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In North America Telephone 1-800-854-9030 or Telefax 1-800-582-6570 Telephone (903) 786-2981 Telefax (903) 786-6407
Bucyrus Mining Equipment, Inc. 3501 S. FM Hwy 1417, Denison, TX 75020 www.bucyrus.com 2010 Bucyrus International, Inc. All Rights Reserved
Introduction
Intended Use
This machine and its approved attachments are designed to drill blast holes for surface and underground quarry, mining and construction applications. Use of this machine in any other way is prohibited and contrary to its intended use.
This safety alert symbol indicates important SAFETY MESSAGES in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.
DO NOT weld on any part of this machine without rst disconnecting the negative battery cable or place the battery disconnect switch in the open position. Disconnect the connections to the Electronic Control Module (ECM) on the engine before welding.
Before Starting Engine, Study Operator's Manual * Read and understand the warnings and cautions shown in Section 1 * Practice All Safety Precautions * Make Pre-Operations Check * Learn Controls Before Operating It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws and regulations.
Specications are subject to change without notice. Information contained in this manual was current at the time of printing. Revised 05/13/2010
Introduction i
Contents
INTRODUCTION SAFETY...................................................................................................................SECTION 1 GENERAL INFORMATION .....................................................................................SECTION 2 OPERATOR CONTROLS .......................................................................................SECTION 3 START-UP, TRAMMING AND SHUTDOWN ...........................................................SECTION 4 DRILLING PROCEDURES .....................................................................................SECTION 5 LUBRICATION AND MAINTENANCE ....................................................................SECTION 6
ii
Introduction
Section 1
Safety
Safety
1-1
Notes
1-2
Safety
Hazard Classication
The hydraulic track drill is a heavy moving machine with a boom capable of extending its reach vertically and horizontally. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly operated, inspected, and maintained. The operator's must read this manual and have been trained to use the machine in an appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer.
Hazard Classication
A multi-tier hazard classication system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specic level of severity of the potential hazard. All are used as attention-getting devices on decals and labels xed to the machine to assist in potential hazard recognition and prevention. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Indicates a potentially hazardous situation which, if not avoided, may result in property or equipment damage.
Safety
1-3
Prevention
See Operator's Manual for instructions. If you do not understand the information the manuals, consult your supervisor, the owner, or the manufacturer. Keep clear of rotating drill steel and drivelines. Switch off engine before performing service. Keep away from fan and belt when engine is running. Stop engine before servicing.
Explosion / Burn Hazard. Will cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.
Keep all open ames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt. READ MANUALS Read all manuals prior to operation.
Explosion Hazard. Death or serious injury can result from the use of ether or other high energy starting aids.
Do not use ether or other high energy starting aids. Engine equipped with grid heating system.
Explosion Hazard. Death or serious injury can result from the use of ether or other high energy starting aids.
Burn Hazard. Death or serious injury can result from release of hot pressurized liquids.
Prevention
Shut off live air at source, and relieve all pressure before removing ller plug.
Flying Object Hazard. Serious injury or death can occur if drill is operated without guards in place.
Flying Object Hazard. Serious injury or death can occur if track tension is adjusted improperly.
Read and understand the procedures in the Operation and Maintenance Manual before adjusting track tension
Electrocution Hazard. Death or injury can result from contacting electric power lines.
Trip & Fall Hazard. Death or serious injury can result from tripping and falling.
Safety
1-5
Prevention
Keep clear of compressor air discharge area.
Injection Hazard. Escaping uid under pressure can penetrate skin, causing serious injury.
Relieve pressure before disconnecting hydraulic lines. Keep away from leaks and pin holes. Use a piece of cardboard or paper to search for leaks. Do not use hand.
Crush Hazard. Death or serious injury can result from contact with moving centralizer.
Keep clear of moving centralizer. Do not actuate centralizer until personnel are clear.
Crush Hazard. Death or serious injury can result from contact with moving machine.
Crush Hazard. Death or serious injury can result from contact with moving feed mast.
Read and understand operator's manual and all safety signs before attempting to remove feed mast swing pin.
Drill Feed And Table Can Fall causing serious injuries or death.
Always raise the drill feed and feed table clear of all obstacles before moving the machine. Raise them high enough to allow for rough ground or small hills. Do Not allow anyone under the drill feed or feed table unless machine parts are not moving and are supported. Do Not attempt to repair a pivot pin that has failed or has been sheared.
1-6
Safety
Safety Information
Before Operation Do study this manual and fully understand the controls. Do be sure all safety guards are securely in place. Replace any damaged or missing guards. Do be sure all nameplates and decals pertaining to safety, operation, and maintenance are in place and not damaged. Replace any damaged or missing nameplates or decals. Refer to decal locator drawings in this section. Do be sure all personnel are clear of the machine and work area before starting the engine or operating the machine. Do be sure drill area is clear of all obstructions before operating machine. Do attach safety chain when using towbar. Do wear safety helmet, glasses and hearing protection when operating or working on machine. Do Not operate machine with: Hydraulic or air leaks. Damaged hydraulic hoses or ttings. Broken or damaged electrical wiring. Damaged or missing guards and shields. Damaged structural members. Worn or damaged mechanical parts. Damaged or missing fasteners. Broken, damaged, or malfunctioning controls. Do examine the surface before drilling to determine the possible presence of unred explosives. Do provide sufcient ventilation when running the engine in an enclosed area. Exhaust gases contain carbon monoxide, a deadly poison, which is colorless and odorless. Do keep work area clean and clear of mud, snow, ice, uids, hand tools and other objects. Do raise the drill feed before moving the machine. Raise it high enough to allow for rough ground or small hills. Drill feed can fall causing serious injury or death. Do wear seat belt and operate machine with door closed on cab machines. Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g. safety helmet, safety glasses, hearing protection, gloves, respirator. Do maintain minimum clearance from high voltage wires (see Table 1-1). Check with power company and local regulations for specic guidelines and safety information. Do Not use the machine for any other purpose than what it was designed for. Do Not wear loose clothing or jewelry; keep clothing and hands clear of moving parts. Do Not travel on steep inclines, soft or unstable ground, or close to unsupported excavations. Do Not move boom or machine if it is in a potentially unstable position. Do Not stand directly under a boom or feed. Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.
Operation
Safety
1-7
Safety Information
After Operation Follow Shutdown Procedures given in Section 4 of this manual.
Maintenance Two people shall be present when performing service work, both being fully trained on safety issues. One person shall supervise from the operator's position and have immediate access to an emergency stop in all situations. Visual, audible or verbal communication signals shall be established and understood by both persons. Do relieve pressure in the hydraulic or pneumatic systems before loosening connections or parts.
Do use only proper tools to make repairs or adjustments. Do be sure of adequate lighting when performing service work at night. Do maintain a metal-to-metal contact between the ll nozzle and fuel tank when lling the fuel tank. This will prevent sparks and the possibility of explosion. Do be sure each person is adequately trained to perform service and maintenance procedures. Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.
Do be sure machine and components are well supported before servicing or replacing parts. Do Not service, or perform maintenance, while machine is running, or capable of being started. Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments. Do Not weld or grind near oil, air, fuel lines, or batteries. Do Not smoke or use an open ame near batteries. Batteries can give off hydrogen which is a highly explosive gas. Do Not direct high pressure cleaning agents or water on electrical connections.
Equipment Transfer If all or part of the equipment is shipped to a new destination, always include a complete Operator's Manual or a copy of the following topics: Safety Section Operation Instructions including: Pre-Start Checks Clearances from High Voltage Lines Start-up Line Voltage Minimum Clearance After Start Checks Shutdown Procedure 0 to 50 kv 10 ft (3 m) Tramming Machine 50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 350 to 500 kv 500 to 750 kv 750 to 1000 kv 20 ft (6.1 m) 25 ft (7.6 m) 35 ft (10.7 m) 45 ft (13.7 m)
1-8
Safety
Safety
1-9
1-10
Safety
Safety
1-11
Notes
1-12
Safety
Safety
1-13
1-14
Safety
Safety
1-15
Safety Signs
429119
428884
429491
429115
429116
428896
1-16
Safety
Safety Signs
428892
429494
429493
429082
428893
429405
Safety 1-17
Safety Signs
428897
429141 428898
1-18 Safety
Safety Signs
429084
429468
409485 429087
Safety
1-19
Safety Signs
429471
429489
427967
429106
435214
1-20 Safety
Section 2
General Information
General Information
2-1
Introduction
This manual contains detailed instructions, maintenance information, and technical data which the operator will need in order to properly operate the R30C Track Drill, and to perform the various maintenance services that are required for keeping the equipment in good working condition at all times. Included herein are complete descriptions of each operating control and step-by-step instructions on how to start, operate, and stop the equipment, and recommended operator's maintenance procedures. The maintenance procedures and service instructions in this manual are included as recommendations only and are based on normal equipment working conditions. Changes should be initiated by the user in order to compensate for other than normal conditions and to meet the working requirements of any specic job application. By faithfully using this manual as a guide, and observing the instructions and recommendations, the R30C Track Drill will provide many years of dependable and efcient service at a minimum cost for operation.
2-2
General Information
General Information
2-3
Rod Changer Linear rod changer for 5 (45 mm) or 4 (51 mm) 12 or 14 ft. (3.7 or 4.3 m) round rods for up to 72 ft.* (21.9 m) drill steel capabiltiy. Carousel rod changer for 5 (38 mm), 5 (45 mm) or 4 (51 mm) 12 or 14 ft. (3.7 or 4.3 m) round rods for up to 88 ft.* (26.8 m). A single rod changer is also availabe for starter and one rod. * Depth capacity includes a 20 ft. starter rod. Additional Standard Features Fully Enclosed Canopy Power Pickup Pot Angle Inclinator Dust Collector Options Detergent System HPR51 Hydraulic Percusion Drill, 30 hp (23 kW)
2-4
General Information
Fig. 2-1 Right Side View of R30C 1. Detergent Tank 2. Engine Air Filter 3. Hydraulic Tank Filters 4. Cab Air Filter 5. Dust Collector 6. Boom Swing Cylinder 7. Feed Dump Cylinder 8. Feed Extend Cylinder
9. Feed Table Assembly 10. Dust Collector Precleaner 11. Feed Swing Cylinder 12. Boom Lift Cylinder 13. Air Receiver Tank 14. Hydraulic Tank 15. Hydraulic Pumps (2) 16. Pump Drive
Fig. 2-2 Left Side View of R30C 17. Drill Slide Assembly 18. Feed Assembly 19. Upper Rod Rack 20. Cab 21. Electrical Enclosure 22. Engine Radiator Shunt Tank 23. Radiator/Cooler
24. Track Oscillation Cylinder (2) 25. Outer Boom Tube 26. Inner Boom Tube 27. Positioner 28. Hydraulic Rock Drill 29. Rod Wrench
General Information
2-5
Fig. 2-3 Top View of R30C 30. Feed Drive Assembly 31. Breather, Hydraulic Tank 32. Batteries 33. Caterpillar C9 Diesel Engine
34. Fuel Tank 35. Air Receiver Tank 36. Air Compressor
Fig. 2-4 Lower Boom/Feed 1. Lower Rod Rack 2. Rope Pull Shutdown Switch 3. Pickup Pot
4. Pendulum 5. Centralizer
2-6
General Information
General Information
2-7
Fig. 2-8 Dust Collector Regulator and Blow Air Valve 1. Regulator (set at 80 PSI (5.5 bar)) 2. Ball Valve
Fig. 2-9 1. Electronic Control Module (ECM) 2. Plug-InsDisconnect from ECM before welding
2-8
General Information
Section 3
Operator Controls
Operator Controls
3-1
Notes
3-2
Operator Controls
Control Panel
OFF to Start, ON to Tram
Fig. 3-1 Cab Control Panel 1. Cab Temperature Control 2. Air Conditioner ON/OFF 3. Cab Fan Speed 4. Warm Oil ON/OFF 5. Washer FRONT/TOP 6. Rear Drill Lights ON/OFF 7. Front Drill Lights ON/OFF 8. Control System ON/OFF 9. Not Used 10. Feed Force 11. Dust Collector ON/OFF 12. Engine Idle LOW/HIGH Adjusts temperature for heater/air conditioner Turns air conditioner on/off Controls fan speed
NEUTRAL to Start
Warms the hydraulic oil in cold conditions 32o F (0o C) or less Turns on windshield washer Turns rear drill lights on and off Turns front drill lights on and off Powers up machine electronic controls; must be OFF when starting engine Rotate knob CW to increase pressure on drill bit, CCW to decrease pressure Turns dust collector on; with air on, dust collector is fully operational, with air off, dust collector operates in pulse mode to clean dust collector lters Switch on LOWengine runs at 1000 RPM (for startup/shutdown), increases to 1500 RPM (for system load) Switch on HIGHengine runs at 1800 RPM (for drilling/tramming functions) Selects rod changer or setup mode while in drill mode. Selects tram or drill mode; tram is disabled in drill mode; drill is disabled in tram mode; must be in neutral position when starting engine Turns on detergent system (if supplied), dust collector must be off Locks or unlocks track oscillation cylinders for different tramming conditions Switch ON activates automatic drilling Shuts down machine engine in case of an emergency Lights when engine start is engaged; shuts off when engine is warmed to start Starts engine
3-3
13. Rod Changer/Setup 14. Tram/Neutral/Drill 15. Water ON/OFF 16. Oscillation LOCK/UNLOCK 17. Smart Drill ON/OFF 18. Engine Stop Switch 19. Cold Start Lamp 20. Engine Start Switch
Operator Controls
2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following functions (ref. g.3-3): Tram/Drill switch in TRAM (14, g. 3-1) boom down, boom up, boom swing left, boom swing right Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER carriage out, carriage in, car riage unlock
3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-3): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading
3-4
Operator Controls
Fig. 3-3 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot
Operator Controls
3-5
2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following function (ref. g.3-4): Tram/Drill switch in TRAM (14, g. 3-1) tram right track forward/reverse Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER carriage out, carriage in, car riage unlock
3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-4): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading
3-6
Operator Controls
Fig. 3-4 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot
Operator Controls
3-7
2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following functions (ref. g.3-3): Tram/Drill switch in TRAM (14, g. 3-1) boom down, boom up, boom swing left, boom swing right Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER carousel counterclockwise, carousel clockwise
3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-3): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading
3-8
Operator Controls
RIGHT JOYSTICK
BOOM DOWN BOOM SWING RIGHT
LEFT
RIGHT
JOYSTICK BUTTONS
DRILL JOYSTICK
RIGHT JOYSTICK
BOOM DOWN FEED UP BOOM SWING RIGHT BOOM UP BOOM EXTEND OUT BOOM EXTEND IN
SET-UP MODE
LEFT JOYSTICK
FEED DUMP IN FEED SWING LEFT FEED SWING RIGHT FEED DUMP OUT FEED EXTEND UP OFF CLOSE DOWN FEED EXTEND DOWN BOOM SWING LEFT
AIR ON
CENTRALIZER OPEN
PICK-UP POT UP
ROTATION FORWARD FEED DOWN COUPLING GREASE COLLAR SYN THREAD FULL HAMMER
AIR ON
CENTRALIZER OPEN
PICK-UP POT UP
JAW CLAMP
JAW UNCLAMP
ROTATION REVERSE
COUPLING GREASE OFF CLOSE DOWN COLLAR SYN THREAD FULL HAMMER
1
2 3
Fig. 3-3 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot
Operator Controls
3-9
2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following function (ref. g.3-4): Tram/Drill switch in TRAM (14, g. 3-1) tram right track forward/reverse Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER cariage counterclockswise carousel clockwise
3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-4): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading
3-10
Operator Controls
RIGHT JOYSTICK
FORWARD
LEFT TRACK
REVERSE
DRILL JOYSTICK
SET-UP MODE
LEFT JOYSTICK
FEED DUMP IN FEED SWING LEFT FEED SWING RIGHT FEED DUMP OUT FEED EXTEND UP OFF CLOSE DOWN FEED EXTEND DOWN BOOM SWING LEFT BOOM UP BOOM EXTEND OUT BOOM EXTEND IN
RIGHT JOYSTICK
BOOM DOWN BOOM SWING RIGHT FEED UP
AIR ON
CENTRALIZER OPEN
PICK-UP POT UP
ROTATION REVERSE
AIR ON
CENTRALIZER OPEN
PICK-UP POT UP
JAW CLAMP
JAW UNCLAMP
ROTATION REVERSE
COUPLING GREASE OFF CLOSE DOWN COLLAR SYN THREAD FULL HAMMER
Fig. 3-4 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot
Operator Controls
3-11
Fig. 3-5 L.H. Joystick Buttons TRAM MODE 9. Oscillation Backward 10. Counter Rotate 11. Oscillation Forward 12. 2-Speed DRILL/SET UP MODE 9. Not Used 10. Not Used 11. Feed Extend Up 12. Feed Extend Down DRILL/ROD CHANGER MODE 9. Rod Wrench Out OR 9. Carousel Sing Out 10. Rod Wrench In OR 10. Carousel Swing In 11. Not Used 12. Not Used
Fig. 3-6 R.H. and Drill Joystick Buttons TRAM MODE DRILL/ROD CHANGER MODE 1. Not Used 1. Full Hammer 2. Not Used 2. Coupling Grease 3. Not Used 3. Collar 4. Not Used 4. Synchronized Threading 5. Not Used 5. Not Used 6. Not Used 6. Not Used 7. Not Used 7. Not Used 8. Not Used 8. Carriage Unlock DRILL/SET UP MODE 1. Full Hammer 2. Coupling Grease 3. Collar 4. Synchronized Threading 5. Boom Extend In 6. Boom Extend Out 7. Not Used 8. Not Used
3-12
Operator Controls
Cab Displays
Drilling Displays
Fig. 3-7 Control Panel Drilling Pressure Readings 1. Hammer Pressure 2. Feed Pressure 3. Rotation Pressure 4. Air Pressure
Operator Controls
3-13
Cab Displays
Engine Displays
Fig. 3-9 Control Panel Engine Readings 1. Engine RPM 2. Engine Hours 3. Compressor Temperature in Fahrenheit 4. Drill Hours
5. 6. 7. 8.
Engine Temperature in Fahrenheit System Operating Voltage Engine Oil Presure Fuel Quantity in Percent
3-14
Operator Controls
Remote Operation
For Emergency Use Only. Owner/Operator must contact manufacturer for proper operation.
Operator Controls
3-15
Notes
3-16
Operator Controls
Section 4
4-1
Notes
4-2
Pre-Start Checklist
CHECK FOR obstructions before moving feed or machine. DO NOT allow any part of the machine to contact or come near electrical power lines (see Table 4-1). BE SURE the feed is high enough to clear ground obstacles and low enough to clear overhead obstacles when tramming.
BE SURE all hydraulic controls are in the OFF or NEUTRAL position BEFORE placing the control system ON/OFF switch to ON. DO NOT operate the machine unless thoroughly familiar with controls and functions. WEAR a protective helmet and eye protection when on or near the machine. WEAR noise reducing ear protectors when near the machine for extended periods while the machine is running. CHECK operation of the brakes before tramming. REMOVE the drill steel and center the drill over the positioner before tramming over rough terrain.
BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. BE SURE machine is OFF and the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts. SHUT OFF engine BEFORE refueling. Clean up any fuel spills immediately. Failure to observe this warning may result in re.
Clearances from High Voltage Lines Line Voltage Minimum Clearance 0 to 50 kv 10 ft (3 m) 50 to 200 kv 15 ft (4.6 m) 200 to 350 kv 20 ft (6.1 m) 350 to 500 kv 25 ft (7.6 m) 500 to 750 kv 35 ft (10.7 m) 750 to 1000 kv 45 ft (13.7 m)
Table 4-1 Minimum Safe Distances From High Voltage Lines
4-3
Pre-Start Checklist
Overall Machine A. Check underside of machine. Look for broken or loose hoses. Tighten any loose hose connections and any loose bolts. If dripping fuel, oil or water is evident, do not operate the machine until the leak is found and corrected. B. C. D. E. Replace any missing or damaged bolts, pins or other retainers. Check tracks for proper tension and clear any debris. Lubricate machine according to Maintenance Schedule and Grease Points chart in Section 6. Check battery cable connections and battery electrolyte level. Switch battery disconnect switch (located behind battery box) to the ON position.
Fuel A. Always shut off engine before refueling. B. C. Wipe up any fuel spills immediately or re may result. Use No. 2-D diesel fuel. Consult engine manual for specic recommendations.
Engine, Gearcases and Hydraulic Fluid Types A. Check engine crankcase oil level. Add oil if necessary. Do not mix types of oil. The machine is factory lled with 15W-40 motor oil unless specied otherwise. B. C. D. E. Check radiator coolant level. Add a 50/50 mixture of anti-freeze and water if necessary. Check battery electrolyte level and ll with distilled water if necessary. Check for clean, tight connections. Check for adequate diesel fuel. To avoid priming and restarting problems, do not allow engine to run out of fuel. Drain water from water separator prior to starting. Check oil level in feed planetary drive assembly. Add HD 80W-90 wt. gear oil if necessary. Do not mix types of oil. Set feed in upright position and remove plug at the 3 o'clock position. Oil level should be at bottom of plug hole. Fill through plug at the 12 o'clock position. Check oil level in track planetary drive. Add gear oil if required. Do not mix types of oil. Machine is factory lled with HD 80W-90 wt. gear oil (see Service Manual for list of approved gear oils). With machine on level surface, position unit so drain plug is at bottom, ll plug will be at about the 2 o'clock position. Oil level should be at bottom of ll plug. Check alternator/water pump drive belt condition. Replace if cracked or worn. See engine manual. Check oil level in hydraulic reservoir. Add oil if necessary. When checking hydraulic uid level, be sure: Reservoir is level Boom is retracted and level Feed is dumped back and extended Do not overll. Machine was factory lled with Chevron AW MV ISO 100 unless specied otherwise. Do Not Mix Hydraulic Fluid Types.
F.
G. H.
NOTE
4-4
Pre-Start Checklist
Pneumatic System A. Be sure hydraulic and pneumatic systems are not pressurized before loosening any connections or parts. Check oil level in compressor receiver. Add oil only if gauge reads in the Add Oil range. Machine is factory lled with Chevron ATF. Boom, Feed and Drill A. Operator must be sure to check all pivot points for signs of wear or damage and grease daily. B. C. D. E. F. Check for loose drill hose retainers. Check feed chain for proper tension (see service manual). Drill ChuckCheck for excessive shank side play indicating chuck wear. Grease chuck end cap after shank is inserted (see Drill Service Manual). Drill ShankInspect shank threads often. Badly worn threads can cause tight steel and premature coupling breakage. CentralizerCheck centralizer alignment with drill shank. Clamp a coupling between the centralizer jaws. Lower the drill so the shank aligns with the coupling. Adjust centralizer as necessary.
Drill Accumulators
DO NOT operate the hydraulic drill until accumulators have been charged.
Because of Federal regulations, the accumulators on the drill cannot be charged at the factory. Both the high and low pressure accumulators on the drill must be charged before the initial round is drilled and checked periodically thereafter. Refer to the Service Manual for pressures and procedures.
4-5
Pre-Start Checklist
Fig. 4-1 Feed Table Pivot Pin 1. Grease Fittings (2) 2. Retaining Bolts (6)Torque to 282 ft. lbs. (384 Nm) 3. Retaining Cap, Feed Table Pin
Weekly Checks 1. Be sure to check torque on the six pivot pin cap retaining bolts weekly. Torque to 282 ft. lbs. (384 Nm). Check for excessive play, cracking or other damage. 2. Check for end play by inserting a feeler gauge between the retaining cap and positioner casting. The gap should be in the range of 0.005 to 0.015 in. (0.13 to 0.38 mm). Retaining cap will have to be removed and shims installed until the correct clearance is obtained. Procedure in service manual must be followed. Check for side play by raising the feed to a 45 degree angle. Have someone watch the pivot pin while you dump the feed back and forth. There should be no rocking of the pin. If so, report to maintenance personnel. Feed table will have to be removed and pin and bushing inspected and necessary repairs made.
3.
4-6
5. 6.
4-7
Start-up Procedure
OFF to Start, ON to Tram
NEUTRAL to Start Fig. 4-4 Cab Control Panel 1. Cab Temperature Control 2. Air Conditioner ON/OFF 3. Cab Fan Speed 4. Warm Oil ON/OFF 5. Washer FRONT/TOP 6. Rear Drill Lights ON/OFF 7. Front Drill Lights ON/OFF 8. Control System ON/OFF 9. Not Used 10. Feed Force 11. Dust Collector ON/OFF 12. Engine Idle LOW/HIGH 13. Rod Changer/Setup 14. Tram/Drill 15. Water ON/OFF 16. Oscillation LOCK/UNLOCK 17. Smart Drill ON/OFF 18. Emergency Stop Switch 19. Cold Start Lamp 20. Engine Start Switch
Fig. 4-6 Hydraulic Pumps and Gauges 1. Pump No. 1 2. Pump No. 2 3. Dust Collector Pump 4. Pump No. 1 Gauge 5. Pump No. 2 Gauge
4-8
Start-up Procedure
DO NOT use ether on engines equipped with an air intake heater. DO NOT put ether into compressor intake.
After completing the pre-start checklist, use the following procedure to start the machine: (ref. g. 4-4) 1. 2. 3. 4. 5. Turn battery disconnect (g. 4-2) located behind battery box to ON position. Be sure all controls are in the OFF or NEUTRAL position. Be sure the Tram/Drill Switch (14) is in the NEUTRAL (center) position. Be sure Control System Switch (8) is in the OFF position. Turn Ignition Switch (20) to START position. When engine starts, release switch to ON position.
NOTE
If engine fails to start within 30 seconds, release start switch. Wait for two minutes to allow starter to cool, and then turn start switch again.
DO NOT begin drilling until hydraulic oil has been warmed up, especially when ambient temperature is below 32oF (0oC). When hydraulic oil tank temperature gauge (g. 4-5) reaches 60oF (15.6oC), oil is warm enough to begin drilling. 6. 7. 8. Let machine warm up for a few minutes and then switch Control System Switch (8) to ON position. Check pump pressure gauges (g. 4-6) . Normal pressure when pumps are loaded is 3200 PSI (241 bar). If not, check hydraulic system. Observe engine RPM displayLow idle is 1000 RPM, System Load (Intermediate) is 1500 RPM, and High idle is 1800 RPM.
4-9
Tramming
DO NOT allow feed to come in contact with or come near high voltage lines. See minimum clearances from high voltage lines chart in Safety Section.
DO NOT tram machine on steep inclines, or horizontal to grades; this greatly increases risk of machine rollover. DO NOT tram machine on soft or unstable ground, or close to unsupported excavations. When tramming on slopes with cab machines equipped with ve or six rod changer, the Oscillation Control Switch MUST BE in the LOCK position.
Retract the telescopic boom when tramming over rough ground and during long moves. Place feed in horizontal position with top of feed resting on mast rest (if equipped).
NOTE
3. 4.
Oscillation Lock Switch (16, g. 4-4) should be in the UNLOCK position when tramming and oscillation is automatically locked in drill mode. Engine Idle Low/High Switch (12, g. 4-4) controls high engine idle speed and low engine idle speed. The engine idle speed increases or decreases maximum ow available for tramming. High engine idle provides approximately 2.5 m.p.h. Low engine idle provides approximately 1.2 m.p.h. To maneuver the machine, the Function switch must be in TRAM mode and the Control System switch must be ON. Using the L.H. joystick, squeeze the dead-man switch to release the brakes, then move it forward or backward (very slowly). To turn the drill, start forward or backward rst and then move the joystick to right or left without allowing the joystick to return to the center position. When tramming on side slopes, swing boom to the uphill side of the machine for better stability. Keep cab on uphill side of machine. For close maneuvering of machine place the Engine Idle Switch in LOW position.
5. 6.
NOTE
4-10
Tramming
Two Joystick Tram
1. 2. Place Tram/Drill Switch (14, g. 4-4) in the TRAM position. Place feed in horizontal position when tramming over rough ground and during long moves. Normally when tramming, the track oscillation cylinders are in the unlocked condition, however when tramming on slopes with a cab machine equipped with a ve or six rod changer the track oscillation cylinders must be in the locked condition.
NOTE
3. 4.
Oscillation Lock Switch (16, g. 4-4) should be in the UNLOCK position when tramming and oscillation is automatically locked in drill mode. Engine Idle Low/High Switch (12, g. 4-4) controls high engine idle speed and low engine idle speed. The engine idle speed increases or decreases maximum ow available for tramming. High engine idle provides approximately 2.5 m.p.h. Low engine idle provides approximately 1.2 m.p.h. To maneuver the machine use the L.H. and R.H. joystick controls. To turn machine, push one joystick forward while pulling the other joystick back. Pushing both joysticks forward will move the machine forward, pulling both joysticks back will move the machine in reverse. When tramming on side slopes, swing boom to the uphill side of the machine for better stability. Keep cab on uphill side of machine. For close maneuvering of machine place the Engine Idle Switch in LOW position.
5.
NOTE
4-11
Shutdown Checklist
BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. DO NOT operate or shutdown the machine with the feed positioned over the operator. Plant (sting) the feed prior to extended shutdowns. 1. 2. 3. 4. 5. 6. Set feed on ground. Place all tramming and drilling controls in the OFF or NEUTRAL position. Place Control System ON/OFF Switch to OFF, this will allow engine to run at low idle. Switch Drill/Tram switch to NEUTRAL or OFF position. Let engine idle at low speed for about 3 minutes, then turn ignition switch to OFF position. If machine will be shut down for an extended period, switch the Battery Disconnect switch to OFF (g. 4-2). This will prevent excess battery drain.
4-12
Section 5
Drilling Procedures
Drilling Procedures
5-1
5-2
Drilling Procedures
Apply adequate lubricant to all couplings and drill rod threads before loading.
NOTE
Three people are required to perform this procedure. One operator and two people loading drill rod.
1. 2. 3. 4.
Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean. Grease threads with coupling grease on upper end of drill rod and install coupling. Make sure each piece of drill rod has a coupling on the upper end. Select DRILL position with switch (14, g. 5-3). Select ROD CHANGER position with switch (13, g. 5-3). Push lower left button (8) on R.H. joystick to UNLOCK rod rack carriage. Move R.H. joystick FORWARD to move carriage out. Use Drill joystick to run drill to bottom of feed so drill shank is positioned just above centralizer. Be sure drill shank is aligned with centralizer when it is closed, if not refer to Service Manual for alignment procedure. Open centralizer jaws. Tilt the feed to a suitable angle which will allow insertion of drill rod through dust collector pick-up pot and be able to align with the drill shank. Open the centralizer (L.H. armrest middle switch) and position drill rod through dust collector pickup pot and hold in alignment with the shank. Use Drill joystick and synchronize thread button (4) to thread the shank into the coupling. Raise the drill and rod so coupling is above the centralizer and close the centralizer. Move L.H. joystick to LEFT to swing wrench IN and clamp the drill rod. Move L.H. joystick RIGHT slightly to open the wrench so it is not clamped on the drill rod. The wrench is now in the "guide" position for the drill rod. Continue to raise the drill up towards the top of the feed so the top coupling is above the upper rack. Press and hold button (8) to UNLOCK rod rack carriage. Move R.H. joystick BACK to move rod carriage IN towards feed. Position rod rack so drill rod is aligned with the outermost socket (farthest from the feed). Release button (8) lock pin will lock into next position. Using the Drill joystick, lower the drill rod until the coupling is level with the upper rod rack. Move the L.H. joystick to RIGHT to LOCK drill rod. This pulls the rod lock bar to lock on the coupling. Slowly reverse the rotation and raise the drill to unthread the shank from the coupling.
5. 6. 7. 8. 9.
10.
11. 12.
Drilling Procedures
5-3
5-4
Drilling Procedures
Drilling Procedures
5-5
5-6
Drilling Procedures
Apply adequate lubricant to all couplings and drill rod threads before loading.
NOTE
Three people are required to perform this procedure. One operator and two people loading drill rod.
1. 2. 3. 4.
Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean. Grease threads with coupling grease on upper end of drill rod and install coupling. Make sure each piece of drill rod has a coupling on the upper end. Select DRILL position with switch (14, g. 5-3). Select ROD CHANGER position with switch (13, g. 5-3). Move L.H. joystick RIGHT and push the yellow button (9) to swing jaws into store position. Move R.H. joystick FORWARD to move carriage out. Use Drill joystick to run drill to bottom of feed so drill shank is positioned just above centralizer. Be sure drill shank is aligned with centralizer when it is closed, if not refer to Service Manual for alignment procedure. Open centralizer jaws. Tilt the feed to a suitable angle which will allow insertion of drill rod through dust collector pick-up pot and be able to align with the drill shank. Open the centralizer (L.H. armrest middle switch) and position drill rod through dust collector pickup pot and hold in alignment with the shank. Use Drill joystick and synchronize thread button (4) to unthread the coupling. Raise the drill and rod so coupling is above the centralizer and close the centralizer. Push the white (10) to swing the jaws in and then move the L.H. joystick to the LEFT to clamp the drill rod. Move L.H. joystick RIGHT slightly to open the jaws so they are not clamped on the drill rod. The jaws are now in the "guide" position for the drill rod. Continue to raise the drill up towards the top of the feed so the top coupling is above the upper rack. Move L.H. joystick LEFT to clamp rod with jaws. Push the white (10) button to swing rod into the carousel. Move L.H. joystick RIGHT until jaws are fully open. Push R.H. joystick back to rotate carousel clockwise to move rod out of the way of the jaws. Move the L.H. joystick to RIGHT to LOCK drill rod. This pulls the rod lock bar to lock on the coupling. Slowly reverse the rotation and raise the drill to unthread the shank from the coupling.
5. 6. 7. 8. 9.
Drilling Procedures
5-7
5-8
Drilling Procedures
Drilling Procedures
5-9
To Position Feed for Vertical Drilling 1. There are two options available: A. The vertical indicator (g. 5-4)Follow the instructions for setting the feed plumb. B. Pendulum (g. 5-5) Position feed plumb by watching the pendulum. When pendulum is centered in the ring, feed is plumb. 2. When feed is plumb, plant the stinger rmly into ground using the Drill joystick. This will prevent the feed from "kicking out" when collaring the hole.
Vertical Indicator The angular display is connected to the sensor mounted on the feed. There are 10 display lights in each axis (Y+, Y, X+ and X). The maximum angle from plumb is + or 6 degrees, thus each light represents 0.6 degrees. The lights remain lit if the feed is more than 6 degrees from plumb. The lights will go out successively as the feed approaches plumb in each direction. Vertical Adjustment 1. 2. Position feed vertical (plumb) and adjust the sensor to indicate plumb (no lights on). Move feed to non-vertical position, then move back until all lights go out (plumb). Feed should be plumb within + or - 0.6 degrees.
5-10
Drilling Procedures
Final Checks When machine is in position and feed is set at the desired angle for drilling you are ready to begin drilling the rst hole. Refer to drilling procedures in this section. Check to be sure that: Track Oscillation Cylinders are Locked. Drill/Tram Selector Switch is in DRILL position. System display readings are in normal operating range. Drill steel is loaded and secured in rod rack. Adequate supply of sharp drill bits. Adequate supply of coupling grease is on hand for greasing drill steel, shank and coupling threads. Grease gun and grease (PG55, P/N 312810 recommended) on hand to grease drill front end every two hours of drill operation. Drill accumulator charge pressure has been checked.
Drilling Procedures
5-11
Drilling Practices
Tips for top drilling performance
Collaring The collar of the drill hole will directly determine the quality of the hole. Hole Deviation The major cause of drill steel breakage is deviation of the drill hole. There is very little tolerance in the drill string for any deviation, due to the high energy output of the rock drill. Feed Pressure "Under-feeding" is a particularly common and bad practice. Feed pressure must be kept to the bit at all times while drilling. "Free-hammering" (hammering with no load on the bit) and "under-feeding" will shorten the drill string life and the hammer seals. Drill Pressures Feed and hammer pressures and rotation ow can and should be adjusted to suit different rock conditions. Optimum settings are reached when the maximum penetration rate is achieved with minimal heat and vibration being generated through the drill string. Incorrect drill pressure settings can be directly related to hole deviation and drill string damage and breakage. Adjusting Drill Pressure and Monitoring the Machine The operator should attempt to maintain a minimum amount of feed pressure, just enough to keep the drill steel couplings tight. This will ensure smooth drilling and maximize penetration rate by: Minimizing heat in the drill string Eliminating "under and over feeding" Minimizing rotation pressure Rotation ow should be increased in softer rock and decreased in harder rock as indicated by the penetration rate. Monitoring of the machine is critical at all times. Monitoring of the machine gauges is especially critical for those unfamiliar with the drill. Increases in air and /or rotation pressures indicate developing blockage and / or jamming situations. Plugged Bit and Stuck Drill Steel Always be alert of air and cuttings coming out of the hole, if not STOP DRILLING. If bit becomes plugged. When blowing air is stopped by a plugged bit, the drill string can become stuck quickly. Work the bit up and down the hole with hammer and rotation on until air and cuttings can be seen coming out of the hole. If bit remains plugged, raise bit out of hole and place bit against solid rock or hard wood and turn hammer on in short bursts with air on to dislodge obstruction. If bit still remains plugged, shut down machine and relieve all air pressure before removing bit. Clear bit manually and reinstall. If drill steel becomes stuck, use the reverse percussion option (if equipped) to "hammer out" of the hole. If machine is not equipped with this option, use the feed override lever to apply extra reverse feed pressure. Work the drill string up and down using slow rotation speed with blowing air on until it is free. Using the "smart drill" option (if equipped) will help prevent stuck steel due to bad ground. Refer to "smart drill" system operation in this section.
5-12
Drilling Procedures
Drilling Practices
System Readings for Clay or Soft Ground. Clay or soft ground may need lower feed pressure. To maintain the correct differential pressure between feed and hammer pressure, and to avoid shortened hammer seal and consumable life, the hammer pressure needs to lowered accordingly.
System Readings for Solid Rock. To maximize penetration rate in solid rock, higher hammer pressure is required. To maintain the correct differential between hammer and feed pressures, and to prevent "under-feeding", the feed pressure needs to be raised accordingly.
Drilling Procedures
5-13
Manual Drilling
5-14
Drilling Procedures
Manual Drilling
KEEP all non-essential personnel away from the hole and machinery while drilling is in progress. DO NOT re-drill a hole that has contained explosives. DO NOT strike drill rod to dislodge it while drill is operating. Fragmentation of the drill rod may result.
WORN THREADS on the drill string can cause premature wear and breakage to new parts mated with the drill string. USE sharp bits. Check for broken or loose carbides. Dull bits can cause stress in drill components. APPLY adequate lubricant to all couplings and drill rod threads before loading. CHECK rock conditions before operating drill rotation and feed at full throttle. Over feeding and over rotation can cause breakage of drill rotation parts and drill string. Place WARM OIL switch (4) in ON position before starting to drill. Drill will not operate when oil is cold. Leave control in WARM OIL position for a few minutes until oil reaches a minimum of 60oF (15.5oC).
Drilling Procedures
5-15
Manual Drilling
5-16
Drilling Procedures
Manual Drilling
1. 2. 3. Once hole is collared, move air switch to fully OPEN position. Move Drill joystick to full LEFT position and push full hammer button (1). Maintain proper feed pressure. If rod starts to bow, you are using too much feed pressure. If drill starts to bounce, or excessive heating in coupling is evident, you are not using enough. Use feed force knob (10, g. 5-3)) to adjust feed pressure. ALWAYS shutdown machine and let air pressure bleed off before removing a plugged bit. NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury. If air and cuttings stop coming out of the hole, the bit is becoming plugged and must be pulled back immediately. When the blowing air is stopped by a plugged bit, the bit and drill rod can become stuck very quickly. Work the bit up and down with the drill and rotation ON until cuttings can be seen coming from the hole. If the bit cannot be cleared, the drill rod and bit must be pulled out of the hole. Try placing bit on solid rock or hard wood and push full hammer button (1) on Drill joystick to clear bit. If bit remains plugged, you will have to shutdown the machine and let the air pressure bleed off and then remove bit and manually unclog bit and or drill rod. If the downward movement of the drill rod increases suddenly, this may mean that the bit has drilled into a void, crack or some soft material. Use Drill joystick to slow down the forward travel of the bit. If the rotation begins to slow down or stops, the bit must be pulled back immediately. Reduce the feed speed to drill through broken ground. If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.
NOTE
Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole. Shut off dust collector if water is coming out of the hole. This will plug the dust collector lters. Turn dust collector on after water stops coming out of the hole. It may be necessary to remove the dust collector hose from the pickup pot to avoid clogging the hose with mud. Connect the hose when dry drilling resumes.
4. 5.
As drill rod coupling approaches centralizer, open centralizer to allow the coupling to pass through. When drilling cycle is complete, turn off feed, hammer, rotation and air. If required, add another piece of drill rod (described in detail, following) and continue drilling or raise drill up until bit clears the hole and move to next hole.
Drilling Procedures
5-17
5-18
Drilling Procedures
Operation
Begin drilling the same as you would for manual drilling as described previously. 1. 2. 3. Once hole is collared, move air switch to fully OPEN position. Move Drill joystick to full LEFT position. Turn smart drill switch (17, g. 5-3) ON. ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit. NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury. If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.
NOTE
Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole. Shut off dust collector if water is coming out of the hole. This will plug the dust collector lters. Turn dust collector on after water stops coming out of the hole.
4. 5.
As drill rod coupling approaches centralizer, the centralizer must be opened to allow the coupling to pass through. When the drilling cycle is completed, turn off feed, hammer, rotation and air. If required, add another piece of drill rod (described in detail, following) and continue drilling or raise drill up until bit clears the hole and move to next hole.
Drilling Procedures
5-19
5-20
Drilling Procedures
NOTE
2. 3. 4.
Move Drill joystick to NEUTRAL position and place air switch to OFF position. Press full hammer button (1) to turn OFF. Turn hammer on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound (hammer frequency) of the drill string. Use the centralizer switch to close centralizer around the drill rod coupling. Use the synchronized threading button (4) on the Drill joystick to unthread rod. When drill shank is in line with automatic thread grease nozzle (g. 5-6), push coupling grease button (2) to grease drill shank thread. Raise drill towards top of feed, so drill shank is above upper rod rack.
5. 6.
7.
Drilling Procedures
5-21
5-22
Drilling Procedures
Press and hold carriage unlock button (8) on R.H. joystick to UNLOCK rod rack carriage. Move right joystick BACK to move carriage IN towards feed to position rst drill rod under drill shank. Release unlock button (8) on R.H. joystick, locking pin will automatically locate the drill rod position. Use synchronized threading button (4) on Drill joystick to thread rod. Continue until coupling is tight. Push L.H. joystick button (10) to move Rod Wrench to IN position. This swings wrench into position and clamps around the drill rod. Push L.H. joystick button (9) slightly to open the wrench so it is not clamped on the drill rod. The wrench is now in the "guide" position for the drill rod. Raise the drill to clear the coupling from the upper rod rack. Move R.H. joystick to LEFT to UNLOCK drill rod. This moves the lock bar IN towards feed to release the drill rod. Press and hold carriage unlock button (8) on R.H. joystick to UNLOCK rod rack carriage. Move the right joystick FORWARD to move rod carriage OUT. Release the carriage unlock button (8), the locking pin will automatically engage in next position in the rod rack. Move R.H. joystick to RIGHT to LOCK drill rod. This moves the lock bar OUT away from feed to lock the drill rod in place. Lower the drill until the threads of the drill rod are in line with the automatic thread grease nozzle (g. 5-4), activate coupling grease button (2) on Drill joystick to grease threads. Use Drill joystick to slowly lower drill rod into coupling. Use synchronized threading button (4) and pull toward operator until all couplings are tight. Place centralizer switch in OPEN position and resume drilling. When coupling clears the centralizer, close centralizer and swing rod wrench out of the way by pressing L.H. joystick button (9). Repeat the above steps for all additional rods to be added.
9. 10.
Drilling Procedures
5-23
5-24
Drilling Procedures
NOTE
2. 3. 4.
Place Drill joystick in NEUTRAL. Place drill rotation and full hammer button (1) in OFF (NEUTRAL) position. Turn full hammer (1) on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound of the drill string and air escaping from around coupling. Once loose, raise the drill until the coupling below the last drill rod is aligned with the centralizer jaws. Do not close centralizer jaws. Place air switch in OFF position. Swing the rod wrench into position around the drill rod by pushing button (10) on L.H joystick. The wrench will clamp drill rod automatically. Slowly begin forward (counterclockwise) rotation to slightly tighten the upper coupling on the drill rod. Stop rotation and push button (9) on L.H. joystick to use wrench as a guide. Place centralizer switch in CLOSE position around the coupling. Slowly begin reverse (clockwise) rotation at the same time utilizing the feed UP to unthread drill rod from coupling in centralizer and making sure you are not unthreading upper coupling. Raise the drill and rod until the coupling on the shank clears the upper rack level. Stop feed and rotation. Move R.H. joystick LEFT to UNLOCK the rod rack. Move joystick BACK while pushing button (8) to move rod rack IN towards feed and position the last empty socket of the rod rack in line with the drill rod. Release unlock button, locking pin will automatically engage in next position. Pull the Drill joystick BACK to lower the rod until the coupling is level with the upper rod rack. Move L.H. joystick to RIGHT to engage lock bar on the coupling, slowly reverse the rotation and raise the drill to unthread the drill shank from the coupling. Move L.H. joystick LEFT to UNLOCK the rod rack. Move R.H. joystick FORWARD and press button (8) to move rod rack OUT away from feed. Release unlock button, locking pin will automatically engage in next position. Using feed DOWN, run drill down the feed and use forward (counterclockwise) rotation to thread the drill shank into the coupling in the centralizer. When shank is threaded into coupling, open centralizer and raise drill up until next coupling is centered between centralizer jaws. Repeat steps 713 until all of the drill rod has been removed from the hole.
5. 6. 7.
8. 9.
10.
11. 12.
13.
14.
Drilling Procedures
5-25
5-26
Drilling Procedures
NOTE
2. 3. 4.
Move Drill joystick to NEUTRAL position and place air switch to OFF position. Press full hammer button (1) to turn OFF. Turn hammer on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound (hammer frequency) of the drill string. Use the centralizer switch to close centralizer around the drill rod coupling. Use the synchronized threading button (4) on the Drill joystick to unthread rod. When drill shank is in line with automatic thread grease nozzle (g. 5-6), push coupling grease button (2) to grease drill shank thread. Raise drill towards top of feed, so drill shank is above upper rod rack.
5. 6.
7.
Drilling Procedures
5-27
5-28
Drilling Procedures
Move L.H joystick LEFT to clamp rod with jaws. While holding L.H. joystick LEFT, push the white (10) to swing rod into place. Lower the drill until the threads of the drill rod are in line with the automatic thread grease nozzle, activate coupling grease button (2) on Drill joystick to grease threads. Use Drill joystick to slowly lower drill rod into coupling. Use synchronized threading button (4) and pull toward operator until all couplings are tight. Move L.H. joystick RIGHT to unclamp rod until jaws are fully open. Push yellow (9) on L.H. joystick to swing jaws out. Place centralizer switch in OPEN position and resume drilling. When coupling clears the centralizer, close centralizer and swing rod wrench out of the way by pressing L.H. joystick button (9). Repeat the above steps for all additional rods to be added.
Drilling Procedures
5-29
5-30
Drilling Procedures
NOTE
2. 3. 4.
Place Drill joystick in NEUTRAL. Place drill rotation and full hammer button (1) in OFF (NEUTRAL) position. Turn full hammer (1) on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound of the drill string and air escaping from around coupling. Once loose, raise the drill until the coupling below the last drill rod is aligned with the centralizer jaws. Do not close centralizer jaws. Place air switch in OFF position. Swing the rod wrench into position around the drill rod by pushing button (10) on L.H joystick. The wrench will clamp drill rod automatically. Slowly begin forward (counterclockwise) rotation to slightly tighten the upper coupling on the drill rod. Stop rotation and push button (9) on L.H. joystick to use wrench as a guide. Place centralizer switch in CLOSE position around the coupling. Slowly begin reverse (clockwise) rotation at the same time utilizing the feed UP to unthread drill rod from coupling in centralizer and making sure you are not unthreading upper coupling. Raise the drill and rod until the coupling on the shank clears the upper rack level. Stop feed and rotation. Move R.H. joystick LEFT to UNLOCK the rod rack. Move joystick BACK while pushing button (8) to move rod rack IN towards feed and position the last empty socket of the rod rack in line with the drill rod. Release unlock button, locking pin will automatically engage in next position. Pull the Drill joystick BACK to lower the rod until the coupling is level with the upper rod rack. Move L.H. joystick to RIGHT to engage lock bar on the coupling, slowly reverse the rotation and raise the drill to unthread the drill shank from the coupling. Move L.H. joystick LEFT to UNLOCK the rod rack. Move R.H. joystick FORWARD and press button (8) to move rod rack OUT away from feed. Release unlock button, locking pin will automatically engage in next position. Using feed DOWN, run drill down the feed and use forward (counterclockwise) rotation to thread the drill shank into the coupling in the centralizer. When shank is threaded into coupling, open centralizer and raise drill up until next coupling is centered between centralizer jaws. Repeat steps 713 until all of the drill rod has been removed from the hole.
5. 6. 7.
8. 9.
10.
11. 12.
13.
14.
Drilling Procedures
5-31
2. 3. 4. 5. 6. 7. 8.
9.
NOTE
10.
Install a new drill shank into the drill chuck, being sure to align the splines on the shank with those in the chuck and being careful not to damage the seal in the bearing plate behind the chuck driver. Install thrust plate. Slide the air swivel into position. Install the four bolts, spring washers and lock nuts. Torque to 483 ft. lbs. (657 Nm). Connect air/water hose to connection on water swivel housing. Apply a liberal coat of coupling grease to the drill shank threads before attaching the drill steel. Be sure to keep rotation housing of drill greased well (every 2 hours with a hand grease gun). If automatic lubrication system is used, check reservoir daily. It is recommended that a new coupling be used whenever replacing the shank. Grease coupling and shank before drilling.
Drilling Procedures
NOTE
5-32
2. 3. 4. 5. 6. 7. 8.
9.
NOTE
10.
Install a new drill shank into the drill chuck, being sure to align the splines on the shank with those in the chuck and being careful not to damage the seal in the bearing plate behind the chuck driver. Install thrust plate. Slide the water swivel housing into position. Tighten side rod nuts. Torque to 500 ft. lbs. (680 Nm). Connect air/water hose to connection on water swivel housing. Apply a liberal coat of coupling grease to the drill shank threads before attaching the drill rod. Be sure to keep rotation housing of drill greased well (every 2 hours with a hand grease gun). If automatic lubrication system is used, check reservoir daily. It is recommended that a new coupling be used whenever replacing the shank. Grease coupling and shank before drilling.
NOTE
Drilling Procedures
5-33
Notes
5-34
Drilling Procedures
Section 6
6-1
Notes
6-2
If stabilized system temperatures have not been established, the oil can be selected based on anticipated ambient temperature range. AMBIENT OPERATING TEMPERATURE oF (32.2oC) or higher 90 32oF to 90oF (0oC to 32.2oC) 20oF to 32oF (28.9oC to 0oC) Under 20oF (28.9oC) OIL SELECTION DTE 19M or equivalent DTE 18M or equivalent DTE 15M or equivalent Consult Manufacturer ISO EQUIVALENT ISO 150/220 ISO 100 ISO 46
These selections assume "normal operating conditions" as expected in quarry or quarry-like operations. Pioneering and secondary drilling normally result in a lower than average operating temperature; the necessity to drill out of the hole to remove stuck steel, as found in badly broken ground, will result in higher than normal operating temperatures. NOTE Since the determining factor for safe and efcient operation is the viscosity of the oil, nal selection for the oil (or changing the oil) should be based on the stabilized oil temperature in your specic drilling application.
In addition to the viscosity at stabilized oil temperature, we also have to consider viscosity at start-up conditions. Limitations are cavitation of the pumps and sluggish controls, and extended warm-up periods that may be required to avoid pump cavitation and to provide adequate control. Oils with high viscosity index (above 120) are better able to cover a wide range of temperatures. Oils with lower viscosity index may need more frequent change of oil based on ambient temperature or may require an oil heater to improve start-up conditions In general, cold starts may be made at a temperature of at least 30oF (16.9oC) warmer than the pour point of the uid. All cold starts should be made at low pressure, low ow, and low speed.
6-3
Max 10 30 40 30 50 40 50 50
* SAE 10W-30 is the preferred viscosity grade when the ambient temperature is above 0oF (-18oC) and below 104oF (40oC)
NOTE
Since the determining factor for safe and efcient operating is the viscosity of the oil, nal selection for the oil (or changing of the oil) should be based on the stabilized oil temperature in your specic drilling application.
To avoid unnecessary machine repairs, keep the following in mind when handling fuel and lubricants: Clean grease ttings with a clean cloth before greasing. Keep all fuels and lubricants stored in clean and tightly sealed containers. Keep ller caps clean of dust and oil. Replace lters inside a shop or when no dust is in the air. Never reuse paper lters. Wash metal parts of lters with clean oil. Do not wipe the parts with a cloth. Keep dirt and dust from entering any uid system. Keep the fuel storage containers and system lled. Watch for metal lings on any magnetic drain plugs. Filings are a sign of internal component wear or misadjustment. If the source can be determined and repaired as a part of scheduled maintenance, costly down time can be avoided later. Ensure that clean fuel of correct grade for winter/summer is used.
6-4
6-5
Bolt Maintenance
Check torque on bolts after rst 50 hours of machine operation. Retorque any bolts that are less than the specied value as listed in the Bolt Torque Specications sheet at the end of this section or as specied on the assembly drawing. Pay particular attention to critical mounting areas, such as; feed mounting, boom pivot, boom mounting, drill mounting slide, or any areas where loose bolts could cause a component to fall and cause injury or machine damage. Refer to drill service manual for bolt maintenance on drill. Periodically inspect bolts for damage and replace as necessary. Check torque and retorque as required.
6-6
Maintenance Schedule
Interval Hours
Every 2 Hours
Service Points
Drill Chuck End Engine Oil Caterpillar C9 Engine Coolant
Service or Maintenance
Lubricate and Inspect (see Drill Service Manual) Check Level - Rell as required
Lubricant
PG55 Grease, P/N 312810 14 oz. tube *SAE 15W-40 See "Recommended Engine Oils" in this section. Water/Permanent Anti-Freeze 50:50 Ratio Chevron AW MV ISO 100
Capacity
32 Qt. / 30 L
Check Level - Rell as required Check. Drain if required Check Level - Rell as required
12 Gal./ 45.4 L
Engine Fuel/Water Separator Hydraulic Oil Air Compressor Oil Engine Air Filter Air Compressor Air Filter Hydraulic Oil Filters Radiator / Oil Cooler Case Drain Filter Batteries Track Chain Tension
Check Level - Rell as required *Chevron ATF Check - Clean or Change if required Check - Clean or Change if required Check Indicators - Change if required Check - Clean if required Initial Change at 24 hours, thereafter every 500 hours Check Level - Rell as required Check and Adjust as required NLGI No. 2 Grease
Drill Slide Wear Pads Feed Table Wear Pads Feed Table Pivot Pin Dust Collector Filters Detergent "Y" Strainer Track Drive Gearcase Oil Engine Oil Engine Oil Filter Engine Fuel Filter Engine Belts / AC Belts Fuel Tank Engine Coolant Conditioner Feed Motor Gearcase Track Drive Gearcase Oil
Check and Adjust as required Check and Adjust as required Check End Play (0.005 in. max.) Torque Retaining Cap Bolts to 282 ft. lbs. (384 Nm) Check - Replace as required P/N 419090 4.8 Qts./ 4.5 L 32 Qt./ 30 L
Every 500 Service Hours Every 1200 Service Hours Every 1500 Service Hours Every 2400 Service Hours
Check - Clean as required Check Level - Rell as required *HD 80W-90 Gear Oil Drain Oil and Replace *15W-40 Replace P/N V012941 Replace P/N V001775 Check and Adjust Drain Water and Sediment Replace P/N 1405131 Check Level, Rell as required *HD 80W-90 Gear Oil Initial Change, then every 1500 *HD 80W-90 Gear Oil hours Compressor Air Receiver Pres- Check and Adjust sure Dust Collector Air Filters Replace P/N 419090 Canopy Hinges Lubricate SAE 30 wt Oil Hydraulic Rock Drill Check for loose bolts Engine Air Filter Replace P/N 1156422 (P), 1156421 (S) Compressor Air Filter Replace P/N 1157641 (P), 1405631 (S) Compressor Oil Drain Oil and Replace *Chevron ATF Compressor Oil Filter Replace P/N 1157245 Hydraulic Oil Filters Replace P/N 99703 Case Drain Filter Replace P/N 1157245 Feed Table Bushing Check and Replace (if necessary) Engine Fuel/Water Separator Drain and Replace P/N V007584 Fan Hub Inspect Track Drive Gear Case Oil Drain Oil, Flush and Replace *HD 80W-90 Gear Oil Every 12 months Engine Coolant Replace Water/Permanent Anti-freeze 50:50 ratio Hydraulic Oil Drain and Replace *Chevron AW MV ISO 100 Compressor Oil Separator Replace P/N 411747 Element Feed Gear Case Oil Drain and Replace *HD 80W-90 Gear Oil
7 Gal. / 26.5 L
17 Oz./503 ml
6-7
Lube Points
4 4 2 2 4 3 3 2 2 2 3 5 6 5 5 1 10 2 1
Frequency
Every 2 hours Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Monthly Weekly Bi-Monthly 250 hours or 6 months
Notes
PG55 grease * 2 cylinder clevis * 1 upper, 1 lower * * * attaches to mainframe * 2 clevis, 1 pivot pin * each clevis * each clevis * each clevis * 2 mounting blocks, 1 clevis * 3 wrench, 2 cylinder clevis * 3 couplings, 3 bearings ( 1 ea. lower, middle, upper) * 4 rollers, 1 rod lock pin * 4 rollers, 1 rod lock pin PG55 grease or equivalent * See Fig. 6-1 * Special Purpose Grease (SPG) See Fig. 6-2
6-8
Fig. 6-1 Mainframe Lube Points (Viewed from Front of Machine) Right Track Left Track 1. Oscillation Cylinder Top 6. Oscillation Cylinder Top 2. Oscillation Cylinder Bottom 7. Oscillation Cylinder Bottom 3. Inner Frame Track Pivot 8. Inner Frame Track Pivot 4. Middle Frame Track Pivot 9. Middle Frame Track Pivot 5. Outer Frame Track Pivot 10. Outer Frame Track Pivot
6-9
Fig. 6-3 Rear View of Machine 1. Oil Filter 2. Oil Fill Tube 3. Oil Dipstick
6-10
Fuel/Water Separator Drain water from fuel water separator daily (g. 6-5).
Fig. 6-4 Rear View of Machine 1. Fuel Filter 2. Fuel Priming Pump 3. Fuel/Water Separator
6-11
The engine air cleaner should be cleaned when the service indicator (g. 6-7) indicates the lter is clogged (check daily or every 10 hours). There is a service window on the indicator that will gradually turn red as the lter restriction increases to a maximum of 30" of H20. After cleaning the lter, reset the service window to green by pressing the rubber diaphragm on top of the service indicator. To replace or clean the engine air cleaner lter: 1. Shutdown the machine. 2. 3. Undo the clamps and remove the lter cover. The primary and safety element are a press t inside the housing. Carefully move the primary element from side to side and slide the element from the air cleaner housing to avoid dislodging dust from element when removing. Be careful not to knock the element against the side of the housing. Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a poor seal. Check seal area of housing for foreign material or damage. Remove safety element in the same manner. Clean the inside of the housing and vacuator valve with a clean cloth. Clean the primary element (up to 6 times) with water, household detergent or compressed air. Do not use more than 40 PSI (2.8 bar) water or 90 PSI (6.2 bar) air. Install new safety element (if need be) and primary element. Push all the way in and be sure the elements are seated against the back of the housing. Install cover and secure with clamps.
4. 5. 6. 7.
Fig. 6-6 Right Rear of Machine 1. Engine Air Cleaner Filter 2. Dust Collector
6-12 Lubrication and Maintenance
Check lter daily or every 10 hours. To replace the compressor air cleaner lter: 1. 2. 3. Shutdown the machine. Loosen the wingnut and remove the lter cover. Clean inside of lter cover with a clean cloth. Unscrew the wing nut and carefully slide the primary element from the air cleaner housing to avoid dislodging dust from element when removing. Be careful not to knock the element against the side of the housing. Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a poor seal. Check housing for foreign material or damage. Clean the inside of the housing with a clean cloth. Install safety element (if removed) and primary element and secure with wingnuts. Reinstall lter cover.
4. 5.
Fig. 6-9 View From Front of Machine 1. Filter Cover 2. Dust Collector
6-13
1. 2. 3. 4. 5.
Remove lter element with lter wrench. Have a cloth handy to catch any oil that may drain from lter. Clean mounting base and be sure old lter gasket is not stuck to base. Lubricate sealing ring on new lter element with clean oil. Screw on new lter element and tighten by hand only. Check oil level in air receiver tank (g. 6-11). Add oil as required through ller neck (g. 6-10). Normal factory ll is Chevron ATF.
Fig. 6-10 Compressor Oil Filter 1. Oil Filter 2. Oil Filler Neck 3. Air Receiver Tank
6-14
3. 4. 5. 6.
Fig. 6-12 Right Rear View of Hydraulic Tank 1. Hydraulic Oil Filter 2. Oil Fill Pump 3. Oil Inlet 4. Oil Level and Temperature Gauge
Lubrication and Maintenance 6-15
There are two (2) hydraulic lter indicators located on the hydraulic oil return lter housings (g. 6-13). Both indicators should be checked daily. Normal operation is the indicator ring in the Clean (green) zone. If the indicator ring (g, 6-14) falls into the Change (yellow) zone, the lter(s) must be changed. Otherwise, replace the lters at 500 hours (See Service Manual for procedure).
Fig. 6-13 Top of Hydraulic Tank 1. Hydraulic Oil Return Filters 2. Filter Indicators
6-16
Coolant System
DO NOT check coolant level when coolant is hot. KEEP AWAY from rotating fan and belts. DO NOT wear jewelry or loose tting clothing when working around machinery.
Check the radiator, hydraulic oil and compressor oil coolers (g.6-15) daily. Clean out any accumulation of dirt, leaves and other debris that would block air ow through the coolers and cause overheating of the engine. Check coolant level through sight glass (g. 6-16) daily. Add 50/50 mix of water/anti-freeze to shunt tank to proper level if required.
Fig. 6-15 Left Rear View of Machine 1. Radiator/Oil Coolers 2. Radiator Shunt Tank
Fig. 6-16 Radiator Shunt Tank 1. Shunt Tank 2. Coolant Sight Glass 3. Radiator Cap/Coolant Fill Neck
6-17
UNC
UNF
10 (13.6) 20 (27.2) 37 (50.3) 60 (81.6) 90 (122.4) 128 (174.1) 180 (244.8) 315 (428.4) 502 (682.7) 746 (1014.6) 1083 (1472.9) 1509 (2052.2) 2034 (2766.2) 2668 (3628.5)
UN
6-18
Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY
6-19
Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY
6-20
Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY
6-21
Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY
6-22
Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY
6-23
Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY
6-24
Bucyrus Mining Equipment, Inc. 3501 S. FM Hwy 1417, Denison, TX 75020 Telephone 1-800-854-9030 Telefax 1-800-582-6570 within U.S.A.