GLOBAL SERVICE TRAINING

MD6540 Rotary Drill

Engine and Support Systems
MODULE 3 - TEXT REFERENCE

SERV2006

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SERV2006 - 12/13 -2- Module 3 - Engine and Support Systems

TABLE OF CONTENTS
SAFETY BRIEFING��������������������������������������������������������������������������������������������������������������������� 3
PURPOSE����������������������������������������������������������������������������������������������������������������������������������� 4
REASON������������������������������������������������������������������������������������������������������������������������������������� 5
HEADER LOOKS LIKE THIS������������������������������������������������������������������������������������������������������ 8
Next Activity������������������������������������������������������������������������������������������������������������������������������� 10
PURPOSE REVIEW�������������������������������������������������������������������������������������������������������������������11
REASON REVIEW�������������������������������������������������������������������������������������������������������������������� 12
COMPETENCY STATEMENT REVIEW������������������������������������������������������������������������������������ 13
LEARNING OUTCOMES REVIEW������������������������������������������������������������������������������������������� 14
MODULE CONCLUSION���������������������������������������������������������������������������������������������������������� 15

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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 Engine and Support Systems

module is designed to prepare the technician to identify
the components in the engine and support systems.

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• Course purpose PURPOSE

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REASON

This training is necessary for participants to be able to

quickly and accurately diagnose performance issues in
the engine and support systems. 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 a post-assessment.

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• Course competency statement COMPETENCY STATEMENT

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LEARNING OUTCOMES

You will meet the following learning outcomes during

this Engine and Support Systems module of the
Rotary Drill MD6540 course:
• Take notes on the operation of the engine and support
systems.
• Identify the components and describe the operation of
the engine and support systems.

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• Learning outcomes (objectives) LEARNING OUTCOMES

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INTRODUCTION

• Identify the main components of
the power train.
The power train for the MD6540 drill consists of four main components:
• Turbocharged and after cooled Detroit (MTU) 16V2000 engine (1) producing
1205 hp at 1800 rpm, with an electronically controlled fuel system,
• Sullair (3600 cfm Diesel) compressor (2) producing 690 kPa (100 psi) service
air pressure. The compressor is driven through a Centamax coupling from the
rear of the engine.
• Pump drive gearbox (3), driven through a Centaflex coupling from the front of
the engine.
• Hydraulic pumps (4) driven through the output of the pump drive gearbox.

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Engine Servicing

• Explain the engine service The Detroit 16V2000 engines take 98 liters of engine oil. The engine oil level must
requirements. be checked at the beginning of every shift using the engine oil dipstick (1).

The engine has 3 oil filters (2) which require replacing at regular service intervals.

Engine fuel is filtered by the primary (3) and secondary fuel filters (4), which must
also be replaced as per the service schedule.

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Air Cleaner Servicing

• Explain the engine/compressor The air cleaners for the MD6540 drill are mounted at the front of the machine. The
air cleaner service requirements. outer two filter assemblies are for the engine, the inner two protect the compressor.

Service for the disposable filter type air cleaner includes general inspection and
replacing the elements as required.

Sensors are installed that measure filter restriction. A signal is sent to two indicators
mounted on the operator control console to monitor the right and left filters. When
restriction indicates that element servicing is required, remove and replace the
primary element.

Dust cups should be emptied when 2/3 full. When replacing, ensure that it seals
completely around the air cleaner body.

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Centreflex Coupling

• Explain the purpose of the The 6540 drill uses a Centaflex universal coupling (1) to transfer the output from
centreflex coupling. the engines (2) to the drive pump gearbox (3).

The Centaflex universal joint shaft is designed to dampen noise, torsional vibration
and shocks.

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Pump Drive Gearbox

• Identify components connected The pump drive gearbox (1) allows the single input from the engine to be split into
to the pump drive gearbox. various outputs, which drive the pumps attached to the gearbox.

Four pumps are driven by the gearbox:

• Auxiliary/dust collection pump (2),
• Fan cooler pump (3),
• LH track/drill rotation pump (4)
• RH track/pull down pump (5)

A dipstick is installed at the top of the gearbox housing to allow the gearbox oil level
to be checked. This check should be performed prior to the start of each shift.

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Compressor Drive Coupling

• Explain the purpose of the The compressor is driven off the rear of the engine via a torsional drive coupling.
compressor drive coupling. The coupling consists of a rubber element, a flange, and taper-lock bush.

Visual inspection of the coupling can be viewed through an opening (arrow) in the
bell housing adapter plate.

The coupling is to be inspected at each scheduled service interval, looking for signs
of any movement of the coupling on the shaft or evidence of fatigue or failure of the
rubber element.

Usually no other service is required, other than replacement of the rubber element
when it is worn out.

Service life of the element is 5000 hrs under normal operating conditions.

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Compressor

• Identify the features of the To provide compressed air to the drill bit and for auxiliary air to operate other
compressor and explain the functions, the MD6540 is fitted with a single-stage, low pressure, positive-
purpose of the compressor oil. displacement, oil flooded lubricated type air compressor located behind the engine.

The compressor operates in association with the separator/receiver tank to provide

compressed air 3600 cfm at 690 kPa (100 psi).

The compressor consists of two rotors, a male rotor and a female rotor. As the
rotors turn, air is drawn into the compressor from the air inlet. At this stage the air is
compressed, before being discharged into the receiver tank via the discharge hose.

Compressor Oil

When operating, compressor oil is injected into the compressor unit from the
separator tank and is mixed with air. Oil is forced from the separator tank by
pneumatic pressure. Therefore, to provide the lubricating oil to the compressor,
there must be pneumatic pressure present.

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The compressor oil has three main functions:

• The oil acts as a coolant by controlling the rise of air temperatures normally
associated with gas compression.
• The oil acts as a lubricating film between the rotors, allowing one rotor to
directly drive the other rotor, which acts as an idler. The oil also lubricates the
rotor bearings.
• The oil seals the leakage path between the two rotors.

Oil is incompressible, therefore as the air and oil mixture passes through the rotors
only the air is compressed. This compressed air/oil mixture is then pumped into the
receiver tank

However, the compressed air cannot be used until the oil has been separated out
of it. This separation occurs in the receiver tank.

When measuring the temperature of the compressor, there will always be a rise in
temperature from the inlet end of the compressor as compared to the outlet end,
due to the rising temperature of air being compressed. If the outlet end is hotter
than the inlet end, it would indicate that the bearings at the outlet end are failing.

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Discharge Check Valve

• Explain the operation of the The air/fluid mixture leaving the compressor unit overcomes a spring loaded piston
discharge check valve. in the discharge check valve and flows into the separator/receiver tank.

On shutdown, back pressure forces the piston closed, restricting flow back into the
compressor unit.

If the piston does not fully close off the compressor discharge port on shutdown,
back pressure will force the rotors to turn in the opposite direction of rotation,
forcing air and oil out of the compressor unit and wet the inlet air filters.

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• Identify and explain the purpose
of the compressor temperature
senders and cutoff switches.
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Temperature Sender Units and Cutoff Switches
Various sender units and temperature activated switches monitor the temperature
of the compressor. Their functions and purpose are as follows:
• Compressor Discharge Temperature Shutdown Switch (1). Shuts the engine
down if the compressor discharge temperature exceeds 121°C
• Compressor Discharge Temperature Sender (2) measures the temperature of
the air/oil mix leaving the compressor and sends the signal to a gauge located
on the console of the operators cabin.
• Compressor Discharge Temperature Switch (3). Switches cooling fans to high
speed mode when temperature exceeds 104°C.
• Compressor Discharge Temperature Transducer (4). Provides an input to the
drill monitor relative to compressor discharge temperature.
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SERV2006 - 12/13
• Identify the components of the
receiver/separator tank and
explain its purpose.
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Receiver/Separator Tank
The receiver/separator tank (1) serves as both a sump for the compressor oil and a
reservoir for the compressed air.
The tank separates the oil from the air by forcing the mixture through two separator
filters. The need for the two filter system within the tank is due to the high volume
(3600 cfm) of air/oil requiring separation. The separated air remains on the “dry”
side of the filters ready for use. The other side of the filter is referred to as the ‘wet”
side.
The separated oil is forced to the bottom of the tank by the head of air pressure.
This pressure is also used to feed the oil back through the circuit to the compressor
via the thermal valve, the cooler pack, and the main filter.
A sight glass (2) at the bottom of the receiver/separator tank allows service
personnel to view the amount of oil in the tank. The oil level should be half way up
the sight glass.
As the air/oil mixture passes through the separator filter, a small amount of oil
will also pass through the filter and collect at the bottom of the separator filter
assembly. This oil needs to be removed or it will be discharged into the service line,
auxiliary air lines, or out the blowdown valves.
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The oil is removed by the scavenge line. A pick up is set 3 mm off the bottom of
each separator filter assembly. The pick up tubes connect to a 1/4” hose, which
runs from the receiver through a strainer and orifice assembly (3) before going
back to the compressor. The strainers are used to capture fibrous material while
the orifice minimizes the flow of air being recirculated.

The strainers are fitted with a sight glass that permits viewing of the flow of
fluid going back to the compressor unit. When the compressor is running at full
load, there should always be a small flow of oil as seen through the sight glass,
approximately 1/3 full.

A sluggish flow at full load may indicate a need to clean the scavenge line strainer
and/or orifice.

Full flow may indicate that the filter is nearing failure.

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Minimum Pressure Valve

• Explain the purpose of the The minimum pressure valve (1), located on the dry side of the separator filter, is
minimum pressure valve. used to ensure that a minimum fluid pressure is maintained in the system.

The minimum pressure valve springs (2) keep the valve closed at pressures below
415 kPa (60 psi) (3). When pressure rises above 415 kPa (60 psi) (4) the pressure
overcomes the piston spring, raising the piston within the housing and allowing air
flow to the service line.

If the sealing ring on the piston is worn or damaged, air could leak by the piston,
thereby preventing full discharge pressure to be achieved. If this situation occurs a
vent orifice located on the housing is incorporated to relieve pressure from behind
the minimum pressure valve piston.

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SERV2006 - 12/13 -21- Module 3 - Engine and Support Systems

From Receiver
Tank

To
Compressor

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Thermal Valve

• Identify the thermal valve. The thermal valve is designed to maintain operating temperature, and is used for
fast warm-up at start-up and to eliminate condensation during operation. The
thermal valve location is identified by the arrow in the top left image.

The compressor oil passes from the separator tank, up through the spear in the
receiver tank and through the thermal by-pass valve before passing through the
filter to the compressor.

When the oil temperature is below 88°C, the thermal valve reduces flow to the oil
coolers and increases flow to the compressor.

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From Receiver
Tank

To
Compressor

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Thermal Valve

• Explain the operation of the Once oil temperature has reached 88°C the thermostat shifts and allows oil flow
thermal valve. into the oil coolers before passing through the filter and onto the compressor.

To test if the thermal valve is functioning properly, operate the compressor until
normal operating temperature is achieved.

Measure the temperature of the four hoses which run from the thermal valve. The
hose from the compressor receiver tank and the hose to the cooler should be the
same temperature.

The hose from the cooler and the hose to the compressor oil filter should also be
the same temperature, but approximately 10-15°C cooler than the other two.

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Butterfly Inlet Valve
• Explain the purpose of the • Compressor inlet (1)
butterfly inlet valve. • Control cylinder (2)
• Stop screw (3)
• Vent orifice (4)

The purpose of the compressor control system is to regulate the compressor air
intake to match the amount of compressed air being used.

The inlet valve consists of a butterfly valve controlled by an air cylinder. The
butterfly is typically open during drilling and shut when unloaded or in shutdown
mode.

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Compressor Control Panel

• Identify the main components on
the compressor control panel.
The control panel contains gauges, filters and solenoids that control and monitor
the output of the compressors. The main components contained within the control
panel are:
• Compressor control manifold (1)
• Running blowdown (2)
• Check valves (3)
• System pressure regulator (4)
• Spiral valve regulator and gauge (5)
• High/low volume solenoid valve (6)
• Run/tram solenoid valve (7)
• Control pressure regulator and gauge (8)
• Run/start solenoid valve (9)
• Second running blowdown (10)
• System blowdown valve (11)

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System Pressure Regulator

• Explain the purpose of the The system pressure regulator is a relieving type pressure regulator.
system pressure regulator.
It is connected between the receiver and the inlet control cylinder.

The regulator controls the receiver pressure by closing the inlet valve when their
settings are reached. When air pressure reaches 690 kPa (100 psi), flow is allowed
through to the inlet cylinder to close the inlet butterfly valve.

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Spiral and Control Pressure Regulator

• Explain the purpose of the spiral The spiral valve regulator (1) and the control pressure regulator (2) are reducing
and control pressure regulators. regulators which are normally open, and close off to maintain a constant pressure
downstream.

The spiral valve system works by having a series of holes down the center of the
air end rotor housing with a spiral valve directly above the holes. The spiral valve
will then move back and forth, opening and closing these holes. As more holes
are “opened” less air can be compressed, as we have effectively “shortened” the
available sealed compression area of the rotors. The spiral valve regulator is used
to tune the spiral valve actuation length.

The control pressure regulator maintains a pressure of 275 kPa (40 psi).

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System Blowdown Valve

• Explain the purpose of the The system blowdown valve (arrow) is a 2-way normally opened valve that is
system blowdown valve. piloted closed from the same pilot line that opens the oil stop valve.

When the compressor first starts up the system blowdown is piloted closed, which
allows the receiver to build up pressure.

When the compressor is shut down the valve opens and vents any remaining
receiver pressure. The system blowdown valve will stay open until the compressor
starts up again.

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Running Blowdown Valve

• Explain the purpose of the The running blowdown valve is a 2-way normally closed valve that vents excess
running blowdown valve. receiver tank pressure to atmosphere when the receiver tank pressure exceeds the
set unload pressure during unloaded operation.

Pilot pressure to control the running blowdown valve is governed by the system
pressure regulators.

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Second Running Blowdown Valve

• Explain the purpose of the The second running blow down valve (arrow) is a normally closed pilot operated
second running blowdown valve. valve which is controlled by the run/tram solenoid valve.

Its purpose is to conserve fuel when tramming by causing the compressor system
to run at a lower pressure.

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Compressor Oil Cooler

• Explain the purpose of the Compressor oil flows through the oil cooler core, where heat is transferred to
compressor oil cooler. ambient air.

At start up and during low operating temperatures, compressor oil flows from the
receiver tank through the thermal by-pass valve, through a filter and then to the
compressor.

Once an operating temperature of 88°C is reached, the thermostat shifts and

diverts oil from the receiver through the thermal by-pass valve, through the cooler
and back to the receiver.

The cooler contains a core that allows the oil to be cooled by ambient air. To assist
the cooling effect, the radiator utilizes cooling fans to draw air across the cooler
core.

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Engine Cooler

• Explain the purpose of the engine Coolant is pumped though the engine by the water pump located on the engine.
cooler. Once operating temperature is reached, the thermostat in the engine shifts and
passes coolant through the radiators.

There is a sight glass on the side of the radiator indicating coolant levels, which
should be checked at the beginning of every shift.

The radiator cap or coolant fill point is located on top of the engine radiator.

NOTE: Never attempt to remove radiator cap when engine is hot or has
overheated.

Relieve the pressure in the radiator prior to removing the cap. This is achieved by
pressing the red button on the radiator fill cap.

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SERV2006 - 12/13 -32- Module 3 - Engine and Support Systems

PURPOSE

This MD6540 Rotary Drill Engine and Support Systems

module was designed to prepare the technician to
identify the components in the engine and support
systems.

32
• Course purpose review PURPOSE REVIEW

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SERV2006 - 12/13 -33- Module 3 - Engine and Support Systems

REASON

This training was necessary for participants to be

able to quickly and accurately diagnose performance
issues in the engine and support systems. Use of
the knowledge gained in this course will ensure the
participant’s ability to provide more effective customer
service, which enhances customer satisfaction.

33
• Course reason review REASON REVIEW

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SERV2006 - 12/13 -34- Module 3 - Engine and Support Systems

COMPETENCY STATEMENT

The participants are now required to successfully

complete a post-assessment.

34
• Course competency review COMPETENCY STATEMENT REVIEW

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LEARNING OUTCOMES

You have met the following learning outcomes during

this Engine and Support Systems module of the
Rotary Drill MD6540 course:
• Took notes on the operation of the engine and support
systems.
• Identified the components and described the operation of
the engine and support systems.

35
• Learning outcomes (objectives) LEARNING OUTCOMES REVIEW
review

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MODULE CONCLUSION

The next module will be the MD6540 Rotary Drill Dust

Collection System.

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• Module conclusion MODULE CONCLUSION

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