Step 1

Check and tighten all electrical and plumbing connections.

Step 2

Ensure isolation valves are open before starting system.

Step 3

Once the heating system is installed and the engine is filled, run the engine for a short period before energizing the heater. This will purge any air from the pump and heating tank. Loosen outlet flange at pump to bleed air.

Step 4

The thermostat is set at 65° from the factory for initial start-up. Energize the coolant heating system by turning the coolant switch on the control box to the ON position. After flow is verified through the tank and any trapped air is expelled, adjust thermostat to the desired temperature.

NOTE:

On initial startup, it may take several attempts to achieve proper flow.

Options and Accessories

7-13

Kim Hotstart

BI006752-06

24 VDC Connection A terminal block, labeled A and B , for the 24 VDC input signal is supplied inside the control box of the Kim Hotstart heating system. The signal source for this connection is usually the fuel pump or alternator. Once the signal is detected at the control circuit, the heating system will automatically shut down during engine operation and re-energize upon engine shutdown.

CAUTION THE HEATING SYSTEM MUST NOT BE OPERATED WHILE THE ENGINE IS RUNNING. IF OPERATED, PREMATURE ELEMENT FAILURE MAY RESULT.

7-14

Options and Accessories

BI006752-06

Kim Hotstart System Components

This section describes the control box and heating tank components of the CSS Heating System.

Control Box The control box used in the Kim Hotstart Heating System is shown. The control box contains the electrical control components of the heating system. Parts in the control box may vary, depending on the particular system configuration you purchased.

Options and Accessories

7-15

Kim Hotstart

BI006752-06

Fuses There are one or two different types of fuses located in the control box depending on the heating system: Transformer Primary Fuses These fuses, located in the control box, protect the power transformer from overloading.

Transformer Secondary Fuse This fuse, located in the control box, protects the control circuit components of the control box and the pump.

Transformer The transformer steps down the source primary voltage to 120 volts. Wiring information is listed on the top of the transformer. This transformer is overload protected with fuses.

NOTE:

7-16

When ordering replacement parts, be sure to reference your heating system's model and serial numbers found on the identification plate.

Options and Accessories

BI006752-06

Kim Hotstart

Coolant Heating Tank Assembly The Kim Hotstart coolant heating tank assembly is shown below.

Following is an overview of operation and replacement instructions for the CSS heating tank assembly and components, including the coolant heating element.

Options and Accessories

7-17

Kim Hotstart

BI006752-06

Heating Element Replacement The heating element heats the engine coolant. To replace the heating element, follow the steps on the following page. Be sure to allow at least 12" of space for element removal. The wattage and phase of the heating element are listed on the identification label found on the base of the heating element assembly.

WARNING DISCONNECT ALL POWER AT THE SOURCE LEADING TO THE KIM HOTSTART HEATING SYSTEM PRIOR TO PERFORMING ANY MAINTENANCE ON THE HEATING SYSTEM.

7-18

Options and Accessories

BI006752-06

Step 1

Kim Hotstart Turn the Kim Hotstart Heating system OFF. Cover

Step 2

Drain the fluid from the heating tank.

Step 3

Open the element enclosure and disconnect the following wires to the heating element assembly:

Enclosure

• L1, L2, L3 (L1 & L3 on single phase units) Conduit

• The 2 wires from the thermister.

• The 2 wires from the hi-limit thermostat.

Thermistor Probe Heating Element

• The heating element ground wire.

Step 4

Remove the conduit connector and electrical wires from the element enclosure.

Step 5

Remove the heating element by loosening the clamp from the heating tank as shown.

Step 6

Replace the heating element or perform the necessary cleaning procedure.

V-Clamp O-Ring

Inlet Tank elemdis.eps

NOTE:

Orientation of element thermister probe must be kept away from inlet opening plumbing. It must be re-installed in the same orientation to the tank as it originally came from the factory.

To re-assemble the heating element and tank, follow the steps listed above in reverse order.

Make sure the green ground and black power electrical wires are properly reconnected. To order a new heating element, refer to part number on the label of the element, or the assembly drawing included with this manual.

Options and Accessories

7-19

BI006752-06

Kim Hotstart High-Limit Thermostat Replacement

The High-Limit Thermostat Sensing Unit is a safety device designed to prevent over heating of the coolant in the event that the heating system’s System Main Thermostat fails. The sensing unit is located inside the element housing and is fixed at 140ºF (ON)/160ºF (OFF). To replace the high-limit thermostat sensing unit, follow these steps.

WARNING DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY MAINTENANCE TO THIS HEATING SYSTEM.

Step 1

Remove the enclosure cover of the element housing.

Step 2

For 3-phase applications only, remove the element jumper strap which crosses over the top of the high-limit sensing unit (red wires).

Step 3

Using a small screw driver, remove the toothed lock ring that holds the high-limit sensor and seat in place.

Step 4

Pull the sensor and seat straight out and disconnect the sensor from its seat.

Step 5

Reconnect the new sensor.

Lock Ring

Sensor Seat Thermostat Sensor

hisenr.eps

Reassemble in reverse order.

High-Limit Sensing Unit Replacement Parts Sensing Unit

Temp. On

Temp. Off

Part Number

LSU 4

40ºF (5ºC)

60ºF (15ºC)

HLC 4*

LSU 6

60ºF (15ºC)

80ºF (27ºC)

HLC 6*

LSU 8

80ºF (27ºC)

100ºF (38ºC)

HLC 8*

LSU 10

100ºF (38ºC)

120ºF (49ºC)

HLC 10*

LSU 12

120ºF (49ºC)

140ºF (60ºC)

HLC 12*

LSU 14

140ºF (60ºC)

160ºF (71ºC)

HLC 14*

* Replacement stats will come with lock ring and sensor seat.

7-20

Options and Accessories

BI006752-06

Kim Hotstart

Coolant System Temperature Setting Adjustments The system temperature setting adjustment is located inside the control box. The solid-state adjustable thermostat provides 5° incremental settings between 65° and 140°. To adjust the heating system's temperature, follow these steps.

CAUTION DISCONNECT ALL POWER AT THE SOURCE PRIOR TO PERFORMING ANY MAINTENANCE TO THIS HEATING SYSTEM.

Step 1

Open the control box.

Step 2

Inside the control box, locate the thermostat control with four dip switches.

Step 3

The system's temperature setting is factory preset at 65°F for initial start-up.

After flow is achieved a setting of 100° under normal conditions is sufficient for normal operation. If a higher or lower temperature is required, reset the dip switches to desired temperature.

CAUTION SEE SET-TEMPERATURE TABLE FOR ORIENTATION OF THE COMBINED SWITCHES THAT ARE NUMBERED 1, 2, 4 AND 8 LOCATED ON TOP OF THE SOLID-STATE CONTROL.

After the desired temperature is achieved, close the control box and re-energize the heating system. A few seconds will pass before the thermostat control begins to energize the element.

Options and Accessories

7-21

Kim Hotstart

BI006752-06

Set Temperature Table

7-22

Options and Accessories

BI006752-06

Kim Hotstart

System Maintenance & Troubleshooting This section describes maintenance procedures for the Kim Hotstart Small Capacity Heating System and provides tips for troubleshooting.

System Maintenance The following maintenance procedures are provided to ensure trouble-free operation of your heating system: • Control Box

•

Plumbing Connections

• Electrical Connections

•

Heating Tank

• System Mounting WARNING DISCONNECT ALL POWER PRIOR TO PERFORMING ANY SYSTEM MAINTENANCE.

Control Box Y Periodically check O-rings and gaskets for proper seals.

Y Check the control box for moisture (if necessary spray with moisture repellent or add desiccant packets).

Plumbing Connections Y Periodically check plumbing connections for leaks and, if necessary, tighten connections. A loose connection on the suction side will cause a loss of flow.

Electrical Connections Y Excessive vibration will eventually cause terminals to loosen. Periodically tighten all electrical connections. Ensure that all connectors to the circuit board are firmly seated.

Y At least once every six months, spray the inside of the main control box with a moisture repellent for electrical connections.

Options and Accessories

7-23

BI006752-06

Kim Hotstart Heating Tank

Y At least once per year, clean the interior of the heating tank and the heating element with a wire brush and/or damp cloth. Periodically check the element for sediment build-up around the hairpins. Any scaling or build-up will shorten element life.

Maintenance and replacement procedures for the heating element are described in Section 3.

System Mounting Y Excessive vibration may cause mounting bolts to loosen. Periodically check and tighten all mounting bolts.

Troubleshooting Symptoms

Coolant is not heating

7-24

Possible Causes

Solutions

Air leaks in suction lines

Tighten suction line connections

No power

Energize main power supply

Blown fuses

Replace primary and/or secondary fuses

Isolation valves are closed (user supplied)

Open isolation valves

Thermostat is not set properly

Adjust thermostat dip switches inside control box

Options and Accessories

BI006752-06

Kim Hotstart

Wiring Diagram

Options and Accessories

7-25

Murphy PowerView

BI006752-06

Description The Cummins QST30 engine operation can be monitored by the optional Murphy PowerView display, located on the engine instrument panel (fig. 7-7). The PowerView is a multifunction gauge, that allows the operator to monitor several engine functions. It also displays fault codes, if there is an engine malfunction. There are four touch sensitive buttons that allows the operator easy access to the displays.

Refer the following PowerView Installation and Operations Manual for complete instructions.

Fig. 7-7 Murphy PowerView Display

7-26

Options and Accessories

BI006752-06

Murphy PowerView PV-02124N Revised 05/04 Section 78 00-02-0528

Installation and Operations Manual Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit.

GENERAL INFORMATION

Display Parameters

WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Read and follow all installation instructions.

Description The PowerView is a powerful new display in a line of components manufactured

by FWMurphy as part of its J1939 MurphyLink™† Family. The J1939 MurphyLink™ Family of products have been developed to meet the needs for instrumentation and control on electronically controlled engines communicating using the SAE J1939 Controller Area Network (CAN).

The PowerView System is comprised of the PowerView and the Mlink™ PowerView Gages. The PowerView is a multifunction tool that enables equipment operators to view many different engine or transmission parameters and service codes. The system provides a window into modern electronic engines and transmissions. The PowerView includes a graphical backlit LCD screen. It has excellent contrast and viewing from all angles. Back lighting can be controlled via menu or external dimmer potentiometer. The display can show either a single parameter or a quadrant display showing four parameters simultaneously. Diagnostic capabilities include fault codes with text translation for the most common fault conditions.

The PowerView has four buttons using self-calibrating charge transfer activation technology, which eliminates the concern for pushbutton wear and failure. In addition, operators can navigate the display with ease.

The enhanced alarm indication has ultra bright alarm and shutdown LEDs (amber & red). It has a wide operating temperature range of -40 to +85º C (-40 to185º F), display viewing -40 to +75º C (-40 to 167º F), and increased environmental sealing to +/- 5 PSI (± 34kPa). It also features Deutsch DT style connectors molded into the case and fits quickly and easily into existing 2-1/16 in. (52 mm) gage opening with little effort.

Other components in the system are microprocessor-based Mlink™ PowerView Gages for displaying critical engine data broadcast by an electronic engine or transmission’s Engine Control Unit (ECU): engine RPM, oil pressure, coolant temperature, system voltage, etc. and a combination audible alarm and relay unit for warning and shutdown annunciation. Up to 32 components may be linked to the PowerView using a simple daisy chain wire connection scheme using RS485. The PowerView and all connected components can be powered by 12- or 24-volt systems.

Warranty A limited warranty on materials and workmanship is given with this FWMurphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty.html † MurphyLinkTM is a registered trademark of FWMurphy. All other trademarks and service marks used in this document are the property of their respective owners.

Options and Accessories

The following are some of the engine and transmission parameters displayed by the PowerView in English or Metric units as well as in Spanish, French, or German (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters): ❖ Engine RPM ❖ Engine Hours ❖ Machine Hours ❖ System Voltage ❖ % Engine Load at the current RPM ❖ Coolant Temperature ❖ Oil Pressure ❖ Fuel Economy ❖ Throttle Position ❖ Engine Manifold Air Temperature ❖ Current Fuel Consumption ❖ Transmission Oil Pressure ❖ Transmission Oil Temperature ❖ Transmission Gear Position ❖ Active Service Codes ❖ Stored Service Codes (when supported) ❖ Set Units for display (English or Metric) ❖ Engine Configuration Parameters

Specifications Display: 1.3 x 2.6 in. (33 x 66 mm), 64 x 128 pixels.

Operating Voltage: 8 VDC minimum to 32 VDC max.

Reversed Polarity: Withstands reversed battery terminal polarity indefinitely within operating temperatures.

Operating Temperature: -40 to +85ºC (-40 to185ºF).

Display Viewing Temperature: -40 to +75ºC (-40 to 167ºF).

Storage Temperature: -40 to +85ºC (-40 to185ºF).

Environmental Sealing: IP68, +/- 5 PSI (+/- 34.4 kPa).

Power Supply Operating Current: (@ 14 VDC)= 52 mA minimum; 268 mA maximum (LCD heater on).

CAN BUS: SAE J1939 Compliant.

Case: Polycarbonate / Polyester.

Clamp: Polyester (PBT).

Connectors: 6-Pin Deutsch DTO6 Series.

Maximum Panel Thickness: 3/8 in. (9.6 mm).

Mounting Hole: 2.062 inch (52 mm) in diameter.

Auxiliary Communications: Either: Gages: One (1) RS485 port, MODBUS RTU master.

MODBUS: One (1) RS485 port, MODBUS RTU slave, selectable baud rate; 9600; 19.2K; 38.4K. Potentiometer (External Dimmer)Input: 1K ohm, 1/4 W Shipping Weights (all models): 1/2 lb. (225 g.)

Shipping Dimensions (all models): 6 x 6 x 6 in. (152 x 152 x 152 mm).

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Murphy PowerView GENERAL INFORMATION continued

Table of Contents

Faceplate Features

General Information page # Description................................................. 1 Display Parameters.................................... 1 Specifications............................................. 1 Key Pad Functions..................................... 2 Mechanical Installation Typical Mounting Dimensions................... 2 Typical Quick-connect Diagram................ 3 Electrical Installation PIN Connectors Nomenclature.................. 3 Typical Wiring Diagrams........................... 4 Operations First Time Start Up................................... 5 Main Menu Navigation............................. 5 Selecting a Language................................. 5 Stored Fault Codes.................................... 6 Engine Configuration Data....................... 6 Faults and Warnings............................... .7 Active Fault Codes................................... 8 Shutdown Codes...................................... 8 Back Light Adjustment............................ 9 Contrast Adjustment.............................. 10 Select Units............................................... 10 Setup 1-Up Display................................... 11 Setup 4-Up Display.................................. 14 Utilities.....................................................15 MODBUS Setup....................................... 15 J1939 Parameters....................................17 Glossary...................................................18

Amber Warning LED

Red Shutdown Derate LED

Display

Bezel

Menu Key

Enter Key

Left Arrow Key (Scroll Up)

Right Arrow Key (Scroll Down)

Keypad Functions The keypad on the PowerView is a capacitive touch sensing system.

There are no mechanical switches to wear or stick, and the technology has been time proven in many applications. It operates in extreme temperatures, with gloves, through ice, snow, mud, grease, etc., and it allows complete sealing of the front of the PowerView. The ‘key is touched’ feedback is provided by flashing the screen. The keys on the keypad perform the following functions: – Menu Key - The Menu Key is touched to either enter or exit the menu screens.

– Left Arrow - The Left Arrow Key is touched to scroll through the screen either moving the parameter selection toward the left or upward.

– Right Arrow - The Right Arrow Key is touched to scroll through the screen either moving the parameter selection toward the right or downward.

– Enter Key - The Enter Key (also known as Enter Button) is touched to select the parameter that is highlighted on the screen.

Typical Mounting Dimensions SIDE 3.489 in.

(89 mm)

HOLE CUTOUT

1.94 in.

(50 mm)

FRONT

2.070 in.

(53 mm) 2.41 in.

(61 mm)

2.062 in.

(52 mm) diameter

1.972 in.

(50 mm) .953 in.

(24 mm)

0.125 in.

(3 mm)

R 0.063 in.

(1.6 mm)

0.78 in. (20 mm)

4.25 in.

(108 mm)

7-28

3.18 in. (81 mm)

Options and Accessories

BI006752-06

Murphy PowerView MECHANICAL INSTALLATION

Typical Quick-Connect Diagram Last PVA Gage or PVAA Audible Alarm

To Engine ECU A

To optional external device

To PVAA Audible Alarm

B

Terminating Resistor PVJR

To Battery Power

PVW-CH

POWERVIEW PV100

A

Relay N.O.

B

Relay N.C.

OR

Ext. Sonalert

PVW-PH

Relay Comm.

Optional PVW-A wire harness

Customer provided wire harness or CAN extension harnesses or power extension harnesses.

(includes terminating resistor) A

B

PVA Gage

Next PVA Gage

Wire harness PVW-J

External Dimmer Wire 24 inch.

A

External Dimmer

B

A

B

B+ GRND

CAN–SHLD CAN–LO CAN–HI

Wire harness PVW-P

Wire harness PVW-J

Wire harness PVW-J

ELECTRICAL INSTALLATION

PowerView Unit Back View Deutsch DT06-6S Style Connections Plug A

Plug B

PIN 3 CAN LO –

PIN 4 CAN SHLD –

PIN 2 CAN HI –

PIN 5 Dimmer Potentiometer

PIN 1 V+

PIN 6 GRND

PIN 3 RS485+

A

PIN 4 RS485 –

B PIN 1 V+

PIN 6 GRND

Recommended Connectors: Body: Deustch DT06-6S Wedge Lock: W6S Terminals: 0462-201-16141 Sealing Plug: 114017

Options and Accessories

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BI006752-06

Murphy PowerView TYPICAL WIRING DIAGRAMS

IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist per inch minimum. CAN–L, CAN–H and CAN Shield should be approved J1939 CAN bus cable (CAN wire for example: RADOX plug and play cable, from Champlain cable). (RS485 wire for example: BELDEN 9841 or 3105A).

PowerView Deutsch DT06-6S Style Unit to PVA Gage NOTE 5

Green-CAN_L Yellow-CAN_H

NOTE 4 RS485 (-) Data

120 ohms

Pin 4

Pin 4

See NOTE 6

Pin 3

120 Ω See Note

Pin 2

PVA Gage Pin 1

NOTE 1

Ignition Switch

Pin 5

Red-V+

V+

Pin 1

Pin 6

ENGINE CONTROL MODULE (SAE J1939 Compliant)

NOTE 2 Gray-CAN_SHLD

RS485 (+) Data

Pin 3

Back View

GRND

Pin 6

Gray-Ground Blue-Back Light NOTE 7 Battery Illumination Control*(optional) NOTE 3

Note 1: Place Resistor between CAN–H and CAN–L Line near PowerView (included in PVW-P or factory purchased panels).

Note 4: Only use 120 ohm

Note 2: Use SAE J1939 compliant

to PowerView end only.

wiring or equipment.

Note 3: Electronic dimmer switch

recommended with 4A, capacity or heavy duty rheostat switch, 1000 ohm, 0.25 watt.

characteristic impedance cable, ex Belden 9841.

Note 5: RS485 shield connected Note 6: Place Resistor at End of

Line on last PVA gage. (Included for factory purchased panels.)

Note 7: If a backlight dimmer is not

used, connect the blue backlight wire to ground. Do not leave the blue backlight wire unconnected.

PowerView Deutsch DT06-6S Style Unit to MODBUS Output NOTE 5

RS485 (+) Data

Pin 3

Green-CAN_L

Yellow-CAN_H

120 Ω See Note

Pin 3

Pin 2

NOTE 1 Pin 6

Note 4: Only use 120 ohm

Gray-Ground Blue-Back Light NOTE 7 Battery NOTE 3 Illumination Control*(optional)

characteristic impedance cable, ex Belden 9841.

Pin 5

Red-V+ Ignition Switch

Note 5: RS485 shield connected Note 1: Place Resistor between

to PowerView end only.

CAN–H and CAN–L Line near PowerView (included in PVW-P or factory purchased panels).

Note 6: Place Resistor at End of Line.

Note 2: Use SAE J1939 compliant

Note 7: If a backlight dimmer is not

wiring or equipment.

Note 3: Electronic dimmer switch

For a complete listing of MODBUS Registers visit our website at www.fwmurphy.com

7-30

to MODBUS Output See NOTES 6 and 8

Pin 4

Pin 4

Pin 1

ENGINE CONTROL MODULE (SAE J1939 Compliant)

NOTE 4 RS485 (-) Data

NOTE 2 Gray-CAN_SHLD

recommended with 4A, capacity or heavy duty rheostat switch, 1000 ohm, 0.25 watt.

(Included for factory purchased panels.) used, connect the blue backlight wire to ground. Do not leave the blue backlight wire unconnected.

Note 8: PVA gages cannot be used

with the MODBUS feature.

Options and Accessories

BI006752-06

Murphy PowerView POWERVIEW OPERATION

PowerView Menus (First Time Start Up) 1. When power is first applied to the PowerView, the "Logo" is displayed.

3. Touching the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down.

ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES

2. The "Wait to Start" message will be displayed for engines with a pre-startup sequence. Once the "Wait to Start" message is no longer displayed the operator may start the engine. Note: Displays only when SAE J1939 message is supported by engine manufacturer.

GO TO 1-UP DISPLAY

LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

WAIT TO START PREHEAT

3. Once the engine has started the single engine parameter is displayed.

0

4. Touch the "Arrows" to scroll to the desired menu item or touch "Menu" to exit the Main menu and return to the engine parameter display.

1500

98%

1000 RPM

LOAD@RPM

ENG RPM

57 PSI

14.2

OIL PRES

BAT VOLT

Selecting a Language 1. Starting at the main menu display use the "Arrows" to scroll to the "Language" menu and once highlighted touch the "Enter" button.

3000

1800 RPM

GO TO 1-UP DISPLAY LANGUAGES LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

ENG RPM COOL TEMP

Main Menu Navigation 1. Starting at the single or four engine parameter display, touch "Menu".

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The language choices will be displayed. Use the "Arrow" buttons to scroll through the selections and touch "Enter" to make a selection.

ENGLISH ESPAÑOL FRANÇAIS DEUTSCH

❋

2. The first seven items of the “Main Menu” will be displayed.

Touching the "Arrow Buttons" will scroll through the menu selection.

GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

Options and Accessories

3. Now that you have selected the language, touch the "Menu" button to return to the main menu display.

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Murphy PowerView POWERVIEW OPERATION continued

Stored Fault Codes

5. Touch the "Menu Button" to return to the main menu.

1. Starting at the single or the four engine parameter display touch the "Menu button".

1500

3000

LOAD@RPM

ENG RPM

ENG RPM

▼

1800 RPM

SPN110 FMI10 HIGH COOLANT TEMP

1000 RPM

14.2

COOL TEMP

BAT VOLT

MORE

▼

0

98%

1 of x

HIDE

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the Stored Fault Codes is highlighted.

GO TO 1-UP DISPLAY STORED CODES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

Engine Configuration Data 1. Starting at the single or four engine parameter display touch the "Menu Button".

3 Once the "Stored Fault Codes" menu item has been highlighted touch the "Enter Button" to view the "Stored Fault Codes" (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters).

GO TO 1-UP DISPLAY STORED CODES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Engine Configuration" is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

4. If the word "MORE" appears above the "Arrow Buttons" there are more stored fault codes that may be viewed. Use the "Arrow Buttons" to scroll to the next Stored Diagnostic Code.

3. Once the "Engine Configuration" menu item has been highlighted touch the "Enter Button" to view the engine configuration data.

1 of x

▼

7-32

MORE

▼

SPN110 FMI10 HIGH COOLANT TEMP HIDE

GO TO 1-UP DISPLAY STORED CODES ENGINE ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

Options and Accessories

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued

4. Use the "Arrow Buttons" to scroll through the engine configuration data.

ENGINE SPEED PT 1

or normal operation an auxiliary gage should fail, the single or four parameter screen will be replaced with the "MLink Gage Fault" message.

1000 RPM

1 of x

ENGINE OIL PRESSURE GAGE NOT RESPONDING

▼

▼

MORE

HIDE

5. Touch the "Menu Button" to return to the main menu.

3. To acknowledge and "Hide" the fault and return to the single or four parameter display, touch the "Enter Button".

ENGINE SPEED PT 1

1000 RPM

1 of x

ENGINE OIL PRESSURE GAGE NOT RESPONDING

▼

▼

MORE

HIDE

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98% LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

4. The display will return to the single or four parameter screen. !

57 PSI OIL PRES

0

1500

3000

1800 RPM ENG RPM COOL TEMP !

Faults and Warnings Auxiliary Gage Fault 1. During normal operation the single or four parameter screen will be displayed.

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

98%

1000 RPM

LOAD@RPM

ENG RPM

!

14.2 BAT VOLT

!

Indicates Auxiliary Gage Fault

.!

Indicates Fault Warning

!

Indicates Derate or Shutdown Condition Fault

57 PSI OIL PRES

!

5. Touching the "Enter Button" will redisplay the hidden fault.

Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display. NOTE: The fault can only be cleared by correcting the cause of the fault condition.

1 of x

ENGINE OIL PRESSURE GAGE NOT RESPONDING HIDE

2. The PVA Series of auxiliary gages can be attached to the PowerView.

These auxiliary gages communicate with the Modbus master PowerView via a daisy-chained RS-485 port. If at any time during system initialization Options and Accessories

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Murphy PowerView POWERVIEW OPERATION continued

Active Fault Codes 1. During normal operation the single or four parameter screen will be displayed.

98% 0

1500

LOAD@RPM

3000

1800 RPM ENG RPM

14.2

COOL TEMP

BAT VOLT

!

1000 RPM

0

ENG RPM

57 PSI

1500

ENG RPM

COOL TEMP

ENG RPM

!

14.2

!

57 PSI OIL PRES

BAT VOLT

!

6. Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display.

WARNING

1 of x

SPN110 FMI0 HIGH COOLANT TEMP

SPN110 FMI0 HIGH COOLANT TEMP ▼

▼

1000 RPM

LOAD@RPM

1800 RPM

WARNING

MORE

98%

3000

OIL PRES

2. When the PowerView receives a fault code from an engine control unit the single or four parameter screen will be replaced with the "Active Fault Codes" message.

1 of x

5. The display will return to the single or four parameter display, but the display will contain the "Active Fault"warning icon. Touching the "Enter Button" will redisplay the hidden fault.

MORE

HIDE

HIDE

3. If the word "MORE" appears above the "Arrow Buttons" there are more active fault codes that may be viewed.

Use the "Arrow Buttons" to scroll to the next "Active Fault Code"

7. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage.

GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1 of x

SPN110 FMI0

1000 RPM

LOAD@RPM

ENG RPM

!

14.2 BAT VOLT

57 PSI OIL PRES

!

▼

MORE

▼

HIGH COOLANT TEMP HIDE

Shutdown Codes 1. During normal operation the single or four parameter screen will be displayed.

98%

4. To acknowledge and "Hide" the fault and return to the single or four parameter display touch the "Enter Button".

0

1500

3000

1800 RPM ENG RPM

1000 RPM

LOAD@RPM

ENG RPM

57 PSI

14.2

COOL TEMP

OIL PRES

BAT VOLT

1 of x

SPN110 FMI0

HIGH COOLANT TEMP ▼

MORE

HIDE

2. When the PowerView receives a severe fault code from an engine control unit the single or four parameter screen will be replaced with the "Shutdown!" message.

1 of x

SHUTDOWN

SPN110 FMI0 HIGH COOLANT TEMP MORE

7-34

HIDE

Options and Accessories

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued

3. To acknowledge and "Hide" the fault and return to the single or four parameter display touch the "Enter Button".

SHUTDOWN

1 of x

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST BACKLIGHT

SPN110 FM10 HIGH COOLANT TEMP MORE

HIDE

4. The display will return to the single or four parameter display, but the display will contain the "Shut Down" icon. Touching the "Enter Button" will redisplay the hidden fault. !

0

1500

98%

1000 RPM

LOAD & RPM

3000

1800 RPM

ENG RPM

!

57 PSI

14.2

ENG RPM COOL TEMP!

OIL PRES

BAT VOLT

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Adjust Backlight" is highlighted.

3. Once the "Adjust Backlight" menu item has been highlighted touch the "Enter Button" to activate the "Adjust Backlight" function.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

5. Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display.

1 of x

4. Use the "Arrow Buttons" to select the desired backlight intensity.

SHUTDOWN

SPN110 FM10 HIGH COOLANT TEMP MORE

ADJUST BACKLIGHT

HIDE

6. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage. !

0

1500

3000

98%

ADJUST BACKLIGHT

1000 RPM

LOAD & RPM

ENG RPM

!

1800 RPM ENG RPM

5. Touch the "Menu Button" to return to the main menu.

14.2

COOL TEMP !

BAT VOLT

57 PSI OIL PRES

!

Back Light Adjustment 1. Starting at the single or four engine parameter display touch the "Menu Button".

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

Options and Accessories

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98% LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

OIL PRES

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Murphy PowerView POWERVIEW OPERATION continued

Contrast Adjustment 1. Starting at the single or four engine parameter display, touch the "Menu Button".

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

ENG RPM

57 PSI

98% LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

OIL PRES

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

3. Once the "Adjust Contrast" menu item has been highlighted touch the "Enter Button" to activate the "Adjust Contrast" function.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

4. Use the "Arrow Buttons" to select the desired contrast intensity.

ADJUST CONTRAST

5. Touch the "Menu Button" to return to the main menu.

7-36

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until "Adjust Contrast" is highlighted.

ADJUST CONTRAST

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

Select Units 1. Starting at the single or four engine parameter display touch the "Menu Button".

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the arrow buttons to scroll through the menu until the "Select Units" is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT SELECTUNITSD UNITS ADJUST BACKLIGHT

3. Once the "Select Units" menu item has been highlighted touch the "Enter Button" to access the "Select Units" function.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT SELECTUNITSD UNITS ADJUST BACKLIGHT

4. Use the arrows to highlight the desired units. "English" for Imperial units i.e. PSI, ºF or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, ºC. ENGLISH METRIC KPA METRIC BAR

Options and Accessories

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued

5. Touch the "Enter Button" to select the highlighted units.

3. Once the "Setup 1-up Display" menu item has been highlighted touch the "Enter Button" to access the "Setup 1-up Display" function.

ENGLISH METRIC KPA METRIC BAR

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP1-UP 1-UPDISPLAY DISPLAY SETUP SETUP 4-UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT

6. Touch the "Menu Button" to return to the "Main Menu".

ENGLISH METRIC KPA METRIC BAR

❉

7. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

LOAD@RPM

14.2 BAT VOLT

1000 RPM

4. Three options are available for modification of the 1-Up display. a). Use Defaults – This option contains a set of engine parameters: Engine Hours, Engine RPM, System Voltage, Battery Voltage, % Engine Load at Current RPM, Coolant Temperature, Oil Pressure. b). Custom Setup – This option allows for the modification of what parameter, the number of parameters, and the order in which the parameters are being displayed. c). Automatic Scan – Selecting the scan function will cause the 1-Up Display to scroll through the selected set of parameters one at a time, momentarily pausing at each.

5. Use Defaults - To select "Use Defaults" use the arrow buttons to scroll to and highlight "Use Defaults" in the menu display.

USE DEFAULTS DEFAULTS USE CUSTOM SETUP AUTOMATIC SCAN OFF

ENG RPM

57 PSI OIL PRES

6. Touch the "Enter Button" to activate the "Use Defaults" function.

Setup 1-Up Display 1. Starting at the single engine parameter display, touch the "Menu Button".

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 1-up Display" is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP1-UP 1-UPDISPLAY DISPLAY SETUP SETUP 4-UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT

Options and Accessories

USE USEDEFAULTS DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF

7. A message indicating the “Single Engine” parameter display parameters are reset to the factory defaults will be displayed, then the display will return to the “Custom Setup” menu.

RESTORED TO DEFAULTS

7-37

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued 8. Custom Setup - To perform a custom setup of the 1-Up Display, use the arrow buttons to scroll to and highlight "Custom Setup" on the display.

USE DEFAULTS CUSTOM CUSTOMSETUP SETUP AUTOMATIC SCAN OFF

13. Touch the "Enter button" to select the highlighted parameter for inclusion in the Single Engine Parameter Display.

ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMP 3

9. Touching the "Enter Button" will display a list of engine parameters.

USE DEFAULTS CUSTOM CUSTOMSETUP SETUP AUTOMATIC SCAN OFF

14. Continue to scroll and select additional parameters for the custom 1-Up Display. Touch the "Menu button" at any time to return to the "Custom Setup" menu.

15. Automatic Scan - Selecting the scan function will cause the 1Up Display to scroll through the selected set of parameters one at a time.

Use the "Arrow Buttons" to scroll to the "Automatic Scan" function.

10. Use the "Arrow Buttons" to scroll to and highlight a selected parameter (parameter with a # symbol to right of it).

USE DEFAULTS ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE

This number indicates the order of display for the parameters and that the parameter is selected for display.

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN OFF

16. Touching the "Enter Button" toggles the "Automatic Scan" function on.

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN ON

11. Touch the "Enter Button" to deselect the selected parameter removing it from the list of parameters being displayed on the 1-up display.

USE DEFAULTS ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE

17. Touching the "Enter Button" again toggles the "Automatic Scan" function off.

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN OFF

12. Use the "Arrow Buttons" to scroll and highlight the desired parameter that has not been selected for display.

ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMP

7-38

Note that the numbers now indicate the new order of display for the parameters.

Options and Accessories

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued

18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set touch the "Menu Button" to return to the main menu.

4. Touch the "Enter Button" to activate the "Use Defaults" function.

This action will reset the unit to the factory default.

USE USE DEFAULTS DEFAULTS CUSTOM SETUP

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN ON

19. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

5. The "Use Defaults"screen will be displayed during the reseting period then will automatically return to the "Setup 4-Up Display" menu.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

0

1500

3000

1800 RPM ENG RPM

RESTORED TO DEFAULTS

COOL TEMP

6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.

Setup 4-Up Display 1. From the single or four engine parameter display touch the "Menu Button".

98% 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

LOAD@RPM

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 4-Up Display" is highlighted.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

3. Once the "Setup 4-Up Display" menu item has been highlighted touch the "Enter Button" to activate the "Setup 4-Up Display" menu.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP SETUP 4-UP 4-UP DISPLAY DISPLAY SELECT UNITS ADJUST BACKLIGHT

Options and Accessories

USE DEFAULTS CUSTOM CUSTOM SETUP SETUP

7. The quadrent with the backlit parameter value is the current selected parameter. Use the "Arrow Buttons" to highlight the parameter value in the quadrant you wish to place a new parameter.

125°F COOL TEMP

1000 RPM ENG RPM

14.2 14.2 BAT VOLT

57 PSI OIL PRESP

8. Touch the "Enter Button" and a list of parameters will appear.

125°F COOL TEMP

1000 RPM ENG RPM

14.2 14.2 BAT VOLT

57 PSI OIL PRESP

7-39

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued 9. The parameter that is highlighted is the selected parameter for the screen. Use the "Arrow Buttons" to highlight the new parameter to be placed in the quadrent selected in the previous screen.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE ENGINE OIL PRESSURE

3 1 2 4

The number to the right of the parameter indicates the quadrant in which it is displayed.

1. = Upper Left Quadrent 2. = Lower Left Quadrent 3. = Upper Right Quadrent 4.= Lower Right Quadrent

10. Touch the "Enter Button" to change the selected parameter in the quadrant to the new parameter.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE ENGINE OIL PRESSURE

4

1 Note the number to the right of the selected parameter indicating that the parameter is now assigned to that display location.

12. The parameter in the selected quadrent has changed to the parameter selected in the previous screen.

125°F COOL TEMP 143°F OIL TEMP

ØRPM 1000 RPM ENG RPM 57 PSI OIL PRESP

13. Repeat the parameter selection process until all spaces are filled.

14. Touch the "Menu Button" to return to the main menu.

125°F COOL TEMP 143°F OIL TEMP

7-40

125% COOL TEMP

143°F OIL TEMP

1000 RPM ENG RPM

57 PSI OIL PRES

Utilities (Information and troubleshooting) 1. Starting at the single or four engine parameter display, touch the “Menu button”.

125%

1 2

3

2 4

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY DISPLAY SELECT UNITS ADJUST BACKLIGHT

3

11. Use the "Menu Button" to return to the “4-UP Custom Setup” screen.

ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE 2 ENGINE OIL PRESSURE

15. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

ØRPM 1000 RPM ENG RPM 57 PSI OIL PRESP

1500

0

3000

COOL TEMP

1800 RPM ENG RPM

143°F

COOL TEMP

OIL TEMP

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

3. Once the “Utilities” menu item has been highlighted, touch the “Enter Button” to activate the “Utilities” functions.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

4. Touch "Select" to enter the “Gage Data” display. When “Gage Data” is selected the PowerView will communicate with the analog gages at a fixed rate of 38.4 k Baud, 8 data bits, no parity check, 1 stop bits, half duplex.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULT CONVERSION DEMO MODE ON

Options and Accessories

BI006752-06

Murphy PowerView POWERVIEW OPERATION continued

5. Use the “Arrow buttons” to scroll through the items or touch “Menu” to return to the “Utilities” menu.

1 of x

ENGINE OIL PRESSURE ADDRESS: 20 SOFTWARE REVISION #: ERRORS: NONE

11. Use the “Arrows” to scroll and highlight the version then touch “Select” and an asterisks appears to the right of the selection.

NOTE: There are four (4) different methods for converting fault codes. The PowerView always looks for J1939 Version 4 and can be set to use one of the 3 other J1939 versions. Most engine ECU’s use Version 4, therefore in most cases adjustment of this menu option will not be required.

Upon receiving an unrecognizable fault, change to a different J1939 Version. If the fault SPN does not change when the version is changed, the ECU generating the fault is using Fault Conversion method 4. If the SPN number does change but is still unrecognizable, try changing to another J1939 Version not yet used and continue to check the SPN number.

6. Touch “Menu Button” to return to the “Utilities” menu.

J1939 VERSION VERSION 11 J1939 VERSION 2 J1939 VERSION 3 J1939 VERSION 4

1 of x

ENGINE OIL PRESSURE ADDRESS: 20 SOFTWARE REVISION #: ERRORS: NONE

7. Use the “Arrows” to highlight “Remove All Gages”. Touch “Select” to clear gage data from memory. It takes a moment to clear all gages.

12. Touch the “Menu” button to return to “Utilities” menu. Touch the “Menu” button again to to return to the “Main” menu.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

CLEARING GAGES PLEASE WAIT

8. When the gage data has cleared, the display automatically returns to the “Utilities” menu. Scroll to “Software Version”. Touch “Select” to view the software version currently in the PowerView.

SOFTWARE VERSION MURPHY: X.XX

MODBUS Setup 1. Starting at the single or four engine parameter display, touch the “Menu button”.

1500

0

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION FAULT FAULTCONVERSION CONVERSION

Options and Accessories

3000

98% LOAD@RPM

1800 RPM ENG RPM

9. Touch “Menu” to return to “Utilities”. Highlight “Fault Conversion” using the “Arrows”. Touch “Select” to enter the Fault convertion menu.

*

COOL TEMP

14.2 BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted, then touch “Enter”.

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

7-41

Murphy PowerView

BI006752-06

POWERVIEW OPERATION continued 3. Once in the “Utilities” menu use the “Arrows” to scroll through the menu until the “Modbus Setup” menu is highlighted, then touch “Enter”.

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP MODBUS SETUP FAULT CONVERSION

4. Use the “Arrows” to scroll down to and highlight either the “Slave Active or Master Active” modes. Touch the “Enter” button to toggle between master and slave.

USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE MASTER ACTIVE

5. Use the “Arrows” to scroll to the “Serial Port” menu to highlight it, then touch “Enter”.

USE FACTORY DEFAULT SERIAL PORT SETUP SETUP SERIAL PORT SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE

6. Use the “Arrow” button to scroll to each selection to configure the MODBUS values for your application.

BAUD RATE PARITY PARITY DATA BITS STOP BITS

7. When finished, touch “Menu” to return to the previous screen.

7-42

Options and Accessories

BI006752-06

Murphy PowerView SAE J1939 MurphyLink System Implementation of J1939 Parameters Source: SAEJ1939-71 Surface Vehicle Recommended Practice

SAE J1939 Section

Description

PGN

Parameter

Display Value

5.3.6

Elec Eng Cont #2 - EEC2

61443

Accelerator Pedal Position Percent Load at Current RPM

THROTTLE LOAD@RPM

5.3.7

Elec Eng Cont #1 - EEC1

61444

Actual engine % torque Engine Speed

ENG TORQ ENG RPM

5.3.14

Vehicle Distance

65248

Trip Distance Total Vehicle Distance

TRIP DIST VEH DIST

5.3.19

Engine hours, Revolutions

65253

Total Engine Hours

ENG HRS

5.3.23

Fuel Consumption

65257

Trip Fuel Total Fuel Used

TRIP FUEL FUEL USED

5.3.28

Engine Temperature

65262

Engine Coolant Temp Fuel Temperature Engine Oil Temperature Engine Intercooler Temperature

COOL TEMP FUEL TEMP OIL TEMP INTC TEMP

5.3.29

Engine Fluid Level/Pressure

65263

Fuel Delivery Pressure Engine Oil Level Engine Oil Pressure Coolant Pressure Coolant Level

FUEL PRES OIL LVL OIL PRES COOL PRES COOL LVL

5.3.31

Cruise Control /Vehicle Speed

65265

Wheel Based Vehicle Speed

VEH SPD

5.3.32

Fuel Economy

65266

Fuel Rate Instantaneous Fuel Economy Average Fuel Economy

FUEL RATE FUEL ECON AVG ECON

5.3.35

Ambient Conditions

65269

Barometric Pressure Air Inlet Temperature

BARO PRES AIR IN TP

5.3.36

Inlet/Exhaust Conditions

65270

Boost Pressure Intake Manifold Temp Air Filter Differential Pressure Exhaust Gas Temperature

BST PRES MANI TEMP AIR DIF PR EXH TEMP

5.3.37

Vehicle Electrical Power

65271

Alternator Voltage Electrical Potential (Voltage) Battery Pot. Voltage (Switched)

ALT VOLT SYS VOLT BAT VOLT

5.3.8

Electronic Transmission Controller #2

61445 61445

Selected Gear Current Gear

SLECT GEAR CURNT GEAR

5.3.38

Transmission Fluids

65272

Transmission Oil Pressure

TRAN PRES

Transmission Oil Temperature

TRAN TEMP

5.3.46

Engine Fluid Level/Pressure #2

65243

Injector Metering Rail 1 Pres Injector Metering Rail 2 Pres

INJ PRES1 INJ PRES2

Auxiliary Temperature

AUX TEMP

Auxiliary Pressure

AUX PRES

5.3.58

Fan Drive

65213

5.3.111

Auxiliary Pressures & Temperatures

65164

FAN SPD

Diagnostic Messages

65226 65227 65228

DM1 - Active Diagnostic DM2 - Previously Act Diag Codes DM3 - Diagnostic Clear

SRVCCODE STORCODE

J1939 N/A

Machine Hours (PowerView Calculated)

N/A

Machine Hours

MACH HRS

5.3.17

Engine Conf.

65251

Engine Configuration

ENG CONF

Electronic Transmission Controller #1

61442

Output Shaft Speed

OUT SFT SP

Electronic Transmission Controller #1

61442

Input Shaft Speed

IN SFT SPD

Electronic Transmission Controller #1

61442

Torque Converter Lockup Engaged

TORQ LOCK

5.3.5

Options and Accessories

7-43

BI006752-06

Murphy PowerView GLOSSARY (Troubleshooting information)

CANBUS FAILURE PowerView has not received any CAN messages for at least 30 seconds.

NO DATA PowerView has not received the particular message being displayed for at least 5 seconds.

NOT SUPPORTED PowerView has received a message from the ECU stating the displayed message is not supperted.

DATA ERROR PowerView has received an error message from the ECU for the displayed message.

EMPTY No parameter selected for this 4-UP quadrant.

WAIT TO START PREHEATING This is a message from the engine indicating it is in a preheating cycle.

Wait until this message clears before starting the engine.

TIMEOUT ECU NOT RESPONDING The ECU did not respond to the PowerView request.

NO GAGE DATA The PowerView has no record of connected gages to the RS485 bus.

7-44

Options and Accessories

BI006752-06

Options and Accessories

Foremost Shock Sub

7-45

Foremost Shock Sub

7-46

BI006752-06

Options and Accessories

BI006752-06

Options and Accessories

Foremost Shock Sub

7-47

Foremost Shock Sub

7-48

BI006752-06

Options and Accessories

BI006752-06

Options and Accessories

Foremost Shock Sub

7-49

Foremost Shock Sub

7-50

BI006752-06

Options and Accessories

BI006752-06

Options and Accessories

Foremost Shock Sub

7-51

Foremost Shock Sub

7-52

BI006752-06

Options and Accessories

Section 8

BI006752-06

Lubrication and Preventative Maintenance NOTE

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

Lubrication and Preventative Maintenance

8-1

Notes

8-2

BI006752-06

Lubrication and Preventative Maintenance

Service Points–Mainframe

BI006752-06

In most cases lubrication points on the drill will be connected to the auto lube system (if used), or will be connected to lubrication lines from a remote lube bulkhead (manual lube system).

Auto Lube System The auto lube system consists of an air powered pump assembly which is fitted to 120 lb. (54 kg.) grease container (Fig. 8-1). The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 90–100 PSI (6.2–7 bar) to the pump.

The system is controlled by a lube & sensor controller mounted in the operator's cab. The controller controls the lubrication system and also will verify delivery of lubricant into a bearing. See Section 10 in the Service Manual for component service information.

Auto Lube System Description

Fig. 8-1 Auto Lube Pump and Grease Container

No. of Lube Points

Mast Crown Sheaves

2

Mast Lower Sheaves

2

Pipe Rack Bearing–Upper

1

Pipe Rack Bearing–Lower

1

Carousel–Upper

1

Carousel–Lower

1

Pipe Rack Roller

1

Mast Pivot Pins

2

Mast Elevating Cylinders

4

Rear Axle

2

Front Axle–Center

1

Front Axle–Ends

2

Jacks–Rear

2

Jacks–Front

2

Regulator

Lubricator Water Trap

Fig. 8-2 Auto Lube Pump Controller in Cab Fig. 8-3 Auto Lube Regulation Lubrication and Preventative Maintenance

8-3

Central Lube System

BI006752-06

Fig. 8-4 Lube Point Locations

NOTE

8-4

Lubrication points may vary by location and/or quantity based upon drill model.

Lubrication and Preventative Maintenance

BI006752-06

Manual Lube System Manual Lube System

R.H. Pump Drive Mount (11) Points Description

No. of Lube Points

Jacks–Front

2

Jacks–Rear

2

Front Axle

3

Rear Axle

2

Lower Mast Raise Cylinder

2

Mast (16) Points Description

No. of Lube Points

Upper Mast Raise Cylinder

2

Mast Pivot

2

Pulldown Sheaves

4

Pipe Rack Bearings

4

Pipe Rack Roller

1

Rotary Air Swivel

1

Mast Lock

2

PUMP DRIVE MOUNT-DUST COLLECTOR SIDE LOWER LEFT ELEV. LEFT REAR JACK LEFT REAR AXLE LOWER RIGHT ELEV. RIGHT REAR JACK RIGHT REAR AXLE LEFT FRONT JACK LEFT FRONT AXLE RIGHT FRONT JACK RIGHT FRONT AXLE FRONT AXLE CENTER

UPPER LEFT ELEV. UPPER LEFT SHEAVE UPPER RIGHT SHEAVE UPPER CAROUSEL UPPER PIPE RACK UPPER RIGHT ELEV. RIGHT MAST PIVOT LOWER RIGHT SHEAVE RIGHT MAST LOCK CAROUSEL ROLLER ROTARY AIR SWIVEL CAROUSEL LOCK LOWER PIPE RACK LOWER LEFT SHEAVE LEFT MAST LOCK LEFT MAST PIVOT

BOTTOM PLATE

NOTE: ROTATED 90° FOR CLARITY

Fig. 8-4a Manual Lube Bulkhead Locations

Lubrication and Preventative Maintenance

8-5

BI006752-06

Service Points ENGINE AIR FILTER ENGINE COOLANT

FAN DRIVE

COMPRESSOR AIR CLEANER COMPRESSOR OIL FILTER

COMPRESSOR AIR/OIL SEPARATOR TANK

DRIVE SHAFT ENCLOSURE

DIESEL ENGINE FUEL FILL

PUMP DRIVE CHARGE FILTER (LOOP FILTERS OPTIONAL) DUST COLLECTOR FILTERS

CHARGE FILTER (LOOP FILTERS OPTIONAL) RETURN FILTERS HYDRAULIC OIL TANK

PRESSURE/VACUUM FILTER

PIPE CAROUSEL

WINDOW WASHER BOTTLE

Fig. 8-5 Service Points

8-6

Lubrication and Preventative Maintenance

BI006752-06

Fig. 8-6 Service Points

Lubrication and Preventative Maintenance

A/C UNIT

HYDRAULIC OIL FILLER PUMP

TRACK FINAL DRIVE

BATTERY BOX

ROTARY DRIVE

Service Points

8-7

Lubrication–General

BI006752-06

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

After lubrication and filling, remove excess spills. Always keep fittings, caps and fill plugs clean of foreign matter.

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

Equipment photo's and drawings have been included to show the general location of points and equipment which require scheduled and periodic lubrication. The lubrication charts list the various lube and check points, filters and filter elements, and provides data such as quantities, types of lubricants recommended, and the recommended frequency of lubrication.

Care of Lubrication Points Before lubricating, or filling hydraulic fluids, the fittings, caps, and filler plugs should be thoroughly cleaned to prevent contamination.

NOTE

8-8

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

Lubrication and Preventative Maintenance

BI006752-06

Lubrication and Maintenance Chart C/A = Check/Add if required

Interval

Service Point

Service Required

Lubricant Required 5

Capacity

Engine Oil

C/A (Cummins QST30) C/A (Cummins QSK19) C/A (Cat C27) C/A (Cat C15) C/A Drain water C/A (QST30 engine only) C/A (QSK19 engine only) C/A (C27 engine only) C/A (C15 engine only) C/A C/A C/A C/A C/A Check Service Indicators Check Service Indicators 4

15W-40 (factory fill) 15W-40 (factory fill) 15W-40 (factory fill) 15W-40 (factory fill) Diesel Fuel 1 ––––– 50/50 Anti-freeze/Water 50/50 Anti-freeze/Water 50/50 Anti-freeze/Water 50/50 Anti-freeze/Water Chevron AW MV ISO 32 3 Dexron III ATF (factory fill) Dexron III ATF (factory fill) Water/Anti-freeze 80W-90 Gear Oil ––––– –––––

35 gal. (133 L) 16 gal. (60.6 L) 19 gal. (72 L) 10 gal. (38 L) varies by model ––––– 23 gal. (85 L) 11.1 gal (42.2 L) 14.5 gal (55 L) 5.4 gal. (20.8 L) 223.5 gal. (846 L) 58 gal. (220 L) 35 gal. (132.5 L) varies by model 6.75 qt. (6.4 L) ––––– –––––

Check/Clean Lubricate Check/Clean Inspect Integrity/Damage Inspect Integrity/Damage Inspect Integrity/Damage Inspect Integrity/Damage Check for leaks & loose bolts Inspect Check they are getting grease Top Up Top Up Top Up Charged Charged/Secure Check for correct function Check for leaks, damage, etc

––––– NLGI No. 2 Grease ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– NLGI No. 1 Grease NLGI No. 2 Grease 9 Rock Drill Oil - Grade 30 ––––– ––––– ––––– –––––

––––– as required ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– 15 gal. (57 L) ––––– ––––– ––––– –––––

Check/Torque mounting bolts Initial Change, then every 500 hrs Initial Change, then every 500 hrs Initial Change, then every 300 hrs Initial Change, then every 300 hrs Initial Change, then every 250 hrs C/A Initial Change, then every 3 mnths Initial Change, then every 300 hrs Initial Change, then every 1000 hrs

––––– ––––– ––––– Dexron III ATF Dexron III ATF ––––– 80W-90 Gear Oil 80W-90 Gear Oil ISO 68 80W-90 Gear Oil

––––– ––––– ––––– 58 gal. (220 L) 35 gal. (132.5 L) ––––– 20 gal. (75.5 L) 1 qt. (.95 L) 42 oz. (1.26 L) 2.1 gal. (8 L)

Fuel Tank Fuel/Water Separator Engine Coolant 2

Daily or Each Shift

Weekly or 50 Hrs

Hydraulic Oil Tank Separator Tank (low press) Separator Tank (high press) Water Tank (optional) Pump Drive Gearcase Air Cleaners Oil Filters Radiator & Coolers Shock Sub & Air Swivel Tracks, Rollers, Sprockets Track Frames, Axles, Mounts Mast & A-Frame Cab Mountings Deck & Surrounds Rotary Head & Motor(s) Pulldown/Hoist Ropes Pulldown Sheaves Grease Pump Lubricator Pipe Thread Lubricator DTH Hammer Reservoir 7 Fire Suppression System Fire Extinguisher Operating Controls Walk Around Inspection Cooler Fan Hydraulic Filters Coolant Filter (if equipped) Separator Tank (low press) Separator Tank (high press) Compressor Oil Filter Rotary Drive Gearbox Water Pump (vertical) Water Pump (horizontal) Track Final Drive Gearbox 6

PLUS ALL ITEMS LISTED IN DAILY SERVICE

Lubrication and Preventative Maintenance

8-9

Lubrication and Maintenance Chart

BI006752-06

C/A = Check/Add if required Interval

Service Point

IInitial Change at 24 hours of winch operation Change Compressor Oil Filter Change at 250 hours Engine Oil & Filter Replace Engine Fuel Filter(s) Replace Engine Air Filter (primary) Check Engine Air Filter (safety) Check/Refill/Test Engine Coolant Replace Engine Coolant Filter Check Condition/Test Radiator Cap Clean/Top Up Batteries Drain Water Fuel Tank Replace Comp. Air Filter (primary) Check Comp. Air Filter (safety) Drain Water Comp. Receiver Tank C/A Oil Receiver Tank Replace Comp. Main Oil Filter Comp. Control Cyl. Orifice (HP) Clean Comp. Control Regulator (HP) Check/Adjust Press. Control Regulators (HP) Check/Adjust C/A Pump Drive Gearbox (Cotta) Drain & Replace Oil Rotary Drive Gearbox Check Pre-Load (0.002–0.004 in.)

Rotary Drive Spindle Check/Replace (shim as required) Rotary Head Wearpads Check, LP=150 PSI (10 bar) Water Pump Pressure HP=375–400 PSI (26–28 bar) C/A Water Pump Oil Level Clean Water Pump Strainer Check Water Pump Coupling Check/Adjust Air Conditioner Belt Check/Adjust Alternator Belt 10 Inspect/Lube Mast Pivot Pins/Bushings Hoist/Pulldown Ropes Check/Adjust per Service Manual Track Chains Check/Adjust per Service Manual Winch

150 to 250 Hrs

Lubricant Required 5

Service Required

Capacity

80W-90 Gear Oil

1/2 to 2 pints (.24 to .95 L) ––––– ––––– 15W-40 (factory fill) see daily ––––– ––––– ––––– ––––– ––––– ––––– Water/Anti-Freeze 50/50 see daily ––––– ––––– ––––– ––––– Distilled Water ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– Dexron III ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– 80W-90 Gear Oil 6.75 qt. (6.4 L) 80W-90 Gear Oil 20 gal. (75.5 L) ––––– ––––– ––––– ––––– ––––– ––––– see 50 hrs ––––– ––––– ––––– ––––– NLGI No. 2 Grease ––––– NLGI No. 2 Grease

see 50 hrs ––––– ––––– ––––– ––––– ––––– ––––– –––––

ISO 68

42 oz. (1.26 L)

Dexron III ATF

see daily

PLUS ALL ITEMS LISTED IN DAILY & 50 HRS SERVICE Water Pump (horizontal) 300 Hrs

Separator Tank8

Change Oil (500 hrs if using special Cat oil) Change Oil

PLUS ALL ITEMS LISTED IN DAILY/50/150–250 HRS SERVICE

8-10

Lubrication and Preventative Maintenance

BI006752-06

Lubrication and Maintenance Chart C/A = Check/Add if required

Interval Service Point

500 Hrs

1000 Hrs or Yearly 2000 Hrs or Two Years

Service Required

Lubricant Required 5

Hydraulic Fluid Hydraulic Filters Engine Air Filter (safety) Engine Crankcase Breather Comp. Control Air Filter Comp. Air Filter (safety) Air Filter Housings Pump Drive Gearbox Water Pump (vertical) Water Injection Pump Strainer Dust Collector

Capacity 3 223.5 gal. (846 L) Initial Change, then every 1000 hrs Chevron AW MV ISO 32 ––––– ––––– Replace ––––– ––––– Replace ––––– ––––– Check/Clean ––––– ––––– Replace ––––– ––––– Replace ––––– ––––– Clean 80W-90 Gear Oil 6.75 gal. (6.4 L) Drain/Replace Oil 80W-90 Gear Oil 1 qt. (.95 L) Change Oil (every 3 months) ––––– ––––– Replace ––––– ––––– Check Timer Cycle

Air Conditioner Filter Winch Rotary Drive Spindle

(3.2 sec. between pulses) Check air pressure (approx. 40 psi [2.8 bar]) Replace Drain Gear Oil/Replace Check–adjust as necessary

PLUS ALL ITEMS LISTED IN DAILY/150–250/300 HRS Track Final Drive Gearbox 6 Drain/Replace Hydraulic Tank

Drain, Clean, Replace Oil

–––––

–––––

––––– 80W-90 Gear Oil –––––

––––– 4 pints (1.9 L) –––––

80W-90 Gear Oil Chevron AW MV ISO 32

see daily 223.5 gal. (846 L)

––––– ––––– Water/Anti-freeze 50/50 ––––– –––––

––––– ––––– see daily ––––– –––––

PLUS ALL ITEMS LISTED IN DAILY/150–250/300/500 HRS Comp. T-Tank Separator Comp. Return Strainer Engine Coolant All Pump Pressure Settings All Valve/Other Settings

Replace Replace Drain/Flush/Replace Check/Adjust per Service Manual Check/Adjust per Service Manual

PLUS ALL ITEMS IN DAILY/150–250/300/500/1000 HRS

NOTES: 1.

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

2.

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

3.

Chevron AW MV ISO 32 is the standard factory fill for hydraulic fluid. Other fluids may be used if they meet the specifications listed in this section.

4.

Indicators may show change or by-pass when fluid is cold; reset and check again.

5.

For severe operating conditions (extreme cold or tropical), use appropriate viscosity of lubricants or use fully synthetic lubricants as shown on the Cold Weather Lubricants chart is this section..

6.

Tropical conditions require initial change at 50 hours then every 250 hours.

7.

Optional for use with down-the-hole hammer.

8.

See compressor oil lubrication chart for alternate oils and change intervals.

9.

Lithium Base with 3% Molydbenum Disulfide.

10.

Replacement of the retaining pins is recommened whenever mast raise/lower cylinder is removed or replaced.

Lubrication and Preventative Maintenance

8-11

BI006752-06

Lubricant Specifications Hydraulic System Selection of Hydraulic Oil

These selections assume "normal operating conditions" as expected in quarry or quarry-like operations.

Hydraulic oils meeting the following specifications will be acceptable for use in the drill. Machines are factory filled with ISO 32 oil, unless specified otherwise when ordered. Consult manufacturer before switching to an oil of different viscosity.

CHEVRON AW MV or EQUAL ISO Grade

15

32

46

68

100

CPS Number

232953

255678

255679

232952

232950

API Gravity

27.3

32.6

31.9

30.9

30.7

15.8 4.0

30.4 6.1

43.7 8.0

64.6 10.6

95.0 13.5

210oF

85.3 39.7

155 46.6

222 53.0

329 62.3

487 73.4

Viscosity Index

159

153

157

154

143

-54 (-65)

-48 (-54)

-42 (-44)

-42 (-44)

-39 (-38)

150 (302)

190 (374)

186 (367)

212 (414)

232 (450)

_

3000+

3000+

3000+

2000+

Viscosity, Kinematic cSt at 40oC cSt at

100oC

Viscosity, Saybolt SUS at 100oF SUS at

Pour Point,

oC (oF) oC (oF),

Flash Point,

min.

Oxidation Life

ASTM D 943 hr.1

DO NOT use these products in high pressure systems in areas subject to fire hazard.

1 6000+ hours for IS0 32, 46 & 68 from the West Coast (Richmond, El Segundo and Willbridge).

NOTE

Diesel fuel or kerosene used as dilutants for cold weather operation are not recommended, as they are not sufficiently refined products. Do not use any fire resistant fluids or non-petroleum oils without consulting the manufacturer.

Hydraulic Tank Capacity Model

Capacity

Notes

MD6290

223.5 gal. (846 L)

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

MD6290

178 gal. (674 L) Fluid level should be near the top of the sight gauge, when all cylinders are fully retracted.

8-12

Lubrication and Preventative Maintenance

BI006752-06

Lubricant Specifications

Compressor Lubrication The chart below lists manufacturer approved oils.

Ambient Temperature Range oF (oC)

Lubricant

Change Interval Hours

-20 to 120 (-29 to 49) 10 to 110 (-12 to 43) 0 to 100 (-18 to 38) 0 to 100 (-18 to 38)

Sullair AWF *D-A Torque Fluid SAE 10W SE, SF, SG, CD MIL-L-2104E 10W

1200 300 300 300

* Product of D-A Lubricant® Company Inc. Ambient Temperature Range oF (oC)

Lubricant

Change Interval Hours

-20 to 120 (-29 to 49) -20 to 100 (-29 to 38) -20 to 100 (-29 to 38) 0 to 100 (-18 to 38)

Sullair AWF Dexron III ATF Mobil SHC-624 Mobil SHC-626

250 to 300 PSIG (1724 to 2068 kPa)

350 PSIG (2413 kPa)

600 400 1200 1000

500 300 1000 800

Compressor Lubricant Specifications

Compressor oil should conform to the following specifications: A. Non-Detergent Turbine or Hydraulic Type Oil Viscosity @ 100oF o

160–200 SSU

Viscosity @ 0 F

11,000 SSU Maximum

Viscosity Index

90 Minimum

o

Pour Point F o

20o Lower than minimum starting temperature

Flash Point F

400 Minimum

Rust Inhibitor

ASTM, D665-54 No Rust after 24 hours

Oxidation Inhibitor

ASTM, D949-54 Neutral No. 2.0 or less after 1000 hours

Anti-Foam Inhibitor

ASTM, D892-46T, 3 cycles stability nil.

B. Automatic Transmission Fluid (ATF) Viscosity @ 100oF

184.2 SSU

Viscosity @ 210oF

49.1 SSU

Viscosity Index

150

o

Pour Point F

-40

Flash Point

390

C. Premium quality heavy-duty engine oil which meets the performance classification, letter designation, SE or CD of SAE J183 or MIL-L-210.

Ambient Temperature o

o

-10 F to 90 F o

Above 90 F

Lubrication and Preventative Maintenance

Grade SAE 10W SAE 20W, 20

8-13

BI006752-06

Lubricant Specifications Final Drive Oil Specifications •

Use only the lubricants listed below or oil that meets the specifications in the chart on the next page. Unit is filled at factory with 80W-90 gear oil, unless special request is made.

•

Oil must meet the specification listed on the final drive label.

•

For ambient temperatures of 50o F to 86o F (10o C to 30o C) use oil with a viscosity of ISO-VG 150 or ISO-VG 220.

•

If ambient temperature is 14o F to 50o F (-10o C to +10o C) use an oil that is one viscosity class lower.

•

If ambient temperature is 86o F to 122o F (30o C to +50o C) use an oil that is one viscosity class higher.

Recommended Oils (per ISO Specifications) ARAL

Degol BG 150

AVIA

Degol BG 220 Avilib RSX 150

BP

Energol GR-XP 150

CASTROL

Energol GR-XP 220 Alpha SP 150

CHEVRON

Alpha SP 220 NL Gear Compound 150

DEUTSCHE SHELL

NL Gear Compound 220 Omala EP 150

ESSO

Omala EP 220 Spartan EP 150

FINA

Spartan EP 220 Giran 150

FUCHS GULF

Giran 220 Renep Compound 104 EP Lubricant Oil HP 150

MOBIL

EP Lubricant Oil HP 220 GF 629 (Mobilgear 629)

TEXACO TOTAL

GF 630 (Mobilgear 630) Meropa 150 Carter EP 150 Carter EP 220

8-14

Lubrication and Preventative Maintenance

BI006752-06

Lubricant Specifications

Final Drive Oil (cont.)

Recommended Oils (per API/MIL Specifications)

For heavy duty gearbox operation use fully synthetic oils only.

Lubrication and Preventative Maintenance

8-15

BI006752-06

Lubricant Specifications Lubricating Grease

Use SAE designation MPGM which contains 3–5% Molybdenum disulfide conforming to MIL-M-7866 and a suitable corrosion inhibitor.

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

Gear Lubricant Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C. Lubricant Grades: Below -10oF (-23oC) ambient use 40W Above -10oF (-23oC) and up to 100oF (37.8oC) ambient use 80W-90 or EP90 Above 100oF (37.8oC) ambient use 85W-140 Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges)

8-16

Lubrication and Preventative Maintenance

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Lubricant Specifications

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

•

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

•

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

Engine Oil Viscosities For Ambient Temperatures o

Min.

-40

10

-40

50

SAE 0W-30

-40

30

-40

86

SAE 0W-40

-40

40

-40

104

SAE 5W-30

-30

30

-22

86

SAE 5W-40

-30

50

-22

122

SAE 10W-30

-18

40

0

104

SAE 10W-40

-18

50

0

122

SAE 15W-40

-9.5

50

15

122

Min.

SAE 0W-20

C

o

Max.

Viscosity Grade

F

Max.

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

Lubrication and Preventative Maintenance

8-17

BI006752-06

Extreme Weather Lubricants

The following chart lists replacement lubricants that are recommended for the temperature ranges shown, typically in extreme cold or tropical weather operating conditions. Consult manufacturer for proper application.

Component Description

Operating Temperature Range (Ambient)

Lubricant Required

Compressor

Mobil SHC 1024 Synthetic

Below -20 to 100oF (-28.9 to 37.8oC)

Engine Crankcase Oil

SAE 15W-40

5 to 120oF (-15 to 48.9oC)

Hydraulic Tank

Mobil Synthetic ATF

Below -10 to 100oF (-23 to 37.8oC)

Pump Drive Gearbox

Mobil Delvac 75W-90 Synthetic

-67 to 100oF (-55 to 37.8oC)

Rotary Head

Mobil Delvac 75W-90 Synthetic

-67 to 100oF (-55 to 37.8oC)

Undercarriage Final Drive

Mobil Delvac 75W-90 Synthetic

-67 to 100oF (-55 to 37.8oC)

General Grease Lubrication Points

NLGI MobilTemp SHC32

10 to 100oF (-12 to 37.8oC) -65 to 50oF (-54 to 10oC)

Drill Rod Thread Grease

Mobil CM-L NLGI 1 Citgo Lithoplex CM1

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

DTH Hammer Oiler

Rock Drill Oil

All

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

8-18

Lubrication and Preventative Maintenance

BI006752-06

Preventative Maintenance

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

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

NOTE

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

Mast Trunnion Bolt Torque Model

Dry Torque

Lube Torque

MD6290 1-1/4-7 UNC Gr8 (4)

1820 ft. lbs. (2468 Nm)

1360 ft. lbs. (1844 Nm)

MD6240 1-1/2-6 UNC Gr8 (4)

3160 ft. lbs. (4284 Nm)

2360 ft. lbs. (3200 Nm)

B

Fig. 8-7 Mast Trunion Assembly Check Torque

NOTE

See additional bolted joint maintenance guidelines in this section.

Lubrication and Preventative Maintenance

8-19

BI006752-06

Preventive Maintenance

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

Charge and Loop Filters The charge and loop filters have an o-ring that helps seal the filter bowl. If the bowl is leaking the o-ring should be replaced. Do not continue to tighten the bowl up, because this will not stop the leak and will lead to damage of the bowl and filter assembly. The o-ring should be changed every time the filter is changed.

The filters have a differential indicator and a bypass check valve to indicate when the filter is blocking, allowing time to change the filters before they are fully blocked.

Fig. 8-9 Hydraulic Loop Filter–Two filters mounted on each side of mast "A" frame.

Fig. 8-10 Hydraulic Pump Charge Filter–One filter mounted on each side of pump drive.

1. Head Assembly 2. Bowl 3. O-Ring, Bowl 4. Filter Element 5. O-Ring, Element 6. Indicator 7. O-Ring, Indicator 8. O-Ring, Indicator 9. Bleed Plug 10. O-Ring, Bleed Plug 8-20

Lubrication and Preventative Maintenance

BI006752-06

Preventive Maintenance

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

Clean the area around the filter covers to prevent dirt entering the filter housings.

•

Pull filters from the housings. Install new filter and install the covers making sure the cover O-ring is in place.

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

•

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

•

A temperature gauge is also provided on the sight gauge.

CLEANLINESS cannot be overstressed: •

Use new oil only from previously unopened containers.

•

Clean all tank openings.

•

Fill tank through return filter.

Compressor Lubrication Procedure •

Drain Receiver Condensate

Service Indicators Fig. 8-11 Return Filters Mounted on Hydraulic Tank

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

•

Tabbed Nut

Check Oil Level The oil level is checked at the sight glass with machine level at each shift. The machine must be shut down long enough to permit oil foam to settle or check before start-up at the beginning of the shift. Oil level should be at the center of the sight glass.

•

Change Oil Every 300 hours or as specified in compressor lubrication chart. Use Dexron III ATF or consult factory for specific recommendations if extremely severe duty is encountered. Change oil filter element.

•

Lubricate control and linkage. Clean oil return line strainer.

Compressor Oil Filter •

Blocked filter indicator will pop up red if the element needs changing.

•

If the filter bowl is leaking, the O-ring needs to be changed. Flogging up the tabbed locking nut will not stop the leak.

Lubrication and Preventative Maintenance

Fig. 8-12 Compressor Oil Filter

8-21

BI006752-06

Preventative Maintenance Winch Lubrication •

Check oil level every 3 months or 500 operating hours whichever occurs first. Remove the large plug located in the center of the drum support. Oil level should be at the bottom of this opening.

•

Gear housing should be drained and filled with new oil after the first 100 hours of operation. Then oil should be changed every 1000 hours of winch operating time or every six (6) months, whichever occurs first.

•

Remove and clean vent plug in solvent every time oil is changed. Vent plug must be kept clean and free from obstructions.

•

The standard factory fill from Braden for the BG8 winch is Texaco Meropa150. Other oils may be used if they meet the following specifications: Do not mix different kinds of oil.

AGMA 4EP or API GL-2 with ISO viscosity grade 150.

The following are recommended oils: Texaco

Exxon

Mobil

Shell

Chevron

Meropa 150

Spartan EP 150

Mobilgear 629

Omala 150

American Industrial Oils 150

Meropa 220

Spartan EP 220

Mobilgear 630

Omala 220

American Industrial Oils 220

NOTE: All gearcases are factory filled with Mobillube SCH 75W-90 Synthetic gear lube for cold weather operation.

Water Pump (Cat Pump) The Cat Pump, Model 1050 is factory filled with Mobil SHC 626. This is suitable for temperatures below 0oF (-17.8oC). Special oil is available from Cat Pump dealers. If another type oil is used, be sure it meets the specifications for Cat Pumps.

•

Fill with oil to red dot in sight window on back of pump (Fig. 8-13).

•

Lubricate the wicks monthly with 2-3 drops of oil in each hole on top of the crankcase (Fig. 8-14).

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

Fig. 8-13 Cat Pump Oil Level Sight Window (back of pump)

8-22

Fig. 8-14 Cat Pump Oil Filler Cap and Wick Lubrication Points

Lubrication and Preventative Maintenance

BI006752-06

Preventive Maintenance

Remove the radiator pressure cap slowly and only when the engine is cool or serious burns could result.

Cooling System–Cummins The engine's cooling system is designed to provide adequate cooling during all normal operating conditions. Engine overheating can become the primary cause for extensive repair work, lost operating time, and possibly result in eventual complete engine failure. Cooling system maintenance should, therefore, hold an important place in the drill maintenance program.

The engine cooling system is filled with a 50/50 mix of anti-freeze and water. Refer to engine operating manuals for complete cooling system specifications and maintenance. The Cummins QST30 is equipped with two coolant filters (Fig. 8-15). These are to be changed every 250 hours of operation. Cooling system is to be drained, flushed, and refilled every 2 years, or 6000 hours of operation, whichever occurs first. Cummins recommends filling system with Fleetguard® Compleat, a fully formulated anti-freeze which contains supplemental coolant additive

Every 250 Hours: Change Coolant Filters 1.

Turn valve to OFF position, and remove filters.

2.

Clean mounting base and be sure old gasket is not stuck to it.

3.

Apply a thin film of oil to the gasket and install new filters. Screw filter on until gasket contacts base, then tighten 1/2 to 3/4 turn by hand. Turn valve to ON position.

Fig. 8-15 Cummins QST30 Engine–right side 1. On/Off Valve 2. Coolant Filters

Fig. 8-16 Engine Radiator

Cooling System–Caterpillar Caterpillar recommends the following coolant types: •

Preferred–Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that meets the Caterpillar EC-1 specification.

•

Acceptable–Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial heavy-duty coolant/antifreeze that meets ASTM D4985 or ASTM D5345 specifications.

Lubrication and Preventative Maintenance

8-23

Preventive Maintenance

BI006752-06

Supplemental Coolant Additive (SCA) Cummins recommends DCA4 as the supplemental coolant additive. DCA4 is compatible with all type of coolant except Methoxy Propanol. Supplemental coolant additive prevents the buildup of corrosion and scale deposits in the cooling system. The correct concentration is 1.5 units for each gallon (3.8 L) of coolant. Concentration must never drop below 1.2 units, nor exceed 3 units per gallon (3.8 L).

If coolant is added between drain intervals, the SCA concentration must be checked, and added, if required. A coolant test kit no. CC2626 is available from Cummins dealers.

When the system is initially filled, the correct amount of liquid SCA is added to make 1.5 units of SCA per gallon (3.8 L) of coolant. In this case, total system capacity is 71 gallons (269 L), so 47.3 SCA units are required. When changing coolant filters at 250 hours, normally 4 SCA units will bring the system up to the required amount. Filters contain SCA in crystal form that dissolves in the system. Filters come in 2, 4, 6, 8, 12, 15, and 23 SCA units. A filter is also available with no SCA units.

At each filter change, check the system with a Cummins coolant test kit. This kit contains strips, to dip in the coolant that will determine the SCA level. If additional SCA is required, add liquid SCA to bring up to correct concentration.

Air Cleaners The air cleaner should be inspected periodically to maintain engine and compressor protection and maximum service life. These inspections should include the following points: 1.

Inspect the air transfer duct between the air cleaner and the engine to be sure all clamps are tight, all flange joints are tight, and there are no cracks in the ducting.

2.

Air cleaner mounting bolts and clamps must be tight to hold the air cleaner securely.

3.

Check the dust cup to make sure it is sealing 360o around the air cleaner body.

4.

Vacuator valve must be in place, not inverted, and free from obstruction.

5.

Check for dents and damage to the air cleaner which could mean a leak.

Fig. 8-17 Air Cleaner Assembly

Air Filter Elements Replace air filter elements as required per maintenance schedule, or when indicated by pressure differential indicator on filter.

DO NOT clean filter element with high pressure air (30 PSI maximum). Advise replacement of filter element.

DO NOT start engine when the filter element(s) is removed from the air cleaner NEVER attempt to clean the element by rapping it. Rapping the element will dent the metal covering. The inner paper element will in turn rub this dent, causing the element to puncture.

8-24

Lubrication and Preventative Maintenance

BI006752-06

Preventive Maintenance

Track Final Drive Gearbox Recommended Service for F130 Gearbox Oil Change 1.

See Lubrication and Maintenance Chart in this section.

Oil Analysis 1.

Oil analysis should be performed on a regular basis (example: quarterly).

2.

Particle ppm levels should be compared to Warning Level Guidelines below and necessary actions should be taken.

3.

Upon high Fe-Cr contamination levels, the sun gear/input shaft should be inspected for wear and replaced as necessary. If the sun gear is ok, further internal gearbox inspection should be performed.

Sun Gear 1.

The sun gear/input shaft should be changed out upon initial wear indication.

2.

The sun gear/input shaft generally has the highest wear rate and needs to be replaced periodically to prevent other gearbox component failures. It is suggested that a maintenance program should consider replacing the sun gear at 6,000–8,000 machine hours.

Warning Level Guidelines for Contamination and Wear Metals Normal

Caution

Serious

Si (Silicon)

200 ppm

>400 ppm

>600 ppm

Fe (Iron)

500 ppm

>1500 ppm

>3000 ppm

Cu (Copper)

80 ppm

>160 ppm

>240 ppm

Cr (Chromium)

10 ppm

>15 ppm

>25 ppm

Al (Aluminum)

50 ppm

>100 ppm

>150 ppm

Caution: In this case the gearbox must be kept under control.

Serious: In this case the gearbox manufacturer suggests changing the oil and repeating the tests after a short period of work. If the values are still serious, the manufacturer suggests rebuilding or replacing the gearbox.

These values are only guidelines and can be modified due to specific applications.

Notes: Si-Al Contamination also from external sources Fe-Cr Wear metals by gears and bearings ''Cu Wear metal be brake discs Lubrication and Preventative Maintenance

8-25

Preventative Maintenance–Mast Pivot

BI006752-06

Mast Pivot Shaft Inspection and Repair Procedure A visual inspection should be performed with the mast in the horizontal position by removing the trunnion cap and bushing. Clean the shaft and shoulder radius free of lubricant and inspect visually for any indication of cracking in the radius. Perform visual inspection at the mid point of non-destructive test (NDT) interval #1 and #2.

Intervals for magnetic particle inspection will be in accordance with AS1171 or a dye penetrant test, post repair. Same inspection intervals apply to new machines or replaced shafts. Intervals are operating hours on shaft.

SHAFT DETAIL

MD6240 Interval #1 <15,000 Hours Inspect every 3000 Hours

Interval #2 >15,000 Hours but <25,000 Hours Inspect every 1500 Hours

MD6290/MD6420 Interval #1

Interval #3

<15,000 Hours Inspect every 5000 Hours

>25,000 Hours Inspect every 1000 Hours

Interval #2 SHAFT DETAIL

RO.25 ORIGINAL RADIUS

>15,000 Hours but <30,000 Hours Inspect every 3000 Hours

Interval #3 RO.38 MAXIMUM RADIUS 30˚ MAX ANGLE

>30,000 Hours Inspect every 2000 Hours

Approved Pivot Shaft Repair Procedure Fatigue cracking in the A-Frame pivot shaft radius of rotary blashole drills may be repaired by completely grinding out cracks up to a maximum depth of 0.12 in. or 3mm. This approved repair method is intended only to extend the service life of a shaft that is in the first stages of fatigue where the cracking is not extensive and is just becoming visible. Shafts with more extensive cracking, i.e. crack depths exceeding 0.12 in.

(3mm) should be replaced by removing the shaft from the A-Frame structure and rewelding a new shaft in place in accordance with the factory repair procedure.

Unapproved Repair No grinding that undercuts the diameter of the bearing surface is allowed. Cracking outside of the hatched area is not repairable by grinding and requires replacement of the shaft. All known fatigue cracking has occured in the hatched area.

8-26

NON-REPAIRABLE FATIGUE CRACK Lubrication and Preventative Maintenance

BI006752-06

Rev A

Preventive Maintenance–Weld Inspection

Lubrication and Preventative Maintenance

8-27

BI006752-06

Preventative Maintenance–Bolted Joints Bolted Joint Maintenance for Rotary Drills Introduction

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

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

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

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

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

Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance x Surface Degradation Surfaces under bolt heads can degrade due to creep failure, embedment, high bearing stress, corrosion or a combination of these. These rotary drills use hardened washers in many situations to help prevent surfaces from degrading. Critical joints may use “Nordlock” washers which are a hardened, zinc coated, two-piece serrated washer incorporating inclined planes at the mating boundary of the two pieces. To loosen a bolt using this locking device, the bolt must be significantly stretched. Critical bolted joints are identified in the “Critical Fastener ID & Inspection Schedule” drawing in this manual. Joints that are assembled with Nordlock washers and hardened washers are less likely to experience surface degradation, as the hardness of the washer is close to the hardness of the fastener and is harder than the surface of most nuts used in these drill assemblies. x Corrosion Most critical bolted joints on these rotary drills contain components that are made from steel. Most bolts used are also steel, and therefore susceptible to rusting. Water is a small molecule and can find its way into the smallest spaces to attack the surfaces of a bolted joint and the bolt head, body and threads. We recommend that all critical fasteners be lubricated using a lubricant that contains Molybdenum Disulfide (NLGI 2 Molycoat or Never-Seize are readily available Worldwide. Good quality NLGI 2 grease can be substituted if a Moly product is not available at the time of service.)

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Lubrication and Preventative Maintenance

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Preventive Maintenance–Bolted Joints

x Vibratory Overload Abusive, unusual or unforeseen loads can cause bolted joint separation. This can result in the loosening of bolts, which in turn can cause bolt fatigue failure. Bolt fatigue will generally result in a fracture surface and ultimately failure at the first engaged thread of the bolt or sometimes in the fillet under the bolt head. Loose bolts can also fail quickly in fatigue. As an example, tests conducted by a bolt manufacturer indicated that a bolt tightened to 1420 lb tension and stressed cyclically to 9215 lb failed after 5960 load cycles. Identical bolts tightened to 8420 lb and stressed to the same 9215 lb survived 4.65 million cycles before failure. If the bolts had been tightened beyond 9215 lb, it would have been impractical to cycle them to failure. x Thermal Relaxation Bolted joints exposed to high temperatures or thermal cycling have a tendency relax or lose bolt tension over time, due to stress creep. Since pre-loading stretches bolts, and only stretches them a few thousandths of an inch. It is easy to imagine that a bolt heated to the operating temperature limits of an air compressor could increase the plasticity of the bolt material, allowing it to lose some of its initial loading. Bolted joints of a new machine that are subjected to high heat should be checked and re-torqued to specification after the first 500 hours of operation.

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

Failure of these joints could endanger personnel or seriously damage equipment. As stated earlier, these are identified in the drawing “Critical Fastener ID & Inspection Schedule. We recommend that critical bolted joints of drills should be checked for proper torque every 120 days or 2000 operating hours for machines that have less than 10,000 operating hours, and every 90 days or 1500 operating hours for machines that have greater than 10,000 operating hours.

If a bolt is found to be loose (less than 90% of specified torque value), it should be removed and replaced. If the joint contains more than one bolt, all bolts in the joint should be replaced. The joint mating surfaces and bolts should be inspected for signs of corrosion, surface degradation, and the presence of hardened washers or Nordlock washers. Joints with Nordlock washers require the replacement of the washers as well. Hardened washers can generally be reused as long as the washer is undamaged. The new bolts should be lubricated with NLGI2 molycoat grease and torqued to the proper specification. Bolts should be replaced with the same grade bolt that was originally in the assembly. These drills primarily use SAE Grade 5 and Grade 8 bolts. These are identified by the markings on the head of the bolt. Chart #1 of the drawing for each machine titled “Critical Fastener Torque Values” graphically depicts the standard indentifying bolt markings.

Bolts in critical joints should also be removed and visually inspected for corrosion and relubricate every 2.5 years or 15,000 hours of operation. If bolts are not damaged, they maybe reinstalled and returned to service. Any damaged or corroded bolts should be discarded and replaced.

In addition, bolts in critical joint should be replaced every 5 years or 30,000 hours of operation, regardless of apparent condition.

Other Bolt Maintenance All bolts contained in these drills are subject to the same topics described above, but generally do not have the same degree of risk involved should a bolt failure occur. Every machine should have a “walk-around” inspection performed at the beginning of each operating shift, which includes looking for loose hardware. Other significant bolted joints include all pressurized fittings, flange connections and all bolted pin retainer/keeper plate bolts. All machine bolts should be inspected for proper torque specification annually at a minimum.

Lubrication and Preventative Maintenance

8-29

8-30

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

REPLACE EVERY 5 YEARS OR 30000 HRS

INSPECT AND RE-LUBRICATE OR REPLACE IF DAMAGED EVERY 2.5 YEARS OR 15000 HRS

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

MACHINE SERVICE HOURS:

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

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

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

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

WINCH MOUNTING FASTENERS

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

LEVELING JACK CAP FASTENERS

REPLACEMENT OF THE RETAINING PINS IS RECOMMENED WHENEVER MAST RAISE/LOWER CYLINDER IS REMOVED OR REPLACED.

UNDERCARRIAGE MAIN AXLE FASTENERS

AFRAME PIVOT CAP FASTENERS MAST PIVOT CAP FASTENERS

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS

CRITICAL FASTENER ID & INSPECTION SCHEDULE

Preventative Maintenance–Bolted Joints

BI006752-06

Lubrication and Preventative Maintenance

BI006752-06

Preventive Maintenance–Bolted Joints

Standard Torque Values SAE Recommended Torque Values SAE Grade 5 Tightening Torque

SAE Grade 8 Tightening Torque

Size

Dry K=.2 (Ft lb)

Lub K=.15 (Ft lb)

Dry K=.2 (Ft lb)

Lub K=.15 (Ft lb)

3/8-16 UNC 3/8-24 UNF

30 35

23 25

45 50

35 35

7/16-14 UNC 7/16-20 UNF

50 55

35 40

70 80

55 60

1/2-13 UNC 1/2-20 UNF

75 90

55 65

110 120

80 90

5/8-11 UNC 5/8-18 UNF

150 170

110 130

220 240

170 180

3/4-10 UNC 3/4-16 UNC

260 300

200 220

380 420

280 320

7/8-9 UNC 7/8-14 UNF

430 470

320 350

600 660

460 550

1-8 UNC 1-12 UNF

640 700

480 530

900 1000

680 740

1-1/8-7 UNC 1-1/812 UNF

800 880

600 660

1280 1440

960 1080

1-1/4-7 UNC 1-1/4-12 UNF

1120 1240

840 920

1820 2000

1360 1500

1-1/2-6 UNC 1-1/2-12 UNF

1940 2200

1460 1640

3160 3560

2360 2660

Lubrication and Preventative Maintenance

8-31

8-32

1 - 8UNC GRD8 680 FT LBS LUBRICATED

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

LUBRICATE BOLTS WITH 3% MOLY NLGI2 EXTREME PRESSURE GREASE, P/N 966825 OR EQUIVALENT.

NOTES

WINCH MOUNTING FASTENERS

5/8-11UNC GRD5 110 FT LBS LUBRICATED

UNDERCARRIAGE MAIN AXLE FASTENERS

NOTE "NORDLOCK" WASHERS

NOTE "NORDLOCK" WASHERS

1-1/2 - 6UNC GRADE8 2360 FT LBS LUBRICATED

MAST PIVOT CAP FASTENERS

1/2 -13UNC GRD5 55 FT LBS LUBRICATED

1/2 -13UNC GRD5 55 FT LBS LUBRICATED

NOTE HARDENED WASHERS

3/4 - 10UNC GRD5 200 FT LBS LUBRICATED (.85 PROOF LOAD)

LEVELING JACK CAP FASTENERS

NOTE "NORDLOCK" WASHERS

NOTE "NORDLOCK" WASHERS

REPLACEMENT OF THE RETAINING PINS IS RECOMMENED WHENEVER MAST RAISE/LOWER CYLINDER IS REMOVED OR REPLACED.

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

1/2 - 13UNC BRASS 55 FT LBS (DO NOT LUBRICATE) USE LOCTITE NOTE "NORDLOCK" WASHERS

NOTE "NORDLOCK" WASHERS

3/4 - 10UNC GRD8 280 FT LBS LUBRICATED

Preventative Maintenance–Bolted Joints

BI006752-06

Critical Fastener Torque Values–MD6240

Lubrication and Preventative Maintenance

Lubrication and Preventative Maintenance

1 - 8UNC GRD8 680 FT LBS LUBRICATED

1-1/4 - 7UNC GRADE8 1360 FT LBS LUBRICATED

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

LUBRICATE BOLTS WITH 3% MOLY NLGI2 EXTREME PRESSURE GREASE, P/N 966825 OR EQUIVALENT.

NOTES

WINCH MOUNTING FASTENERS

5/8-11UNC GRD5 110 FT LBS LUBRICATED

UNDERCARRIAGE MAIN AXLE FASTENERS

NOTE "NORDLOCK" WASHERS

NOTE "NORDLOCK" WASHERS

MAST PIVOT CAP FASTENERS

NOTE HARDENED WASHERS

3/4 - 10UNC GRD5 200 FT LBS LUBRICATED (.85 PROOF LOAD)

LEVELING JACK CAP FASTENERS

3/8 -16UNC GRD5 23 FT LBS LUBRICATED

1/2 -13UNC GRD5 55 FT LBS LUBRICATED

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS REPLACEMENT OF THE RETAINING PINS IS RECOMMENED WHENEVER MAST RAISE/LOWER CYLINDER IS REMOVED OR REPLACED.

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

1/2 - 13UNC BRASS 55 FT LBS (DO NOT LUBRICATE) USE LOCTITE NOTE "NORDLOCK" WASHERS

NOTE "NORDLOCK" WASHERS

3/4 - 10UNC GRD8 280 FT LBS LUBRICATED

BI006752-06

Preventive Maintenance–Bolted Joints

Critical Fastener Torque Values–MD6290

8-33

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Preventive Maintenance Electrical System

Be sure battery is filled and kept charged. A discharged battery will freeze at much higher temperatures than a fully-charged battery.

Battery terminals should be kept clean and tight for dependable operation.

See engine manual for engine electronics and diagnostic codes for electronic engines.

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

1.

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

2.

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

3.

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

4.

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

5.

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

Scheduled Oil Sampling Analysis The manufacturer recommends that scheduled oil sampling be taken at regular intervals. This will maintain all warranty requirements and monitor condition of component wear in the system.

Oil sampling must be carried out at regular intervals to serve as an effective indicator for component wear. Intermittent oil sampling does not allow a wear pattern to be established. Samples should be taken from the following components.

• Hydraulic Oil •

Compressor Oil

•

Engine Oil

•

Rotary Gearbox and Pump Drive Gearbox Oil

Sampling Criteria •

Recommended interval for oil samples is every 200 hours.

•

Take samples when oil is warm and well mixed to assure an accurate reading.

•

A proper oil analysis should include the following three elements: 1. Wear Analysis 2. Chemical and Physical Tests 3. Oil Condition Analysis

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Drill Stem Thread Lubricator

Description and Adjustments The drill can be equipped with an optional automatic drill string thread greasing system. The system uses an air powered grease pump attached to a 35 lb. (15.9 kg.) grease container. The system is activated by a switch on the drill control console, and the pump delivers grease to the nozzle mounted adjacent to the drill stem.

Air supply is filtered, lubricated and regulated by the filter/regulator/lubricator mounted on the left rear jack housing. Normal pressure setting is 80 PSI (5.5 bar). See Section 10 of the Service Manual for component servcie information.

Thread Lube Pump

Thread Lube Pump Regulation

Fig. 8-18 Drill Stem thread Lubricator System Lubricator

Lubrication and Preventative Maintenance

Water Trap

8-35

BI006752-06

Metric Conversions METRIC CONVERSION TABLE English to Metric

Metric to English LINEAR

inches (in.) feet (ft.) miles (mi.)

X 25.4 X 0.3048 X 1.6093

= millimeters (mm) = meters (m) = kilometers (km)

millimeters (mm) meters (m) kilometers (km)

inches2 (sq.in.) feet2 (sq.ft.)

X 645.15 X 0.0929

= millimeters 2 (mm 2) = meters2 (m 2)

inches3 (cu.in.) quarts (qts.) gallons (gal.) inches3 (cu.in.) feet3 (cu.ft.) feet3 (cu.ft.) fluid ounce (fl.oz.)

X X X X X X X

= liters (l) = liters (l) = liters (l) = centimeters3 (cc) = liters (l) = meters3 (m 3) = millileters (ml)

X 0.3937 X 3.281 X 0.6214

= inches (in.) = feet (ft.) = miles (mi.)

AREA millimeters 2 (mm 2) meters2 (m 2)

X 0.000155 = inches2 (sq.in.) = feet 2 (sq.ft.)

X 10.764

VOLUME 0.01639 0.94635 3.7854 16.39 28.317 0.02832 29.57

liters (l) liters (l) liters (l) centimeters3 (cc) liters (l) meters3 (m3) milliliters (ml)

X X X X X X X

61.024 1.0567 0.2642 0.06102 0.03531 35.315 0.03381

= = = = = = =

inches3 (cu.in.) quarts (qts.) gallon (gal.) inches3 (cu.in.) feet 3 (cu.ft.) feet 3 (cu.ft.) fluid ounce (fl.oz.)

X X X X X

0.03527 2.2046 0.001102 1.1023 0.000984

= = = = =

ounces (oz.) pounds (lbs.) tons (2000 lbs.) tons (2000 lbs.) tons (long) (2240 lbs.)

X X X X X X

0.2961 0.145 14.22 14.5 4.0193 0.01

= inches Hg (60oF) = pounds/sq.in. (PSI) = pounds/sq.in. (PSI) = pounds/sq.in. (PSI) o = inches H2O (60 F) = bars

MASS ounces (oz.) pounds (lbs.) tons (2000 lbs.) tons (2000 lbs.) tons (long) (2240 lbs.)

X X X X X

28.35 0.4536 907.18 0.90718 1013.05

= grams (g) = kilograms (kg) = kilograms (kg) = metric tons (t) = kilograms (kg)

grams (g) kilograms (kg) kilograms (kg) metric tons (t) kilograms (kg)

PRESSURE inches Hg (60 F) pounds/sq.in. (PSI) pounds/sq.in. (PSI) pounds/sq.in. (PSI) o inches H2O (60 F) bars

X X X X X X

horsepower (hp) ft.-lbs./min.

X 0.746 X 0.0226

o

3600 6.895 0.0703 0.069 0.2488 100

= kilopascals (kPa) = kilopascals (kPa) = kilograms/sq.cm. (kg/cm 2) = bars = kilopascals (kPa) = kilopascals (kPa)

kilopascals (kPa) kilopascals (kPa) kilograms/sq.cm. (kg/cm2) bars kilopascals (kPa) kilopascals (kPa)

POWER = kilowatts (kW) = watts (W)

kilowatts (kW) watts (W)

X 1.34 X 44.25

= horsepower (hp) = ft.-lbs./min.

X 8.851 X 0.7376 X 7.233

= pound-inches (in.lbs.) = pound-feet (ft.-lbs.) = pound-feet (ft.-lbs.)

X 0.6214 X 3.281 X 3.281

= miles/hour (m/h) = feet/second (ft./sec.) = feet/minute (ft./min.)

TORQUE pound-inches (in.-lbs.) X 0.11298 pound-feet (ft.-lbs.)

X 1.3558 pound-feet (ft.-lbs.)

X .1383

= newton-meters (N-m) = newton-meters (N-m) = kilograms/meter (kg-m)

miles/hour (m/h) feet/second (ft./sec.) feet/minute (ft./min.)

= kilometers/hour (km/hr) = meter/second (m/s) = meter/minute (m/min)

newton-meters (N-m) newton-meters (N-m) kilogram/meter (kg-m)

VELOCITY X 0.11298 X 0.3048 X 0.3048

kilometers/hour (km/hr) meters/second (m/s) meters/minute (m/min)

TEMPERATURE o

Celsius = 0.556 ( F - 32) o

o

Fahrenheit = (1.8oC) + 32

COMMON METRIC PREFIXES mega kilo hecto deka

8-36

(M) (k) (h) (da)

= = = =

1,000,000 or 106 1,000 or 103 100 or 102 10 or 101

deci centi milli micro

(d) (c) (m) (m)

= = = =

0.1 or 10-1 0.01 or 10-2 0.001 or 10-3 0.000.001 or 10-6

Lubrication and Preventative Maintenance

BI006752-06

Torque Values for Split Flange Connections

The following chart provides the tightening torques for split flange connections used in hydraulic systems.

Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly.

NOTE

Over-torquing bolts will damage the flanges and/or bolts, which may cause leakage.

Bolt Torque Flange Size in Inches (*) 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2

Bolt Size in Inches 5/16 3/8 3/8 7/16 1/2 1/2 1/2 5/8 5/8

Newton Meter (Nm) 20–24 30–37 37–47 47–61 62–79 75–88 107–123 187–203 159–180

Pound-Force/Foot (ft. lb.)

15–18 22–27 27–35 35–45 46–58 55–65 79–91 138–150 117–133

(*) Inside diameter of hydraulic tube or hose fitting.

Lubrication and Preventative Maintenance

8-37

BI006752-06

Torque Values for Hydraulic Tubes & Fittings O-Rings Boss Plugs and Swivel Nuts JIC 37o Seat

Tube Nuts for 37o Flared Fittings Torque

Torque

Size

Tubing O.D. in Inches

Thread Size in Inches

Newton Meter (Nm)

PoundForce/ Foot (ft. lb.)

Newton Meter (Nm)

PoundForce/Foot (ft. lb.)

4

1/4

7/16-20

14–27

10–20

8–14

6–10

5

5/16

1/2-20

20–34

15–25

14–20

10–15

6

3/8

9/16-18

34–47

25–35

20–27

15–20

8

1/2

3/4-16

54–75

40–55

34–41

25–30

10

5/8

7/8-14

75–102

55–75

47–54

35–40

12

3/4

1-1/16-12

102–129

75–95

81–95

60–70

14

7/8

1-3/16-12

129–156

95–115

95–108

70–80

16

1

1-5/16-12

156–197

115–145

108–122

80–90

20

1-1/4

1-5/8-12

203–244

150–180

129–156

95–115

24

1-1/2

1-7/8-12

271–339

200–250

163–190

120–140

32

2

2-1/2-12

407–475

300–350

339–407

250–300

NOTES: 1. Above Torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations.

2. Swivel nuts either swaged or braxed.

3. These torques are not recommended for tubes with wall thickness of 0.89 mm (0.035 in.) or less.

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DATE

Maintenance Record

HOUR METER

MAINTENANCE PERFORMED

Lubrication and Preventative Maintenance

WORK WORK PERFORMED AUTHORIZED BY BY

8-39

BI006752-06

Maintenance Record DATE

8-40

HOUR METER

MAINTENANCE PERFORMED

WORK WORK PERFORMED AUTHORIZED BY BY

Lubrication and Preventative Maintenance

BI006752-06

DATE

Maintenance Record HOUR METER

MAINTENANCE PERFORMED

Lubrication and Preventative Maintenance

WORK WORK PERFORMED AUTHORIZED BY BY

8-41

BI006752-06

Maintenance Record

DATE

8-42

HOUR METER

MAINTENANCE PERFORMED

WORK WORK PERFORMED AUTHORIZED BY BY

Lubrication and Preventative Maintenance

BI006752-06

BI006752-06

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