CAT Rotary Track Drill MD6540 Rotary Blasthole Drill Operation & Maintenance Manual - PDF D0WNLOAD

EM027298-0 (EN-US) December 2016

Operation and Maintenance Manual MD6540 Rotary Blasthole Drill DR5-Up

SAFETY.CAT.COM

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

Delivery Date

Product Information Model Product Identification Number Engine Model/Serial Number Compressor Model/Serial Number Undercarriage Model/Serial Number Rotary Drive Model/Serial Number Pump Drive Model/Serial Number Rock Drill Model/Serial Number Customer Equipment Number Dealer Equipment Number

Dealer Information Name

Branch

Address

Dealer Contact

Phone Number

Sales Parts Service Caterpillar Global Mining LLC Mining Products Division 3501 S. FM Hwy 1417 Denison, TX 75020 For Factory Spare Parts Ordering, Contact Your Local Cat Dealer Technical Parts Support Technical Service Support Machine Breakdown Emergency

+ 1.903.415.4021 + 1.903.786.6455 + 1.903.814.3744

Hours

Contents INTRODUCTION .........................................................................................................................II PRODUCT DESCRIPTION ........................................................................................................III SAFETY......................................................................................................................SECTION 1 GENERAL INFORMATION.........................................................................................SECTION 2 OPERATOR CONTROLS ...........................................................................................SECTION 3 OPERATING INSTRUCTIONS...................................................................................SECTION 4 DRILLING PROCEDURES.........................................................................................SECTION 5 LUBRICATION AND MAINTENANCE ........................................................................SECTION 6 OPTIONS AND ACCESSORIES ................................................................................SECTION 7

Specifications are subject to change without notice.

09/15/2014

Introduction

i

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

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

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

Before Starting Engine, Study Operator's Manual * Read and understand the warnings and cautions shown in Section 1 * Practice All Safety Precautions * Make Pre-Operations Check * Learn Controls Before Operating It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws, and regulations.

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

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

ii

Introduction

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

The MD6540 is a crawler mounted drill rig, which consist of two (2) major assemblies: 1.

Rotary Drill Assembly

2.

Excavator Type Undercarriage (Crawlers)

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

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

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

NOTE

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

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

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

Introduction

iii

Notes

iv

Introduction

Section 1

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

Safety

1-1

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

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

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

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

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

Safety Alert Symbol

Hazard 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 1-2

Safety

Overview of Potential Hazards Potential Hazard

Safety

Prevention

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

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

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

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

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

Keep clear of rotating drivelines.

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

Entanglement Hazard. Rotating parts can cause personal injury.

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

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

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

Burn Hazard. Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

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

Keep hands clear of moving parts during equipment operation.

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

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

1-3

Overview of Potential Hazards Potential Hazard

Prevention

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

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

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

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

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

1-4

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

Maintain required clearance.

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

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

Flying Object & Spray Hazard.

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

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

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

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

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

Safety

1-5

Safety Before Operation •

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

•

Do be sure all safety guards are securely in place.

•

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

•

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

•

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

•

Do attach safety chain when using towbar.

•

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

Operation •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

1-6

Safety

Safety After Operation Normal Shutdown 1.

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

2.

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

3.

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

4.

Turn the ignition key to OFF position.

5.

Check machine for any unusual conditions.

6.

Report any defects to your immediate supervisor.

Maintenance •

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

Do Not weld or grind near oil lines.

•

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

•

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

•

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

Safety

1-7

Safety Equipment Transfer •

If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics from the operator's manual:

•

Safety Section

•

Operation Instructions including:

•

Pre-Start Checks

•

Start-up

•

After Start Checks

•

Shutdown Procedure

•

Propelling Machine

Clearances from High Voltage Lines Line Voltage Minimum Clearance 0 to 50 kv 10 ft (3 m) 50 to 200 kv 15 ft (4.6 m) 200 to 350 kv 20 ft (6.1 m) 350 to 500 kv 25 ft (7.6 m) 500 to 750 kv 35 ft (10.7 m) 750 to 1000 kv 45 ft (13.7 m) Table 1-1 Minimum Safe Distances from High Voltage Lines

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

1-8

Safety

Safety Sign List Diesel Drill Refer to Figures 1-1 and 1-2 for locations Item Description 1 WARNING - Falling Objects (Winch) 2 WARNING - Falling Objects (Carousel) 3 WARNING - Rotating Shaft 4 WARNING - Entanglement 5 WARNING - Falling Mast 6 WARNING - Hot Pressurized Fluid 7 WARNING - Climbing Raised Mast 8 WARNING - Modification or Alteration 9 WARNING - Hazardous Voltage 10 WARNING - Riding Rotary Head 11 WARNING - Flying Objects & Spray 12 WARNING - Rotating Parts 13 WARNING - Falling Rotary Head 14 WARNING - Combustible Gas (Batteries) 15 WARNING - Combustible Gas (Ether) 16 WARNING - Crush Hazard (HOBO) 17 WARNING - Fall Hazard 18 DECAL - Lift Point 19 WARNING - Crush Hazard (Stairway) 20 WARNING - Crush Hazard (Hand) (ref. 429429 rev. B)

Part No. 429414 429448 429406 428893 429418 429449 429404 429445 429437 429420 429141 429431 429426 429439 429444 T105427 428885 409673 439015 T105425

Qty. 1 2 2 6 2 1 2 1 1 1 1 2 2 1 4 1 2 8 2 5

Part No. 429414 429448 429406 428893 429418 429404 429445 429437 429420 429141 429431 429426 429439 429444 428885 409673 T105427 439015 T105425 T105487 T105496 T105489 T105490

Qty. 1 2 2 4 2 2 1 1 1 1 2 2 1 4 2 8 1 2 5 4 2 8 4

Electric Drill Item Description 1 WARNING - Falling Objects (Winch) 2 WARNING - Falling Objects (Carousel) 3 WARNING - Rotating Shaft 4 WARNING - Entanglement 5 WARNING - Falling Mast 6 WARNING - Climbing Raised Mast 7 WARNING - Modification or Alteration 8 WARNING - Hazardous Voltage 9 WARNING - Riding Rotary Head 10 WARNING - Flying Objects & Spray 11 WARNING - Rotating Parts 12 WARNING - Falling Rotary Head 13 WARNING - Combustible Gas (Batteries) 14 WARNING - Combustible Gas (Ether) 15 WARNING - Fall Hazard 16 DECAL - Lift Point 17 WARNING - Crush Hazard (HOBO) 18 WARNING - Crush Hazard (Stairway) 19 WARNING - Crush Hazard (Hand) 20 DANGER - Electrocution 21 DECAL - 380 VAC 22 DECAL - 6600 VAC 23 DECAL - 240/120 VAC (ref. T105357) Safety

1-9

Safety Sign Locations

Fig. 1-1 (20M Diesel) 1-10

Safety

Safety Sign Locations

Fig. 1-2 (20M Diesel)

Safety

1-11

Safety Signs

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.

429418

429448

429448

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.

429406

429406

429418

WARNING

WARNING Entanglement Hazard

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

Burn Hazard Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

429449

429449

1-12

Safety

Safety Signs DANGER

WARNING

Maintain required clearance.

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

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

Always contact the electric power line owner.

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

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

Crush / Fall Hazard

429404

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

Safety

1-13

Safety Signs

WARNING

WARNING

Entanglement Hazard

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

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.

Do not operate with guard removed.

Keep all guards in place.

READ MANUALS Read all manuals prior to operation.

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

429431

Consult your supervisor, the owner or the manufacturer.

429431

429439

WARNING

429439

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

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

429426

429426

Combustible gas can cause severe injury or death.

WARNING

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

Explosion Hazard

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

429444

429444

Stay clear of moving breakout wrench.

Be sure personnel are clear before actuating breakout wrench.

T105427

T105427 1-14

Safety

Safety Signs

WARNING

WARNING

Crush Hazard

Fall Hazard Death or serious injury can result from falling.

Use the access system provided when servicing the machine.

Standing on stairway when raising or lowering can result in death or serious injury.

428885

428885

WARNING

Stay clear of moving stairway.

439015

439015

Crush Hazard Contact with moving parts can cause severe injury.

Keep hands clear of moving parts during equipment operation.

T105425

T105425

Safety

1-15

Safety Signs DANGER

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

NOTICE

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

Read manuals.

T105487

ELECTRICAL SHOCK. CAN CAUSE SEVERE INJURY OR DEATH.

T105487

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

422855

422855

409673

1-16

Safety

Safety Signs (International)

429740

Flying Object & Spray Hazard (429740)

429712

429720

Explosion/Burn Hazard (429720)

Fall Hazard–Mast (429712)

T104915

Fall Hazard (T104915)

429713

Explosion Hazard–Ether (429713) 429705

Entanglement Hazard (429705) Safety

1-17

Safety Signs (International)

429718

XXXX lbs/ XXXX kg

Crush Hazard–Carousel (429718) 429721

Crush Hazard–Winch (429721)

429715

Crush Hazard–Mast (429715) 429719

Crush Hazard–Rotary Head (429719)

1-18

Safety

Safety Signs (International)

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) Safety

1-19

Safety Signs (International)

T105428

Crush Hazard–HOBO (T105428)

T105426

Crush Hazard (T105426)

T104915

Fall Hazard (T104915)

T105488

Electrocution Hazard (T105488)

T105374

Crush Hazard–Stairway (T105374)

1-20

Safety

Section 2

Machine Specifications and Transport

Specifications and Transport

2-1

Introduction This manual contains detailed instructions, maintenance information, and technical data which the Operator will need in order to properly operate the MD6540 Rotary Blasthole Drill, and to perform the various maintenance services that are required for keeping the equipment in good working condition at all times.

Included herein are complete descriptions of each operating control and step-by-step instructions on how to start, operate, and stop the equipment, and recommended Operator's maintenance procedures.

The maintenance procedures in this manual are included as recommendations only and are based on normal equipment working conditions. Changes should be initiated by the Owner/Operator in order to compensate for other than normal conditions and to meet the working requirements of any specific job application.

By faithfully using this manual as a guide, and observing the instructions and recommendations, the drill will give many years of dependable and efficient service at a minimum cost for operation.

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

MD6540 Rotary Blasthole Drill 2-2

Specifications and Transport

Machine Specifications Rated Capacity Hole diameter

Cooler Assemblies 229-381 mm (9-15 in)

16 meter config Depth single-pass Depth multi-pass

Up to 16.15 m (53 ft) Up to 84.73 m (278 ft)

20 meter config Depth single-pass Depth multI-pass

Operating Temperature Min. ambient rating standard unit &ROG ZHDWKHU RSWLRQ Max. ambient rating standard unit Altitude

Size Top tank

Up to 19.86 m (65 ft 2 in) Up to 65.58 m (215 ft 2 in) 2LO &RROHU T\SH &RPSUHVVRU VHFWLRQ VL]H Û & Û )

Û & Û )

+\GUDXOLF VHFWLRQ VL]H

Û & Û )

P RYHU IW

)DQ FRPPRQ WR HDFK XQLW

6 blades, 1 per motor )DQ VSHHG

Pull-down/Hoisting Capacity 3XOO GRZQ FDSDFLW\ Up to 489 kN (1 OEI

+RLVW FDSDFLW\ 8S WR N1 OEI

'ULOOLQJ IHHG UHWUDFW UDWH P PLQ ISP

T\SH &ORVHG ORRS K\GUDXOLF VWDWLRQDU\ URG PRYLQJ barrel) 1XPEHU RU F\OLQGHUV 1 &\OLQGHU ERUH 222 mm (8.75 in) diameter &\OLQGHU URG 121 mm (4.75 in) diameter &DEOH W\SH 29 mm (1.125 in) '<)250 &DEOH VKHDYHV F\OLQGHU

(QJLQH 5DGLDWRU &RROHU T\SH

559 mm (22 in) PD

&DEOH sheaves (top and bottom) PP (24 in) PD Sheave guards Standard at bottom plate Adjustable head guide shoes Steel Zith rHSODFHDEOH N\ODWron™

)DQ JXDUG Max. ambient rating

Torque

5RWDWLRQ SRZer Gearbox Main thrust bearing LubrLFDWLRn Gearing 5DWLo Drive motor Specifications and Transport

- rpm HSLT (std) -124 rpm LSHT option -17 219 Nm ( ft-lb) standard HSLT - Nm (15,4 ft-lb) LSHT option 271 kW (363 hp) &Dsting design Taper roller 2LO IORRGHG Straight spur 16:1 SHH K\GrDXOLF s\stem

6HSDUDWH FRUHV VWDFNHG PP LQ ZLGH [ PP LQ WDOO PP LQ

2 per FRROHr PP diameter (42 in) 2-speed fans KLJK VSHHG USP Welded Û & Û )

Compressor &RPSressor (Standard) T\SH

2LO IORRGHG VLQJOH VWDJH VFUHZ 'LVFKDUJH DLU IORZ VHD OHYHO P3 PLQ FIP

Max. operating pressure EDU SVL

'LVFKDUJH IORZ PD[ VHWWLQJ P3 PLQ FIP

(sea level) $GMXVWDEOH GRZQ WR 'LVFKDUJH IORZ PLQ VHWWLQJ (sea level) 51 m3 PLQ FIP

$LU FOHDQHU T\SH

Rotary Drive System 5RWDWLRQ speed

-DFNHW ZDWHU DQG VHFRQGDU\ ORRS VWDFNHG PP LQ ZLGH [ PP LQ WDOO Sealed deaeriation tank, SUHVVXUH FDS RYHUIORZ WXEH and sight glass

Model 2LO FRROLQJ 2LO VHSDUDWLRQ

2LO ILOWUDWLRQ Drive &RQWUROV Air shut-off

'U\ W\SH ZLWK VDIHW\ element 66* WZR HDFK

Air WR RLO FRROHr, WKHUPRVWDWLFDOO\ FRQWUROOHG VHUWLFDO EDUULHU HOHPHQW pre-separation in 189 L JDO VXPS YHUWLFDO WDQN PLFURQ UHSODFHDEOH element 'LUHFW FRXSOHG WR HQJLQH IO\ZKHHO $XWRPDWLF ZLWK VDIHW\ VKXW GRZQ +\GUDXOLF F\OLQGHr-operated from operator’s seat

2-3

Machine Specifications Engine (Standard) Manufacturer Model Rated horsepower Full load RPM Starting system Safety shut-down system Air cleaner Type Model Batteries

Detroit Diesel Series 2000 16V 899 kW (1,205 hp) 1800 24 VDC, dual starters Energized to run

Dry-type with safety element 55G 20 Four (4) each 8-D Two 127 mm (5 in) inlet and Muffler 152 mm (6 in) outlet Fuel tank 2055 l (543 gal) + 1234 L (326 gal); total 3289 L (869 gal) Turbo and manifold covers Blankets, custom-fitted

Mast Construction Main chord size Front Rear Pivot and raising area

Hydraulic lines Hose tray

Operator’s Cab Location Type

Length at floor

Adjacent to the drill deck One piece, three man; shockmounted; integrated FOPS certified, fully electrical/ electronic 2581 mm (102 in)

Width at floor

1822 mm (71.75 in)

Floor area

4.4 m2 (47.3 ft 2)

Height inside

2121 mm (83.5 in)

Construction

12-gauge steel welded to 51 mm (2 in) steel tube

Windows

Tinted thermopane glass in rubber mounting

Number of windows

12

Number of doors

Two with 2 (ea) windows (included in above)

Left door to drill deck

Swing-type HD hinge

Right door

Swing-type HD hinge

ASTM 500 grade B rectangular tubing

Operator’s seat

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

203 mm x 102 mm (8 in x 4 in) 127 mm x 127 mm (5 in x 5 in) Rectangular tubing A frame, reinforced in high-stress areas, with 127 mm (5 in) high-strength plate Pressure-rated steel hydraulic tubing Bolt-on fabrications, steel lower, aluminum upper

Helper’s seat

Full-cushion type, collapsible, stow-away and removable

Insulation, floor

3 mm (.125 in) pyramid vinyl surface

Door latches

Large heavy-duty latches with lockable handles

Sound levels

72 db(A)

Climate control

Roof-mounted, AC/heating/ pressurizing unit

Roof

Roof viewing hatch with window (protected with FOPS-certified cage)

Pipe rack 194 mm (7.625 in) through 235 mm (9.25 in) OD (5 each) 254 mm (10 in) and 273 mm (10.75) OD (4 each) Feed cable tensioner Automatic

Mast Elevating Cylinders Number of cylinders 2 Cylinder bore diameters 216 mm (8.50 in); 184 mm (7.25 in); 152 mm (6 in) Cylinder rod 203 mm (8 in); 171 mm (6.75 in); 114 mm (4.5 in) Cylinder stroke

4 110 mm (161.8 in)

Lift capacity each cylinder 671 kN (150,800 lbf)

2-4

Specifications and Transport

Machine Specifications Operator’s Controls/Gauges Location Split console at front and side cab wall, placed so controls in operator’s reach while arms resting on seat armrests.

Standard Engine Controls/Indicators Water temperature High water temperature shut-down Oil pressure (electric)

Drill Monitor System Split console controls are configured with touch-screen interface to display drill health and performance One-touch auto-leveling; one-touch single-pass drilling functions included Drill performance and monitoring includes a downloadable memory function The Auto-drill system is fully configurable with any GPS/ tracking or fleet management/optimization system with one point of plug-in

Low-pressure shut-down Electric voltmeter Undercarriage Type Pad width Pad type Rollers Number of rollers-each side Upper track chain support Rock guards Overall length

Auto shut-down bypass Start button Stop button Fuel primer Tachometer Throttle control On/off light switch Hourmeter

Drive horsepower per track Brakes Brake release Tram speed max Gradeability mast down Rear axle Front Track adjustment means

11 Three (3) carrier rollers Standard full-length guards 6706 mm (264 in) (variable with adjustment) Independent hydrostatic motors 268 kW (360 hp) maximum Spring set, hydraulic release Automatic 2.09 km/h (1.3 mph) 66% 356 mm (14 in) Three-point oscillating type Hydraulic with grease gun

Track drive disconnect

Standard (manual)

Drill hour Final drive

Fuel level Diagnostic connection Diagnostic fault and indicator lights

Standard Compressor Controls Compressor discharge temperature Air pressure gauge Compressor start/run control High compressor discharge temp., engine shut-down Low compressor oil pressure, engine shut-down

Excavator type 900 mm (35.4 in) Triple grouser Sealed, oil-flooded

Full/minimum displacement switch Standard Drilling Controls: All Electric/Electronic Leveling jacks controls Dust/water injection HOBO wrench control Dust curtain Mast elevation control

Deck wrench control

Pull-down control

Level indicator

Pull-down pressure control

Winch control

Rotation control

Rod catcher control

Propel controls

Viewing hatch door control

Pipe rack in/out control

Compressor controls

Mast lock

Specifications and Transport

2-5

Machine Specifications Mainframe, Decks & Walkways Main rails Box section construction comprised of top, bottom and vertical plates, and internal stiffeners – made of ASTM Grade 50 Construction Electric-welded plate box design, sculpted to reduce stress Jacks, mast pivot and deck Welded integrally to mainframe Tools and battery box In-board extra-large toolbox (sunk in drilling deck) Machine deck Access all sides Hand rails 48 mm (1.9 in) diameter x 3759 mm (48 in) high – steel tube Tow eyes Welded, two front Leveling Jacks Number Location Cylinder bore diameter

Cylinder rod diameter

Cylinder stroke Lift capacity

Pad connection Pad diameter Safety check valves

4 2 front, 2 rear 203 mm (8 in) drilling end; 178 mm (7 in) non-drilling end 127 mm (5 in) drilling end; 102 mm (4 in) non-drilling end 1219m (48 in) drilling end; 1524 mm (60 in) non-drilling end 671 kN (150,796 lbf) each drilling end; 513 kN (115,423 lbf) each non-drilling end Ball and socket 1067 mm (42 in) CBVs internal at each cylinder

Drill Table and Work Deck Table height off ground 1854 mm (73 in) drill on tracks Deck floor material Drill deck length Drill deck width Hand rails Wide walkways Viewing hatch operated from the cab Dust curtain Material Length Width Dust Reflector Material

2-6

Ry-grip non-slip floor plate 5664 mm (223 in) workdeck 6147 mm (242 in) 48 mm diameter x 1 219 mm high (1.9 in x 48 in) steel tube In the drill deck; hydraulically

6 mm (.25 in) rubber nylon reinforced 5893 mm (232 in) 2896 mm (114 in) Directly below table bushing Natural rubber seal, 23 mm (.9 in) thick; 559 mm (22 in) diameter with hinged retainer

Hydraulic System Left Track/Rotation Pump (Closed-Loop) Type Axial piston, variable volume 473 L/min (125 gal/min) Max. flow Pressure Rating 400 bar (5,800 psi) Right Track/Feed Pump (Closed-Loop) Type Axial piston, variable volume 473 L/min (125 gal/min) Max. flow Pressure Rating 400 bar (5,800 psi) Accessory Circuit Pump (Open-Loop) Type Axial piston, variable volume Max. flow 189 L/min (50 gal/min) Pressure Rating 400 bar (5,800 psi) Fan Circuit Pumps for Split Coolers (2) Type Double gear 264 L/min (65 gal/min) dual Max. flow fan Pressure Rating 241 bar (3,500 psi) Track Drive Motors (2) Type Operating Pressure

Axial, piston 414 bar (6,000 psi)

Rotation Drive Motors (2) Type Pressure Rating

Axial, piston 345 bar (5,000 psi)

Fan Drive Motors for Split Coolers (2) Type Piston Pressure Rating 414 bar (6,000 psi) Pump Drive Gearbox Type Drive

4 pad Rubber coupler/drive shaft to front of engine

Filtration (All filters have indicators and bypass) Loop 12 micron 2 per loop Charge 3 micron 1 per loop Main return (2 each) 12 micron Case return 12 micron Oil Cooling System (Hydraulic Tank) Reservoir 1363 L (360 gal) with sight and temperature gauge Atmospheric, filtered Reservoir breather breather 10 micron Lubrication System Automatic lubrication system

Specifications and Transport

Machine Specifications Accessories, Tools & Handling Equipment Drill Pipe (optional) Diameter

Winch Location

Customer specifications, 194 mm x 273 mm (7.625 in-10.75 in)

Rating

Threads

25 mm (1 in) 13.7 m (45 ft) only for 16 m mast; 9.1 m (30 ft) only for 20 m mast (2 each on starter string) Depends on pipe size

Cable size Safety hook Brakes Auto shut-off

Adapter Sub Diameter Wall thickness Length Top thread Bottom thread

Depends on pipe diameter 25 mm (1 in) 927 mm (36.5 in) 140 mm (5.5 in) API reg.

Depends on pipe diameter

Bit Sub Diameter Wall thickness Top thread Bottom thread

Depends on pipe diameter 25 mm (1 in) Depends on pipe diameter Depends on pipe diameter

Wall thickness Length

Table Bushing Roller deck bushing Deck Wrench Location Wrench plate Wrench positioning Impact means HOBO Wrench Location Support Wrench type Power Pipe rack (inside the mast)

Typical configuration:

Front of mast in mast pivot area 3629 kg (8,000 lb) rated winch; 5 443 kg (12,000 lb) optional 16 mm (.625 in) Swivel-type positive lock Automatic Located in crown, automatically shuts off winch when ball weight is seated

Options Dust Collection Designed for high-capacity air systems, the Dry Dust Suppression System uses a fan-wheel arrangement with aggressively pitched fins/vanes that provide 173 m3/min (6,100 cfm) air flow and can develop up to 508 mm (20 in) water vacuum at the deck inlet.

Water Injection Hydraulic pump and motor arrangement with below-deck tanks, 2,922 L (772 gal) capacity.

Cold Weather Package Temperatures to -40º C/F Heating & Circulation Drainage for water-injection system temperatures to -40º C/F.

Drill deck 76 mm (3 in) T1-steel Hydraulic cylinder Stationary jaw, flats at 15 deg. off axis Lower left, outside mast Mast-mounted Patented HOBO (Hydraulic Operated Break Out) Hydraulic cylinders (3) Typical configuration: 5-pod pipe carousel for up to 235 mm (9.25 in) OD 4-pod pipe carousel for 273 mm (10.75 in) OD

Note: Final dimensions, GVW and corresponding load-out vary based on optLRQV VHOHFWHG DQG ¿QDO FRQ¿JXUDWLRQ 3HUIRUPDQFH UDWLQJV DUH EDVHG RQ HI¿FLHQFy DQG RQ HQJLQHHULQJ VSHFL¿FDWLRQV DQG FDOFXODWLRQV LQ DFFRUGDQFH ZLWK DFFHSWHG LQGXVWU\ VWDQGDUGV 7KHVH FDSDFLWLHV ZLOO YDU\ ZLWK GULOOLQJ FRQGLWLRQV $OO VSHFL¿FDWLRQV DUH VXEMHFW WR FKDQJH ZLWKRXW QRWLFH

Specifications and Transport

2-7

Dimensions

2-8

Specifications and Transport

Equipment Locator (Diesel) PIPE SUPPORT ROLLER (FOR LOADING PIPE)

JIB CRANE

JIB CRANE CONTROLS

TOOL BOX

OPERATORS CAB

H.O.B.O. WRENCH ROTARY DRIVE GEAR BOX CAB SIDE REAR JACK MAST ASSEMBLY CASCADING STAIRWAY

DUST COLLECTOR SIDE REAR JACK

LOOP FILTERS

DUST COLLECTOR PRE-CLEANER

586.98

DUST COLLECTOR (OR TOP DECK WATER TANK) CASE RETURN FILTER MAIN RETURN FILTER MAIN RETURN FILTER HYDRAULIC TANK (367 GALLON)

MAST RAISING CYLINDERS

CHARGE FILTER

CHARGE FILTER

PUMP DRIVE ASSEMBLY

ENGINE RADIATOR ENGINE MUFFLER

COMPRESSOR OIL COOLER/ HYDRAULIC OIL COOLER

AIR COMPRESSOR 3600 CFM / 100 PSI (DIESEL ENGINE OR 60 hZ MOTOR) 3150 CFM / 100 PSI 50 hZ MOTOR

DIESEL ENGINE ENGINE MUFFLER

COMPRESSOR AIR/OIL RECEIVER TANK

DUST COLLECTOR SIDE FRONT JACK

CAB SIDE FRONT JACK

ENGINE AIR FILTER

ENGINE AIR FILTER

COMPRESSOR AIR FILTERS MAST ACCESS STAIRWAY

275.90

FRONT OF MACHINE

Specifications and Transport

2-9

Equipment Locator (Electric) PIPE SUPPORT ROLLER (FOR LOADING PIPE)

JIB CRANE

JIB CRANE CONTROLS

TOOL BOX

OPERATORS CAB H.O.B.O. WRENCH

ROTARY DRIVE GEAR BOX CAB SIDE REAR JACK MAST ASSEMBLY CASCADING STAIRWAY

DUST COLLECTOR SIDE REAR JACK

LOOP FILTERS

DUST COLLECTOR PRE-CLEANER

586.98

DUST COLLECTOR (OR TOP DECK WATER TANK) CASE RETURN FILTER MAIN RETURN FILTER MAIN RETURN FILTER HYDRAULIC TANK (367 GALLON)

MAST RAISING CYLINDERS

CHARGE FILTER

CHARGE FILTER

PUMP DRIVE ASSEMBLY COMPRESSOR OIL COOLER/ HYDRAULIC OIL COOLER

MOTOR STARTER CABINENT

ELECTRIC MOTOR

AIR COMPRESSOR 3600 CFM / 100 PSI (DIESEL ENGINE OR 60 hZ MOTOR) 3150 CFM / 100 PSI 50 hZ MOTOR

COMPRESSOR AIR/OIL RECEIVER TANK

DUST COLLECTOR SIDE FRONT JACK

CAB SIDE FRONT JACK

COMP AIR FILTERS MAST ACCESS STAIRWAY

275.90

2-10

Specifications and Transport

Equipment Locator

Specifications and Transport

2-11

MD6540 Transient Stability Limits Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be stopped, mast lowered and machine shutdown.

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

7.0o

o

20.0

o

o

9.1

o

18.4

20.0

20.0

o

Approximate Transient Stability Limits for MD6540 Drills with 16M mast with long carousel and 20M mast with short carousel.

NOTE

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.

2-12

Specifications and Transport

Line of Sight Limits

Area of Vision from Operators Position Operators seat

Cameras are used in some areas of limited visibility Hatched Areas define clear vision areas from operators position

Specifications and Transport

2-13

Transporting Machine

MAST LIFTING FIXTURES (INCLUDED IN SHIPPING KIT)

MAST PIVOT CAP 1 1/4” GR8 CAPSCREWS (4 EACH SIDE) 1800 – 1820 FT. LBS. DRY TORQUE (2440 – 2468 Nm)

Fig. 2-4 Mast Assembly

NOTE

2-14

Follow the torquing procedure in Section 6 of the service manual.

Specifications and Transport

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.

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 5) and swing carousel all the way in.

2.

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

3.

Shutdown 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.

4.

Attach mast lifting fixtures (2) to the mast as shown in fig. 2-4. Use a crane(s) 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 guide ropes as necessary to control swinging of the mast.

5.

Remove the 1 1/4" GR8 capscrews and washers that secure the mast pivot caps and remove the caps.

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 pins, spacers and retainer bars.

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.

Mast Installation To install the mast on the machine, refer to the mast installation procedure in Section 6 of the service manual.

Specifications and Transport

2-15

Transporting Machine 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.

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

2.

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.

3.

Secure mast to trailer as shown in fig. 2-5.

Unloading Mast 1.

Unloading the mast is basically the reverse of loading.

Fig. 2-5 Mast Ready for Transport

2-16

Specifications and Transport

Transporting Machine 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.

Shipping Kit required to transport the drill is shown on the last page of this section.

1.

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

2.

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

3.

Support mast raise cylinders using the bracket in the Shipping Kit. Secure the cylinders to the bracket.

4.

Install the shipping beam called out in the Shipping Kit on the underside of the machine.

5.

Fully extend front and rear jacks. Disconnect hydraulic lines and remove the tracks using the track lifting fixture in the Shipping Kit.

NOTE

Due to weight constraints, tracks must be transported separate from the machine.

6.

Remove dust collector, all walkways, steps and handrails except where the cab is mounted.

7.

Attach a steel cable lifting sling to the front lifting lugs as shown in fig. 2-6. Use a crane capable of supporting the weight of the machine and raise machine to enable the trailer to be driven under. Fully retract front (non-drilling end) jacks.

NOTE

8.

Set up 6 in. to 12 in. thick timbers under the rear (drilling end) jack pads to gain the height necessary for the trailer to clear the rear of the machine.

Raise the rear (drilling end) with the jacks while hoisting the front (non-drilling end) with the crane to a height sufficient to drive the trailer under the frame.

Fig. 2-6 Front Lifting Lugs Specifications and Transport

2-17

Transporting Machine Loading Machine (cont.)

9.

Once the trailer is positioned under machine, retract rear (drilling end) jacks and lower sling to rest machine on trailer (fig. 2-7 and fig 2-8).

10. Remove the cab and walkway. Support walkway with forklift or overhead lifting device and remove the bolts that secure walkway to frame. Support cab by attaching lifting straps to lifting eyes on roof.

Disconnect all wiring and hosing. Remove all bolts that secure cab. Remove walkway and cab for separate transport.

11. Tape exhaust(s) closed, to prevent turbo charger from spinning dry. Clip all chains on handrail openings, check to see that all doors are closed tight. Turn battery disconnect switch OFF. 12. Machine should be secured to trailer at four places on each side. Secure machine to trailer at front and rear.

Fig. 2-7 Rear of Machine on Trailer with Shipping Beam Attached

Fig. 2-8 Front of Machine on Trailer Resting on Jack Pads 2-18

Specifications and Transport

Transporting Machine 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.

Unloading the machine is basically the reverse of the loading process. A crane and forklift or overhead lifting device is required to install the cab and platform and raise the machine for unloading. There are also two rear lifting lugs welded on the jack housings.

1.

Inspect machine for damage before unloading.

2.

Install platform and cab to start machine. Switch battery disconnect switch ON. Remove tape from exhaust(s).

3.

With all tie-downs removed and jacks raised, remove machine from trailer, allowing it to rest on the jacks.

4.

Install tracks.

5.

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

6.

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

Specifications and Transport

2-19

Shipping Kit Description

P/N

Quantity Req'd

Mast Cylinder Shipping Assembly

439233

2

Track Lifting Fixture

432325

1

Flat Washer, 0.750, Type A

42630

8

Lock Washer, Spring, 3/4

5965

8

Hex Nut, GR5, 3/4 - 10UNC

6371

8

Shipping Support Bracket U-Bolt Protective Hose

433649

4

Mast Lifting Fixture

438881

2

Front Lifting Lug

438954

2

Mast Elevating Cylinder Shipping U-Bolt

439237

2

Mast Pivot Shipping U-Bolt

439238

2

Lock Washer, Spring, 1/2

5975

5

Hex Nut, GR5, 1/2 - 13UNC

5973

5

Hexhead Capscrew, GR5, 1/2 - 13UNC

5977

5

Mast Shipping Brace

439343

2

Shipping Beam

433683

1

Cable Reel Shipping Cradle*

442218

1

Cable Reel Clevis Lug*

442219

1

Cable Reel Shipping Cradle Clevis Pin*

442220

1

Cable Reel Lifting Lug*

442221

2

* Electric machines (ref. 442521)

2-20

Specifications and Transport

Section 3

Operator Controls NOTE

The use of "(Electric)" following a title refers to the electric drive motor powered machine. "(Diesel)" refers to all diesel engine powered machines, unless otherwise noted for a specific model.

Operator Controls

3-1

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

Pipe Rack – SWING IN

Left Rear Jack – RAISE/LOWER

Pulldown Relief – INCREASE/DECREASE

Pipe Rack – SWING OUT

Front Jack – RAISE/LOWER

Drill Rotation Relief – INCREASE/DECREASE

Pipe Rack – ROTATE CCW

Right Rear Jack – RAISE/LOWER

Manual Pulldown – RAISE/LOWER

Pipe Rack – ROTATE CW

Mast – RAISE/LOWER

Winch – RAISE/LOWER

Auto Leveling

Stairway – RAISE/LOWER

Drill Propel – FORWARD/REVERSE

3-2

Operator Controls

Graphic Symbol Legend

Deck Wrench – ENGAGE/DISENGAGE

Dust Curtain – UP/DOWN

Lube – AUTO/MANUAL

HOBO – CLAMP/UNCLAMP

Rod Catcher – OPEN/CLOSED

Mast – LOCK/UNLOCK

HOBO – SWING IN/SWING OUT

Pipe Rack – LOCK/UNLOCK

Compressor Volume Control

Drill Pipe – CLAMP/UNCLAMP

Viewing Hatch – OPEN/CLOSED

Compressor – ON/OFF

Drilling Air – ON/OFF

Auto Pulldown – ON/OFF

Propel – Drill

Water Injection – Dust Collector

Water Injection Flow Control

Window/Deck/Roof Wipers

Rotation – FORWARD/REVERSE

Operator Controls

3-3

Graphic Symbol Legend

Auxiliary Functions Pressure

Rotation Pressure

Compressor Air Cleaner H2O

Compressor Discharge Pressure Drilling Air Pressure

Engine Air Cleaner H2O

Voltage (Battery Charging)

Fuel Level

Tram Hourmeter

Drill Hourmeter

Engine Coolant Temperature

Fuel Primer

Dust Collector Timer

Engine Oil Pressure

Compressor Temperature

Horn

Engine Hourmeter

Engine START

Power ON/OFF

3-4

Pulldown Pressure

Operator Controls

Operator Controls and Indicators LOOK UP before raising or lowering mast. DO NOT allow any part of the machine to contact or come near electrical power lines. See Section 1 for clearances.

Check for obstructions before moving machine or mast.

NOTE "PUSH" LEVER–Move lever AWAY FROM OPERATOR "PULL" LEVER–Move lever TOWARDS OPERATOR

CIRCUIT BREAKERS AND INSTRUMENT PANEL

RH UPPER CONSOLE

B

RH CONSOLE LH CONSOLE

Fig. 3-1 Operator Controls

Cab Console Layout 3-5

Operator Controls and Indicators

Fig. 3-2

2

1

3

4

5

6

7

8

R.H. Console

9

10

13 11

12

Right Hand Console 1.

Snake Light

2.

Winch Lever Controls the raising and lowering of the winch. PUSH to raise, PULL to lower.

3.

Mast Lever Controls the raising and lowering of the mast. PUSH to raise, PULL to lower.

3-6

Operator Controls

Operator Controls and Indicators Right Hand Console (cont.)

Jack Levers Used for raising and lowering the jacks. Always level rear (cab end) of machine first.

PUSH to raise jacks, PULL to lower.

4. Left Rear Jack 5. Front Jacks 6. Right Rear Jack 7.

Left Propel Lever Controls the speed and direction of the tracks. PUSH to propel forward, PULL to propel in reverse.

8.

Right Propel Lever Controls the speed and direction of the tracks. PUSH to propel forward, PULL to propel in reverse.

9.

Drill/Propel Switch Three position switch that engages the drilling controls or the propel system. LEFT to propel, RIGHT to drill. MIDDLE position is neutral position and used when machine is off or unattended.

When in the propel position, the cable reel on electric machines is energized to automatically pay out or retrieve the electric power cable.

10.

Rotation Pressure Control Controls forward (CW) rotation torque by controlling the circuit pressure. Turn CW to increase pressure and forward rotation torque, CCW to decrease.

11.

Bullseye Level Gauge Indicates when the machine is level.

12.

Hoist\Pulldown Control Controls raising and lowering of the rotary head. PULL for down, PUSH for up.

13.

Rotation Control Controls rotary head speed and direction. PULL for forward (CW) rotation, PULL for reverse (CCW) rotation.

Operator Controls

3-7

Operator Controls and Indicators

Fig. 3-3

L.H. Console

19 18 17 20

16 15

21

14

22 13 1 2

12 3

4

5

6

7

8

9

10

11

Left Hand Console 1.

Deck Wrench/Hydraulic Operated Bit Basket (HOBB) (optional) Switch LEFT for deck wrench function, RIGHT for HOBB function.

2.

Hydraulically Operated Deck Wrench (HOBO) Reverse (optional) Switch reverses function of HOBO. Switch LEFT for counterclockwise operation , RIGHT for clockwise operation.

3.

Mast Lock Switch Locks and unlocks the mast in the vertical or angle drilling positions. Turn and hold switch LEFT to unlock (retract) mast pins, RIGHT to lock (engage) BE SURE to visually check to see that the mast lock pins are fully engaged in the locating holes before drilling or tramming and fully retracted before lowering the mast.

3-8

Operator Controls

Operator Controls and Indicators Left Hand Console (cont.)

4.

Side Wiper Switch Activates wiper/washer for side (deck) window.

5.

Compressor Pressure Control Switch Controls compressor high/low air volume. Switch LEFT for low air volume (2400 CFM), RIGHT for high air volume (3600 CFM).

6.

Water Injection/Dust Collector Switch Three position switch that engages the water injection system or dust collection used for dust suppression. Switch LEFT to engage water injection, MIDDLE for neutral, RIGHT to engage dust collector.

7.

Dust Curtains and Viewing Door Four way lever used to raise and lower the dust curtains at the rear and side of the machine and to open and close the viewing door to enable viewing of the drill hole for setup and collaring. PUSH to open viewing door, PULL to close. Move LEFT to lower dust curtains, RIGHT to raise.

8.

Water Injection Flow Control Controls the volume of water being injected into the air line. CW to decrease volume, CCW to increase.

9.

Auto Pulldown Switch Engages and disengages the auto pulldown for drilling operations.

10.

Carousel Swing and Rotate Used for indexing the carousel for differing pipe locations and to swing the carousel out from and into the center of the mast. Utilized when adding and retracting drill pipe and storing the carousel when propelling or lowering the mast. PUSH to swing in, PULL to swing out, LEFT to rotate CW, RIGHT to rotate CCW. Always ensure the pipe loader is fully swung out when bring the rotary head down the mast, unless adding or retracting drill pipes. Ensure the rotary head is well clear of the pipe loader swing range before swinging the pipe loader in.

11.

Pulldown Pressure Control Controls the pulldown pressure for both auto feed and manual feed to increase or decrease the weight on the drill bit. Turn clockwise (CW) to increase pressure, counterclockwise (CCW) to decrease.

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

12.

Drilling Air Control Turns drilling air on and off for drilling operations. PULL to turn air on, PUSH to turn air off.

Always check for personnel standing near the machine BEFORE turning air ON.

Operator Controls

3-9

Operator Controls and Indicators

Fig. 3-3

L.H. Console

19 18 17 20

16 15

21

14

22 13 1 2

12 3

4

5

6

7

8

9

10

11

Left Hand Console (cont.)

13.

Deck Wrench Retracts or extends the deck wrench to hold the drill pipe when breaking or threading joints or when multiple pass drilling is required. PUSH to retract wrench, PULL to engage.

14.

Drill Pipe Support Control Used to support the drill pipe in the center of the mast when using the drill pipe loader for multiple pass drilling. PUSH to unclamp from drill pipe, PULL to clamp.

Always ensure the pipe support is fully retracted (disengaged) when drilling and when bringing the rotary head to the bottom of the mast.

15.

3-10

Hydraulically Operated Breakout Wrench (HOBO) Four way lever used to undo tight thread connections. PULL to swing wrench in to drill pipe, PUSH to swing wrench out away from drill pipe. Move LEFT to unclamp (open) wrench, RIGHT to clamp (close) and turn the wrench.

Operator Controls

Operator Controls and Indicators Left Hand Console (cont.)

16.

Carousel Index Lock Used to lock or unlock the drill pipe loader left or right to enable it to be indexed. LEFT unlocks, RIGHT locks.

Always have the carousel in the LOCKED position when breaking out connections.

17.

Pipe Retaining Safety Arm Retracts or extends the pipe retaining safety arm. PUSH to extend, PULL to retract.

Always have the carousel IN prior to activating to prevent the arm fouling on the carousel.

18.

Roof Wiper Switch Activates wiper/washer for roof window.

19.

Front Wiper Switch Activates wiper/washer for front window.

20.

Rear Wiper Switch Activates wiper/washer for rear window

21.

Track Spray Switch Activates track sprayer. LEFT for manual spray, RIGHT for auto spray.

22.

Turkey Nest Sprayer Switch Activates turkey nest spray. LEFT for manual spray, RIGHT for auto spray.

Operator Controls

3-11

Operator Controls and Indicators Circuit Breaker and Instrument Panel

1 2 3 4 5 6

7 8 9 10 11

12

13

14

15

16

18 17 21

19

22

20 24

25

23

Fig. 3-4

3-12

Circuit Breakers and Instrument Panel Controls

Operator Controls

Operator Controls and Indicators Circuit Breaker and Instrument Panel Circuit Breakers 1..

Interior Lights - 15 AMP

2.

Engine Switch - 5 AMP

3.

Gauge - 15 AMP

4.

Monitoring - 15 AMP

5.

Aux - 15 AMP

6.

Wipers - 20 AMP

7.

Fridge - 10 AMP

8.

Radio - 15 AMP

9.

Camera - 10 AMP

10.

Air/Con - 40 AMP

Gauges and Switches 11.

Tachometer/Hour Gauge

12.

Cabinet Panel Latch

13.

Tram Hour Gauge

14.

Drill Hour Meter Gauge

15.

Compressor Temperature Gauge

16.

Voltmeter Gauge

17.

Main Lights Switch

18.

Work Lights Switch

19.

Mast Lights Switch

20.

12 Volt Outlet

21.

Horn Push button Switch

22.

Start Switch

23.

Engine Idle Speed Select Switch

24.

ON/OFF Key Switch

25.

Stop Switch

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3-13

Operator Controls and Indicators Right Hand Upper Console Camera Display

Emergency Stop Button

Boarding Stairs Up

Boarding Stairs Light

Boarding Stairs Down

Fig. 3-5 Camera Screen and Boarding Stairs Control

NOTE

3-14

Emergency stop button should not be used for normal engine stop.

Operator Controls

Operator Controls and Indicators Remote Mounted Cameras There are two remotely mounted cameras (fig. 3-7) 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 (fig. 3-6) 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.

Fig. 3-6 Remote Camera Display in Cab 1

Fig. 3-16 Camera Display Controls 2 3 4 5 6 7

9

8

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

View of Left Side of Machine

View of Front of Machine Fig. 3-7 Remote Cameras Mounted on Front of Machine Operator Controls

3-15

Operator Controls and Indicators Inclinometers There are two lighted inclinometers (fig. 3-8) mounted in the top right front corner of the cab, measures the level of the machine in degrees. In addition, a mast mounted inclinometer (fig. 3-9) shows the operator the approximate position of the mast in five degree increments.

Fig. 3-8 Cab Inclinometers 1. Measures degrees of the machine from front to rear.

2. Measure degrees of machine from side to side.

Fig. 3-9 Mast Inclinometer

Fig. 3-10 Remote Keyboard/Display on Circuit Breaker Panel

Fig. 3-11 Thread Grease Foot Control (Cab Floor)

Pre-programmed at factory–used for starting electric drive motor and fault code displays.

Operator presses to apply thread grease while connecting drill pipe.

3-16

Operator Controls

AC/Heater/Pressurizer Unit AC/Heater Controls-Manual The AC/Heater controls (fig. 3-12) are designed to provide a simple means of maintaining a comfortable in-cab environment with varying external conditions.

1.

Fan Speed Switch Provides three fan speeds for varying supply airflows to be selected by the operator for their comfort. The switch must be set to of these speeds for the unit to operate.

2.

Mode Switch Vent—Provides for supply air fan operation only. No cooling or heating takes place. It is recommended that this mode be used if neither heating nor cooling is required to help maintain a dust free cab.

Fig. 3-12 Heater/Air Conditioner Controls (Diesel)

Cool—Energizes the compressor circuit via the thermostat so that cooling can occur. Maximum cooling is obtained when the fan speed is set to HI and the thermostat is turned fully CCW. Heat—Energizes the heater hot water solenoid valve via the thermostat so that heating can occur.

Maximum heating is dependent on water temperature but is obtained when the fan speed is set to HI and the thermostat is turned fully CW. Demist—In this mode, both the compressor and heater solenoid valve circuits are energized with only the compressor being controlled by the thermostat. Maximum demisting is obtained when the fan speed is set to LO and the thermostat is turned fully CCW. 3.

Thermostat Controls the cab temperature between 64oF and 82oF (18oC and 28oC) by measuring the return air temperature inside the unit. Excessive fiddling with this control should be avoided so that the system can operate on a balanced cycle.

4.

Supply Air This plenum incorporates multi-directional diffusers through which supply air is discharged into the cab. The diffusers can also be directed away from the operator onto windows for demisting.

Fig. 3-13 Heater/Air Conditioner Controls (Electric)

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3-17

AC/Heater Controller AC/Heater Controls-Electronic Different models of AC/Heater units can be installed in these machines. Some models have the Sigma with manual controller while other models have the MI Air (roof mounted) with an electronic controller. For programming and fault code information for the electronic unit, refer to the following MI Air user manual.

3-18

Operator Controls

AC/Heater Controller (MI AIR)

AIR CONDITIONING SYSTEM CONTROL

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3-19

AC/Heater Controller (MI AIR)

VENTILATION

HEATING

FAILURE MODE

REFRIGERATION

INCREASE

DECREASE

TEMPERATURE ENTER

Introduction The control panel consists of a keyboard for operational programming of the air conditioning system and a numerical display to visualise parameters and operational status.

The controller is designed to operate in a temperature range of -40°C to +90°C (-40°F to +194°F). The system measures the temperature within the cab of the machine.

3-20

Operator Controls

AC/Heater Controller (MI AIR) Initial Adjustments Date and Time When turning the controller ON for the first time, the software version will show in the display window. After that, you should adjust the clock and date using the UP and DOWN arrows on the control panel. Additionally, whenever power is disconnected and reconnected to the unit, the system will request the operator to adjust the clock and date

Hour

Year

Day

Month

Set Point The desired temperature inside the cab is called the setpoint.

To adjust the setpoint use the up

or down

keys.

General On-Off From the “Off” position, the following will start the system: • Pressing either the heat or cool buttons. Red LEDS will be displayed if the selection is active.

• Pressing the fan button and moving the fan speed off U-0.

From the “On” position, the following will stop the system: • Pressing either the heat or cool buttons. Red LEDS will be turned off.

• Pressing the fan button and moving the fan speed to U-0.

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3-21

AC/Heater Controller (MI AIR) Manual Ventilation The manual ventilation is activated by pressing the key. There are six evaporator fan speeds. To change the evaporator speed, the fan button must be pressed, and then adjusted up or down by the arrow keys. The arrow keys must be pressed within a certain time period before it reverts back to automatic. The ventilation speed will be shown by the bar graph on the display.

To shut down the ventilation, press the fan key twice.

Automatic Ventilation The automatic ventilation fan speed is controlled by the setpoint and internal adjustable parameters. The difference between the setpoint and cab temperature will determine the fan speed - the larger the difference, the faster the fan speed.

Cooling As soon as you press the key and with the temperature inside the cab above the setpoint, the system will start the cooling process.

Every time the system starts in cooling mode, the evaporator fan will operate in AUTO mode. By pressing the key, it’s possible to change the fan speed manually.

Heating As soon as you press the key and with the temperature inside the cab below setpoint, the heating system starts.

3-22

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AC/Heater Maintenance Schedule All work performed on the air conditioning system should be done by qualified personnel who adhere to the relevant refrigeration codes of practice.

To ensure dependable, efficient operation, the units require a certain amount of preventative maintenance to be carried out at regular intervals between services. These regular inspections will ensure that the unit is always operating at peak efficiency and will provide early warning of potential problems. For regular servicing procedures, refer to the Service Manual.

DAILY INSPECTION Control switches

Check for proper operation.

Fresh Air and return air filters

Check for cleanliness and deterioration.

Refrigeration/heating hoses

Check for damage or deterioration.

Compressor clutch drive belt

Check for correct tension and deterioration.

Fresh air filtration

Check pre-cleaner for cleanliness, damage or deterioration.

MONTHLY INSPECTION Condenser coil

Check for cleanliness and clean if necessary.

Evaporator coil

Check for cleanliness and clean if necessary.

Condenser fan motor

Check for cleanliness and clean if necessary.

Compressor clutch

Check clutch mounting screws and electrical connections. Check for excessive noise during operation.

NOTE

The air conditioning system must be run for a minimum of five minutes each week regardless of the season. The compressor oil level should be checked whenever the refrigeration system is opened due to breakdown.

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3-23

Motor Starter Cabinet (Electric) High Voltage Danger. Repairs and maintenance must only be carried out by properly trained personnel.

Always place the lockout switch in the lockout (OFF) position when the machine is shut down or any maintenance is being performed on the machine.

Keyboard/Display

Motor Lockout Switch

Non-Functional Switches Local-Off-Remote Switch

Fig. 3-14 Electric Drive Motor Starter Cabinet

The motor starter cabinet consists of the necessary circuits and fuses to allow motor starting then provide electrical protection throughout the motor circuit. The keyboard/display is also present in the cab circuit breaker panel and is used to start the motor from inside the cab with the Local-Off-Remote switch set to Local. Only the keyboard/display in the cab is functional (fig. 3-10).

The lockout switch is set to ON whenever the drill is to be started.

The keyboard/display is pre-programmed at the factory and no other action should be required by the Operator other than to recognize a fault code on the display. These codes will be displayed on the keyboard/display mounted in the cab.

Refer to the following keyboard/display user manual for programming and troubleshooting/maintenance information.

Motor Starter Uninterrupted Power Supply (UPS) If the main power supply is not sufficient and the usage of the supplied UPS is necessary, then the UPS battery must be charged before the machine can be started. In order to charge the UPS, main power must be supplied to the machine and the main disconnect closed. This condition will allow the UPS battery to charge, which may take a few hours. After charging, the UPS will provide motor starter control power a clean power source.

3-24

Operator Controls

Keyboard/Display Benshaw Display

/ŶƚƌŽĚƵĐƟŽŶ The LCD Keypad Display is mounted in the operator cabin and on in the Motor Starter Cabinet The display has keys susch as START, STOP, MENU and ENTER as well as three ĚŝƌĞĐƟŽŶĂů keys to enable scrolling through the parameter groups Status indicators provide ĂĚĚŝƟŽŶĂů ŝŶĨŽƌŵĂƟŽŶ for the starter ŽƉĞƌĂƟŽŶ

Description of the LEDs on the Keypad The keypad provides three LED indicators in addition to the 2x16 character display. The LEDs provide starter status information.

NOTE: By default, the [STOP] key is always active, regardless of selected control source. It may be disabled though using the Keypad Stop Disable (I/O26) parameter. For more information refer to the Keypad Stop Disable (I/O26) parameter in the Vendor Manual.

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3-25

Keyboard/Display

3-26

Operator Controls

Distribution Breaker Box Power Distribution The distribution breaker box (fig. 3-15) allows the operator to connect or disconnect power from different systems on the drill. Of particular importance is the ability to disconnect power from heating elements connected to systems that for some reason, heat should not be applied.

The distribution breaker box is located adjacent to the motor starter cabinet, mounted on the compressor air cleaner housing.

Water Line Heater

Compressor Heater Pads

Thread Grease/Auto Lube Grease Bucket Heater Pads Battery Box Heater

Power Outlet in Cab 24V Power Supply AC/Heater in Cab

Hydraulic Oil Tank Heater

Rear Water Tank Heater

Front Water Tank Heater

Fig. 3-15 Power Distribution Breaker Box (Electric Drill with Cold Weather Package)

Operator Controls

3-27

Cable Reel (Electric) Manual Operation The cable reel on electric motor machines is a level winding reel for retrieving and paying out power cable. Normal operation is controlled by the drill's electrical system in that, whenever the drill/propel switch is in the propel position, the cable reel is energized and set to run in the auto mode. However, there can not be too much deviation in the lay of the electric cable when tramming.

For maintenance and repair purposes a switch is located on the housing adjacent to the reel (fig. 3-16) to manually pay out or retrieve electric cable without the machine's motor running.

Power Switch for Manual Operation

Fig. 3-16 Cable Reel Electric Power Enclosure

3-28

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Cab Seat Operation and Maintenance

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3-29

Cab Seat Operation and Maintenance

3-30

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Drill Control System

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3-31

Drill Control System

3-32

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Drill Control System

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3-33

Drill Control System

3-34

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Drill Control System

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3-35

Drill Control System Editing the Dashboard User Database The dashboard application running on the Drill Monitor is password protected. The user can access different screens of the dashboard depending on the access level.

The name of the users, access level, user ID and passcode are stored in the user database (db3 file) on the monitor. The user database can be modified with the DBTool application.

To modify the user database, follow the following steps: 1. Login to the dashboard to at least Supervisor level.

2. Navigate to the Config Screen by tapping the button 3. Tap Exit.

.

4. Plug in a USB keyboard and touch pad combination. If you don’t have the device available, you can go to Windows Start Button – Programs – Accessories – Accessibility – On-Screen Keyboard to bring up the on-screen keyboard for entering alphanumeric.

5. Tap Tools icon on the desktop 3-36

.

Operator Controls

Drill Control System Editing the Dashboard User Database (cont.)

6. Tap on the DBTool icon .

7. Enter the provided Supervisor password.

8. The application should already open the correct db3 file. However, tap the Open button to ensure that the application is opening the db3 file at D:/Bucyrus/userDB/user2E69F67.db3.

9. Tap “New user” to add new user login. Once you tap “New user”, a new entry will be added.

Double tap the corresponding field (Family name, First name, User ID and Passcode) to enter the information. Then the user can be made Operator or Supervisor level access.

10. To delete a user, tap the corresponding entry, then tap “Delete user”.

11. Once you are done, tap the Save button 12. On the desktop, tap the Dashboard icon

Operator Controls

. Then close the application. to restart the dashboard application.

3-37

Drill Control System

3-38

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Drill Control System

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3-39

Drill Control System

3-40

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Drill Control System

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3-41

Drill Control System

3-42

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Drill Control System

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3-43

Drill Control System

3-44

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Drill Control System

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3-45

Drill Control System

3-46

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Drill Control System

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3-47

Drill Control System

3-48

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3-49

Drill Control System

3-50

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3-51

Drill Control System

3-52

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3-53

Drill Control System

3-54

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Drill Control System

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3-55

Drill Control System

3-56

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3-57

Drill Control System

3-58

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3-59

Drill Control System

3-60

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Drill Control System

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3-61

Drill Control System Base Machine and Dashboard Monitor Software Update There are three main devices on the drill require software updates: 1. ID1 electronic controller module software (hex file) 2. ID2 electronic controller module software (hex file) 3. Dashboard monitor software (exe file) The software provided will indicate which of these devices need to be updated. The update procedure is as follows.

Electronic Controller Module Software Update Note: It is highly recommended to use a laptop that comes with serial port (DB9 connector). Otherwise, a USB-to-serial adapter can be used (Cat PN: 370-8059) to convert the USB port to the serial one.

You will need a serial cable to communicate from the laptop to the serial ports on the drill.

The Windows software Bootloader Toolkit 3.0 is also required. This can be obtained from the factory and installed on the laptop.

You will be provided two different hex files labeled ID1 and ID2. Make sure that the correct software is downloaded to the correct controller module.

The following software update procedure is for electronic controller module ID1 and ID2: 1. At the isolation box, turn on the battery (red) isolator , but leave the starter isolator (yellow) off.

2. Turn on the key switch.

3. Locate the serial ports indicated below. There are 2 serial ports, the left one is for ID1 and the right one is for ID2. Ensure that the correct software is being downloaded to the correct controller.

ID1

ID2

4. Open the Bootloader Toolkit 3.0. If you are connecting the serial port without using the USB-toserial adaptor, the “Com ports” should be set as COM1. If you are using the USB-to-serial adaptor, you may need to try different Com ports available. Make sure that the pulldown menu of the Devices is DCF.

3-62

Operator Controls

Drill Control System Base Machine and Dashboard Monitor Software Update (cont.)

5. Click Login to login to the controller. Once you prompted to reset the device, click OK. Turn off the key switch then turn on after 1 to 2 seconds. The taskbar should begin to start.

6. Once the login process reaches 100%, the taskbar is now enabled. We now create the backup of the program that is running on the drill so that if there is any issue, it can be reverted to the software that was working. Click Upload, then Application.

You will be prompted for filename to save this backup program from the controller currently.

Save it at the convenient location. It will be useful to revert back to this old program if there is something wrong with the new program.

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3-63

Drill Control System Base Machine and Dashboard Monitor Software Update (cont.)

Click Save, the application will start uploading the hex file to your computer.

7. Now, click Download, then Application. Navigate to the new hex file (make sure to download to the correct ID), and click OK.

Wait for the program to download to the controller.

3-64

Operator Controls

Drill Control System Base Machine and Dashboard Monitor Software Update (cont.)

Once it reaches 100%, repeat the steps for ID2 with the ID2 hex file.

8. Turn off the keyswitch, and turn it back on after 1 to 2 seconds. The software update process is complete.

Dashboard Monitor Software Update

The dashboard monitor is running Caterpillar user interface. In order to update the software, at least Supervisor Level access is required.

The software update is provided in an exe installer file. You will need a USB thumb drive to transfer the software.

The following steps are required to install the Caterpillar user interface software: 1. Copy the exe installer file to a USB thumb drive.

2. Locate the USB port shown below:

Plug in the USB drive.

3. Login to the dashboard to at least Supervisor level.

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3-65

Drill Control System Base Machine and Dashboard Monitor Software Update (cont.)

4. Navigate to the Config Screen by tapping the button 5. Tap Exit.

.

6. Make sure to kill all processes associated with the Dashboard to prevent installation failure. On the desktop, double tap the Tools folder , double tap on Process Explorer. Within the Process Explorer look for the processes dashboard.exe, multimapper.exe and ojnodemanager.exe and make sure you kill them by tapping on the process in the left panel, and “X” at the top of the window (if they are running). Once you are done you may close the Process Explorer.

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Drill Control System Base Machine and Dashboard Monitor Software Update (cont.)

7. Now, create a backup of the current software. On the desktop, double tap my computer, double tap on “C” drive, double tap Bucyrus folder, double tap dashboard folder, copy current version folder onto your USB stick.

8. Run the exe installer file stored in the USB earlier. When running the installer, follow its instructions by clicking Next. On the “Choose Components” page make sure to not select “MachineConfig” unless you got special instructions that this is necessary.

9. Once you finished running the installer make sure you remove the USB stick. After removing the USB stick, navigate to the Tools folder on the desktop again and double tap the Write2Disk icon.

The dashboard will now save the configuration and reboot.

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3-67

Notes

3-68

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Section 4

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

NOTE

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

Refer to the Service Manual for more in-depth lubrication and maintenance procedures. "(Electric)" following a title refers to the electric drive motor powered drill. "(Diesel)" refers to all diesel engine powered models, unless otherwise noted for a specific model.

Pre-Start Checks and Lubrication

4-1

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

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

Electrical Cables •

Proximity to electrical cables

•

Condition of electrical cable (electric)

Access stair, Walkway and Handrails •

Check emergency stops

•

Check for damage

•

Cleanliness

•

Serviceable

•

Check all signage

Undercarriage •

Condition of track chains and rollers and stone guards

•

Broken or loose grouser plates

•

Loose or missing bolts

•

Main pivot point bolts

•

Lubrication of main pivot point and stabilizer pins

•

Condition of final drive and propel motors

•

Excess build up of debris

•

Check under machine for leaks

•

Check damage to water and fuel tanks

•

Check jacks for damage and lubrication

•

Check dust curtains and lifter

4-2

Pre-Start Checks and Lubrication

Pre-Start Checks Walk Around Inspection (cont.)

Mast •

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

• Check pipe safety arm is closed and locked • Rope condition and tension • Check retaining plate in top of carousel for damage • Check bull hose whips check in place • Check rotary head guides, loose bolts missing slides • • Check rotary head for oil leaks • Check mast crown for damage • Check carousel indexing cylinders pins • Check lubrication of all pivot points • Check mast grates for loose or missing bolts

On Deck Checks •

Hydraulic system condition and leaks

•

Engine condition and leaks

•

Compressor condition and leaks

•

Cooler pack for leaks, damage and cleanliness

•

Dust collector

•

Ensure guards and covers are in place and secure

•

Structural integrity

•

Fire suppression and extinguishers are charged and within service date

•

Drain water from control air manifold and water traps

Fire Extinguishers Fire extinguishers shall comply with EN79:1995 paragraph 5.12.2 and EN 3:1975. Each 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. As part of pre-start checks, check that fire extinguishers are fully charged.

Pre-Start Checks and Lubrication

4-3

Lubrication 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.

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

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

NOTE

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

Care of Lubrication Points Before lubricating, or filling hydraulic fluids, the fittings, caps, and filler plugs should be thoroughly cleaned to prevent contamination.

After lubrication and filling, remove excess spills. Always keep fittings, caps and fill plugs clean of foreign matter.

4-4

Pre-Start Checks and Lubrication

Lubrication Checks Interval

Daily or Each Shift

Service Point

Lubricant Required 5

Service Required

Capacity

Engine Oil

Check/Add if required

SAE 10W-30

137.4 qt (130 L)

Fuel Tank

Check/Fill if required 1

---

876 gal (3316 L)

Fuel/Water Separator

Drain water

---

---

Engine Coolant

50/50 Water/Anti-freeze

Hydraulic Oil Tank

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

AW ISO 32

250 gal (946 L)

Air/Oil Separator Tank

Check/Add if required

Synthetic ATF

Water Tank

Check/Add if required

Water/Anti/freeze

422 gal. (1597 L)

Pump Drive Gearcase

Check/Add if required

Mobillube SHC (SYN) 75W-90 Gear Oil

3.5 gal (13L)

Air Cleaners

Check Gauge Reading

---

---

Oil Filters

Check Service Indicators

Note: Indicators may show change or by-pass when fluid is cold.

Radiator & Coolers

Check/Clean

---

---

Shock Sub & Air Swivel

Lubricate

NLGI 2 Grease

---

Tracks, Rollers, Sprockets

Check/Clean

---

---

Track Frames, Axles, Mounts

Inspect Integrity/Damage

---

---

Mast & A-Frame

Inspect Integrity/Damage

---

---

Cab Mountings

Inspect Integrity/Damage

---

---

Deck & Surrounds

Inspect Integrity/Damage

---

---

Rotary Head & Motor(s)

Check

---

---

Pulldown/Hoist Ropes

Inspect

---

---

Pulldown Sheaves

Check that they are getting grease

---

---

Grease Pump Lubricator

Top Up

NLGI 1 Grease

---

Pipe Thread Lubricator

Top Up

NLGI 2 Grease 4

---

Fire Suppression System

Charged

---

---

Fire Extinguishers

Charged/Secure

---

---

Operating Controls

Check that all function correctly

---

---

Cable Reel Hyd. Reservoir

Check/Add if required

AW MV ISO 32

10 gal. (37.8 L) (plus pump case)

Walk Around Inspection

Report any leaks, damage, etc.

---

---

Notes: 1.

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

2.

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

3.

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

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

4.

Lithium Base with 3% Molybdenum Disulfide.

5.

Fluid types will be temperature dependent (see Service Manual for lubricant specifications.)

Pre-Start Checks and Lubrication

4-5

Recommended Lubricants Fluids and lubricants for drive plants may be hazardous materials. Local regulations must be obeyed when handling, storing and disposing of these substances.

Component Description Compressor

Lubricant Required 1

Operating Temperature Range (Ambient)

System Capacity

Mobil Synthetic ATF

-20–120 deg F (-28.9–49 deg C)

Synthetic ISO 46 Compressor Oil

-20–120 deg F (-28.9–49 deg C)

Synthetic ISO 68 Compressor Oil

40–125 deg F (4.4–51.7 deg C)

Mobil Synthetic ATF

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

AW ISO 32

-10–90 deg F (-23.3–32.2 deg C)

AW ISO 46

10–105 deg F (-12.2–40.5 deg C)

AW ISO 68

15–125 deg F (-9.4–51.7 deg C)

Rotary Head

GL-4 Full PAO-based ISO 150 Synthetic Gear Oil 2

-50–125 deg F (-45.5–51.7 deg C)

13 gal (49 L)

Pump Drive Gearbox

Mobillube SHC (Syn) 75W-90

-67–100 deg F (-55–37.8 deg C)

3.5 gal (13 L)

Synthetic 85W-140

0–125 deg F (-17.8–51.7 deg C)

Mobillube SHC (Syn) 75W-90

-67–100 deg F (-55–37.8 deg C)

80W-90

-10–100 deg F (-12.2–37.8 deg C)

85W-140

0–125 deg F (-17.8–51.7 deg C

Mobiltemp SHC32

-65–50 deg F (-53.9–10 deg C)

NLGI 0

-20–50 deg F (-28.9–10 deg C)

NLGI 1

10–100 deg F (-12.2–37.8 deg C)

NLGI 2

30–125 deg F (-1.1–51.7 deg C)

NLGI 1

-30–350 deg F (-34.4–176.7 deg C)

Hydraulic Tank

Undercarriage Gear Final Drive

General Grease Lubrication Points

Pipe Thread Grease

NLGI 2 3

60 gal (227L)

250 gal (946 L)

5 gal (19 L)

N/A

N/A

-10–350 deg F (-12.2–176.7 deg C)

1.

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

2.

No EP oil allowed.

3.

Lithium Base with 3% Molybdenum Disulfide.

4-6

Pre-Start Checks and Lubrication

Lubricant Specifications Engine Oil (Detroit Diesel) Selection of a suitable engine oil is based on fuel quality, projected oil drain interval and on-site climatic conditions. At present there is no international industrial standard which alone takes into account all these criteria.

Detroit Diesel recommends engine oil meeting the following specifications: •

API CG-4/CH-4 and ACEA E2–96 (Category 1)

•

ACEA E7–04 (Category 2)

•

ACEA E4–04 (Category 3)

•

ACEA E4–04, E6–04 (Category 3.1)

Note: These engine oils are marketed under the name Power Guard DEO SAE 40 and SAE 15W-40.

Oil Fill Engine Oil Dipstick

Fig. 4-1 Diesel Engine Oil

Pre-Start Checks and Lubrication

Engine Oil Filters

4-7

Lubricant Specifications Compressor Lubrication • •

•

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

Check oil level each shift. The level is checked at the upper sight glass with machine leveled. To check the oil level, the machine must be shut down long enough to permit oil foam to settle or check before start-up at the beginning of the shift. Oil level should cover the lower sight glass and be at the center of the upper sight glass (fig. 4-2).

Change oil after first 50 hours, then change oil annually when using Mobil Synthetic ATF, or as specified in the Service Manual. Consult factory for specific recommendations if extremely severe duty is encountered.

Fig. 4-2- Receiver Tank Sight Glass

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

Special oil is available from Cat Pump dealers.

•

Fill with oil to red dot in sight window on back of pump (Fig. 4-3).

•

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

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

Fig. 4-3 Cat Pump Oil Level Sight Window (back of pump)

4-8

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

Pre-Start Checks and Lubrication

Auto Lube System Auto Lube The Drill is provided with an auto lube system which consists of an air powered pump assembly fitted to a grease container. The pump supplies grease under pressure to manifolds containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 60 PSI (4.1 bar) to the pump.

The system is controlled by the Drill PLC System in the cab. The system will verify delivery of lubricant into a bearing and also controls the lubrication system (fig. 4-8).

In most cases, the service points in Table 4-4 are connected to the auto lube system or will be connected to lubrication lines from a remote lube bulkhead.

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

Fig. 4-5 Auto Lube Filter/Regulator/Lubricator Set to 60 PSI Check that auto lube oiler is working properly each shift.

Fig. 4-6 Air Powered Lube Pump and Lube Bucket

Pre-Start Checks and Lubrication

4-9

Auto Lube System Operation The lube cycle time and lube pressure setting can be set from the password protected area. The time is set in minutes. If a 60 minute cycle is set, the lube solenoid is activated each 60 minutes (lube solenoid will run for 2 minutes). If the lube pressure switch (fig. 4-7) is not up to pressure within 2 minutes, a lube alarm will occur. If the manual lube is activated, the lube solenoid will run for 30 seconds. If pressure is not reached in 30 seconds, a lube alarm will occur. If the lube alarm continually occurs, then inspect for broken grease lines or faulty field devices.

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

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

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

Fig. 4-7 Auto Lube Pressure Switch

4-10

Pre-Start Checks and Lubrication

Auto Lube System

Manual Lube/Test Button

Fig. 4-8 Drill PLC Lube Setting/Configuration Screen

Pre-Start Checks and Lubrication

4-11

Auto Lube–Service Points Table 4-4 Crawler Final Drive

check oil level

Front Axle

grease 3 places

Pivot shaft

grease 2 places

Upper Mast Crown Sheaves

grease 4 places

Rotary Gearbox

check oil level

Winch

check oil level

Upper Carousel Bearing

grease 1 place

Pipe Rack Swing cylinders (2)

grease 2 places

Upper Pipe Rack Support Bearing

grease 1 place

Feed Cylinder Hoist/Pulldown Sheaves

grease 4 places

Mast Raise Cylinders Upper Pins

grease 2 places

Lower Pins

grease 2 places

Mast Pivot Area Pivot Pins

grease 2 places

Lower Mast Breakout Wrench Swing Cylinder

grease 2 places

Breakout Wrench Pivot Pin

grease 1 place (from bottom)

Telescoping Cylinder Pivot

grease 1 place

Rotate Cylinder

grease 2 places

Clamp Cylinder

grease 2 places

Clamp Pivot Pin

grease 1 place

Lower Pipe Rack Support Bearing

grease 1 place

Carousel Rotate Cylinder

grease 1 place

Pipe Rack Roller

grease 1 place

Lower Carousel Bearing

grease 1 place

Lower Mast Sheaves

grease 4 places

Pipe Positioner Pivot Pin

4-12

grease 1 place

Pre-Start Checks and Lubrication

Auto Lube–Service Points

Note: actual layout varies from Drill to Drill including size, type and location of injectors.

Fig. 4-9 Typical Grease System Layout

Pre-Start Checks and Lubrication

4-13

Mainframe Service Points

Fig. 4-10 Drill Service Points

Fig. 4-11 Crawler Service Points 1. Final Drive 2. Front Axle 3. Pivot Shaft

4-14

Pre-Start Checks and Lubrication

Preventive Maintenance In order for an operator to be sure the 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 with the Service Manual.

Engine Fuel/Water Separator (Diesel) Drain the engine fuel/water separator (Fig. 4-13) daily to remove any water from the diesel fuel.

Fig. 4-12 Hyd. Tank Filters

Fig. 4-13 Engine Fuel/Water Separator

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 insure the expected life of the system—CLEANLINESS. Sight gauges are provided on the sides of the tank for checking the oil level daily.

•

Oil level should be almost full in the sight gauge (fig. 4-14) 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.

Fig. 4-14 Hyd. Tank Level Gauge

Pre-Start Checks and Lubrication

4-15

Preventative Maintenance Critical Bolted Joint Maintenance

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. These are identified in the illustration on the following page.

Caterpillar recommends that critical bolted joints of drills should be checked for proper torque every 120 days or 2000 operatinghours 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 operatinghours. Refer to SENR3130 for proper torque specifications.

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

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

Bolts should be replaced with the Grade 8 bolts.

Refer to SENR3130 for proper torque specifications.

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

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

4-16 REPLACE BOLTS EVERY 2.5 YEARS OR 15000 HRS REGARDLESS OF CONDITION

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

MACHINE SERVICE HOURS:

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

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

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

WINCH MOUNTING FASTENERS

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

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

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

LEVELING JACK CAP FASTENERS

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS

UNDERCARRIAGE MAIN AXLE FASTENERS

AFRAME PIVOT CAP FASTENERS MAST PIVOT CAP FASTENERS

CRITICAL FASTENER ID & INSPECTION SCHEDULE

Preventive Maintenance

Pre-Start Checks and Lubrication

Preventive Maintenance CRITICAL FASTENER ID & INSPECTION SCHEDULE Contintued

Typical example of grates located on the mast.

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

Mast Grate Bolts

Pre-Start Checks and Lubrication

4-17

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

1.

Position the machine in a safe place on level and solid ground. Do not park close to a highwall 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 and drain water injection system (see Section 5 of the Service Manual).

3.

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

4.

Follow pre-start checks in this section 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 shutdown procedures in Section 5 of this Manual, allowing engine to idle for at least five minutes before shutdown.

Service Center Oil fill and evacuation facilities are provided through the Wiggins service center (fig. 4-15) located at the front corner of the machine. Fill and drain points provided in the service center are optional. Oil evacuation from the Rotary Head and Final Drive gearboxes are from the components themselves. The fuel fill point is also located at the service center. A sight gauge gives indication of fuel level in percentage.

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

Engine oil

•

Engine oil reserve

•

Engine coolant

•

Hydraulic oil

•

Compressor oil

•

Pump Drive oil

•

Fuel Fig. 4-15 Wiggins Service Center (different options shown)

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

4-18

Pre-Start Checks and Lubrication

Section 5

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

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

NOTE

"(Electric)" following a title refers to the electric drive motor powered drill. "(Diesel)" refers to all diesel engine powered models, unless otherwise noted for a specific model.

Operating Instructions

5-1

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

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

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.

Fig. 5-1 Actuator Mounted in Cab

Fig. 5-2 Actuator Mounted on Front of Machine

Operation When the system is activated, the fire suppression agent in the tanks is released and discharged through a series of nozzles, located in critical areas around the machine (fig. 5-3). At the same time, the battery cut-off switch cuts off voltage to the machine.

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

In Case of Fire Locate the nearest actuator.

1.

Turn ignition switch OFF if possible.

2.

Pull ring pin and push red button on actuator.

3.

Get away from machine and call for help.

5-2

Operating Instructions

Operating Instructions

SYSTEM ACTUATOR LOCATED IN CAB NEXT TO DOORWAY AND WITHIN REACH OF OPERATOR.

CONE NOZZLE

FAN NOZZLE

CONE NOZZLE

CONE NOZZLE

CONE NOZZLE

CONE NOZZLE

FAN NOZZLE

CONE NOZZLE

DRY CHEMICAL 125 LB (56.7 kG)

SYSTEM ACTUATOR LOCATED BELOW DECK LEVEL TO BE ACTUATED FROM GROUND LEVEL.

SYSTEM ACTUATOR

NOZZLE

Fig. 5-3 Fire Suppression Nozzle Locations

SYSTEM ACTUATOR

FAN NOZZLE

CONE NOZZLE

DRY CHEMICAL 125 LB (56.7 kG)

Fire Suppression System

5-3

Start-Up Procedure Before starting the engine or electric drive motor, warn nearby members of the work crew that you are starting the machine.

To Start Diesel Engine 1.

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

2.

Check that all circuit breakers are ON.

3.

Check that the air control switch is in the start position.

4.

Ensure the engine idle switch (23) is in LOW.

5.

Turn the ignition key (24) on.

6.

Press and hold the engine start button (22) until the engine starts. Do not crank engine for more than 30 seconds.

To Start Electric Drive Motor 1.

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

2.

Check that all circuit breakers are ON.

3.

Check that the air control switch is in the start position.

4.

On the motor starter cabinet, be sure the lockout handle is ON and the local and remote switch is set to LOCAL.

5.

Turn the key switch on the circuit breaker panel in the cab to ON.

6.

When the "K Ready Ia= 0" is displayed on the keyboard/display in the circuit breaker panel, press the green start button.

Push To Start Motor

5-4

Fig. 5-4 Start-Up Controls (Diesel Circuit Breaker Panel) 22. Engine Start Button 23. Engine Idle Speed Selector Switch 24. ON/OFF Key Switch (allows engine and motor starting)

Fig. 5-5 Keyboard/Display in Cab

Operating Instructions

Start-Up Procedure After-Start Checks After-start checks are carried out to ensure that the machine is in a safe working condition before the Operator commences drilling procedures. The machine should be left running in low rpm until all after-start checks have been carried out.

1.

Check that the control system digital screen is running and not indicating any machine abnormalities.

2

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

3.

Check to ensure compressor air pressure is at least 100 PSI (7 bar).

Compressor air pressure must not exceed 150 PSI (10.3 bar). The machine should run with the compressor unloaded until the compressor temperature reaches 180oF (82oC).

The air control valve should be not be switched into HIGH unless the engine is running at high rpms and the compressor temperature has reached at 180oF (82oC).

4.

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

5.

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

6.

Check all filter indications at operating temperature.

7.

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

8.

Check rotation motors and head guide bolts and slides.

9.

Grease swivel seal and shock sub (if fitted).

NOTE

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

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

Operating Instructions

5-5

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

To shutdown the machine, proceed as follows: 1.

Fully retract the drill string from the drill hole.

2.

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

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

•

Away from areas that can obstruct movement of mine traffic;

•

With mast either resting on supports or locked in vertical position by mast locking pins;

•

Leveling jacks on the ground supporting the weight of the machine.

3.

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

4.

Reduce engine speed to LOW idle.

5.

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

6.

Wait approximately five (5) minutes then turn ignition key to OFF.

7.

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

8.

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

9.

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

5-6

Operating Instructions

Emergency Shutdown Use the emergency shutdown devices ONLY IN CASE OF EMERGENCY.

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

Description The drill is equipped with devices which enable the Operator to shut down the engine or electric drive motor in case of an emergency. There is an emergency stop button in the operator's cab right hand gauge panel (fig. 5-6). There are also ground level engine stop buttons (fig. 5-7) located on the right side of the machine in close proximity of the cab, in the engine/motor area and at the front of the machine. The Operator must become familiar with the location of these devices.

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 emergency stop device.

Fig. 5-6 Emergency Stop Switch on RH Upper Console

Twist and Pull Out to Reset (Electric)

Fig. 5-7 Ground Level Engine Stop Switch

Pull Out to Reset Operating Instructions

5-7

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

1.

2.

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

•

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

•

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

•

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

Raise the mast.

LOOK UP before raising or lowering mast.

See Section 1 for Clearances from High Voltage Lines table.

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

•

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

•.

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

•

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

•

Place mast raising control lever in MAST UP position.

•

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

3.

5-8

•

Engage mast locks.

•

Set Drill/Propel switch to DRILL.

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

Operating Instructions

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

4.

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

5.

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

Compressor Warm-Up (Low Pressure) 1.

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

2.

After warm-up, turn selector to RUN position.

3.

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

Operating Instructions

5-9

Drilling and Operating Controls Use the following two figures to identify the levers and switches necessary to operate the drill as described in the following pages. The functions are detailed in Section 3.

19 18 17 20

16

21

15

14

22 13 1 2

12 3

4

5

6

7

8

9

10

11

Fig. 5-8 LH Console Drilling Controls

5-10

1. Deck Wrench/Hydraulic Operated Bit Basket (HOBB)

12. Drilling Air Control

2. Hydraulic Operated Deck Wrench (HOBO) Reverse

13. Deck Wrench

3. Mast Lock Switch

14. Drill Pipe Support Center

4. Side Wiper Switch

15. HOBO

5. Compressor Pressure Control Switch

16. Carousel Index Lock

6. Water Injection/Dust Collector Switch

17. Pipe Retaining Safety Arm

7. Dust Curtains and Viewing Door

18. Roof Wiper Switch

8. Water Injection Flow Control

19. Front Wiper Switch

9. Auto Pulldown Switch

20. Rear Wiper Switch

10. Carousel Swing and Rotate

21. Track Spray Switch

11. Pulldown Pressure Control

22. Turkey Nest Sprayer Switch

Operating Instructions

Drilling and Operating Controls 2

1

3

4

5

6

7

8

9

10

13 12

11

Fig. 5-9 RH Console Operating Controls 1. Snake Light

8. Right Propel Lever

2. Winch Lever

9. Drill/Propel Switch

3. Mast Lever

10. Rotation Pressure Control

4. Left Rear Jack Lever

11. Bullseye Level Gauge

5. Front Jacks Lever

12. Hoist/Pulldown Control

6. Right Rear Jack Lever

13. Rotation Control

7. Left Propel Lever

Operating Instructions

5-11

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

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

•

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

•

Do not travel on steep slopes or crosswise to grades.

•

Visually inspect the path to be taken.

•

Adhere to all precautions relating to underground workings.

•

Never tram through areas of soft unconsolidated materials holding water.

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

NOTE

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

1.

Select PROPEL mode with the Drill/Propel switch (fig. 5-10).

2.

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

3.

Fig. 5-10 Drill/Propel Switch

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

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

4.

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

5.

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

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

Propelling Up, Down and Across Grades 1.

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

2.

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

5-12

Operating Instructions

Propelling Machine NOTE

Refer to Section 2 for Transient Stability Limits.

DOW

OP L S N

E

24.7o

UPS

LOP

E

24.7 o

Fig. 5-11 Proper Machine Positioning for Propelling Grades

3.

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

4.

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

5.

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

Propelling Over Cables 1.

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

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

2.

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

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

•

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

•

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

•

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

Operating Instructions

5-13

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

DO NOT position jacks on cribbing or timber bridging.

DO NOT position machine close to a highwall.

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

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

Refer to leveling procedure that follows.

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

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

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

Distribute the weight evenly on the jacks

•

Keep the machine as close to the ground as possible

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

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

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

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

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

5-14

Operating Instructions

Leveling Machine Leveling Procedure (cont.)

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

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

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

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

•

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

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

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

2.

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

Operating Instructions

5-15

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

Refer to the Clearances from High Voltage Lines chart below.

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

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

Clearances from High Voltage Lines Line Voltage

Minimum Clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv

45 ft (13.7 m)

1.

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

2.

Check mast for loose drilling tools or parts.

3.

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

4.

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

5.

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

6.

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

7.

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

NOTE

5-16

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

Operating Instructions

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

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

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

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

1.

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

NOTE

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

2.

Rotate the drill pipe loader to the stored position.

3.

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

4.

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

Operating Instructions

5-17

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

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

Equipment Required 1.

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

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.

3.

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

4.

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

5.

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

6.

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

7.

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

8.

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

9.

Repeat steps 3–8 for the remaining pipe sections.

5-18

Operating Instructions

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

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

THE DRILL PIPE MUST NOT BE ROTATING WHEN ANYONE IS ON THE DECK AND PERFORMING BIT CHANGING PROCEDURES.

Before drilling can commence, drill bit sub and the drill bit must be installed as follows: 1.

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

2.

Place the drill bit into the bit basket.

3.

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

4.

Engage the drill pipe to the bit sub and rotate drill pipe clockwise slowly until the thread joint becomes tight. Tighten thread joint to 3000 PSI (207 bar) on the Rotary Hydraulic Pressure Gauge.

5.

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

6.

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

7.

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

Operating Instructions

5-19

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

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

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

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

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

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

1.

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

2.

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

3.

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

4.

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

5.

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

6.

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

NOTE 7.

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

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

NOTE

8.

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

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

NOTE

5-20

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

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

Excessive water injection will reduce drill bit service life.

Operating Instructions

Drilling Operations Rotary Drilling (cont.)

9.

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

NOTE

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

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

Adding Drill Pipe 1.

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

2.

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

3.

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

4.

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

5.

Turn off drilling air control switch.

6.

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

7.

Apply thread grease to the drill pipe threads.

8.

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

9.

Swing the drill pipe loader to load position.

10.

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

Carousel must be LOCKED to add/retract drill pipe.

11.

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

12.

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

13.

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

14.

Turn drilling air on and re-commence drilling activity.

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

Operating Instructions

5-21

Drilling Operations To Rotate Drill Pipe Loader 1.

Switch the carousel locking pin to Index.

2.

Index the carousel to the next position.

3.

Switch the carousel locking pin to lock position.

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

ALWAYS torque the drill pipe joints in the pipe loader.

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

1.

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

2.

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

3.

Turn off drilling air.

4.

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

5.

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

6.

Unthread and align tooling flats with carousel breakout plate.

7.

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

8.

Swing pipe loader to load position.

DO NOT force carousel onto pipe.

9.

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

10.

Raise rotary head above head clear position.

11.

Retract pipe loader to parked position.

12.

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

13.

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

14.

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

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

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

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

5-22

Operating Instructions

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 in the compressor, engine, hydraulic system and gearboxes. See the Recommended Cold Weather Lubricants on the following page for lubricant recommendations.

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.

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

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

Additional measures included for extreme cold protection are: • Thermo-glass cab windows • Additional heater in cab • Spray-on insulating material under the cab, water and fuel tanks • Cold weather wiring for AC/DC systems including low temperature conduit There are no additional 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. 5-12 shows a typical installation. A 24VDC motor operates the water pump.

Diesel fuel is used to fuel the heating system.

Fig. 5-12 Heater/Pump Installation 1. Heater/Pump Unit 2. Manifold Operating Instructions

5-23

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

Component Description

Operating Temperature Range (Ambient)

Lubricant Required

Compressor

Mobil SHC 1024 Synthetic

Below 10oF (-12.2oC)

Engine Crankcase Oil

SAE 5W-40 Synthetic

Below -10oF (-23.3oC)

Hydraulic Tank

Mobil Synthetic ATF

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

Pump Drive Gearbox

Mobillube SHC 75W-90 Synthetic

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

Rotary Head

Mobillube SHC 75W-90 Synthetic GL-4 Full PAO-based ISO 150 Synthetic Gear Oil

-67 to 100oF (-55 to 37oC) -50 to 125oF (-45.6 to 51.6oC)

Undercarriage Final Drive

Mobillube SHC 75W-90 Synthetic

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

General Grease Lubrication Points

NLGI 1 Mobil Temp SHC32

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

Drill Rod Thread Grease

Mobil CM-L NLGI 1

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

DTH Hammer Oiler

Rock Drill Oil

All

5-24

Operating Instructions

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

Operation The pre-heat system is energized prior to starting the machine in temperatures less than 32oF. (0oC) by a switch located on the front of the operator console. Warm up periods are in relation to outside temperatures, but normally 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. Refer to the GenSet operating manual in Section 10 of the Service Manual for operation and maintenance.

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

ON/OFF Switch

Heater

Pump

Fig. 5-14 Heat Exchanger Element in Hydraulic Tank

Fig. 5-13 Heater/Controller Installation

Fig. 5-15 Heating Pad on Auto Lube Grease Container

Operating Instructions

5-25

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

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

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

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

Order repair parts from Parts Manual for your 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 5-26

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

Operating Instructions

Section 6

Drilling Practices

Drilling Practices

6-1

Drilling Terminology A.P.I. Thread American Petroleum Industry Standard type thread.

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

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

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

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

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

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

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

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

Stabilizers Stabilizers are used to reduce possible hole deflection.

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

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

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

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

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

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

Used to control dust exiting the drill hole.

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

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

6-2

Drilling Practices

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

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

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

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

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

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

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

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

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

2.

Penetration rate is directly proportional to the rotary speed.

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

In soft, easily drilled formations, the use of high pulldown pressures are restricted due to the drill bit's tendency to "Ball Up" thereby reducing its 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 the rotary speed can be increased is limited by the presence of abrasive properties and the ability to clear the cuttings immediately from the bit face, which would prematurely erode the cutting structure or bit bearings under excessive rotary speeds.

Drilling Practices

6-3

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

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

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

6-4

Drilling Practices

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

Drag or Blade Bits

2.

Tri-Cone Roller Bits

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

Thrust "Weight on Bit"

2.

Torque "Rotation"

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

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

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

Advantages of Drag Bits 1.

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

2.

High penetration rates in soft formations.

3.

Good penetration of 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.

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

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

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

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

Drilling Practices

6-5

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

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

Tri-cone bits are 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.

4 to 10 times more footage per bit than conventional hard formation steel tooth bits.

2.

The penetration rate will usually equal or exceed that of conventional hard formation bits.

3.

Higher feed pressures can be used in hard formations.

4.

Bits can be used in both soft and hard formations.

Disadvantages of Tungsten Carbide, Tri-Cone Roller Bits 1.

More expensive than conventional bits.

2.

Generally not good for drilling clay formations. Tungsten carbide bits may cost more than steel tooth bits and economics must be considered when choosing the correct bits for each application and should enter into your decision when to use them.

All tungsten carbide bit designs incorporated the use of compacts in the gauge surface or the cones, and varying combinations of compacts and hard facing on the gauge surface of the bit leg to provide increased resistance to abrasive wear.

When the formation is relatively uniform, these bits characteristically drill at a constant penetration rate throughout their life.

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 from 100 to 500 revolutions per minute.

6-6

Drilling Practices

Rotary Blast Hole Drill Strings Drill Pipe Drill pipe is used as a modem to transfer rotation to the drill bit and to convey air to clean the cuttings from the hole.

Blast hole drill pipe is selected to suit the diameter of the hole being drilled, the pulldown and hoisting capacity of the machine, and up-hole velocity requirements to clean the hole.

Standard drill pipe is designed to be run in tension. Drill pipe run in tension is held relatively straight, bending and wear are therefore kept to a minimum. However, blast hole rigs apply pressure to the bit through the pull-down system on the machine.

Since blasthole drill pipe is run in compression it must be made from heavy wall tubing to resist forces which not only may be high, but are also changing rapidly. The pipe must continue to do this in spite of abrasive wear and continual bending stresses. Drilling operations often place great stresses on the drill string, therefore the drill pipe must be manufactured to the highest degree to achieve the ultimate service life.

Periodic inspections should be made of the condition of your drill pipe and should include the following items: 1.

Outside diameter measurement of pipe.

2.

Welded joints for cracks or excess wear.

3.

Threads for excessive wear or galling.

4.

Pipe for bends or eccentric joints.

Fabricated Drill Pipe Blast hole drill pipe design features tool joints made from steels selected 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.

Thread Grease Precision machined threads and shoulders must be protected from damage. Threads are subjected to a lot of abuse, therefore it is imperative that they are inspected and greased regularly. Prior to each use, clean and visually inspect each pin and box for thread and shoulder damage. Check carefully for galls, burrs, scratches and particularly for cracks. Clean or repair if necessary. Use a zinc, lead or copper based lubricant that is recommended for rotary connections and apply thoroughly to all thread and shoulder surfaces. Ensure grease is clean and free of dust and debris.

Substitutes Substitutes (subs) or adapters are used where threads of one size or type must be coupled with threads of another size or type. They are also used at points of heat wear to provide readily replaceable threads.

Changes in drill pipe diameter must occur gradually. Subs should be gently tapered.

Drilling Practices

6-7

Rotary Blast Hole Drill Strings Pipe Threads There are many different types of threads available for drill pipe connections, most of which are not acceptable for blast hole drilling because of their vulnerability to damage from excessive forces to the drill string in blast hole drilling.

The two most commonly used threads are: 1.

A.P.I. Regular (American Petroleum Industry Standard)

2.

BECO style thread

With the increase in demand for 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 to wear and easier to loosen from a tight condition. Since the incorporation of the BECO thread system in the early 1960's, the thread has become an unofficial world wide standard for drill pipe used in rotary blast hole drilling operations.

6-8

Drilling Practices

Rotary Blast Hole Drill Strings

1 API Box Thread

2

API Thread BECO Thread 3 Sub Length Measured Shoulder to Shoulder

4

5

6

Bit Sub Length Measured Shoulder to Shoulder

9

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Pipe Length Measured Shoulder to Shoulder

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

Drilling Practices

6-9

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.

6-10

Drilling Practices

Compressed Air Compressed air is the most common method used with blast hole drills for clearing chips from the hole.

The advantages of drilling blast holes with compressed air are fast chip removal, and that holes are normally left dry.

In some circumstances a controlled amount of water or foam can be injected into the air stream to aid chip removal, enhance hole stability and control dust problems.

Chips not cleared immediately will be broken into smaller pieces. Secondary breaking wastes energy and increases bit wear.

Air Requirements In rotary blast hole drilling we must always be concerned with delivery of air in 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 (Bit Diameter 2 - Pipe Diameter 2) in inches

Meters Per Minute Velocity =

Drilling Practices

Free Air L.P.M. x 2 (Bit Diameter 2 - Pipe Diameter 2 ) in inches

6-11

Drilling Related Problems The majority of drilling problems originate from errors in judgement or simply from making a bad decision.

Drilling problems generally offer several courses or action to overcome the problem, therefore we must make a decision to try another method of operation to rectify the problem. Drilling decisions often avert or accelerate the complex drilling 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.

6-12

Drilling Practices

Operating Problems and Indicators 1.

Drill Bit Penetration Slows or Stops This is a statement of an indicator rather than a problem. The solution depends on the correct diagnosis of the problem, which could be:

2.

a.

Formation Change

b.

Drill Bit Blocked Up

c.

Incorrect Bit Type

d.

Dull Drill Bit

e.

Incorrect Pulldown Pressure or Rotary Speed

f.

Inadequate Hole Cleaning

High Drill String Torque Excessive drill string torque is also an indicator of a pending problem, some of which might be:

3.

a.

Excessive Pulldown Pressure

b.

Inadequate Hole Cleaning

c.

Crooked Hole

d.

Damaged or Badly Worn Drill Bit

Drill String Vibration This itself often seems like a problem, but the true problem usually lies in the reason for the vibration, some of which are:

4.

a.

Incorrect Rotary Speed

b.

Bent Drill Pipe

c.

Eccentric Drill Pipe Joints

d.

Incorrect Drill Pipe to Hole Size

e.

Crooked Hole

f.

Worn Deck Bushing or Stabilizer

Stuck Drill Pipe a.

Inadequate Hole Cleaning

b.

Crooked Hole

c.

Faulty Formations

Drilling Practices

6-13

Solving Drilling Problems 1.

Recognize the problem. The Operator must be aware of the small problems before they develop into bigger ones.

2.

Analyze the problem. Determine exactly what the problem is, what caused it and what is involved to rectify the problem.

3.

Compare the current problem with others previously encountered to assist in 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, the Operator will: 1.

Maximize the quality of the products of drilling.

2.

Maximize drilling production.

6-14

Drilling Practices

Section 7

Options and Accessories

Options and Accessories

7-1

Loading Crane Overview of labels The labels are part of the unit, they serve to protect the operator and others and facilitate correct crane operation.

Missing or illegible labels increase the risk of injury.

Missing and illegible labels lead to operating errors and mistakes during crane operation; they must be replaced immediately.

1

2

7

5

4 6 3 7-2

Options and Accessories

Loading Crane Company name label

1.

Position: Both sides of main boom.

Crane model label

2.

Position: Both sides of main boom.

Meaning: Product title.

Identification plate

3.

Position: On the crane column.

Meaning: Information about 1 Crane type 2 Internal code 3 Serial number 4 Year built 5 Company address The identification plate may not be changed or removed.

4. Load capacity label Position: Operating stand Meaning: Specification of loads, load ranges and ranges.

Risk if ignored: Overloading the crane, danger of the vehicle tipping over.

5. Identification plate for manual boom extensions Position: On manual extensions.

Meaning: Information about year built, device type, maximum capacity.

Risk if ignored: Damages to the crane and risk of fatal injury.

6. Operating lever instruction label Position: On operating stand.

Meaning: Indicates the functions of the operating levers.

Risk if ignored: Risk of unintended crane operations and danger to life.

7.

Warning sign ‚Keep out from under suspended loads.’

Position: On both sides of outer boom or main boom.

Meaning: It is prohibited to step under the suspended load.

Risk if ignored: Risk of fatal injury by falling loads.

Options and Accessories

7-3

Loading Crane Additional labels only for North America Following labels are only used in USA and Canada. Operators have to read and understand all additional labels.

Electrocution hazard

NOMINAL VOLTAGE, Kv (Phase to Phase) to Over 50 to Over 200 to

MINIMUM REQUIRED DISTANCE

Position:

On both sides of the outer boom.

Meaning:

Shows minimum required distances to live electrical power lines.

Risk if ignored:

Death or serious injury.

Position:

On both sides of outer boom

Meaning:

Keep distance from live power lines or from crane, boom, rope, load line, load if one of them becomes electrically charged.

Risk if ignored:

Death or serious injury

50 ___________________________ 10 feet 250 ___________________________ 15 feet 350 ___________________________ 20 feet

Over 350 to

500 ___________________________ 25 feet

Over 500 to

750 ___________________________ 35 feet

Over 750 to 1000 ___________________________ 45 feet

Electrocution hazard

Never ride the boom Position:

On both sides of the outer boom.

Meaning:

Under no circumstances shall any personnel be transported on a boom, hook, load, or any device attached to the crane, boom or load line.

Risk if ignored:

Death or serious injury.

Position:

On both sides of the column.

Meaning:

Personnel shall only be transported in an approved workman basked.

Risk if ignored:

Death or serious injury.

Position:

On both sides of the column.

Meaning:

Stand on the side opposite the boom when folding or stowing the crane. Stay clear of the boom when operating or servicing the crane.

Risk if ignored:

Death or serious injury

DEATH OR SERIOUS INJURY

Never hoist people

DEATH OR SERIOUS INJURY

Stay clear of the boom

7-4

Options and Accessories

Loading Crane Well trained operator

DEATH OR SERIOUS INJURY

Position:

On both sides of the column.

Meaning:

Only well trained operators must operate the crane.

Risk if ignored:

Death or serious injury.

Operating conditions and requirements

DEATH OR SERIOUS INJURY

Position:

On both sides of the column.

Meaning:

Observe all operating conditions and requirements.

Risk if ignored:

Death or serious injury.

Position:

On both sides of the column:

Load and work area

DEATH, SERIOUS INJURY INSTABILITY OR STRUCTURAL DAMAGE

Meaning:

Don't exceed loads, work areas, ratings.

Risk if ignored:

Death or serious injury.

Operate manual extension booms

DEATH OR SERIOUS INJURY

Position:

On both sides of the column.

Meaning:

How to operate manual boom extensions.

Risk if ignored:

Death or serious injury.

Keep clear of rotating drive shaft, power take off or driveline.

Options and Accessories

Position:

On both sides of the column.

Meaning:

Keep clear of rotating drive shaft. Never work on or near an installed power take off or driveline with the engine running.

Risk if ignored:

Death or serious injury.

7-5

Loading Crane Danger of moving outrigger Position:

On every stabilizer cylinder.

Meaning:

Do not operate any outrigger unless you or a signal person can see that all personnel are clear of the outrigger and its ground contact point.

Risk if ignored:

Serious crushing injury.

Position:

On every stabilizer cylinder.

Meaning:

Keep distance from outriggers and stabilizer cylinder.

Risk if ignored:

Serious crushing injury.

SERIOUS CRUSHING INJURY

Danger of outrigger

Crane mounting and prescribed inspections

DEATH OR SERIOUS INJURY

7-6

Position:

On both sides of the column.

Meaning:

Do all prescribed inspections and maintenance practices.

Risk if ignored:

Death or serious injury.

Options and Accessories

Loading Crane Function labels The function labels are explained below. The order of crane function symbols may be different on your crane from the example shown below. Therefore it is absolutely essential to familiarize yourself with the symbols and how they are arranged on your crane.

For the symbols on the remote control refer to the remote control operating instructions.

Retract

Extend

Clockwise (right) Counter-clockwise (left)

Lower

Lift (hoist)

Extend

Retract Options and Accessories

7-7

Loading Crane

%,

Working range There is acute danger to life for operators and others in the entire working range of the crane (slewing range and under suspended loads). Allowing bystanders in the working range is grossly negligent.

• • • • •

*

The operator must have full view of the crane movements and the working range. If this is impossible the operator must be aided by a qualified signaller.

Provide for sufficient clearance for crane operation and the supports. Crane movements must not be obstructed by cables, poles, trees, buildings or other obstacles.

The entire working area of the crane is a danger zone.

Any other work must not be carried out in the working range.

Crossing streets, path ways, bicycle lanes or sidewalks must be blocked during the entire crane operation.

The entire working range must be lit during low light conditions.

Note! Operation of this crane requires the operator to be specifically trained and authorized.

7-8

Options and Accessories

Crane Power Pack

Options and Accessories

7-9

Crane Power Pack

7-10

%,

Options and Accessories

Crane Power Pack

Options and Accessories

7-11

Crane Power Pack

7-12

%,

Options and Accessories

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