PDF System Operation Manual CAT MD6640 Blast Hole Drill - 967 KB
Master the operation of your CAT MD6640 Blast Hole Drill with this comprehensive system operation manual.
It details the functionality of all onboard systems, controls, and safety features.
Understanding these complex systems is crucial for efficient and safe drilling operations in any mining environment.
This manual is an essential resource for operators and maintenance personnel alike.
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System Operation
BI012656 MD6640 Blasthole Drill
Introduction
GENERAL INFORMATION
This manual is designed to assist the owner in the operation of this machine. By following easy to
understand step-by-step procedures the operators can perform all tasks in a safe manner.
THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order
parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in
it. All parts are listed by group and/or product code numbers with the associated item/part numbers
for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to
machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state
the correct machine SERIAL NUMBER when corresponding or contacting the factory service or
parts departments. Records on each machine are filed by serial number and when given this
number, your machine’s specific design and original equipment is accessed quickly by the Caterpillar
Global Mining parts representative. Periodic additions or revisions may be made to this manual.
Should you require additional information or factory service assistance contact your regional service
representative or:
Caterpillar Global Mining, LLC
Mining Products Division
3501 S FM 1417
Denison, TX 75020
903-786-9621
The company reserves the right to make changes or add improvements to its machines at any
time. This will be without incurred obligations to install such changes on machines sold
previously. Due to this ongoing program of product research and development some
procedures, specifications and parts may be altered in a constant effort to improve our
machines.
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Stored Energy Signs
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PULLDOWN GEARCASE
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ROTARY DRIVE SPEED SELECTOR SWITCH
The rotary speed selector switch is a three position switch located above the rotary rheostat. This
switch determines the speed/torque range of the rotary motor. In the LOW position, the motor has
the highest torque capability but is limited in speed to about 85-100 RPM at the bit. In the HIGH
position, the motor has a higher speed capability (110-140 RPM range) but motor torque will be
less (typically 68% to 74%). The MEDIUM position provides for operation between the HIGH and
LOW positions.
The switch should be set to the range that most closely matches the desired bit speed range. The
LOW setting is sufficient for most conditions. If more speed is desired, select the desired range as
needed.
HOIST/PULLDOWN RHEOSTAT
The hoist/pulldown rheostat controls the speed and direction of the hoist-pulldown motor for hoisting
or lowering the rotary drive unit.
Turning the rheostat in the hoist direction from the “0” position will raise the rotary drive unit. Maximum
speed is available at full clockwise position.
Turning the rheostat in the pulldown direction from the “0” position will lower the rotary drive unit.
Maximum speed is available at full counterclockwise position.
NOTE: The rheostat utilizes a reference scale and pointer. When the rheostat is turned, the
pointer indicates, on the reference scale, the relative percentage of full speed being set.
The panels with controls as shown on the following pages are typical of what could be
included on a console.
DUST CONTROL ON/OFF SWITCH — OPTION
The dust collector switch is a two position switch used to start the fan on the dust collector hopper.
When the switch is in the OFF position, it will shut the dust collector fan motor off.
DUST CURTAIN SWITCH — OPTION
The dust curtain switch is a two-position switch. Turning the switch to the UP position will raise the
dust curtains. Turning it to the LOWER position will lower the dust curtains.
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functionality of the operator display and it’s interface with the machine’s PLC controller. They have
no effect on machine operational use.
All of the machine controls can be found on the Operator’s Display Panel touch sensitive screen or
the left and right Control Consoles of the operator’s seat.
DISPLAY SCREENS
The information provided in the central area of the title screen is machine specific and lists the
machine serial number and a copyright notice relating to the control and display software.
TITLE SCREEN
The Main Menu Icons appear at the bottom of all screens allowing quick navigation.
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RADIO REMOTE PROPEL STATION (Optional)
The radio remote propel station is located in the operator’s cab. To enable the station, position the
operating mode switch located on the left control console to Remote Propel. The station includes
two joysticks, one for each crawler frame; an emergency stop push-button; function selector
switches as described below; and an indicator which will light up when communication is established
between the transmitter and the receiver. There is also an indicator light for the status of the e-stop
and the battery charge.
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PROPEL PROCEDURE
Before beginning the propel operation, the operator should first inspect the travel route for large
rocks, deep ruts, or uneven contours. When working on a grade, verify the slope and compare to
the allowable maneuvering slope limits at the end of this section.
CAUTION: Do not attempt to maneuver or steer the machine on grades which
exceed the allowable maneuvering slopes without consulting the
special propel section. Failure to follow these instructions could
result in a machine tip-over, damaging the equipment and resulting in
possible serious injury or death.
The operator’s display terminal leveling/propel screen should be monitored during propel to make
sure the allowable machine stability limits are not exceeded.
Once it has been verified that the travel route is in good condition, the machine is now ready to
propel.
NOTE: This machine should only be propelled long distances with the mast fully lowered, fully
raised and locked, or locked at an ANGLE HOLE setting.
For long propels of 1,000 feet (304.8 meters) or more, or if the machine is to be propelled over
grades which approach the allowable stability limits, the tool string should be disassembled, the
rotary drive unit lowered, and the mast lowered. This achieves the most STABLE condition for a
machine against tipping and also reduces stresses in the mast structure.
For long propels of 1,000 feet (304.8 meters) or more, the temperature of the undercarriage
components should be monitored. The lower rollers, take-up tumblers and propel planetaries should
operate below 95 degrees C. The propel motor should operate below 90 degrees C. If these
temperature limits are reached, stop the machine and allow the track components to cool down.
Note that propelling in low speed reduces the heat build up in these components.
If while propelling with the MAST-DOWN and the HEAD-DOWN the drill starts to list, it will continue
to list until the upper works contacts the pivotal axle. The machine will reach equilibrium when the
upper works contacts the pivotal axle and WILL NOT TIP OVER. With the mast-down and the
head-down, full listing will NOT cause the machine to tip over. The operator should attempt to
propel toward a more level area on the bench to correct this condition.
All of the stability values shown are based on a fully loaded machine (i.e. full water tank, cable on
cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by
the Customer and shipped by Bucyrus International, Inc.
This machine is propelled using the controls on the operator’s console in the operator’s cab or
radio controlled from the remote propel station outside the machine.
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MAST RAISING
CAUTION: Raising or lowering the mast is a two-person job. Do not attempt to
raise or lower the mast without the assistance of a helper familiar
with the procedures involved.
CAUTION: During the mast raising procedure personnel should be kept clear of
the machine and the area immediately surrounding the machine,
especially the front of the machine. No one is to be allowed on the
mast, operator’s cab roof, or machinery house roof while the mast is
in the air. Failure to heed this caution may result in the death or
serious injury of personnel struck by the mast should it fall for some
reason.
CAUTION: Limitations exist as to the length, diameter, wall thickness and
number of drill pipes that may be stored in the pipe racks when
raising or lowering the mast. Refer to the pipe size limitation chart in
the appendix before attempting to raise or lower the mast. Failure to
comply with these limitations will overload the mast, mast support
and hydraulic system possibly causing loss of control of the mast.
1. Inspect the mast and machine exterior to ensure that all wires, hoses, cables, etc. are clear
of the machine to prevent damage to the machine or equipment during the raising procedure.
Check that the mast cylinder pins, mast hinge pins, and mast brace pins are in place and
secured. Verify on the operator’s display terminal operator’s display screen that no reference
to A-frame pins is shown. Verify that the operating mode selector switch is in the DRILL
mode.
2. The main air compressor motor must be energized. Move the operation selector switch to
the MAST/WINCH position. Slowly raise the mast by lifting and then slowly pushing the mast
joystick, located on the right control console, forward. As the mast reaches an angle of 70
degrees it will begin to go over center and tend to come into the vertical position by itself.
Care should be used once the mast has gone over center since the speed of the mast will
increase sharply.
CAUTION: The mast joystick should be moved away from and returned to the
neutral position very slowly. Sudden starts and stops can be
damaging to the mast and hydraulic system. Be extremely cautious as
the mast approaches 70 degrees as once the mast goes over center
only a very slight movement of the joystick is necessary to cause
motion in the mast.
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DRILL TOOL STRING ASSEMBLY
The tool string consists of one or more sections of drill pipe, a stabilizer (drill collar) and a bit. In
assembling the tool string, the stabilizer is the first item installed, then comes a section of drill pipe
and finally the bit.
To install the stabilizer proceed as follows:
1. Place the stabilizer to be installed in a position so as to
be accessible to the auxiliary winch line. Clean and
lubricate the threads and shoulders on each end of the
stabilizer. Install a lifting bell on the pin (upper) end of
the stabilizer and lift it onto the drilling deck with the
auxiliary winch line. Securely block the stabilizer
horizontally on blocking sufficient enough to place the
stabilizer 8-10 inches above the drill deck. Remove the
auxiliary winch line.
2. Remove the guide bushing from the hole in the drill deck.
Place the guide bushing on the upper end of the stabilizer
with the tapered end of the bushing toward the lower
(box) end of the stabilizer. Reattach the auxiliary winch
line to the lifting bell.
3. Install the stabilizer and drill bushing in the hole in the
drill deck. Make sure the drill bushing is seated properly.
Lower the stabilizer until the slots in the stabilizer are
aligned with the tool wrenches. Extend the tool
wrenches to hold the stabilizer in place.
4. Remove the auxiliary winch line from the stabilizer and
secure it out of the way. Remove the lifting bell from the
stabilizer and store it.
TOOL STRING
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ANGLE DRILLING
ANGLE DRILLING EQUIPMENT
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ENDING THE HOLE (MULTIPLE PIPE SECTIONS)
Reaming the hole with multi-section tool strings is the same as reaming with single pipe section
strings. The reaming procedure must be done in stages as the pipe sections are removed.
While removing the drill pipe the cuttings dislodged from the sides of the hole and the cuttings
generated by reaming will fall to the bottom of the hole. To effectively clean the hole, it would be
necessary to reassemble the tool string and lower it to the bottom of the hole. This is not desirable
as it is time consuming. One method to eliminate the need to clean the hole is to overdrill the depth
and allow cuttings to fill the hole to the desired finishing depth. Experience in this area will show
how much to overdrill the hole. A good practice is to overdrill the hole by 1 to 2 feet (0.3 to 0.6 m)
over the estimated finished hole depth. This way, if the estimate is wrong, the hole will be 1 to 2 feet
(0.3 to 0.6 m) too deep. This can easily be corrected by a few shovels full of cutting thrown into the
hole. Underestimating, on the other hand will require that the tool string be reassembled and the
hole cleaned.
DRILLING DIFFICULT FORMATIONS
For the purpose of explanation, the drilling procedure given in the DRILLING section of the manual
assumes that drilling takes place in consistent, consolidated rock formation. Unfortunately, not all
drilling is in this type of formation. This section of the Operator’s Manual will detail, in general, some
typical drilling difficulties encountered.
The main cause of difficult drilling are unconsolidated material or wet sticky material. Unconsolidated
material causes vibration far greater than experienced in consolidated formation, and if severe
enough, may also decrease the bailing velocity of the main air stream. Wet, sticky material causes
problems with cleaning the hole since the material may coat the hole and the drill pipe, increasing
the air pressure above the working range. Wet material may also plug the bit orifices, freeze the bit
cones, or compact into balls that refuse to be bailed out of the hole. The general procedure for
drilling in difficult formations is the same as the procedure for drilling in good formations. The hole
is collared, drilled, reamed, and cleaned using the standard operating procedures. Monitoring of the
machine is, however, critical while drilling in difficult formations.
NOTE: Failure to closely monitor the machine and its bar graphs as shown on the operator’s
display terminal operator’s display screen will result in damage to the machine or a
stuck drill pipe.
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ATTENDED LONG TERM STORAGE
The attended long term storage procedure combines the short term storage procedure with monthly
start-up and running periods. To store the machine for a long period of time it is necessary to
complete the procedures listed in the SHORT TERM STORAGE topic in this manual. Then, once a
month for the duration of the storage period, complete all start-up inspection and lubrication
procedures listed in this manual and start the drill. Run all of the gear trains for 10-20 minutes to
distribute the oil over the gears and bearings. Hoist and lower the rotary/pulldown unit the full length
of the mast 4-6 times to distribute lubrication to the mast and rotary/pulldown unit components.
Cycle the tool racks 2-3 times. Run the air compressor for 1 hour. Propel the drill at least 6 times
the length of the machine. After running the machine components, follow the short term storage
procedure once again and store the machine for another month. Repeat this procedure every
month until the machine is returned to service.
UNATTENDED LONG TERM STORAGE
It is not within the scope of this manual to detail the procedures involved in the long term storage of
a drill. These procedures will involve disassembly of the major units on the drill, duties that are not
usually performed by operating personnel. Refer to the Mechanical Maintenance Manual for details
concerning the long term storage of the machine.
The procedure listed here is an outline intended only to give a general idea of the effort involved in
proper storage of the machine. To store the unattended machine for an extended period of time,
proceed as follows:
1. Complete all short term storage procedures.
2. Remove the motors from the drill and store in a heated building.
3. Completely fill the rotary and pulldown gear cases with an approved oil. Both cases can be
filled completely by adding the oil through the breather openings. Remove all water from the
cases.
4. Loosen the guide rollers on the rotary/pulldown unit frame to provide one-half inch clearance
between the rollers and the mast.
5. Remove the auxiliary winch line.
6. Cover the rotary gear case and hoist/pulldown gear case with a waterproof tarp.
7. Remove the air compressor from the machine and store in an attended heated building.