SKL-Topic7-Mast Handout Reduced

MD6540 Mechanical Training
Topic 7 Mast, Rotary Head, Pipe Rack
Ross Hoult
July 24, 2011
Mast
Weldment
Prior to undertaking any repairs to the
Mast Structure, contact the Reedrill
factory for proper welding procedures
and material specifications. Any welding
repairs must be carried-out by a certified
welder.
If welding repairs are required, first
disconnect (isolate) the negative battery
cable, failure to do so may result in
damage to various mechanical
components and sensitive electronic
equipment
2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

MAST
STRUCTURE
The SKL mast design has longer life and fewer

structural problems than comparable competitive
equipment.
Double-cut lacing and amply sized main chords

ensure a strong tower structure that can endure
harsh mining environments with constant-use duty
cycles.
SKL LONG MAST SPEC SUMMARY
20-Meter Version
• For use with two 30 ft (9.14 m) long pipes
and long bit sub for up 65.7 ft (20.0 m)
single-pass (clean hole), changing bit
above deck
• Multi-pass hole depths down to 215.6 ft

(65.7 m)
• Angle drilling up to 30o in 5o increments
• Up to 110,000 lb (49,895 kg) pull-down and

86,000 lb (39,009 kg) of hoist
• The rotary head generates up to 363 hp

(271 kW) at the spindle with variable
rotation speed from 0 to 134 rpm, and
torque of up to 15,400 ft-lb (20,880 Nm)

SKL SHORT MAST
SPEC SUMMARY
16.5-Meter Version
(Deep Hole)
For use with 45 ft (13.7 m) long pipes and
bit sub for up 54 ft (16.5 m) single-pass
(clean hole), changing bit above deck
Multi-pass hole depths down to 279 ft

(85.0 m)
Angle drilling up to 30o in 5o increments
Up to 110,000 lb (49,895 kg) pull-down and

86,000 lb (39,009 kg) of hoist
The rotary head generates up to 363 hp

(271 kW) at the spindle with variable
rotation speed from 0 to 134 rpm, and
torque of up to 15,400 ft-lb (20,880 Nm)
A-FRAME
Pivot Shaft
The SKL mast pivot shaft design
incorporates a bolt-on pivot shaft
with replaceable coated bushings
for ease of maintenance, four
mounting bolts per side.
The A-frame (mast pivot) and rear
deck are integrally welded to the
main frame, providing additional
torsional strength and overall rig
stability.
The pivot caps hold the mast assembly onto the ‘A’
frame. Correct Torque is 1800ft/lb. Each service it is
imperative that their bolt tension is checked. The
bolts should be replaced if any movement is
encountered to achieve the correct tension. The ‘A’
frame pivot and the pivot cap must also be checked
regularly for signs of wear.
“The bolts require checking daily to ensure that they
have not come loose.”

ANGLE DRILLING PACKAGE
Mast locks are integral to the main frame and configured with three-piece
bushings for strength, reliability and ease of field maintenance.
The SKL’s angle drilling package allows up to 30o angle holes in 5o increments.
Limit Switches are fitted on each mast lock assemble to indicate the mast lock status and lock out drilling
function if unlocked
SKL DOUBLE ROD

PULL-DOWN CYLINDER
The SKL uses a pull-down cylinder with a rod fixed at both the base
and crown of the mast. The sheave carriage and cables are actuated
by double-acting barrel movement.
When loaded, the cylinder is in tension, which minimizes deflection

and wear of feed components, providing high efficiency and minimal
servicing.
This system develops less buckling load on the pull-down cylinder

since the piston constantly pulls rather than pushes against the rod.
This cylinder arrangement also allows for a closed-loop hydraulic

system, which greatly simplifies hydraulic design.
Cycle times for both pull-down and hoist are equal, as hydraulic
flow/forces are the same on both sides of the piston.
Pull-down forces are up to 110,000 lb (49,895 kg) and hoist forces

up to 86,000 lb (39,009 kg) for the SKL.

Feed Cylinder
The Feed cylinder is a “Through Rod” design. This means that hydraulic fluid
enters and leaves the cylinder through the centre of the Rod at either end, and is
ported internally both sides of the Cylinder Piston.
The Cylinder Rod is fixed at both ends to the Mast and remains stationary, while
the Cylinder Tube travels along the length of the rod. The Cylinder Tube is
bolted to the Travelling Sheave assembly, which in turn is connected to the
Rotary Head via feed ropes and sheave rollers ‘See next slide’
Feed cylinder Piston
mounting nuts retainer Cylinder Tube Head
Cylinder Rod assembly Head Cap
assembly Piston
Dependant on direction, Hydraulic fluid

enters or leaves cylinder through the
9
Cylinder Rod ends.
/ Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING
Hoist/Pull down Cable System

Feed System
Cylinder Rod
fixed to Mast
(Top end)
Cylinder Rod
fixed to Mast
(Bottom end)
CABLE SYSTEM WITH AUTO-

TENSIONING
The SKL is configured with pull-down and hoist cables 1 1/8 in. (2.85 cm) Dyform8. Cables are interchangeable
(left and right). Manual adjustment can be made at both ends of the cable via threaded stud/nuts.
An auto-tensioning system powered by hydraulic cylinders delivers maximum cable service life with minimum
maintenance by maintaining constant force on pull-down and hoist ropes.
The cable system absorbs shock loads and is safer than chain systems.
CABLE SYSTEM WITH
AUTO-TENSIONING
Operating Principle
The auto tensioning system consists of
hydraulic cylinders anchored to the
feed cylinder and attached to a slider
block with guide grooves that cable
sheaves move up and down in. A
separate cylinder is used for each
sheave. Hydraulic valves are used to
limit cable tension maximum and
minimum values. The system operates
in balanced tension, so that, if one
cable wears or stretches more than
another there will still be equal tension
on all cables.
Cable Tensioning
• Control Manifold 1. Control manifold

2. Cable tensioner Cylinder

Hoist Pull Down Cables
Adjustment
1. Ensure rig is jacked correctly and level. Rack the drill pipe in the carousel and
engage the flats of the bit sub with the deck wrench. Lower mast.
2. Relieve cable tension by backing out the RDFA relief on the tensioner manifold
(The hoist and pull down cables will immediately loose tension).
3. Shutdown and isolate (LOCKOUT) machine.
4. Check the lay/hang of the bottom cables, if the bottom cables do not hang
exactly the same, adjust the most loose cable to match the tighter cable using
the two pull down adjusters.
5. Adjust RDFA relief fully in.
6. Start machine. Set PBDB pressure reducing valve to 300 PSI (20.6 bar).
Measure at port GA. Apply minimal feed pressure (approximately 500 to 600
PSI) to bring the cable slack onto the hoist cables, then activate the auto feed
to maintain the determined pressure. Check the hang of the top cables and
adjust both to hang the same, using the hoist cable adjusting nuts.
7. Apply 1000 PSI pull down pressure and engage auto feed switch. Check the
hang of the top cables and adjust to hang exactly the same. Then adjust each
top cable so they both hang approximately 2 in. (50 mm) below the bottom of
the top mast rail. Release hydraulic on the system. Ensure all locknuts are
tightened. The cables are now adjusted.
Hoist/ Pull Down Cables
• Cable
Adjustment
NOTE
Over time, as the cables are adjusted, it will be noticed that the rotary head does
not travel all the way to the bottom of the mast, potentially causing non-
engagement of the breakout wrench on the flats of the drill stem. At this point it
will be necessary to loosen the top cable adjustment nuts and then tighten the
lower cable adjustment nuts and locknuts up, 3 to 4 in. The lower cable adjusters
may require removing, cleaning and lubricating to enable adjustment. Once this is
done, the normal cable adjustment procedure is to be followed. Before removing
locknut and adjustment nut, measure the amount of thread protruding from the
locknut and record. This length can them be added to the 3 to 4 in. adjustment
made.

Hoist/Pulldown Cables
Adjustment - Step 9
Pulldown
Pressure
Applied
Top Sheave
Roller
Rotary
Mast Rail
Head
50mm/2”
Deck Spanner
engaged onto Both Hoist ropes Rope
Top Head Sub adjusted equal and Adjuster
tensioned to lay 50mm/2”
below top mast rail.
Hoist/Pull Down Cables

Wire Rope
The wire ropes need regular inspection for wear or damage. Deterioration of wire ropes
occurs both internally and externally from abuse, wear and corrosion. Research by wire rope
manufactures has shown that internal failures are followed by external failures visible by
inspection. Therefore careful examination of the outside of the wire rope is a satisfactory
means of determining the condition of the rope.
Since safety is dependent on the proper operation of the wire ropes , a visual inspection of
the ropes should be performed daily. The whole length of the rope need to be inspected for
signs or wear and damage. Such signs include kinks or severe twists; broken wires and nicks;
deformed, worn or flattened wires; corroded or pitted surfaces; shortened or lengthened
ropes.
NOTE: If more than Ten (10) broken wires are found within any One (1) metre section of
the pulldown rope, then the rope/cable must be replaced.
A more detailed inspection of the ropes should be done at each service, such as cleaning the
ropes and closely inspecting the ropes.

SKL ROTARY HEAD
The rotary head is driven by two (2) fixed-displacement, axial piston motors that deliver 363 hp (271
kW) capacity at the spindle and provide a variable rotation speed from 0 to 134 rpm, and torque of up
to 15,400 ft-lb (20,880 Nm)—or 0 to 160 rpm rotary head motors also available.
This capacity allows the operator to select the most suitable rotation speed
for any given application, and therefore achieve optimal penetration rates for each specific drilling
condition.
SKL ROTARY HEAD
The heavy-duty rotary head, with a 5 ½

in. (140 mm) API regular bull shaft, is
moved up-and down the mast by pull-
down and hoist cables anchored to the
rotary head guides. The rotary head
slides on adjustable steel guides with
replaceable Nylatron® pads. The long,
robust head carriage design ensures
the head rides the main chords evenly
with minimal wear.

Rotary Head
Page 19
Rotary Head - Drive system

Rotary drive system:
• Rotation speed - 0 -134rpm (Optional-150rpm)

• Torque - 0 - 15,400 ft/lbs (20,880Nm)
• Gearbox Reedrill Design Denison M7 Motors
• Manufacturer Cotta
• Main thrust bearing Timken taper roller
• Lubrication Oil Flooded
• Gearing Straight Bevel
• Ratio 16:1
• Motor displacement Denison M7 – 7.25cu/i

Rotary Head and Carrier
Rotary Head carrier - Rotation Motors Travelling
attached to Hoist and Hose
Pulldown ropes manifold
Hoist Air Swivel

Direction
Rotary Head
Pulldown Fluid and Air lines

Main shaft
Direction anchor to manifold,
then continue onto
Head Carrier runs on wear pads, supply components
left - right sides and top -
23 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING bottom.
Rotary Head
• Mounting

ROTARY HEAD
• Locator
Dowels
Rotary Head
Air Swivel
The Rotary head uses a swivel seal assembly to seal the rotary gear case from the rock oil,
water and air flowing down through the bull hose and bull shaft.
When the seal fail, a mixture of air, water, and rock oil will be seen coming out the tell tale hole in
the top hat. The seal may need more crush, or require replacing. Seal crush is achieved by
placing or removing shims under the swivel adaptor plate. A new seal require about 1mm
(0.040”) crush. It is extremely important that the correct amount of shim and therefore crush is
placed on the swivel seal. Too much and the seal will fail, too little and seal will not seal.
Air Swivel seal 1mm
Air swivel under (0.040”) crush
adaptor
Top hat
shims
Tell-tale hole
When replacing the swivel seal, ensure that all parts are thoroughly cleaned, pay particular
attention to shim surfaces, seal housings and the spacer ring. Check the surface of the spacer
ring for burrs, erosion and excessive grooving, discard and replace if damaged or severely
worn. Lubricate seal and spacer ring liberally with clean grease before reassembly
Rotary Head Top Oil Seals Fitted
“back to back”
Air Swivel Seals Main Shaft Bearing
(max 1mm crush) Adjustment/Locknut
“L/H thread”
Intermediate Shaft
and Bearings Main “Bull”
(0.003”-0.005”) Shaft Rotation Motor
End Float mounting
Intermediate Shaft
Main Shaft Bearings Bearings (0.003”- 0.005”)
(0.002” - 0.004”) End float
Pre-load
Female thread in Main shaft -
threads onto Top Sub
Rotary Head
• Bull Shaft Bearing Preload checking

1. Place a dial indicator base on the rotary head housing and the needle on the
seal plate.
2. Engage the deck wrench on the pipe or sub flats and apply 2500psi pull down.
3. Any movement is too much.
The Main shaft bearings must
have .002”-.004’ Preload.
4. Adjust preload as per the
following instructions if
required

Rotary Head
During the daily inspection for leaks, pay particular attention to the seal plate at
the bottom of the rotary head for leaks. This could indicate the following faults, (1)
The seal plate is loose, (2) The duo cone seals are U/S, (3) The main bull shaft
bearings have insufficient pre-load.
If there is a leak from the seal plate, first check that the bolts are tight.
If they are tight, then check if there is any end float in the bull shaft bearings. This
can be done by placing a Dial indicator on the rotary head with the needle on the
seal plate. With a block under the rotary head, drive the head down on to the block,
then lift it up again. There should be NO movement registered. The bearings
MUST be pre-loaded. If the Dial indicator shows any movement, then the
bearings have end-float, so the locknut holding the bull shaft bearings must be
tightened so the bearings can be pre-loaded. There is a set procedure for pre-
loading the bearings, this MUST be followed, and the correct amount of pre-
load MUST be placed upon the bull shaft bearings. See the next slide for this
procedure.
If there is no movement registered on the Dial indicator and the bearings are pre-
loaded, than the duo cones are no longer sealing and will need to be replaced.
The pre-load on the bull shaft bearings is 0.004”. This MUST not be confused
with the bearings on the intermediate gear. These bearings MUST have end-float.
They MUST be shimmed to allow 0.003” - 0.005”end-float (end play).
Rotary Head
Bull shaft bearing Pre-load
If for any of the following reasons, (1) Rotary Head repairs (2) Scheduled service
maintenance, or (3) Movement detected in Bull-shaft, the Pre-load of 0.002” - 0.004”
must be set on the Bull shaft bearings. This requires “Loosening or adjusting” of the pre-
load locknut which is carried out as follows.
1) With the rotary head installed on the mast, place an 8” x 8” block of hardwood on top
of the deck wrench, and lower the main shaft of the rotary head so it is against the block.
2) Apply 2500psi (172 bar) pulldown pressure, this serves to load up the bearings to
achieve the desired pre-load.
3) Cover the exposed bearing with a sheet metal disc or cloth to avoid contamination of
the rotary gearcase. The locknut has four kidney shaped slots machined into the face of
the nut, Setscrews pass through these slots and when tightened, “clamp” the nut onto
the main shaft. These set screws MUST be loosened off completely, then using a
hammer and steel dolly firmly strike the outside of the locknut in the four areas that are
between the slots.This will return the locknut to its original shape and allow the nut to
turn freely on the thread.
Note: If the locknut is not freed up, it may catch on the thread and bind up. A steel dolly
MUST be used, copper dollies might chip and put metal into the gearbox and bearings
Rotary Head
Bull Shaft Bearing Locknut
Note: Locknut is
Left hand thread
Rotary Head
Bull shaft bearing Pre-load

4) Once the locknut has been loosened and can turn freely, tighten the nut by
hand until it contacts the upper bearing cone and there is no movement in the top
bearing rollers, then turn (tighten) the locknut another 15 degrees. This will place
between 0.002” - 0.004” pre-load on the bearings.
5) Tighten the set screws (50) in the locknut, that pass through the kidney shaped
holes. They must be tightened evenly and opposite one another, gradually
increasing torque to specifications, which is 57ft.lb. (77.5Nm) for ½”UNC grade 5
set screw. DO NOT tighten screws prior to assembling locknut to shaft or before
correct pre-load is achieved. The set screws push on the inside diameter of the nut
and deform it so that it will lock on to the bull shaft.
6) Install Loctite 515 (Master Gasket) sealant to all mating faces unless shim or
gasket is used.

Rotary Head
Intermediate Shaft Bearings
Check/Adjust End Play.

Remove plug and fit 1/2 in. capscrew into the thread of the shaft. Set a dial
indicator needle on the capscrew head.
Use a lever to check the end float. X = End Play (0.003 – 0.005”) Add shims as
necessary to achieve 0.003 -0.005” end float.
Break-out Arrangement
Lower Carousel Break-out plate Deck Wrench

15°
15°
15°
Note: The 15° angle must be maintained if the Deck
wrench requires “building up” by means of welding

Deck Wrench
This wrench is used to hold the Top Retaining
drill pipe or string down a hole Plate
while the joint above is broken, or Deck Wrench
when pipe-changing procedures
take place. The jaw of the wrench
is shaped to engage the flats near
the top of the drill pipes. It is
mounted inside the mast structure
on top of the deck, and a hydraulic
cylinder actuates the wrench to
engage or disengage the drill pipe.
FRONT
DOWN
Caution: The Deck Wrench can
physically be fitted upside down. This
Side View of Deck Wrench
will lead to damage to the Wrench
cylinder, should it become caught on the
Drill pipe when being raised.
Rod Handling - Deck Wrench
If damage has been sustained to

Cylinder Mount
either the Deck Wrench cylinder
mount or the top retaining plate, it is
imperative that the position of both
components is back to its exact
original location. The extended and
retracted position of the deck
spanner and cylinder is extremely
important to enable the spanner to
engage the drill pipe sufficiently, as
well as being able to clear the drill
pipe when rotating whilst drilling.
The top retaining plate must be
Top Retaining sitting flush down and level on the
Plate spanner guide assembly, to prevent
the spanner from lifting, allowing the
Deck Bush to also lift up and jam
under the spanner.
VARIABLE GRIP HOBO
Breakout System - HOBO

• 1, Pivot Jaw
• 2. Arm
• 3. Rotate Arm
• 4. Jaw Clamp
• 11. Rod End Pin, Swing
Cylinder
• 13. Rotate Arm Rod Pin
• 14. Jaw Clamp Base Pin
• 16. Jaw Clamp Pivot Pin
• 17. Jaw Pivot Pin
• 18. Jaw Inserts Keeper
Plate (8)
• 19. Die Insert (8)
• 20. Telescoping Cylinder
• 21. Clamp Cylinder
• 22. Rotate Cylinder
• 23. Pivot Cover (2)
• 24. Lock Washer (24)
• 28. Grease Fitting (3)
• 31. Sequence Valve (2)
• 36. Hexhead Capscrew (8)
• 39. Hexhead Capscrew (16)

HOBO
• Dies The Hydraulically Operated Break Out

(HOBO) wrench has four dies which grip
the drill pipe. They are secured by
means of die holders which have a
female dovetail shape that the dies then
slide down into. The dies are made from
hardened steel and should be a neat tap
in fit to the holder. The die holders have
keeper plates at the top and bottom of
the die which prevents the dies from
slipping out. When the dies become
worn they WILL NOT grip the pipe, so
they must be checked regularly.
Dies
Rod Handling
Pipe Positioner
The function of the Pipe positioner is to stabilise and guide the drill pipe to and
from the Carousel. The positioner consists of the main swing arm and the sliding
guide assembly, both of which are connected to hydraulic cylinders. The cylinders
are sequenced to allow the main arm to swing in to the mast, and once it has
reached its extended position, then divert oil to the guide assembly cylinder to
slide into the drill pipe and essentially hold it in position.

Rod Handling
Lower Carousel Retaining Plate The standard Carousel is designed
to carry Five (5) drill pipes, with
Holding pots each pipe secured within its own
holding pot and retaining (Spider)
plate. The lower or “ bottom” end of
the carousel incorporates the
holding pots and the retaining plates
15º which also perform the “breakout” of
the pipes. As drill pipe is stored into
the carousel the joints are loosened
15º for unthreading by means of reverse
rotation whilst the drill pipe is
prevented from rotating by the
retaining plate, thus “breaking” the
tight joint.
Designed angle (15º) on
retaining plates allow the drill
pipe to turn slightly and “slap”
against the plates to aid in
“breaking out”.
Rod Handling
Upper Carousel Retaining Plate
The top end of the Carousel consists of the retaining plate and top retaining drum.
The top retaining plate in conjunction with the design of the drill pipe allows the
carousel to swing over the drill pipe and as the pipe is lowered, secure it within the
retaining plate. “The top retaining plate does not play a part in “breaking out”,
it only retains the drill pipe”. The retaining drum prevents the drill pipe from
moving upwards and potentially falling out from within the carousel, this could occur
when the mast is folded horizontal and the drill is being trammed backwards up
sloping ground.

Rod Handling
Carousel Indexing
To position the drill pipe the Carousel must be rotated or “indexed”. This is achieved by main
carousel shaft rotating within bushings by means of the Indexing cylinder. The indexing
cylinder will move (rotate) the carousel exactly one pipe position for each full extension of the
cylinder provided the indexing pin is engaged. This pin is attached to a hydraulic cylinder
which engages the pin in to a hole, between each of the carousel holding pots. The carousel
is then locked in to position by the carousel lock pin which operates off the same switch as
the indexing pin but in the opposite direction. The indexing pin is disengaged when the
carousel lock pin is engaged.
Indexing locking
hole
Indexing pin and

cylinder housing
Carousel lock
pin cylinder
Indexing cylinder
Pipe Support
The pipe support is used to guide the drill pipe to align the pipe with the rotary head and
deck bushing. A proximity switch in the center of the mast is triggered off the mast feed
cylinder when the rotary head is above or below the support assembly to open and fold the
support out of the way. A sequence valve is used to allow the assembly to swing down in
place before clamping the drill pipe. A cross port check valve is used to lock the hydraulic
cylinder in the clamp position. The stabilizer arms have two grease fittings that are
connected to the auto lube system. The arms and rollers are replaceable and sized
appropriately for the drill pipe.

Pipe Support
Valves
Pipe Support Operation

• The SKL Pipe Support is a specialized feature inherent to the SKL equipped
with the 20 Meter mast. It’s primary purpose is to provide structural support
to the starter drill string while the mast is in the horizontal, or tramming
position reducing stresses and strains on intermediate tool joints. It’s
secondary purpose is to provide stabilization to the upper starter string drill
rod during drilling while rotating the drill string through rough conditions.
This capability reduces the wobble in the drill string thus causing a
stabilizing effect.
• Operation of the pipe support is fully automatic and is controlled by the on-
board PLC system. A series of proximity switches and a limit switch are
utilized to determine head position, pipe support position, and switching
conditions. These are fed into the PLC controllers to tell the pipe support
when to engage the drill pipe, or stow in the back of the mast, and also tell
the rotary head that it is o.k. to advance or stop if there’s a possibility of a
collision.

Head Position Switches
(Switches located 2/3rds up from bottom and on cab side of mast)
Rocker Limit Switch – Indicates position Proximity Switch- This switch checks for
of the drill head. a failed rocker limit switch.
Head Position Indicator
This switch indicates the head position at which the

pipe support is either extended or retracted
depending on direction of head travel. Switch is
located on the underside (or back) of the mast just
above the pivot and senses the feed cylinder.

Pipe Support Switches
Proximity Switch and redundant Limit Switch (not shown) – This switch
indicates that the pipe support is retracted to its stowed position as shown.
Sequence when feeding down
H
E Proximity Switch – resets down feed lockout.
A
D
T
R
Proximity Switch – activates pipe support to retract to a safe position while drill head
A
passes below.
V
E
L
Rocker Limit Switch – if pipe support is not stowed at this point, then feeding down is
locked out until reset by activation of the top prox switch.
Proximity Switch – checks validity of the rocker limit switch, if rocker limit switch does not
agree with this prox switch then feeding down is locked out until reset by activation of the
top prox switch.

Sequence when hoisting up
Proximity Switch – resets down feed lockout.
Proximity Switch – activates pipe support to clamp the pipe
H
Rocker Limit Switch – indicates that it is safe to clamp the pipe when it reaches the next
E proximity switch.
A
D
Proximity Switch – checks validity of the rocker limit switch, if rocker limit switch does not
agree with this prox switch then feeding down is locked out until reset by activation of the
T
top prox switch.
R
A If the pipe support moves away from the stowed position while the head
is below the rocker limit switch the pipe support will attempt to retract
V
back until it has reached its stowed position. If it does not reach that
E stowed position within 2 seconds then hoisting is locked out until it
L reaches its stowed position.
Pipe Catcher
The drill pipe catcher is used to prevent a drill pipe from falling out of the mast if
accidentally unscrewed from the top. It is controlled from the operator's cab.

Winch Assembly
The winch assembly consists of 5 main components: Drive Motor, Planetary
drive, Brake assembly, Drum and Winch rope. It is imperative that daily inspections
are carried out to ensure the integrity of all components. Particular attention should
be given to the winch rope, clamps and safety hook. Inspect the rope for any signs
of corrosion/rust, wear spots/flats, kinks/severe twists and broken or frayed wires.
Hydraulic Winch rope
Drive drum Winch Rope
Motor (Smooth)
Winch Assembly
Checking Oil Level

Winch Assembly -
Rope Attachments
The dead end of the rope should extend from the socket for a short distance
approximately nine times the rope diameter. The wedge is now placed in the
socket, and a wire rope clip is placed around the dead end by clamping
a short, extra piece of rope to the tail,
(do NOT clamp to the live part). The
U bolt should bear against the tail; the
saddle of the clip should bear against
the tail; the saddle of the clip should bear
against the short extra piece.
Mast
• Notes

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MD6540 Mechanical Training

Topic 7 Mast, Rotary Head, Pipe Rack

2 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

The SKL mast design has longer life and fewer

Double-cut lacing and amply sized main chords

3 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

SKL LONG MAST SPEC SUMMARY

• Multi-pass hole depths down to 215.6 ft

• Angle drilling up to 30o in 5o increments

• Up to 110,000 lb (49,895 kg) pull-down and

• The rotary head generates up to 363 hp

4 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

 Multi-pass hole depths down to 279 ft

 Angle drilling up to 30o in 5o increments

 Up to 110,000 lb (49,895 kg) pull-down and

 The rotary head generates up to 363 hp

5 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

6 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

SKL DOUBLE ROD

When loaded, the cylinder is in tension, which minimizes deflection

This system develops less buckling load on the pull-down cylinder

This cylinder arrangement also allows for a closed-loop hydraulic

Pull-down forces are up to 110,000 lb (49,895 kg) and hoist forces

8 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

Dependant on direction, Hydraulic fluid

Hoist/Pull down Cable System

10 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

11 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

CABLE SYSTEM WITH AUTO-

13 / Caterpillar Confidential: GREEN / WHEREVER THERE’S MINING

• Control Manifold 1. Control manifold

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Hoist/ Pull Down Cables

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Hoist/Pull Down Cables

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SKL ROTARY HEAD

The heavy-duty rotary head, with a 5 ½

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Rotary Head - Drive system

• Rotation speed - 0 -134rpm (Optional-150rpm)

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Hoist Air Swivel

Pulldown Fluid and Air lines

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• Bull Shaft Bearing Preload checking

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Bull shaft bearing Pre-load

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Check/Adjust End Play.

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Lower Carousel Break-out plate Deck Wrench

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Rod Handling - Deck Wrench

If damage has been sustained to

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Breakout System - HOBO

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• Dies The Hydraulically Operated Break Out

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Multi-pass hole depths down to 279 ft

Angle drilling up to 30o in 5o increments

Up to 110,000 lb (49,895 kg) pull-down and

The rotary head generates up to 363 hp