Introduction to Blasthole DrillingTABLE OF CONTENTS vie 262 INTRODUCTION............-+5 wee 11 Hydraulic Track Motors oo ise Brake Units. ra Leveling Jacks 7s FUNDAMENTALS OF DRILLING AIRSYSTEM 2... 75 DESCRIPTION : DUST COLLECTION SYSTEMS (option) =... 7-8 DRILLING METHODS WATER INJECTION SYSTEM (option) 7 DRILLING EQUIPMENT DRILLING COMPONENTS.......... 3-4 GENERAL a4 FEED (pulldown)... ceeeeeeeeee BT ROTATION (torque) a4 Parcussive Driling 32 Rotary Diiling 32 PERCUSSION sees 32 Down the Hole Hammer (OTH) 32 FLUSHING. tee 38 Bailing Air 33 SURFACE DRILLING METHODS & APPLI- CATIONS. ......ceceee cece eee e ee el GENERAL... 44 BLAST HOLE DRILLING ........... 5-1 GENERAL 51 BLAST DESIGN AND DRILL PATTERNS Bt Bench Height 52 Hole Diameter 52 ‘Burden and Spacing. C8 Movement Throw : 53 Fragmentation 53 Blast Damage to New Highwall 53 Environmental Controls 53 Vertical and Angled Holes cs Standoff (Coal Mining) 55 RIG COMPONENTS ........-2-0-0+ 6-1 MAST ASSEMBLY «0... 62 LOADER . : fee 82 ROTARY HEAD ..... nase OS DRILL STRING TOOLING and Power Wrench (breakout system) 63 Holding Wrench (deck wrench) ea Bt Wrench es WINCH vives Bob POWERUNIT. oo. o.oo cee cone Bd UNDERCARRIAGE «6... 65 MACHINERY DECK 65 RIG SYSTEMS .............0.0005 7-4 HYDRAULIC SYSTEM 7A Reservoir Tank 74 Pump Drives 72 Mast Raising and Locking Gylinders 73 CONTROLS, OPTIONS AND MONITORING EQUIPMENT... INSTRUMENTS ANI ELECTRONIC DEPTH COUNTER (EDC option) The Pipe-in-Hole Alarm DRILL MONITORING SYSTEM (OMS option) TRAMMING INTERLOCK (option) LOADER/ROTARY HEAD INTERLOCK (enon) ANGLE DRILLING GROUP (option) REMOTE SERVICE CENTER (option) LUBRICATOR (option) FIRE SUPPRESSION SYSTEM (option) ‘AUTO LUBE SYSTEM (option) AUTO THREAD LUBE (option) ARTIC COLD HEATERS (option) . MISCELLANEOUS OPTIONS. Electrical Hydraulic Compressor Tools Machine Accessories Dill Accessories Cabin Special Applications DRILL STRING COMPONENTS. ..... 9-1 DRILL STRING ot Dri Pipe ot Stabil2ers eS) Subs 92 Dail Bits cece DOWN THE HOLE HAMMERS (OTH) ........ 4 Hammer Selection Size of Hammer Hammer Air Consumption Hammerdril® Rigid Valve Selection Flecommended Lubrication Bit Design TOOL JOINT THREAD CHARTS ...... a8 DRILL SPECIFICATIONS. = 10-1 DESCRIPTION : wees 104 LUBRICANT SPECIFICATIONS 10-2 General Engine Oils (CH) 102 Lubricating Grease (MPGM) 102 Compressor Ois (COMP) 2102, Hydraulic Oils (HYDO) 102 Tatteot Conteris Page |Multipurpose - Type Gear Lubricant (MPL) 102 Ftrigeration Oil (REF) 102 MINIMUM PERFORMANCE STANDARDS FOR HY- DRAULIC OILS 10-6 AIR COMPRESSOR LUBRICANT RECOMMENDA- TIONS 10-7 GLOSSARY OF TERMS .... 11-1 Page iSection 1 INTRODUCTION ‘Welcome to the first series of the new genera- tion training manuals offered by one of the world's leaders in earth drilling equipment. The purpose of this manual is to introduce blasthole drilling techniques and components to our customer. Successive manuals will give specific system, operating, maintenance, troubleshooting, and repair procedure. Driltech Mission, LLC serves the worlds drill- ing industry for rotary, DTH, blasthole and waterwell products. With manufacturing plants located in Florida and Texas in the United States, and Mexico and India, Driltech Mission offers a complete drill package. Rotary, blasthole and waterwell drills are manufactured in the Alachua, Florida facility DTH products are manufactured in Mansfield, Texas - Mexico City, Mexico, Poona, India and Sandviken, Sweden. The manufacturing plant in Alachua is also home for the product marketing, testing, engi- neering research and development, service and training departments on a 68 acre prop- erty, with over 168,775 square feet of work space. We are proud to provide a quality product based on customer requirements. Please visit us at our scheduled Drill Schools. Contact the product service secretary for details. (904) 462-4100. Inveaucton to Basta’ Dring Page 1Section 1 REFERENCE MATERIAL: Sandvik Rock Tools - SD and XL hammer operation manuals Sandvik Roller bit manual ‘Sandvik Tamrock - Rock excavation for civil engineers handbook Denison Hydraulic - Application manual Mills Machine Co. Inc. - Drill accessory man- ual Driltech Mission - Technical publication and service training departments Sullair Corporation Published by Dritech Mission, LLC - USA All rights reserved. No part of this manual may be reproduced in any form without prior written consent from Dritech Mission, uc. Page2DESCRIPTION Drilling is all about making a hole in the ground. The two fundamental components of making blastholes are: + Chip making + Chip clearing CHIP, SWEEP, CHIP, SWEEP! Section 2 MENTALS OF DRILLING TWISTING/TEARING ‘GRINDING/ABRADING THRUST ) GRINDING | TORQUE <_— One or more of the following processes can produce chips: + Cutting/tearing + Twisting/tearing zs * Grinding/abrading * Crushing GRINDINGS CUTTINGTTEARING CRUSHING ANGLE OF CUTTING Peheacr ACCUMULATION OF FINE 4 CHIPPING Sy ROCK DEPTH PER BLOW BUTTON INDENTION \ CRUSHED ROCK POWER POTENTIAL CHIP LOOSENING CRACK} (CRACKED FORMATION ZONE Invodvcton Basta Orting Page 1Section 2 The four main components of drilling are:: * Feed * Rotation * Percussion + Flushing FEED FORCE FLUSHING SS5 rotation ROTARY DRILLING DRILLING METHODS Blasthole drilling has been performed by two different methods: Percussive drilling, made up of: + Top hammer tools * Down-the-hole (DTH) tools Rotary drilling The choice of drilling method is mainly depen- dent upon the physical and geological proper- ties of the rock to be drilled. Hard formations generally require percussive drilling, while soft or non-consolidated rock may need only rotary drilling. Percussive drilling utilizes all four compo- nents, feed, rotation, percussion and flushing. Rotary drilling does not use percussion, but compensates by having increased feed force and rotation torque. Rotation speeds and feed forces will vary according to ground condi- tions. Each drilling application requires mod- erate changes in the rotary drilling technique. Page2 PERCUSSION ROTATION AND ‘COMPRESSED FEED ons FLUSHING r Orns gyi oa PERCUSSION DRILLING Hardness and mineral composition of the rock will also be major factors in wear of the drill string components. DRILLING EQUIPMENT There are many types of surface drills, which can be grouped according to their operating principles mentioned above: + Top hammer drilling DTH drilling Rotary drilling Auger drilling Core drilling Driltech Mission, LLC manufactures a range of drill igs suitable for both DTH and rotary drilling. Driltech Mission does not manufac- ture top hammer drills. Drill rigs use drill steel equipment (when con- nected these are called a ‘drill string’) to drill the hole. The drill steel equipment includes components such as drill pipes, adapter subs, DTH hammers and drill bits.DRILL PIPES. OTH HAMMER DRILL BIT. DTH DRILLING The choice of drill steel equipment should be carefully selected to meet the needs of the machine it is intended to be fitted to. Other factors may be ground condition and hole depth of rock to be excavated Section 9 gives details to the drill string com- ponents utilized for rotary and down the hole percussion drilling, Invecicton Blea Ontng Page 3Section 3 DRILLING COMPONENTS GENERAL The four components of drilling are’ 1. Feed 2. Rotation 3. Percussion 4. Flushing FEED (pulldown) Feed force is required in order to press the drill bit against the rock. This in itself will only produce minor crushing of the rock immedi- ately under the drill bit. Combined with the forces of rotation and/or percussion, the feed force enables the processes of cuffing, tear- ing, grinding and abrading to occur. As the bit cuts, it must be fed down to keep the drill bt in constant contact with the rock surface. HOIST CHAIN SY ed FEED oan FEED /PULLDOWN) ‘OruNDeR ‘The pulldown cylinder moves the rotary head up and down via an arrangement of chains and sprockets. Every formation requires a minimum feed force before the drill bit will penetrate, as the tooth pressure must exceed the rock strength. Soft rock such as shale will require a lower feed force than hard rock such as granite. Rotary drilling will be more efficient, if the feed force is greater than the minimum needed, as the bit will break out rock chips, rather than abrading fine grindings. In practice, a ‘pulldown’ system is needed on a drill machine, so that feed force additional to that exerted by the weight of the drill string can be placed onto the bit. Effectively, part of the rig weight is added to the drill string weight. The feed force must be capable of being varied. Control valves allow adjust- ments to be made to suit driling conditions. Too MUCH! NOT ENOUGH! neuen ted ore wit ctaten i peton sce led co wilonse ‘aes gh wen nd omaoe ‘oa ng component isting component PULLDOWN SYSTEM ROTATION (torque) Rotation components are adjustable to suit drilling conditions. Single and twin motor arrangements are available for the many Invostoton fo Betoe Oring Page 1Section 3 different drilling applications. Single motor applications are applicable for DTH percus- sion drilling, whereas two motors may be required to turn large drill pipe and rotary bits. Percussive Drilling Percussion energy is generated by a moving piston. With each piston impact from the ham- mer, the tungsten carbide buttons in the bit body penetrate the rock surface. The function of rotation is to turn the dill bit to a new posi- tion between percussive impacts, so that the drill bit carbides strike fresh rock surfaces. ‘Slow to medium rotation speeds assist the bit buttons to penetrate new rock with each pis- ton impact. Hammer manufacturers specify applicable rotation speeds. Rotary Drilling Rotation is torque, used to roll the bit around while the feed force holds it firmly against the ground. Rotary bit manufacturers specify maximum rotation speeds and maximum pull- down ratings. The combination of rotary torque and feed- force enables the bit to produce chips by crushing and cutting. ROTARY DRILL BITS A ‘rotary’ system is required to turn the drill string and drill bit. The rotation speed must also be variable, so it can be adjusted to pro- duce the largest cuttings possible (to optimize penetration rates), as well as suit either rotary or DTH hammer drilling applications. PERCUSSION In general, percussion drilling produces more efficient drilling in medium to hard formations. Rocks that are not easily abraded by drag force of rotary drilling alone may be more effi- ciently drilled with percussive blows. Two types of percussion methods are the pneumatic or hydraulic top hammers, or a pneumatic down the hole hammer. Down the Hole Hammer (DTH) Down the hole hammer drilling requires high- pressure compressed air. Use light to medium feed force for best results. Air pressure is pro- portional to penetrate rates. In harder rock for- mations it is essential to maintain the highest recommended air pressure. Specific care should be given to drill bit selection according to the rock material being excavated. DOWN THE HOLE HAMMERS Page 2A DTH hammer provides drilling energy right at the bit. Its highly efficient because piston ‘energy is transmitted directly to the bit at the rock surface. DTH hammers are best suited for medium to hard rock materials. FLUSHING Flushing is necessary to remove cuttings from the drill hole. Flushing should be sufficient to clear chips away from the bit immediately. Otherwise the chips will be reground, increas- ing bit wear and reducing the penetration rate. Flushing (Baling Ait) Dill Steal Air Passage Dail Bit Bit Flushing Ports Cuttings Removal pete FLUSHING SYSTEM Section 3 Bailing Air Compressed air is the most common medium used with blasthole drills to clear chips from the hole. It is referred to as ‘bailing air’, as it bails the chips from the hole. The annular air velocity or ‘up-hole velocity’ (UHV) determines whether or not there is sut- ficient bailing air to ensure effective removal of rock cuttings from the hole. Theoretically UHV will depend on these factors; + The capacity of the compressor * The diameter of the drill bit in the hole + The outside diameter of the drill pipe The last two factors together determine the volume of the drill hole that needs to be bailed. If the drill pipe diameter is small com- pared to the hole diameter, then there will be a large volume to be bailed and the UHV will be low. If on the other hand, the diameters are fairly close, there is a small volume to be bailed and the UHV will be greater. If rock is abrasive, rapid drill string wear will occur with the higher UHV. Water, foam or polymer may be injected into the air stream to aid in dust suppression, chip removal or to improve hole stability. [Fon pmunre © so0cru Pir a a prc EHH t TYPICAL UP-HOLE VELOCITY (UHV) CHARTS: “ntoducton to Biestole Onvng Page 3Section 3 or [coupnesson] — upwoue se ‘output "| yevocrry Ba aa a a ae el pe Sue [a [re rst aes rae aa oor |e ret UP-HOLE VELOCITY (UHV) TABLE Insufficient flushing leads to low penetration (increased recutting), decreased drill pipe life (bit wear and jamming of drill string) and high bit wear. Optimum driling occurs when dry air flushing up-hole velocity factors can be main- tained between 4000 to 9000 FPM depending on rotary or DTH driling methods. Higher UHV may be acceptable for drilling depending on ground conditions such as con- sistent and solid low abrasive formations. Select higher UHV when drilling occurs in bad fractured ground, with voids or caverns, high rock density or long hole depths. Page 4Section 4 SURFACE DRILLING METHODS AND APPLICATIONS GENERAL Selection of the appropriate drill method will depend on factors such as the rock strength, diam- eter and depth of hole required. Typical applications are shown below. TONS = ROLLER BIT ROTARY 45°. 16 (143 -sotmm) HOLE DIAMETER 4000-000 Pst 1002545. MPa) ROCK Rotany APpLeATION ROWER BTS 1 resttasae t2fem) HOLE DIAMETER 2 $00 22000 et Guase151s8 Pa) ROCK. 3. ROtaRY APPLICATION DRAG BIT DRAG BIT ROTARY TOP HAMMER PERCUSSIVE 1"-6°(054. 1524nm) HOLE DIAMETER {o1000-eoon0 Pat ea 413 MPa) ROCK surToN sis DOWN - THE - HOLE 39° 40-89-1016) HOLE DIAMETER 4000-69060 PSI (10135-4134 MPa) ROOK eurioneits Irrcbcton Baste Ontng PageSection 4 ROCK HARDNESS & COMPREHENSIVE ‘STRENGTH TABLE RELATIVE MOH'S COMPRESSIVE ——— HARDNESS HARDNESS | STRENGTH - PSI INDEX ere NUMBER Extremely sot 1-2 < 2,000 Soft 2-3 2,000- 5.000 1 Tac Medium 3.45 5,000 - 10,000 5 qrrsum Medium hare 45-6 — | 10,000- 20,000 Hard 67 20,000 - 30,000 3 caLerre Exemely hard 37 > 30,000 ni Tene 5 APATITE RELATIVE MOH'Sy COMPRESSIVE 6 ORTHOGLASE HARDNESS HARDNESS | STRENGTH - MPa 7 age Extremely soft = 18 8 TOPAZ Soft la. 3s Medium 35-70 8 ‘CORUNOUM Medium hard 70-140 DIAMOND Hard 140-210 2. a Extremely hard > 210 MOHS SCALE OF HARDNESS C mprssy Sr ah ROCK TYPE ‘Mpa IGNEOUS Ads 300 | “oo | 2.660 | 56.980 IGNEOUS [Basal 250 | oo [35.550 | 56,880 | seDImenTaRY [Ca mra_| 10 19,908 IGNEOUS Ip + 170 {300 | 217 | 2,660 seomentary [D1 m 150 21,330 IGNEOUS Igabbr 260 | 350 | 36,972 | 9.70 METAMORPHIC |G ss so | 300 | 19,908 | 2,660 | liGNeous [Gra 200 | 350 [28 o| 9.770 Isepimentary [Lm r_k 30_| 100 [266 [7 220 SEDIMENTARY [Lm s 120 17.06 METAMORPHIC [Marbl 100 | 200 [1 220 [26.0 METAMORPHIC [Quar z sso | 220 foarsa | a.28 | IGNEOUS Rhy 1 120 17.06 SEDIMENTARY [Sa ds 160_| 255 | 22,752 | 36,261 METAMORPHIC [S hs eo | 00 | a.s32 | 56,880 METAMORPHIC [S 1p 30_| 150 | 266 | 21,330 SEDIMENTARY —|Shal 70 9.95 METAMORPHIC [Sia 150 21,330 liGNEous. [tra ty 330 6.926 ROCK COMPRESSIVE STRENGTH Page 2Section 5 BLAST HOLE DRILLING GENERAL Blast hole drilling is used in the extraction of rock products and minerals from surface mines and quarries. A blast hole drill pro- duces holes to a predetermined plan. The holes are then charged with explosive and the rock is blasted and broken A typical drilling sequence involves: * Driving or tramming the machine to the required location. + Raising the machine on the leveling jacks to provide a stable drilling platform + Raising the mast (from the horizontal) to the desired drilling position. * Lock the mast into position. * Commence rotation, feed and air flushing, air percussion for DTH applications. * Drilling to the required depth. A ‘single pass’ operation, is a hole depth no more than one drill pipe length. A ‘multi-pass' operation, is where drill pipes must be added as the hole is drilled. + Retracting the drill string. * Lowering the mast (to horizontal if neces- sary), prior to tramming * Always lower the mast to horizontal with truck mounted drilling equipment prior to moving the machine. (A) orILLNc (®) Leveun {C) PIPE HANDLING (0) TRAN TYPICAL DRILLING CYCLE ‘The type of blasted product or ‘fragmentation’ required from the blast will determine the way in which a blast hole drill will be used. For example: + Ina quarry, most of the material broken out will be given further treatment. The rock will need to be broken into fragments Which are easily dug, fill haulage units to capacity, cause few interruptions to the primary crusher feed and are free from excess fines. * Open pit or surface mines differ from quar- ries in that large quantities of overburden or waste rock may need to be moved quickly and will have no further treatment. Therefore rock may be broken to a lesser degree than quarry rock. Both examples move material by large machinery such as front-end loaders, shovels and/or draglines. BLAST DESIGN AND DRILL PAT- TERNS Take the example of an open cut coal mining operation. The engineer will need to design a ‘drill pattern’, mark it, so the machine operator can drill it. To produce the desired fragmenta- tion, a number of factors must be taken into account, including: ‘+ Type of rock or formation * Degree of blast movement / ‘throw’ required Explosive selection Terrain conditions Environmental conditions Damage to the product Factors, which can be varied by the engineer designing the blast, may include: Inocbcton Batol Oring Page 1Section 5 APPARENT BURDEN” HoLe-To-cREst > FLOOR Of FINAL GRADE suscaane (soem) / Hote paMereA BACKBREAK New crest ee MOCKING) BANK ANGLE * NOTE! TRUE burden and spacing may oitfer from APPARENT burden and spacing due to the delay between fring adjacent lines. BLAST DESIGN TERMINOLOGY Bench height Hole diameter Type/quantity of explosive Burden Spacing Vertical or angled holes, Standoff These factors are interrelated in their effects. Some of these are discussed below. Bench Height When rock is drilled and blasted to create steps, itis known as bench driliing. The bench height may be determined by factors such as the stability of the rock, the type of driling equipment available, or the access available. Hole Diameter Hole diameter is closely related to bench height and burden, and should be between Page 2 0.5 — 1% tace height. Mine location, produc- tion rates, rock density, explosive factors for air and ground vibration monitoring may play an important role in what type of machine and related hole diameter best suits the specific mine. Burden and Spacing Burden and spacing are terms used to describe the dimensions of a drill pattern. + Burden is the distance between each row. + Spacing is the distance between the holes along a row. SeerMovementThrow Drill pattems are designed to obtain a suitable blast profile for loading equipment like shov- els or draglines. The most critical factor con- trolling the movement of a shot is the burden. A throw shot in a coal application may utilize approximately 23ft (7m) of burden for 10 5/8” holes. Likewise a shot to be “stood up" may utilize approximately 33ft (10m) of burden for the same hole. The selection of burden will also depend on the width of the bench. 'A. SECTION OF ‘STOOD UP” SHOT B, SECTION OF THROWN SHOT MOVEMENT/THROW Fragmentation Fragmentation is a general term that describes the size of individual rocks after blasting. Once the burden has been selected, the spacing must be selected to provide sufi- cient fragmentation. Spacing is calculated using the volume of rock to be blasted and the tonnage of explosives to be put in each hole ay aaa TONNAGE CALCULATION Section 5 Blast Damage to New Highwall Often the row of holes that create the new highwall will be spaced more closely together. This allows weaker explosives to be used and creates a better highwall. When the row has half the spacing of the rest of the pattern, itis said to be a ‘staggered pat- tern’, STAGGERED PATTERN WITH PRE-SPLIT LINE (ROW 4) Environmental Controls Most mines have limits for noise and vibration produced by blasting, imposed by an environ- ment protection agency. Noise is increased if nroducton to Basthte Orting Page 3Section 5 holes “blow out” because the charge is uncon- fined. The burden on the highwalll row is. selected with this in consideration. ‘Sal ren one gal ow ‘nau to grotto Bow ‘StS eau n gh note, BLOW-OUT Vertical and Angled Holes Inclined or angled holes, result in more pro- ductive blasting than vertical holes however each have advantages and disadvantages. VERTICAL: ‘+ Movement of the drill is quicker. + Less wear to the drill accessories. + Easier machine set-up for operators. + Greater disturbance to the new highwall. Iie not pose cit his ole angle, VERTICAL HOLES. ez reas ANGLED HOLES. peer Page + ANGLED: * Better burden is produced on the highwall row. + Machine can be set-up away from the highwall. + Used where the burden on the highwall Tow may be too large for vertical holes. + Angle drilling may hinder dust suppression systems. + Operation set-up time and techniques are affected.Section 5 ‘STANDOFF DRILL PATTERN Standoff (Coal Mi 9) If holes are drilled to or into coal, the explo- sives will damage the coal product. Blast damage reduces recovery and increases dilu- tion of the coal. With smaller coal seams a “standoff” drill pattern may be used to prevent product damage. With this system, not all holes are drilled to the coal. The engineers drill plan may indicate to drill every third hole to the coal. Other holes standoff the coal product 5 feet (1.5 m). In this situation a hole is drilled to find the depth of the coal seam and the next two holes are 5 feet (1.5 m) shallower. Invesucton Basie Oning Page 5Section 6 RIG COMPONENTS ZS cS MODEL D90KS SHOWN SAS eS SDS = 26 25) 24. 23 22 2 20 i9 Ye YW Ye is 4 Ys 1. Mast Crown 10. Mast Rest 19. Crawler Frame 2. Mast 11, AirCleaners 20. Idler 3. Mast Raising Cylinders 12, Cooler 21, Boarding Ladder 4, Hydraulic Tank 19. Front Levelling Jacks 22, Rear Leveling Jack 5. Hydraulic Pump Gearbox 14, Main Frame 23, Dust Hood 6. Water injection Pump 415. Machinery Deck 24, Operator's Cab 7. Water Tank 16. Final Drive Sprocket 25. Air Conditioner 8. Engine 17. Track 26. Hydraulic Lines to Rotary Head 8. Compressor 18. Crawler Axle Innccvoton Bisa Critng Page 1Section 6 MAST ASSEMBLY The mast supports the rotary drive and drilling accessories. It may be constructed to allow the machine to drill vertical and/or angle holes. + The mast assembly pivots upon a mast pedestal frame. The pedestal is fabricated to the machinery deck. * Two hydraulic cylinders are used to raise and lower the mast. Vertical or angle drill positions and horizontal travel position are normal positions. * Hydraulic motor(s) and planetary gears mounted to a rotary head provides the drilling torque necessary to rotate the drill string + Hydraulic cylinder(s) with sprockets and chains provides the necessary force to raise and lower the rotary head and drill string. + Aloader on the mast structure provides drill pipe storage. It can be indexed (rotated) for drill pipe loading/unloading to from the rotary head. * Compressed air from the air receiver tank is piped up the mast. The air swivel on the rotary head allows air through the drill string to the drill bit. Compressed air is used to bail cuttings from the hole during drilling. * The bottom end of the mast supports a table and work deck. Drilling tools to assist in pipe connections are available from the work deck. Page 2 CCARDUSEL, Unb sta cfUnDER obec ‘Wsrek op MAST & LOADER COMPONENTS LOADER Alloader carries a number of drill pipes, which allows for a multi-pass drilling operation. When the drill rig is equipped with a loader, the operator can change pipes quickly and efficiently from inside the cab. A loader consists of: + Hanger - typical hanger arrangements are pivoted, and the carousel is swung in and out of position by operator controlled hydraulic valves and cylinders. Optional sliding hanger arrangements may be fitted for larger drill pipe configurations.* Carousel - A top latch plate and bottom pods hold up to 6 pieces of drill pipe. Mounted below the bottom pods is an index lock plate which has locating holes used for indexing the pipe position. * Indexing System - A hydraulic locking pin moves in and out of the locking plate. A hydraulic cylinder rotates the assembly. When the pin is in the ‘unlock’ position, only the indexing assembly is rotated. When the pin is in the ‘lock’ position the hydraulic cylinder rotates the carousel. ROTARY HEAD Piston-type hydraulic motor(s) provide mechanical torque to reduction gears mounted to the rotary head housing. A large bullgear and shaft transmit rotation directly to the top sub and drill pipe. The bull shaft is hol- low to permit compressed air to be passed down the drill pipe to the blast hole. Mounted on top of the bull shaft is an air swivel assem- bly with seals. This swivel allows oil to remain in the rotary head and air to be supplied to the drill string Hydraulic cylinders and roller chains raise and lower the rotary head, which is secured to the mast with adjustable wear pieces (guide shoes). The replaceable wear pieces are made of a nylatron fiber. This material pro- tects the sliding areas of the mast. GUIDE SHOES' ROTARY HEAD Section 6 DRILL STRING TOOLING Tooling is necessary to enable joints (connec- tions) in the drill string to be made (tightened) or broken (loosened). Power Wrench (breakout system) The “power wrench’, is used to break tight pipe joints and drill bit accessories which can- not be broken by reversing the rotation of the drill string. This tool is a hydraulic powered, jaw-type breakout wrench mounted below the pipe loader. The wrench is controlled by the ‘operator from inside the cab. ‘A tong wrench may be supplied. This is a hydraulic actuated cylinder with a “Stilson” type wrench. The tong wrench is manually placed onto the pipe during joint breaking. TONG WRENCH Invecvotont Bishoe Oring Page 3Section 6 Holding Wrench (deck wrench) This sliding wrench is used to hold the drill pipe, while the joint above it is broken (loos- ened) or pipe-changing procedures take place. The jaw of the wrench is shaped to engage the top flats of the drill pipe, and it is mounted on the mast table. The operator con- trols the ‘engage’ and ‘disengage’ positions of the wrench from inside the cab. HOLDING WRENCH. we Bit Wrench A special wrench shape is required to hold the drill bit during bit changing procedures. Precut wrenches and blank wrenches are available. The bit wrench tool is put into the mast table in place of the table bushing, It can be held in place with the holding wrench. When the drill bit is lowered into the bit wrench it is held securely and cannot turn. Reverse rotation or the power wrench can assist thread breaking. The winch is controlled by the operator from inside the cab and is used to lift accessories such as hammers, bits, and subs, to and from the work deck. The winch can also be used to change drill pipes when the mast is in a verti- cal position. From the spool, a wire rope with a lifting hook attached runs up and over the top of the mast, via a set of sheaves. POWER UNIT The engine is the prime source of mechanical power for the entire drill. Driltech Mission blasthole drills use Caterpillar or Cummins diesel engines running at ‘high idle’ speed of 1800 rpm. Engine power is transmitted to hydraulic pumps via drive shafts and gear- boxes. A rotary screw compressor is driven from the engine flywheel. Engines are water cooled with radiator(s) and are temperature protected with safety switches. Caterpillar ‘E’series engines also utilize air-to-air aftercool- ers (ATAAC). A hydraulically driven cooling system provides airflow through the radia- tor(s) and oil coolers. ‘COMPRESSOR ENGINE \ceM (nin) PSI bat) MODEL HP(Kw) RPM aoer| fiona) [arose —Yasovsse) | — 1800) [750 21-1) [100 (6.3) JasK 130 __|s00 (73) | 1.800] (goo 255) —[100(6.9) [soe [as0 (638) | 1.500 (2007285) —[100(6.9) ask 19 |s00373) | 1.800) F050 9.7) [100 (69) |seoee [40 (336) | 1.800] Pros a.7) [100 (69) [ask 136 [500 (373) | 1,809) frso0 6a) [100 (63) |seoxe [500 (373) | 1.800] Fso0sa) [100 (63) [ask 190 —|s00°s73) | 1.800] faoo25.5) —[s50 24.1)|seose [aso (336) | 1.800] [0 (25.5) [350 (24.1) JOSK 196 [500 (373) | 1.00) [1.000 (26.5 | 360 (24.1) [3406E 521 88)| 1,800] fico 3) [360 24.1) [SK 136 —_|s00773) | 1.800} TYPICAL D40KS, D45KS & DSOKS MODEL HORSEPOWER CHART Pre-cleaners treat incoming air prior to final fle tration through paper elements. An electronic metered ether injection system assists in cold starts. UNDERCARRIAGE Track undercarriages, manufactured by Cat- erpillar are the most common track drive sys- tems (Badger and American undercarriages have also been used). Two independently operated crawler units, are driven by bent axis axial piston type hydraulic motors. Hydraulic, Section 6 motor drive torque is transmitted to planetary reduction gears in the final drive assembly. Control of these drive motors can provide an infinite range of steering maneuvers, from gradual to radical comering, by varying the control lever positions in the forward and reverse ranges. Counter steering is possible if one track is placed in forward while the other is placed in reverse. Each track chain, fitted with triple-lug grouser plates, is supported and guided by track roll- ers, a front idler and carrier rollers. Large coil springs counter the recoil of the front idler to cushion shocks and maintain track tension. An adjustable cylinder provides track chain slack adjustment. Track guides protect bottom rollers from rocks. Both track frames are piv- oted on an axle and equalizer beam to pro- vide some degree of track oscillation. Both undercarriage members are fitted with hydraulic multi-disc brakes to prevent track movement while the drill is not propelling. MACHINERY DECK The machinery deck (frame) is steel fabrica- tions which mount and support most machine operating components such as: diesel engine, radiators and oil coolers, mast rest, compres- Invidicton Besta Oning Page Sor, air receiver, air/oil separator, hydraulic tank and oil filters, fuel tank, batteries, hydrau- lic pump drives, water system, mast support structure and cab. Access ladders and railed walkways extend around the deck to facilitate access to machinery for inspection and ser- vicing, while the cab access is ladder or deck. All leveling jacks are mounted securely to the frame, Pages 28 23. at 19 6 ws 16 18 1 FRONT ALKA 13 2 FRONTUAGKOWUNDER 4 3 coouea 18 & ComPressoa 16 6 ENGINE 18 8 Dresher 2. 9. Propelpumponve 31 No HYORAULIC PUMP ORIVE 22 Mf AIRLUBRIGATORTANK 28, 12. RYORAULIC TANK 28 a 2 13 4 ‘OPERATOR'S STATION WoRKOECK DusTHooD cruneR Bust couecrom NAST RAISING CYLNDER WATER RUESTION PUMP WATER INJECTION TANK NUFFLER IA CLEANER D5SSP MACHINERY DECKSection 7 HYDRAULIC SYSTEM The track drive and rotation systems are fully hydrostatic with independent pumps for each circuit. The result is @ system that is much cleaner and easier to troubleshoot. These systems are closed loop and equipped with three-micron filtration. Seamless steel tubing is utilized wherever possible to enhance sys- tem cooling and decrease the maintenance cost. The hydraulic system has a supercharge sup- ply to assist the rotation and feed pump cir- cuits. This auxiliary replenishment is pressurized to 125-175 psi (8,6-12 bar). The primary function is to keep the feed pump full during cylinder actuations. The secondary is to protect the rotation system from high shock loads during the drilling sequence. HYDRAULIC [em TEST STATION es An optional on-board hydraulic monitoring system allows rapid diagnosis of hydraulic systems. Reservoir Tank The hydraulic reservoir tank performs the fol- lowing functions: + Takes up the variations in oil volume, which occur through the operation of actu- ators, * Assists in the cooling of the oil before being recirculated through the system. Serves as a storage vessel for hydraulic oil. Oil is filtered before returning to tank. ‘The D40KS through the D75KS use a two reservoir system, the second being a supercharge manifold. The reservoir tank supplies oil for the follow- ing pumps; propel pumps, rotation pump, feed Pump, cooling fan and accessory pumps. Oil retumed to the reservoir passes through 10- micron return filter(s), The hydrostatic systems use 3-micron loop fil- tration fitted with service indicators, which warn if the filter becomes clogged. ‘3 MICRON FILTERS Invosicton Bishole Oring Page 1Section 7 HYDRAULIC RESERVOIR, The reservoir is pressurized by air pressure via a regulator valve to maintain 20 to 33 CPA (3-5 psi), which decreases ingress of con- taminants and provides pump inlet super- charging Pump Drives All pumps are direct drive by fixed ratio gear- boxes. Engine derivations inputs connect to the first gearbox. Most model machines have a speed increase ratio input gear in the first gearbox. For cold weather conditions a gear- box fitted with disconnecting input shaft may be ordered. This option will allow engine start- ing without the hydraulic system loads. AUXILIARY, | pump prive | Zev) PUMP DRIVE i4 gy GEARBOXES PROPEL PUMPS Variable displacement pumps supply oil to propel motors on the undercarriage. The operator may vary the speed at which the machine is propelled by moving the propel control levers. Propel pump volumes vary from machine models. Output flows range from 0 to 65 GPM (246 LPM). Maximum sys- tem pressures also vary between models and range from 3000 psi (204 bar) up to 4200 psi (285 bar). AXIAL PISTON PUMP ROTATION PUMP Avariable displacement pump supplies oil to rotation motor(s) positioned on planetary drive gears and the rotary head assembly. The ‘operator controls allow pump volume and sys- tem pressure changes for different drilling conditions. © 500 1000 1600 2000 2500 3000 3500, 4200 HYDRAULIC PRESSURE D75KS TORQUE CURVE @ 190 HP Page2Rotation pump volumes will vary from machine model. Output flows range from 0 up to 113 GPM (428 LPN) and pressures are adjustable from 200 up to a range between 3000 - 4200 psi (206.9-289.6 bar). FEED PUMP. A variable displacement pump supplies oil through the hydraulic pulldown system. The amount of (pulldown pressure) which is devel- oped in the circuit is operator controlled by the feed pressure control valve. Feed pump systems will have output flows from 0 to 102 GPM (387 Ipm) with working Pressure of up to 3000 psi (204 bar). All feed systems use a circuit protection called lift-off. This protection limits the machine capacity. In design it will keep the feed force below machine weight limits, protecting the machine from accidental lift-off. o ‘00 2000 000 D40KS FEED PERFORMANCE CURVE (BASED @ 81% EFFICIENCY) ACCESSORY PUMP These are fixed displacement vane type pumps. One stage delivers oil to a hydraulic motor, fixed size fan, thermostat and oil cooler. This may be one of two designed cool- ing systems for engine, compressor and hydraulic fluid cooling. A second stage sup- plies oil to accessory valve banks for the ‘operator selected features such as drill pipe loader controls, dust control, angle drilling accessories to name a few. These pumps Section 7 serve the return system and provide a super- charge pressure for the main drilling pumps, (feed and rotation). ‘Some machine applications will use a flow divider to allow multiple use of one vane pump output. OTHER PUMPS * Variable displacement pump/motor for system cooling. * Fixed displacement vane pump for 240- volt generator. + Vane pumps for dust collector and water injection options. Mast Raising and Locking Cylinders Two double acting hydraulic cylinders are pinned and supported to the rear mast chord and machinery deck structure. Operators con- trol the raise and lower mast sequence. Refer to mast locking feature to position the mast for drilling and tram modes. In order to ensure the cylinders actuate together and at the same speed, counterbal- ance valves are fitted. Should hose failure occur during mast positioning, these same valves prevent the mast from falling. Inrocictonto Bish Dring Page 3Section 7 Hydraulic actuated controls allow mast-lock- ing pins to secure the mast in a vertical or angled position for drilling = i CYLINDER __ [CH WAST LOCKING PIN Hydraulic Track Motors Track drive motors convert hydraulic flow and pressure into rotational speed and torque, which is then, modified by the final drive reduction gears. Page 4 All track drive motors have a mat mounted on the motor ports (hot oil shuttle valve) with a spool valve and relief valve fit- ted. This shuttle allows additional cooled and filtered oil into the closed loop drive circuit. Disc Brake Units ourput ‘SHAFT Inpur. SHAFT 2 NV baz y RA 7 iG [4 SPRINGS CRAWLER BRAKE UNIT Each final drive unit is provided with a multi- disc brake unit connected directly to the hydraulic motor output shaft extension. This spring applied, hydraulically released brake will securely hold the final drive input inion when the machine is not tramming act- ing as a park brake. When tram is selected, hydraulic fluid from the propel pump servo system will compress the belville springs, Which engage the brake, to release the pack of discs, Optional electronic interlock switches/sole- noids may be added to the propel pump cir- cuits. Interlocks will disable tramming until operators have all conditions ready for mov- ing the machine. Refer to jack brake and head interlock optionsLevelling Jacks Hydraulic cylinders are operator controlled to take the machine weight from the undercar- riage, level and stabilize the machine during drilling operations. Pilot operated check valves are fitted to the cylinders to prevent cylinder movement in the event of hose fail- ure, and prevent the cylinder from drifting down during drill operation. _— CYLINDER, LEVELLING JACK Section 7 The hydraulic cylinders are protected inside two wear pieces called the jack boot and jack hanger. A jack pad is attached to the end of the jack-boot to provide firm footing for the machine on stable ground surfaces. AIR SYSTEM The rotary screw compressor is driven by a coupling to engine flywheel connection. High volume compressed air provides receiver and working air, which is available for drilling and accessories. Working air is piped up the mast to an air swivel, then into the drill string. The air has two functions; one is to cool the drill bit and bit bearings; the other is to bail the drill cuttings out of the hole. SINGLE STAGE AIR END. (LOW PRESSURE COMPRESSORS) BIG, tat STAGE 2-STAGE AIR END (HIGH PRESSURE COMPRESSORS) Intoductont Busta Dning Page SSection 7 Filtered air drawn into the compressor intake system compress by means of a matched set of male and female rotor screws. Oil is injected into the compressor mixing with the air to lubricate loaded components, seal the rotor screws and act as a coolant. Air/oil mixture discharges from the compres- sor into the receiver tank where the majority of the oil is separated from the air. The air receiver tank serves as the compressor oil sump. refer to diagram on page 7. Oil in the receiver tank flows under air pres- ‘sure to thermal and bypass valve(s), to oil coolers and main filters back to the compres- sor. Oil separated in the air/oil separator returns to the compressor via scavenge lines, each fitted with a strainer and a sight-glass, Asservice indicator will show red if there is an abnormal pressure drop through the separa- tor element. When this occurs, the element(s) should be replaced. x i : BG, A closed inlet system relieves the compressor load, during machine start-up. When sufficient pressure(s) accumulates in the receiver tank, air pressure will signal the Pages air inlet valve (cylinder type, poppet type or diaphragm) and the compressor inlet will close (unload), reducing the volume of air being compressed. Blow-down valves vent a portion of air from the receiver tank during the. run - unloaded mode. A relief valve deter- mines the maximum air pressure in the sys- tem. All receiver air pressure will vent to atmosphere through a final (shutdown) blow- down valve when the machine is stopped. The main valves and controls in the air sys- tem are: * Oil Stop Valve* - Stops the back flow of oil into the compressor at shutdown. (Not used on poppet style inlet valves). + Discharge Check Valve" - Stops the reverse flow of air/fluid mixture through the compressor system at compressor shut- down. (Not used on poppet style inlet valves), * Thermal Valve — Used to regulate flow of fluid to the coolers. Designed to maintain minimum operating temperatures. Vari- ‘ous thermostats are available for different ambient and operating conditions. Ther- mal manifolds have bypass valves fitted to protect the compressor oil cooler. + Minimum Pressure Valve - Maintains a minimum receiver air pressure of 60 psi (4.14 bar) for low pressure, and 140 psi (9.65 bar) for high pressure units. This pressure is necessary to ensure proper oil circulation and oil cooling. + Pressure Relief Valve - Opens the receiver pressure to the atmosphere should pressure inside the tank become too high. Low pressure machines use (140 psi), high pressure machines use (400 psi) safety valves. * Check Valve - Prevents working line pres- sure back flow into the sump during unload conditions and after shutdown.Section 7 AIR FILTER, AIR INLET ContROL VALVE layne essa on poppe se nt vales) AIR AIROILE = COMPRESSOR ‘Joateioe oc ee VALVE Or VALVE ia} MAIN OIL FILTER SEPARATOR ELEMENT lL cooLNG AIPVONL, MANIFOLD SEPARATOR TANK PRESSURE BYPASS, Ol COOLER TYPICAL COMPRESSOR OIL LUBRICATION CIRCUIT (HIGH OR LOW PRESSURE APPLICATIONS) Control Regulators - Opens a pressure + High Discharge Temperature Switch - A line between the receiver tank and the air fast acting temperature switch will shut- inlet, cylinder, poppet or sullicon control down the machine if the air discharge tem- diaphragm. Regulators control compres- peratures raise above the switch value. sor loads according to air demand. SHUTDOWN SAFETY SWITCHES Pilot Valve - Bypasses the control regula- tor. The poppet inlet valve will open, load- HIGH PRESSURE ing the compressor allowing pressure to COMPRESSORS build in the receiver tank. This feature is 250°F (121°0) INTERSTAGE used with low pressure poppet inlet valves 265°F (129°C) FINAL only. Blow-down Valves - Vents receiver tank pressure to the atmosphere during unload conditions, and after machine shutdown. Invadscton to Blasio Dring Page 7Section 7 DUST COLLECTION SYSTEMS (option) When drilling is performed without water, bail- ing air from the blast hole will be dust laden. This section describes a typical dry dust sup- pression system. Dust collectors do not per- form when contaminated with any means of moisture or ground water. Operator controlled, hydraulic motor driven, exhauster fan draws bailing air from the area within the dust curtain surrounding the top of the blast hole. The dust laden air passes through numerous dry dust filters within the dust collector housing. Large particulate mat- ter and coarse dust are collected within the dust collector assembly. Periodic impulse air blasts dislodge the fine trapped dust and enable this material to exit the dropout cone and curtain. WORKING AIR. BACKELUSHING PRESSURE FROM COMPRESSOR (Fagssure " tase BUSHING, TABLE ete DUST CURTAIN DEFLECTOR CLEAN AIR DISCHARGE DRIVE MOTOR (HYDRAULIC) BLOWER Ff Page 8A dust hood and/or curtain may be lowered and raised by operator controls. Raising the curtain allows ground clearance from drill cut- tings prior to ramming machine away from blast holes. WATER INJECTION SYSTEM (option) A piston type, positive displacement water pump injects water under pressure into the compressed air system to provide a means of dust suppression. Water tanks are available in 150 to 1000 gallon (568 to 3785 |) capaci- ties. The pump shown, is belt driven by a hydraulic motor. WATER INJECTION PUMP & MOTOR Water injection can be used for collaring holes in bad, broken ground conditions. Foam injec- tion can be added to the water to stabilize the blast hole and assist in drill cutting removal. Additional attachments can allow for a machine wash option. Section 7 Invoduoon to Batol Dring Page 9Section 8 CONTROLS, OPTIONS AND MONITORING EQUIPME INSTRUMENTS AND CONTROLS. Drills will have different arrangements of the instruments and controls; however, they will generally be grouped as follows: 1. Drilling controls actuate all drill and tooling functions. 2. Air and hydraulic pressure gauges monitor drilling system pressures to allow the most efficient machine operation. 3. Engine and compressor temperature gauges monitor and control these major ‘components. 4, Tram, Mast and Jack hydraulic controls enable these functions. NOTE! Hydraulics may be direct, cable and linkage or electronic controlled. ELECTRONIC DEPTH COUNTER (EDC option) The electronic depth counter has been designed to assist the operator in drilling blast holes. OPERATOR CONTROLS The function of the EDC is to supply the oper- ator with information on: * ‘Bit Position’ (6) position * ‘Distance From Bottom’ of hole (7) position + ‘Accumulated Depth’ (8) position + ‘Penetration Rate’ (9) position ‘A push button panel is used to program the EDC and the readings are displayed on the LED screen. Input to the EDC comes from an ENCODER that is mounted on the pulldown sprocket shaft. Input signals from the encoder are measuring distance moved. From these signals, the EDC computes the depth and rate of penetration. Intodvcton te Baste Ding Page 1Section 8 A PROXIMITY SWITCH mounted on the hold- ing wrench is used to stop the counting sequence when a drill pipe is being held. Con- tact terminals inside the EDC open to stop the counting, and close to start the counting sequence Stopping the EDC from counting the head dis- tance moved while the pipe changing sequence takes place is essential for accu- rate hole depth measurements. A preset hole depth indicator light on the front of the EDC cover panel will illuminated when the drill bit reaches or is greater than the pro- grammed depth. Position 1 on the EDC panel can be programmed for drilling depths to suit specific bench heights. The ipe-In-Hole Alarm This alarm is designed to prevent the operator from propelling the machine away from a hole when drill pipe is in the hole. This system uses the holding wrench proximity switch, a proximity switch mounted on the mast at the rotary head top position, and a pressure switch mounted on the hydraulic valves for the leveling jacks. When the head is not fully raised, or the hold- ing wrench is out, and the mast or jack valves Page 2 are operated, the pipe-in-hole alarm (indicator light and buzzer) will be activated. Stop oper- ation to verify fault. DRILL MONITORING SYSTEM (DMS option) The Drill Monitor System provides a warning signal to the operator and/or shuts down the machine (for critical out-of-limit conditions) in the event that the monitored operating condi- tions are not within safe limits. DRILL MONITOR SYSTEM The system is provided with a thirty second delay for start up, a system test push button, audible alarm, and a ‘first out’ indication for shutdowns. There are three different levels of fault sens- ing Level 1 - Flashing amber light. Level 2 - Flashing amber light and audible alarm. Level 3 - Flashing red light, audible alarm, and machine shut down. The audible alarm can be silenced at any time by means of a silence push button. The light will continue to flash until the fault condition is cleared. Only one level three fault will be indicated at any one time (first out).This will allow the cause of the shut down to be easily determined. The items monitored are: Level 1 * Compressor air filter pressure + Engine air filter pressure + Fuel level + Alternator charging + Engine radiator coolant level + Air/oil separator pressure differential Level 2 + Hydraulic oil level + Hydraulic oil temperature + Hydraulic oil filter pressure + Engine oil temperature Level 3 + Compressor discharge temperature + Compressor interstage temperature (high pressure only) * Compressor oil pressure + Engine oil pressure (prior to 1996 elec- tronic engines) + Engine coolant temperature (prior to 1996 electronic engines) + Engine coolant flow NOTE! 1996 and later model engines do not have DMS connected ‘Engine Oil Pressure’ and ‘Engine Coolant Temperature’ shutdown switches. Engines manufactured with an ‘ECM and ‘Select’ computers, monitor these functions and are programmed to shutdown the engine. TRAMMING INTERLOCK (option) Several tram interlock systems may be built into the wiring system. The tram circuit for both left and right crawler assemblies will not operate if any of the following conditions exist: Section 8 + All leveling jacks are not fully retracted. * The rotary head is not retracted to the top of the mast. This allows proper clearance with the drill pipe, dril bit to the ground. ‘+ The tram foot switch is not depressed. An additional switch for dust hood may be added in this system. The switch for the rotary head may be part of the electronic depth counter (EDC) system. An indicator lamp will be lit, and a warning buzzer will sound when the operator tries to ‘operate any jack control lever or mast control lever if a drill pipe is stil in the ground. (Pipe- in-hole alarm) If any above systems are not in the proper position to allow the machine to be moved, a visual indicator lamp will not light until the conditions are corrected. Once these systems are corrected, the indicator light will illumi- nate, indicating the tramming circuit is pow- ered and the machine can be moved. In an emergency case, the tram interlock cir- cuit can be bypassed. A by-pass switch is inside the tram junction box located directly underneath the operator control panel. LOADER/ROTARY HEAD INTER- LOCK (option) This system is designed to prevent the rotary head from placing excessive feed force on the loader assembly when making up drill pipe. When the loader is out from its stowed posi- tion, proximity switches will cause the feed pump to vent feed pressure as the rotary head approaches the drill pipe in the loader. ANGLE DRILLING GROUP (option) Blast hole drills may be fitted with attach- ments to give them the ability to drill holes up to 30° from vertical, 20° for most machines. Invochcton fast Osing Page 3Section 8 Mast position locks are: + Mast or frame mounted + Holes at the bottom of the mast table are spaced at 5° increments. Hydraulic cylin- ders with lock pins engage these holes to support the mast at the required angle, or vertical position. Operators select the mast raise position and mast locking sequence. FRAME MOUNTED MAST LOCKS + Pivoted work deck: The deck is pinned and pivoted under the mast table. Adjust- able chains support the position. The work deck can be raised or lowered for angle drilling to maintain a horizontal workspace. * Drilling angle indicator: A pendulum pointer pivots on a flat plate positioned on the left side of the mast. As the mast is tilted, the pointer indicates the vertical position in 5° increments, up to 30°. PIPE POSITIONER/ CENTRALIZER Page 4 + Pipe guide mechanism: This swing arm will hold drill pipe during the pipe changing sequence. One hydraulic cylinder swings the support arm across the mast; a second cylinder clamps a support around the drill pipe. A sequence valve allows one opera- tor control for this feature. REMOTE SERVICE CENTER (option) Diesel fuel, engine coolant, engine crankcase oil and hydraulic oil may be pumped on board the machine via the ‘Wiggins’ quick-fll cou- plings. This system provides fast, efficient transfer of fluids and minimizes the tisk of contamination, The result is less downtime when servicing equipment in the field LUBRICATOR (option) Oil reservoirs in 10 and 30 gallon (38 and 133.5 |) capacities are available for DTH and/ or rotary applications. The lubricator system uses an air regulator, an air assisted pump and manual controls or electronic controls to Move oil into the flushing air to lubricate a DTH and drill bit. Use the grade of rock drill oil that is proper for the climactic and operating condition at the machine site.'30 GALLON LUBRICATOR This option is required for all DTH applica tions, and is preferred by rotary bit manufac- turers. FIRE SUPPRESSION SYSTEM (option) Amanually actuated (shown) or an electrically sensed system delivers a dry chemical extin- guishing agent through hoses to pre-set noz- 2les in fire prone areas and surfaces. AUTO LUBE SYSTEM (option) a ‘ a =a - ‘AUTO LUBE SYSTEM] |/ This is a centralized lube system designed to deliver lubricant automatically to various grease points around the machine. The sys- tem uses control air regulation with airline lube, control via central timer assembly to an air operated pump, to deliver lubricant grease at timed intervals. Distribution lines and vari- ous sized grease injectors lubricate fixed pins, bearings and bushings only. The cycle is started by the electrical timer, which turns the pump on. The pump builds up pressure in the supply line until the injectors discharge the lubricant. The pump keeps building pressure until the back pressure in the line opens an electrical pressure switch circuit and stops the pump. Invodueson to Bisincle Dring Page 5Section 8 “ae CRS AUTO LUBE SYSTEM INJECTORS A bleed valve opens to allow the pressure in the lines to vent back to the lubricant con- tainer, When pressure decreases in the line, the injectors reset ready for the next timed cycle. The reservoir may be as illustrated (30 Ib/13.5 kg) grease containers. AUTO THREAD LUBE (option) ‘The automatic thread lube system is designed to spray thread grease directly on to the male thread of a drill rod held in the holding wrench tool. This system allows the operator to apply as much thread lubricant as needed. The sys- tem consists of an air operated pump, foot pedal or toggle switch, distribution tube, noz~ zle and a reservoir for the pumpable thread- grease. Use premium quality thread compounds only. Consult a local supplier of lubricating oils and grease for a pumpable drill pipe thread com- pound. Page 6 When the foot pedal is depressed, the pump is activated and pumps grease directly to the ischarge nozzle. The pedal also opens an air valve, which injects air into the distribution tube directly behind the discharge nozzle. This injected air helps to spray the grease directly onto the pipe thread. ARTIC COLD HEATERS (option) The arctic cold heater system is designed to heat the following system fluids: + Hydraulic tank + Water injection tank + Pump drive gearboxes) + Batteries * Air receiver tank * Engine oil, fuel and coolantWATER I “TANK HEATERS Items shown are not the full compliment of arctic weather accessories. MISCELLANEOUS OPTIONS When placing a machine order, consider optional equipment carefully. Group numbers are assigned to each of the options. Some of these items may not be available for all products and options men- tioned herein are subject to change without notice, Section 8 Electrical Remote start group Battery disconnect group High ambient engine switch group Ground level shut-off group Remote tram group Tram control (deadman) Tramijack/head interlock group Rotary headiloader interlock group Variable speed throttle control Engine timer group (5 minute idle) ‘Strobe light roof mounted (amber, blue or red) Electronic depth counter (EDC) Stratologger 2 data recorder Drill monitor system (OMS Rotation hour meter group CE certification group Premium lighting package Under deck lighting group Hydraulic Holdback kit for deep holes, Hydraulic test station Antijam group feed and rotation Compressor Air cleaning hose Compressor air volume control Electric operated Manual operated High pressure compressor oil recovery group (tropical) Tools Barber cushion connector Drileo shock sub Foremost cushion connector Barber table bushings Subs Drill pipe DTH hammers Drill bits Break-out tools Machine Accessories Machine wash group (requires water injection system) Selt-retracting hose reel - Wash/with wand Selt-retracting hose reel - Air cleaning Fluid sampling group (engine, compressor, hydraulic) Magnetic drain plug group Tow bar ‘Shipping lift kit Dry chemical fire extinguishers Fire suppression systems Pin style feed chain adjuster wiport-a-power Larger OD jack pads Ground level service center wiwiggins connections Inresuoton Basil Dig Page 7Section 8 Auxiliary fuel tank group Rearview mitror group Front walkway group Right walkway group cab to deck Drill Accessories Power-tong breakout group ‘Automatic thread lube system Hammer lubricator tank standard or heated (10 or 30 gallon capacity) ‘Angle dill group ‘Angle dill workdeck Dust hood with spotting door Dry dust collection system - Drilplex. Dry dust collection system - Tipton Extended mast lengths Hammer holder Bit storage boxes at workdeck Cabin 2-way radio Lap belt Auxiliary heater Nameplate groups for operator controls, Page 8 Special Applications Hydraule generator (19kv, 220vac, S0hz) Cold weather group ‘Arctic machinery house - insulated Fabric cold weather curtain Heated water injection tank Insulated/heated water injection tank Insulated water injection pump Centrifugal engine oil iter - Caterpillar engines Prelude engine starter kt Fourth leveling jack Mast ladder assembly Mesabi cooler Auto dill controls Foam injection - used with water injection Australian electrical code group Hydraulic welder 200 amp Vandal cover groups Swing cab - T40KSSection 9 ILL STRING COMPONENTS DRILL STRING Drill Pipe A drill pipe is a steel pipe through which air is passed to the bit. It has a female thread (box) at the bottom and a male thread (pin) at the top. Machined flats at the top of the pipe are used to hold the pipe while threads are being made. Typical DTH drilling threads are API - regular and API IF - internal flushing. RH - right hand or Beco are most common for rotary drilling (refer to the thread tables at the end of this section). PIN THREAD TOOL JOINT FLAT DRILL PIPE BOX THREAD TOOL JOINT The diameter of the pipe must be smaller than the bit diameter to allow the cuttings to pass to the top of the hole. Stabilizers Because of the feed forces exerted on the drill string during rotary drilling drill pipe may tend to bend under compression. This will cause the drill bit to tlt slightly, placing unequal stress on the cones of a rotary type drill bit. Stabilizing the bit will improve performance and service life by preventing misalignment of the bit to the surface. si | 8 LI 33 al STRAIGHT SPIRAL REPLACEABLE was Bit ade STABILIZERS A stabilizer resembles a short length of heavy pipe. Male (pin) or female (box) thread may be cut for either end. This tool may be hard surfaced to resist wear. On the outside diameter of the stabilizer, straight, spiral blades, or rollers, project to match the circumference of the bit. These blades or rollers wear or roll on the sides of Intoducton to Blast Ong Page 1Section 9 the hole and keep the drill bit aligned with in the hole. Subs ‘Subs are drill string connectors, available in a variety of length, OD, and threads to suit dif- ferent purposes. Some examples are: + TOP SUBS (saver sub) are connected to the rotary head. Thread type and overall length are factors in selecting a top sub. It is preferred for the sub thread to wear verses the rotary head API threads. + BYPASS TOP SUB (not shown) is a spe- cial sub used with a DTH in bad ground conditions. It allows a restricted amount of air to bypass the hammer case. The unused air will be directed upwards to assist in hole cleaning, This is a special order sub. + BIT SUBS adapter subs in various lengths and cross over subs with differing thread configurations are used to connect rotary bits, and DTH hammers that have API thread to drill pipes. The short sub is a wear item and is easier to replace than a full-length dril pipe. + SHOCK SUBS are an after market tool, designed to absorb shock and vibration from the drilling application. A resilient rub- ber element(s) prevents metal to metal contact from the drill string to the rotary head. Rotation speed, bit weight and ground formation can cause unexpected uphole vibration frequencies from the bot- tom of the hole to a rotary head. When adequate down pressure cannot be main- tained to the dil bit, or when rotation torque is high due to ground conditions a shock sub will be required. + LIFTING PLUGS screw onto drill string ‘components so that a winch may be used to maneuver them. Page 2 vs DRILLING TOOLS UETING PLUS [\¢ top sus of} 'e a7 DRILL PIPE STABILIZER ‘Sue A | er sub STABILIZER, 1 (7 oN HAMMER! a i_. orH O) oges BUSHING A ~O BASKET ROTARY TONG WRENCH ‘J! WRENCH = PETOL WRENCH PIPE & BIT BAAPI REGULAR THREAD ‘SHOCK SUB Drill Bits ROLLER BITS Arroller bit consists of a bit body with three moveable conical rollers equipped with cemented carbide inserts or steel teeth. The idea is to crush the rock by rolling the inserts against the rock with appropriate rota- tion speed and feed force. ‘SCREEN TUBE BITLEG NozzLe COOLING AIR, SHIRT TAL, (CHANNEL PROTECTION BALL PLUG ROLLER BEARING Section 9 Carbide inserts are distributed over the three rollers in such a manner that the entire bottom of the hole is worked on when the drill bit is rotated. Roller bits for hard and abrasive rock have spherical cemented carbide inserts closely spaced. Roller bits for softer rock may have the chisel cemented carbide teeth or quality milled steel teeth as the cutters. Three types of cemented carbide inserts used for roller type drill bits are shown. lax CONICAL, CHISEL HEMISHPERICAL| (CEMENTED CARBIDE INSERT SHAPES A roller bit will utilize nozzles from which the compressed air escapes to lift cuttings from the bottom of the hole, Nozzle dimensions need to be selected carefully with production rates and drill string wear being the concerns. Additional air passages in the bit allow air to pass through to the bearings for cooling and lubricating purposes. DRAG BITS A drag bit is used in clay or very soft material where a roller bit will tend to clog or bind. These bits have good flushing characteristics and are economical, but they are limited in size and carbide inserts are not designed for hardrock material. 4-way 3- WAY DRAG BITS Inroducton to Bustoe Critng PageSection 9 CLAW BITS ‘A claw bit is used in soft to medium material where the driller may encounter alternating layers of soft clay then sand rock or hard shale formations that would cause a a drag bit to over-torque and stall. These bits have a design which allows drilling as fast as a drag bit while being as tough as a roller bit. They feature inexpensive replaceable conical shaped self-sharpening cutters which rotate in their blocks. Claw bits range in size from 3-1/2" to 24” in diameter. CLAW BIT DOWN THE HOLE HAMMERS (DTH) NOTE!High pressure compressed air is required, Hammer Seles There are many factors involved in selecting the right hammer for the job. These factors include the size of the hammer, the hammer's air consumption and, with the Driltech Mission Hammerdril® series, the correct rigid valve. Size of Hammer Ahammer size should be selected as close to the intended size of the hole drilled. The big- ger the hammer diameter, the bigger the pis- Page 4 4. Top sus 7. RETAINER RING 2. DART 8, GUIDE SLEEVE 3, SPRING 9. BITRETAINER, 4, RIGID VALVE 10, DRIVER SUB 5. PISTON 11, FOOT VALVE 8. PISTON CASE 12, HAMMERBIT® HAMMERDRIL® XL. ton diameter, the bigger the performance. tis important to keep the hammer diameter and bit diameter as close as possible, while stil maintaining enough clearance around the hammer for cuttings to pass. For example, an XL 6 hammer should be chosen when drilling a6 1/2" hole rather than an XL 4 with a 6 1/2" bit. An oversized bit on a small hammer drops hammer performance. A larger diameter ham- mer allows a larger bit shank, better energy transfer resulting in greater strength and lower stresses, more reliability and a lower operating cost per foot.Hammer Air Consumption It is best to select a hammer nearest the max- imum operating conditions of the compressor. The higher the hammer operating pressure, the better the performance. Use the following altitude correction chart for applications above 4000 ft (1200 m) to assist in calculating the proper compressor output and hammer selec- tion. Feet Welers Cortection Factor| 4,000 11,200 88 5.000 11500 Bg 6,000, 11300 73 7,000 21100 78 8.000 2.400 B 3,000 2.700 70 10,000 3,000 68 15,000 3.400 65 12,000 3,700 63 900 CFM @ 5,000 Feet ‘Compressor Output = 900 x 82 = 738 SCFM 850 CFM @ 8,000 Feet ‘Compressor Output = 850 x .73 = 620 SCFM ALTITUDE CORRECTION TABLE Hammerdril® Rigid Valve Selection The Hammerdril series hammers can be cus- tomized to a particular air compressor by a simple change of the rigid valve. The descrip- tions below provide a guide for the selection of rigid valves. -BA rigid valve for maximum air, maximum flushing. The BA rigid valve should be used with a large capacity compressor. This rigid valve/ hammer combination requires maxi- mum air to run efficiently. This is the rigid valve to select if you need to efficiently pass maximum air to flush the hole or to obtain maximum penetration rates with low pressure, high volume compressors. -BB rigid valve for average air. In most cases, this rigid valve is designed for the most popular size of compressor allowing the ham- Section 9 mer to run at the highest operating pressure and use all of the available air. -BC rigid valve for low volumes of air. This rigid valve option can be used to increase operating pressure and performance with small compressors. Although each rigid valve option comes with 3 integral chokes (1/8", 1/4" and 3/6"), it will always be more efficient to select the next higher volume rigid valve rather than use chokes to increase air consumption. Recommended Lubrication Correct lubrication during drilling operation is extremely important. Inadequate lubrication is, a major cause of hammer wear and failure. RIGID VALVES “Rock aril’ oil is the only lubricant recom- mended by Driltech Mission for use in the Hammerdril® XL. Use the grade of rock drill oll that is proper for the climactic and operat- Invodveton to laste Dring Page 5Section 9 ing conditions at the drill site. Use the chart below as a guide for selecting the proper grade rock drill oil to use. When using new drill pipe or pipe that has not previously been coated with oil, pour a quart/ liter of rock drill oil down the drill pipe each time a new joint of drill pipe is added. ‘The recommended amount of rock drill oil for efficient operation of the hammers is shown below. An alternative method is to calculate the oil requirements using the general rule “.15 -.25 quarts of oil per hour divided by 100 CFM". Example: XL 6/BA with a 9/8" choke uses 1335 SCFM. 1335 X.2 100 = 2.7 qts/hr This method is more accurate, especially when using chokes or high/low operating pressures. Check oil levels each shift. Monitor the oil delivery to the hammer by looking at oil drip- ping from the bit after each hole is drilled. NOTE! When drilling with water injection, use the next higher grade of Rock Drill oil The hammer will not be damaged by too ‘much oil, but it will be damaged by not enough oil. ‘Speran Press PSIG) RECOMMENDED ROCK DRILL OIL Design Choosing a percussive bit is not a simple mat- ter of requesting a bit with a particular shank and head diameter. Many options are avail- able and some of these options can have a dramatic effect on how a bit performs. If you are not sure about which particular bit is suited for an application, Driltech Mission rec- commends testing that bit at the application site before commitments are made for large project purchases. Several of the options of the bit design are: * Bit face design * Carbide button shape and hardness grade + Wing design + Number of flushing air holes + Good in hard and abrasive formations. + May cause hole deviation in broken formations + Large bits not collating friendly ‘+ Easy to sharpen buttons + Most resistant to steel wash + Collars well + Reduces load and wear on ‘gauge buttons + May need faster rotation to run smoothly ‘+ Most popular design + Goodin soft to medium hard formations + Often dis the straightest holes: + More diffcult to resharpen CONCAVE BIT FACE SHAPES