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GLOBAL SERVICE TRAINING

MD6540 Rotary Drill


Operator's Station
MODULE 1 - TEXT REFERENCE

SERV2006

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SERV2006 - 12/13 -2- Module 1 - Operator's Station

TABLE OF CONTENTS
SAFETY BRIEFING��������������������������������������������������������������������������������������������������������������������� 3
PURPOSE����������������������������������������������������������������������������������������������������������������������������������� 4
REASON������������������������������������������������������������������������������������������������������������������������������������� 5
COMPETENCY STATEMENT����������������������������������������������������������������������������������������������������� 6
LEARNING OUTCOMES������������������������������������������������������������������������������������������������������������ 7
INTRODUCTION������������������������������������������������������������������������������������������������������������������������� 8
PURPOSE REVIEW������������������������������������������������������������������������������������������������������������������ 42
REASON REVIEW�������������������������������������������������������������������������������������������������������������������� 43
COMPETENCY STATEMENT REVIEW������������������������������������������������������������������������������������ 44
LEARNING OUTCOMES REVIEW������������������������������������������������������������������������������������������� 45
MODULE CONCLUSION���������������������������������������������������������������������������������������������������������� 46

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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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PURPOSE

This MD6540 Rotary Drill Operator’s Station module is


designed to introduce the operator controls and the drill
monitor.

4
• Course purpose PURPOSE

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REASON

This training is necessary for participants to be able


to quickly and accurately identify components in the
operator’s station. Use of the knowledge gained in this
course will ensure the participant’s ability to provide
more effective customer service, which enhances
customer satisfaction.

5
• Course reason REASON

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COMPETENCY STATEMENT

At the completion of the session, the participants will be


required to successfully complete lab exercises and a
post-assessment.

6
• Course competency statement COMPETENCY STATEMENT

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LEARNING OUTCOMES

You will meet the following learning outcomes during


this Operator's Station module of the Rotary Drill
MD6540 course:
• Take notes on the location of switches and controls in the
operator’s station.
• Identify the location of switches and controls in the
operator’s station and identify the drill monitor screens
during a post-assessment.

7
• Learning outcomes (objectives) LEARNING OUTCOMES

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INTRODUCTION

• Identify the operator consoles. Within the MD6540 operator cabin are two operator consoles.

The left console (1) is referred to as the switch and lever control panel. Mounted
above the left console is the radio communication set.

The right console (2) contains the control levers, drill monitor and rear camera
screen.

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Switch and Lever Control Panel

• Identify the switches and controls The switches and controls located on the left control panel are:
on the left control panel.
• Wiper switches (1)
• Inspection hatch and dust curtain (2)
• Safety bar open/close (3)
• HOBO (4)
• Pipe positioner (5)
• Deck wrench (6)
• Carousel locking pin (7)
• Carousel swing (8)
• Air on/off (9)
• Pull down pressure (10)
• Auto feed switch (11)
• Water flow switch (12)
• Water on/off and dust collector (13)
• Air volume switch (14)
• Mast locking pins (15)

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Right Control Panel

• Identify the controls on the right The controls fitted to the right control panel are:
control panel.
• Winch (1)
• Mast raise/lower (2)
• Left rear jack (3)
• Front jacks (4)
• Right rear jack (5)
• Tramming control (6)
• Drill/propel switch (7)
• Rotation control (8)
• Pull down/hoist control (9)
• Leveling bubble (10)

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Camera Panel

• Identify the devices fitted to the The devices located on the vertical console of the right control panel are:
right vertical console.
• Camera screen (1)
• Emergency stop (2)
• Stair raise (3)
• Stair lower (4)
• Stair light (5)

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Circuit Breaker and Instrument Panel

• Identify the devices fitted to the The circuit breaker and instrument panel is located adjacent to the right operator
circuit breaker and instrument console. The controls on the circuit breaker and instrument panel are:
panel.
• Circuit breakers (1)
• Tachometer (2)
• Tram hour meter (3)
• Drill hour meter (4)
• Compressor temperature (5)
• Voltmeter (6)
• Lights (7)
• 12 volt power (8)
• Horn (9)
• Start switch (10)
• Engine idle (11)
• On/off switch (12)
• Stop switch (13)

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Drill Monitor

• Identify the drill monitor controls. The drill monitor is located to the left of the right vertical console.

The drill monitor features a 25 key front panel that has the following controls:
• Power on/off for turning the unit on and off (1)
• Manual brightness control with + or - (2)
• Turning the backlighting ON or OFF (3)
• LEDs for device temperature, HD access and power status (4)
• Function and number keys (5)
• Scroll keys (6)
• Esc key and Enter key (7)

Touch Screen Operation

The resistive touch screen allows the operator to select changes by touching the
desired part of the screen. To protect the screen, the operator should have clean
dry fingers or wear soft gloves.

Using sharp objects such as screwdrivers can irreparably damage the resistive
touch screen.

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Cleaning the housing

The housing of the drill monitor is best cleaned with a damp cloth.

Do not use compressed air, a high-pressure cleaner or a vacuum cleaner, as this


can damage the surface.

Cleaning the touch screen

Clean the resistive touch screen with a clean, damp, and non-scouring towel
soaked with dishwashing detergent.

Do not use cleaning agents that contain ammonia or sulphur.

Do not use scouring substances, as these can scratch the touch screen.

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• Identify the function and number Function and number keys (1)
keys and the LEDs.
The SHIFT key enables the operator to toggle between the function printed on the
white half and the function printed on the gray half of the buttons, and is indicated
by the yellow LED.

LED status (2)

Red (temp) LED indicates an excessively high or low temperature inside the unit.
The unit will not operate in this condition.

Green (HD) LED indicates access of the hard drive.

Green (Power) LED indicates available internal power.

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Login Screen

• Identify the drill monitor startup The dashboard is the main application for drill operation, service and
screen. troubleshooting. The program is started automatically once the operational system
is running.

The start screen of the dashboard is the login screen. The user access level
determines which screens are accessible. To log in, press the “person”
symbol (arrow) on the bottom row. Once selected the icon will appear green.

Without login it is possible to switch to the help and engine screens. This allows
access to stored documents such as manuals and schematics as well as being
able to view engine hours and engine fault codes.

Apart from the login function, the start screen provides information about bit life,
drill, tram, service and refill hours. In addition to the hour meter, the screen displays
the shift time passed and the shift footage.

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Login and Access

• Explain how to access the drill Once the login button has been pressed the key pad (1) will appear.
screens.
To login, the user has to enter the service ID and the passcode using the number
pad as shown.

Once logged in, the user can access various screens using the bottom row (2).

The symbols on the bottom row represent:


• Drill screen (3)
• Tram screen (4)
• Level screen (5)
• Engine screen (6)
• Event screen (7)
• Login screen (8)
• Status screen (9)
• Help screen (10)
• Configuration screen (11)

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Drill Screen

• Identify the drill screen sections. The drill screen is the main screen for drilling operation.

The screen is divided into four main sections:


• Depth system (1)
• Drill pressures and rotation (2)
• Drill status and override (3)
• Auto drill and auto water (4)

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Depth Panel

• Identify the information on the The drill depth panel displays the:
depth panel.
• Hole depth
• Rate of penetration
• Advance per revolution
• Number of pipes on the drill string

The hole depth can be preset using the +/- buttons on either side of the depth
preset display.

The depth of the actual hole will be determined only in drill mode. In all other
modes the depth will be reset to zero.

Regardless of the mode, the pipe counter will display the number of pipes currently
on the rotary head.

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Pressure and Rotation Panel

• Identify the information on the The pressure and rotation panel features four dual scale gauges. The scaling of
pressure and rotation panel. these gauges can be set to customer specific requirements.

The factory setting for the pull down gauge is actual pull-down pressure in lb/f on
the outer scale and Nm on the inner scale.

The rotation pressure gauge shows rotational torque in lb/f on the outer scale and
Nm on the inner scale.

The bit air and auxiliary hydraulic pressure gauges read psi on the outer scale and
bar pressure on the inner scale

The pressure and rotation panel also displays the rotation speed as a digital value.

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Drill Status and Override Panel

• Identify the meaning of status The drill status and override panel displays the status of the functions indicated by
displays on the drill status and the icon for each.
override panel.
Green is normal status.

Red indicates an alert.

Blinking indicates the system is unsure of the position of the function and needs to
be checked or re-set.

Safety Interlocks

Auto Drill

Auto drill function is locked out if the mast is not locked out or if the machine is not
adequately levelled. Once the auto drill function is locked out the auto drill button
on the drill screen will be RED.

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Auto drill requires the following active sensors:


• Mast lock and unlock limit switches
• All pressure transducers in jacks
• RH pump/pull down pressure sensor
• LH pump/rotation pressure
• Laser depth system
• Heat speed sensor
• Front jacks must be activated as last part of the jacking procedure

Pipe in Hole

This option inhibits the movement of the mast, jacks and tram motors. The head
must be at the top of the mast to tram, jack or raise/lower the mast and the pipe in
hole symbol on screen must be out of hole (GREEN).

The following conditions must be met to verify that the pipe is out of the hole.
• The depth must equal zero (the actual depth must have counted all the way
back to zero).
• The head must be above the pipe in hole set point (the head must be at the
top of the mast).
• The pipe count must be 2 or less.

Override Function

The Icon for each function is an active override for that function, any time the
system is overridden, the event will be recorded in the alarm screen and event
section.

NOTE: Overriding any system has the potential for component or machine
damage. This action must be done only after fault evaluation and with due
care.

The override function enables the operator to override the pipe in hole in either drill
or tram mode.

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Tram Screen

• Identify the information provided Once the drill is switched to tram mode, the dashboard will automatically change to
on the tram screen. the tram screen. This screen provides the user with information about tram
pressures, machine inclination, mast angle, and tram interlock status.

The tram pressures are displayed for the left and right track.

The park brake icon in the middle displays the status of the brake. It shows red if
the park brake is engaged and black if the brake is released.

If the mast is up the park brake will release when the following conditions are
satisfied:
• Tram mode is selected
• All jacks are up, ladder is up
• Machine inclination fulfils the transient stability limits
• Dust curtain is up
• Pipe is out of hole
• Mast locks are engaged and the tram joysticks are activated

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SERV2006 - 12/13 -24- Module 1 - Operator's Station

The pipe in hole condition is cleared if the following conditions are met:
• The pipe on string must be 2 or less (the last pipe in the string will still be on
the head).
• The depth must equal zero (the actual depth must have counted all the way
back to zero).
• The head must be above the “Pipe in Hole” set point (the head must be at the
top of the mast).

If the mast is on the mast rest, the park brake will release when the following
conditions are satisfied:
• Tram mode is selected
• All jacks are up
• Ladder is up
• Machine inclination fulfils the transient stability limits
• The dust curtain is up and the tram joysticks are activated

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Artificial Horizon

• Explain the artificial horizon The artificial horizon gauges on the left side of the tram screen represent the drill in
displays. both side and front view.

Depending on the mast position, the drill is displayed with the mast up or the mast
on the rest.

The gauges turn red 2 degrees before the machine exceeds the stability limits,
accompanied by an audible alarm.

Once the machine exceeds the stability limit, tramming is locked out and the park
brake is applied.

The inclination override button accessible from the tram screen can be activated
to enable tramming at levels exceeding stability limits. This will be recorded on the
event screen.

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Level Screen

• Identify the level screen display The Level screen displays three sets of information sections:
sections.
• The level gauge (1)
• The status of jacking interlocks (2), together with the access stairs up and
down icons (3)
• The auto level (4) and auto retract icons (5)

The level gauge in the upper left corner displays a digital readout of the angle and
an analogue bubble gauge to depict the machine angle.

The interlock panel displays the functions that will stop the jacks from being raised
or lowered, such as stairs down, pipe in hole, mast locks, dust curtain position and
the inclination override button.

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Auto level

The auto level button will automatically level the machine at gradients less than
6 degrees if all the interlocks are not active. For this to occur the following
conditions must be met:
• The mast to be raised with locks engaged or mast down on mast rest
• Ladder raised
• Ground inclination not greater than 6 degrees in any direction
• Pipe in hole indicator must be green

For gradients greater than 6 degrees the drill needs to be manually levelled.

Auto retract

When activated, the auto retract will retract all four jacks to the fully raised position.
For this to occur, all interlock indicators must be green.

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Engine Screen

• Identify the information provided The engine health surveillance system constantly monitors the performance of the
on the engine screen. engine and records all running parameters, alarms and faults as they occur.

The engine monitoring panel (1) displays the following:


• Current engine RPM
• Engine oil pressure
• Engine load and intake pressure
• Engine oil, coolant and intake temperatures
• Fuel level
• Battery condition
• Engine hours
• Fuel consumption per hour

The error dialog (2) lists the Parameter Identification (PID), the Failure Mode
Identification (FMI) and the description of the fault.

The arrow up and arrow down buttons to the right of the description allow the user
to scroll through the list of logged faults.

The alarm panel (3) on the right of the screen displays active alarms as icons.

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Event Screen

• Identify the information displayed The event screen allows access to logs of all events outside normal operating
on the event screen. parameters that have occurred on the drill. This includes occurrences where a
system override has been selected.

Each event is accompanied by a brief description. Further information provided


includes index, code, time of event, and the time the event was actioned. The
events can be viewed by using the scroll buttons on the right side of the screen.

The screen includes selectable icons for operator acknowledgement of alarms and
faults, system override and file export.

If an event occurs it is displayed in the event table and in the event bar. New events
or still active but not acknowledged events are highlighted in red.

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Machine Status

• Identify the information provided The status screen can be accessed from the main menu.
on the status screen.
The screen shows a plan view of the drill rig providing a general indication of the
overall status of the machine.

Major components such as tanks, coolers, compressors, etc. are depicted on the
diagram. Green indicates that component is operating normally.

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Sub Screen - Gauges

• Identify the information provided By selecting the gauge icon at the top of the machine status screen, a sub screen
on the gauges sub screen. appears providing digital readouts of all the operating parameters on the drill.

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Sub Screen - Network

• Identify the information provided By selecting the network icon at the top of the machine status screen, a sub screen
on the network sub screen. appears providing a visual representation of the machines computing system and
Can-Bus network.

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Sub Screen - Input

• Identify the information provided By selecting the input screen icon at the top of the machine status screen, a sub
on the input sub screen. screen appears providing a representation of the layout of the drill.

Two sub menus can be accessed from this screen. By touching the cab icon (1),
input data from the cab can be accessed.

Similarly, touching the mast icon (2) provides input data from the sensors located
on the mast.

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Sub Screen - Cab Input

• Identify the information provided The cab input screen shows the position and operating status of various controls
on the cab input sub screen. within the operators cabin.

This screen provides maintenance personnel with valuable fault finding information
when investigating system failures.

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Sub Screen - Mast Input

• Identify the information provided All mast inputs and laser depth set points are visible from this screen. Again a
on the mast input sub screen. useful fault finding tool ensuring inputs are valid.

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Sub Screen - Output

• Identify the information provided This screen provides a virtual representation of control outputs.
on the output sub screen.

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Help Screen

• Identify the information provided The help screen displays a list of all icons, functions and symbols. A short
on the help screen. description is provided to explain what each symbol represents.

The arrow UP and arrow DOWN buttons on the right of the screen allow the
operator to scroll through the icons and view each description.

The operator and service manuals as well as the electrical and hydraulic
schematics are accessed through this screen via the buttons located on the right.

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Configuration Screen

• Identify the information provided The configuration screen is only accessible to field service personnel.
on the configuration screen.
This screen allows the user to change settings for the lubrication interval and the
depth system or to re-calibrate sensors that are used with auto drill and auto level
systems.

The override panel allows service personnel to allow functions to be operated that
would be locked out under normal operating conditions.

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Configuration Screen - Lubrication

• Explain how to adjust the The lubrication interval can be set from the configuration screen. The time is
lubrication cycle. displayed in minutes. The default value setting is 60 minutes. This value can be
changed by selecting the + or - icons.

The lubrication solenoid is activated at the configured value, causing the grease
pump to start, and will run for two minutes or until the required lubrication pressure
is reached.

If manual lubrication is selected, the lubrication solenoid will allow one 2 minute
greasing cycle.

If the lubrication pressure is not reached within the two minutes, in either manual or
automatic mode, the lubrication alarm will be activated.

NOTE: If the lubrication alarm continually sounds, inspect for broken


grease lines or faulty field devices.

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Configuration Screen - Sensor Calibration

• Explain how to calibrate the The sensor calibration panel allows the following adjustments to be made:
sensors.
• Head up calibration (1)
• Head down calibration (2)
• Mast vertical (3)
• Analogue level sensor (4)
• Can open level sensor (5)

To calibrate the depth system, drive the rotary head all the way up and press the
calibration button with head up icon. The icon on the button will change from black
to green if the calibration is valid. It will turn red if invalid or error.

After the calibration of the first set point, move the rotary head all the way down
and press the calibration button showing the head down icon. The icon on button
will behave in the same way as for the first calibration, green for calibrated, red for
invalid or error.

To calibrate the mast incline sensor the machine has to be levelled first and the
mast has to be in vertical position. Then select the calibration button with the mast
inclination icon.

The machine incline sensors should be calibrated with the level bubble. Once
the level bubble shows that the drill rig is levelled the button with the machine
inclination icon has to be pressed.
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Configuration Screen - Overrides

• Identify the functions that can be The override panel allows service personnel to allow functions to be operated that
overridden via the configuration would be locked out under normal operating conditions. The following can be
screen. overridden:
• Compressor oil shutdown (1)
• Winch up cut-off (2)
• Low bit air (3)
• Pipe support in/out (4)
• Low fuel condition (5)
• Low hydraulic oil (6)

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SERV2006 - 12/13 -42- Module 1 - Operator's Station

PURPOSE

This MD6540 Rotary Drill Operator’s Station module


was designed to introduce the operator controls and
the drill monitor.

42
• Course purpose review PURPOSE REVIEW

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SERV2006 - 12/13 -43- Module 1 - Operator's Station

REASON

This training was necessary for participants to be able


to quickly and accurately identify components in the
operator’s station. Use of the knowledge gained in this
course will ensure the participant’s ability to provide
more effective customer service, which enhances
customer satisfaction.

43
• Course reason review REASON REVIEW

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SERV2006 - 12/13 -44- Module 1 - Operator's Station

COMPETENCY STATEMENT

The participants are now required to successfully


complete lab exercises and a post-assessment.

44
• Course competency review COMPETENCY STATEMENT REVIEW

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SERV2006 - 12/13 -45- Module 1 - Operator's Station

LEARNING OUTCOMES

You have met the following learning outcomes during


this Operator's Station module of the Rotary Drill
MD6540 course:
• Took notes on the location of switches and controls in the
operator’s station.
• Identified the location of switches and controls in the
operator’s station and identified the drill monitor screens
during a post-assessment.

45
• Learning outcomes (objectives) LEARNING OUTCOMES REVIEW
review

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SERV2006 - 12/13 -46- Module 1 - Operator's Station

MODULE CONCLUSION

The next module will be the MD6540 Rotary Drill


Undercarriage and Mainframe.

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• Module conclusion MODULE CONCLUSION

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