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GLOBAL SERVICE TRAINING

MD6540 Rotary Drill


Introduction
TEXT REFERENCE

SERV2006

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SERV2006 - 12/13 -2- Introduction

TABLE OF CONTENTS
SAFETY BRIEFING��������������������������������������������������������������������������������������������������������������������� 3
PURPOSE����������������������������������������������������������������������������������������������������������������������������������� 4
REASON������������������������������������������������������������������������������������������������������������������������������������� 5
COMPETENCY STATEMENT����������������������������������������������������������������������������������������������������� 6
LEARNING OUTCOMES������������������������������������������������������������������������������������������������������������ 7
INTRODUCTION������������������������������������������������������������������������������������������������������������������������� 8

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SAFETY BRIEFING
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

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SAFETY BRIEFING

Before beginning this module, the following topics will be reviewed:


• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

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SERV2006 - 12/13 -4- Introduction

PURPOSE

This MD6540 Rotary Drill course is designed to


introduce the technician to the major structures and
components of the drill, the service station components,
and the operation of the autolube system.

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• Course purpose PURPOSE

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SERV2006 - 12/13 -5- Introduction

REASON

This training is necessary for participants to be able to


recognize components and to quickly and accurately
diagnose performance issues. Use of the knowledge
gained in this course will ensure the participants's
ability to provide more effective customer service,
which enhances customer satisfaction.

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• Course reason REASON

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COMPETENCY STATEMENT

At the completion of this course, the participants will be


able to identify the major structures and components of
the MD6540 Rotary Drill.

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• Course competency statement COMPETENCY STATEMENT

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LEARNING OUTCOMES

You will meet the following learning outcomes during


this Rotary Drill MD6540 course:
• Locate and identify the major structures that make up the
drill.
• Utilize the correct terminology when describing the
components that make up the sub elements of the drill.
• Identify the fill and drain connectors on the service
stations installed on the drill.
• Describe the operation of the auto lubrication system.

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• Learning outcomes (objectives) LEARNING OUTCOMES

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Single Pass Multi-Pass


Model Bit Load Hole Diameter Working Weight
Hole Depth Hole Depth
up to 75000 kg 273 - 445 mm 187.3 m Up to 39.6 m 183500 kg
MD6750 Series
(up to 165,347 lb) (10.8 - 17.5 in) (60 ft) (130 ft) (404,548 lb)
up to 54000 kg 244 - 406 mm 18.3 - 21.3 m Up to 85.3 m 154000 kg
MD6640 Series
(up to 141,096 lb) (9.6 - 16 in) (60 - 70 ft) (280 ft) (339.512 lb)
up to 54000 kg 229 - 381 mm 16.5 - 20.0 m Up to 85 m 131000 kg
MD6540 Series
(up to 119,050 lb) (9.0 - 15 in) (54.1 - 65.6 ft) (279 ft) (288,806 lb)
up to 42999 kg 229 - 311 mm 10.53 - 16.5 m Up to 74.4 m 91500 kg
MD6420 Series
(up to 92,594 lb) (9.0 - 12.3 in) (33.8 - 54 ft) (244 ft) (201,723 lb)
up to 29000 kg 152 - 270 mm 8.6 - 11 m Up to 52.7 m 54500 kg
MD6290 Series
(up to 63,934 lb) (6.0 - 10.6 in) (28.2 - 36.1 ft) (173 ft) (120,152 lb)
up to 24000 kg 152 - 270 mm 12.8 - 15.8 m Up to 55.5 m 62500 kg
MD6240 Series
(up to 52,911 lb) (6.0 - 10.6 in) (42 - 52 ft) (182 ft) (138,891 lb)

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INTRODUCTION

• Identify the major features of the The MD6540 series is one of the top of the range rotary drill rigs produced by
MD6540 Rotary Drill. Caterpillar.

The MD6540 series machines produce a bit load of up to 54 t and drill 17 m single-
pass blastholes up to 381 mm in diameter.

The MD6540 cab is all-electric and has no hydraulic lines entering into it or the
control panels, and visibility around the cab is excellent.

The machine is designed with an advanced auto drill, auto level and on-board
drill-health and drill-performance monitoring system, which includes diagnostics
and a downloadable memory function.

Rapid pipe changing is achieved with the Cat Hydraulically Operated Break Out
(HOBO) wrench and highly effective deck wrench.

Cat one-touch auto-drill system optimizes the drilling process, so drilling is efficient
and excessive equipment wear is prevented

Auto cable tensioning, powered by two hydraulic cylinders, maintains constant


force on pull-down and hoist ropes for efficient energy transfer and accurate head
alignment.

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Unique three-stage, twin hydraulic mast-raise cylinders are positioned away from
the mast pivot, minimizing loads on the mast and main frame.

A 102 m3/min (3,600 cfm) single-stage rotary screw compressor provides ample air
for large-hole and high-altitude drilling.

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General
Arrangement

• Identify the major structures of The major structures that make up the MD6540 Rotary Drill are:
the rotary drill.
• Mast assembly (1)
• Operator's cabin (2)
• Hydraulic tank (3)
• Service Center (4)
• Compressor receiver (5)
• Undercarriage (6)

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• Identify the major structures of The major structures that make up the MD6540 Rotary Drill are:
the rotary drill.
• Mast rest (1)
• Air filters (2)
• Cooler pack (3)
• Diesel engine (4)
• Mast raise cylinder (5)
• Pipe positioner (6)
• Hydraulically Operated Break Out (HOBO) wrench (7)
• Hydraulic crane (8)
• Rear jack (9)
• Dust collector (10)
• Front jack (11)

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Masthead

• Identify the major components The major components that make up the mast assembly on the MD6540 Rotary
that make up the mast assembly. Drill are:
• Pipe positioner (1)
• Drill pipe safety bar (2)
• Drill pipe (3)
• Carousel (4)
• Pipe loader (5)
• Rotary head (6)
• Rotation motor (7)
• Winch (8)
• Crown sheave (9)

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Wiggins Service Station

• Identify the fill and drain The Wiggins service station, located below the main deck, provides quick
connectors on the Wiggins disconnect couplings to allow service personnel to replenish or drain fluids. The
service station. following connectors are provided:
• Hydraulic oil fill (1)
• Hydraulic oil drain (2)
• Engine coolant (3)
• Engine oil (4)
• Fuel receptacle (5)

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Lubrication Station

• Identify the major components The MD6540 is provisioned with an automatic lubrication system, which consists of
located at the lubrication station. an air powered pump (1) assembly fitted to a grease container (2). The pump supplies
grease under pressure to manifolds containing injectors, which supply grease to
various points on the machine as required.

Associated with the automatic lubrication system are the following components:
• Solenoid control valve (3)
• Water trap (4)
• Regulator (5)
• Oiler (6)

Also located at the lubrication station is the drill pipe thread greaser (7), which is
operated by a foot pedal.

The auto lubrication system is actuated automatically by compressed air at


predetermined intervals, and is programmed via the drill monitor. The air-operated
pump delivers lubrication to the injectors. When all injectors have cycled, the pump
shuts off automatically and vents lubricant pressure.

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