49R3ncbr R 49RIII BLAST HOLE DRIL L OPERATOR’S MANUAL 10258 49RIII BLAST HOLE DRIL L Manual No. SN: 141139 SN: 141138 Bucyrus International, Inc. 1100 Milwaukee Ave. • P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA 10258 OPERATOR’S MANUAL 2 BI616871
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49RIII Blast Hole Drill
IMPORTANT NOTE
This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.
Dec. 2004 49RIII Electric Blast Hole Drill 1 Manual No. 10258 Bucyrus International, Inc.
Operator’s Manual Manual No. 10258 sn: 141138, Lot: 65 sn: 141139, Lot: 67 Table of Contents GENERAL INFORMATION ............................................................................................................5 SAFETY ..................................................................................................................................6 SAFETY PRECAUTIONS ........................................................................................................7 FIRE PREVENTION CONSIDERATIONS...................................................................................10 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS............................11 WARNING SIGNS AND DECALS ..........................................................................................14 Stored Energy Signs ......15 OPERATION NEAR ELECTRICAL LINES.............................................................................16 PRESTART CHECKS.................................................................................................................17 EXTERNAL INSPECTION .....................................................................................................17 ONBOARD INSPECTION.....................................................................................................19 PRESTART LUBRICATION...................................................................................................22 CONTROLS - LOCATION AND FUNCTION..............................................................................22 OPERATOR’S CONTROLS CONSOLE....................................................................................23 OPERATOR’S CONTROL CONSOLE - OVERVIEW ..................................................................23 MAIN CONTROL PANEL .......................................................................................................24 MAIN CONTROL PANEL - OVERVIEW.....................................................................................24 HOIST/PULLDOWN RHEOSTAT....................................................................................24 ROTARY RHEOSTAT.....................................................................................................25 DRILL/PROPEL CONTROLS ON AND OFF PUSH-BUTTON.......................................25 HOIST/PULLDOWN SPEED SELECTOR SWITCH......................................................26 ROTARY SPEED SELECTOR SWITCH........................................................................26 HOIST BRAKE SWITCH.................................................................................................27 PIPE RACK SELECTOR SWITCH.................................................................................27 PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL)...................................................27 WINCH/MAST SELECTOR SWITCH..............................................................................27 MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL)..............................................28 TOOL WRENCH SWITCH..............................................................................................28 DUST CURTAIN SWITCH...............................................................................................29 BIT VIEW HATCH SWITCH.............................................................................................29
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Bucyrus International, Inc. All Rights Reserved.
Manual No. 10258 49RIII Electric Blast Hole Drill 2 Dec. 2004 Bucyrus International, Inc. PROPEL CONTROL PANEL................................................................................................30 PROPEL CONTROL PANEL - OVERVIEW...............................................................................30 EMERGENCY STOP PUSH-BUTTON (OPTIONAL)......................................................30 PROPEL SPEED SELECTOR SWITCH........................................................................30 COMPRESSOR STOP PUSH-BUTTON........................................................................31 COMPRESSOR VENT/DRILL SWITCH.........................................................................31 HEATER/VENT/AIR CONDITIONER CONTROLS..........................................................31 OPERATING MODE SELECTOR SWITCH....................................................................31 PROPEL JOYSTICKS.....................................................................................................31 SELECTOR SWITCH PANEL...............................................................................................32 SELECTOR SWITCH PANEL - OVERVIEW.............................................................................32 BREAKOUT WRENCH SWITCH....................................................................................33 PIPE POSITIONER SWITCH (OPTIONAL)....................................................................33 DUST SEAL SWITCH (OPTIONAL)................................................................................33 A-FRAME LOCK SWITCH (OPTIONAL).........................................................................33 MAST BRACE LOCK SWITCH.......................................................................................33 MAST LOCK SWITCH....................................................................................................34 BOARDING STAIRS SWITCH.........................................................................................34 PEDESTAL HEATER SWITCH (OPTIONAL)..................................................................34 FIRE SUPPRESSION SYSTEM INDICATORS (OPTIONAL)..........................................34 RADIO .............................................................................................................................34 LEVELING CONTROL PANEL ..............................................................................................35 LEVELING CONTROL PANEL ...................................................................................................35 MANUAL LEVELING JOYSTICKS ....................................................................................36 AUTOMATIC LEVELING SWITCH ...................................................................................36 WATER INJECTION ON/OFF SWITCH (OPTIONAL).....................................................36 WATER INJECTION FLOW CONTROL (OPTIONAL)....................................................36 HORN PUSH-BUTTON...................................................................................................37 DEPTH INDICATOR RESET PUSH-BUTTON................................................................37 PROGRAMMED DRILL CONTROL SWITCH.................................................................37 EMERGENCY STOP PUSH-BUTTON (OPTIONAL)......................................................37 OPERATOR’S DISPLAY TERMINAL.....................................................................................38 OPERATOR’S DISPLAY PANEL ................................................................................................38 MACHINERY HOUSE CONTROLS ......................................................................................39 LIGHTING LOAD CENTER ..............................................................................................39 LIGHTING LOAD CENTER ........................................................................................................39 CONTROLS LOCATED ON LOW VOLTAGE START CABINET....................................40 TYPICAL LOW VOLTAGE START CABINET............................................................................40 CONTROLS LOCATED ON LOW VOLTAGE CABINET.................................................40 TYPICAL LOW VOLTAGE CABINET .........................................................................................40 CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET.....................41 TYPICAL PROGRAMMABLE CONTROL CABINET ...................................................................41 BI616871
Dec. 2004 49RIII Electric Blast Hole Drill 3 Manual No. 10258 Bucyrus International, Inc. HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS...............................41 TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS...........................41 CONTROLS LOCATED ON OR NEAR AIR COMPRESSOR........................................42 AIR COMPRESSOR MOUNTED CONTROLS ............................................................................42 MISCELLANEOUS CONTROLS.....................................................................................42 PORTABLE REMOTE PROPEL STATION (OPTIONAL)................................................42 PORTABLE REMOTE PROPEL STATION .................................................................................43 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL......................................43 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................................................43 LUBE CONTROL PANEL................................................................................................44 LUBE CONTROL PANEL ...........................................................................................................44 START-UP...................................................................................................................................45 MACHINE START UP............................................................................................................45 MACHINERY CHECK ......................................................................................................46 BREAK-IN OF NEW COMPONENTS.............................................................................46 ROTARY DRIVE UNIT BREAK-IN.............................................................................46 HOIST/PULLDOWN GEARCASE BREAK-IN...........................................................46 ELECTRIC MOTOR BREAK-IN................................................................................46 OPERATION ...............................................................................................................................47 PROPELLING .......................................................................................................................47 DEFINITIONS ..................................................................................................................47 PROPEL PROCEDURE .................................................................................................48 PROPEL CONTROLS - OVERVIEW .........................................................................................49 STRAIGHT PROPEL .................................................................................................................50 GRADUAL RIGHT HAND TURN .................................................................................................50 GRADUAL LEFT HAND TURN ...................................................................................................51 COUNTER-ROTATION LEFT HAND TURN ................................................................................52 ENSURE GRADUAL TURNS ARE MADE - 15o INCREMENTS ................................................52 TOWING PROCEDURE.................................................................................................54 TOWING PROCEDURE .............................................................................................................54 CABLE REEL OPERATION..................................................................................................56 CABLE REEL............................................................................................................................56 LEVELING .............................................................................................................................57 MACHINE ORIENTATION ..........................................................................................................57 LEVELING CONTROLS .............................................................................................................58 MAST RAISING AND LOWERING .........................................................................................59 MAST RAISING ................................................................................................................59 MAST RAISING/LOWERING CONTROLS .................................................................................60 MAST LOWERING ..........................................................................................................61 MAST CONTROLS TO ADJUST FOR ANGLE DRILLING ..........................................................61 BI616871
Manual No. 10258 49RIII Electric Blast Hole Drill 4 Dec. 2004 Bucyrus International, Inc. PULLDOWN MACHINERY OPERATION..............................................................................63 HOIST/PULLDOWN CONTROLS ...............................................................................................63 AUXILIARY WINCH OPERATION ..........................................................................................64 WINCH OPERATION CONTROLS .............................................................................................64 PIPE RACK OPERATION...............................................................................................65 PIPE RACK OPERATING CONTROLS ......................................................................................65 PIPE RACK OPERATION..........................................................................................................66 TOOL HANDLING ..................................................................................................................68 PIPE LOADING AND UNLOADING ..................................................................................68 DRILL TOOL STRING ASSEMBLY..................................................................................70 TOOL STRING ..........................................................................................................................70 STABILIZER INSTALLATION .....................................................................................................71 DRILL PIPE INSTALLATION CONTROLS ..................................................................................71 BREAKOUT WRENCH OPERATION...................................................................................74 DRILL TOOL STRING DISASSEMBLY..................................................................................76 ADDING ADDITIONAL DRILL PIPE ..................................................................................78 REMOVAL OF MULTIPLE SECTION DRILL PIPE...........................................................79 ANGLE DRILLING .................................................................................................................80 ANGLE DRILLING EQUIPMENT ................................................................................................80 PIPE POSITIONER ...81 JIB CRANE ..........82 DUST SUPPRESSION SYSTEM OPERATION....................................................................83 WATER INJECTION SYSTEM..................................................................................................84 DRILLING ..............................................................................................................................85 VERTICAL DRILLING ......................................................................................................85 CONTROLS UTILIZED WHILE DRILLING .................................................................................85 STARTING THE HOLE (COLLARING)......................................................................86 NORMAL DRILLING ...................................................................................................88 ENDING THE HOLE..................................................................................................89 ENDING THE HOLE (MULTIPLE PIPE SECTIONS).................................................90 DRILLING DIFFICULT FORMATIONS .............................................................................90 UNCONSOLIDATED MATERIALS ...................................................................................91 WET OR STICKY FORMATIONS.........................................................................................93 ANGLE DRILLING .................................................................................................................94 PROGRAMMED DRILL CONTROL DRILLING .....................................................................95 PROGRAMMED DRILL CONTROLS UTILIZED .........................................................................95 PREPARING TO MOVE..................................................................................................96 MACHINE SHUTDOWN ........................................................................................................98 SHUT DOWN PROCEDURE...................................................................................98 SHORT TERM STORAGE........................................................................................99 LONG TERM STORAGE.........................................................................................100 ATTENDED LONG TERM STORAGE....................................................................101 UNATTENDED LONG TERM STORAGE................................................................101 TOOL RECOVERY...................................................................................................................102 DRILL STABILITY CHART .........................................................................................................104 BI616871
49RIII Blast Hole Drill Operator’s Manual
GENERAL INFORMATION
This manual is designed to assist the owner in the operation and maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative.
Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed directly from the factory. Should you require additional information or factory service assistance contact your regional service representative or:
Bucyrus International, Inc.
1100 Milwaukee Avenue
P.O. Box 500
South Milwaukee, Wisconsin, USA53172-0500
Telephone (414)-768-4000
It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously.
Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.
Dec. 2004 49RIII Electric Blast Hole Drill 5 Manual No. 10258 Bucyrus International, Inc.
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The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine.
Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used.
NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.
CAUTION:This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.
DANGER:This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.
DANGER:This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.
Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.
CAUTION: STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/ordamage to the front-end of the machine.
Safety must always be paramount!
Consult your supervisor when safety is in doubt.
Manual No. 10258 49RIII Electric Blast Hole Drill 6 Dec. 2004 Bucyrus International, Inc.
SAFETY
BI616871
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