BI616951
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39HR Blast Hole Drill Manual No. 10395 Feb 2007 Bucyrus International, Inc. BI616951
DANGER:
THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/ OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.
DANGER:
DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.
The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.
THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.
DANGER:
DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.
39HR Blast Hole Drill Feb 2007 Manual No. 10395 Bucyrus International, Inc.
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39HR Blast Hole Drill Manual No. 10395 Feb 2007 Bucyrus International, Inc. BI616951
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39HR Blast Hole Drill Bucyrus International, Inc. Feb. 2007 1 Manual No. 10395
Blast Hole Drill Operator’s Manual Manual No. 10395 sn: 141166 lot 8 Always refer to the safety information in this section of this manual before starting any maintenance procedure on this machine. Table of Contents GENERAL INFORMATION ............................................................................................................5 SAFETY ..................................................................................................................................6 SAFETY PRECAUTIONS ........................................................................................................7 FIRE PREVENTION ..............................................................................................................10 WARNING SIGNS AND DECALS ..........................................................................................11 Standard Warning Signs ...11 Stored Energy Warning Signs .................................................................................................... 12 Machine Overview ......................................................................................................................13 LOWER WORKS .......................................................................................................................14 MAIN FRAME 15 OPERATOR’S CAB....................................................................................................................16 OPERATOR’S SEAT..................................................................................................................17 POWER MODULE......................................................................................................................18 MAST ...........................................................................................................................................19 DRILL STRING COMPONENTS .................................................................................................20 MAST HOIST CYLINDERS ...................................................................................................21 MAST MACHINERY ...............................................................................................................22 HOSE DRUM CARRIER ASSEMBLY....................................................................................23 UPPER WINCH BEAM..........................................................................................................24 LOWER TENSIONING ARM ..................................................................................................24 BREAKOUT WRENCH...............................................................................................................25 TOOL WRENCH.........................................................................................................................26 PIPE RETENTION DEVICE..................................................................................................27 PIPE HANDLING ARM .................................................................................................................28 PIPE CAROUSEL.......................................................................................................................29 FUEL TANKS 30 WATER TANKS..........................................................................................................................31 OPERATION NEAR ELECTRICAL LINES...................................................................................32 STANDARD HAND SIGNALS - CRANE OPERATIONS..............................................................33 BI616951
39HR Blast Hole Drill Bucyrus International, Inc. Manual No. 10395 2 Feb. 2007 OPERATIONAL INFORMATION AND THEORY ..........................................................................36 Typical Tri-Cone Roller Drill Bit Components ...............................................................................37 Carbide Drill Teeth Used For Various Formations .......................................................................38 Formation - Bit Selection Compatibility Chart .............................................................................40 MACHINE SPECIFIC CONSIDERATIONS ..................................................................................41 OPERATOR CONTROLS ..........................................................................................................42 CONTROL CONSOLES AND PANELS......................................................................................42 Operator’s Cab ...........................................................................................................................43 OPERATOR’S DISPLAY............................................................................................................. 44 LEFT CONTROL CONSOLE......................................................................................................44 CONTROLS ON THE LEFT CONTROL CONSOLE......................................................45 RIGHT CONTROL CONSOLE..............................................................................................50 CONTROLS ON THE RIGHT CONTROL CONSOLE....................................................51 AUXILIARY OPERATOR’S CONTROL CONSOLE...............................................................55 MACHINE OPERATION ...............................................................................................................57 DAILY INSPECTION PROCEDURES...................................................................................58 PRESTART LUBRICATION...................................................................................................60 ENGINE START-UP AND SHUT DOWN.....................................................................................61 MACHINERY CHECKS 62 BREAK-IN OF NEW COMPONENTS...................................................................................62 ENGINE SHUTDOWN ...........................................................................................................63 OPERATING PROCEDURES....................................................................................................64 PROPELLING .......................................................................................................................64 Gradual Turns - 15° Increments..................................................................................................66 LEVELING .............................................................................................................................67 MAST RAISING/LOWERING .................................................................................................68 RAISING THE MAST ........................................................................................................68 LOWERING THE MAST..................................................................................................69 PULLDOWN ..........................................................................................................................71 CHECKING THE HOIST BRAKE....................................................................................71 PULLDOWN OPERATION..............................................................................................71 AUXILIARY WINCH ................................................................................................................72 PIPE LOADING AND UNLOADING ........................................................................................73 PREPARATION ...............................................................................................................73 LOADING PIPE ................................................................................................................73 UNLOADING PIPE .................................................................................................................74 PIPE CAROUSEL & HANDLING ARM .........................................................................................76 PIPE CAROUSEL & HANDLING ARM OPERATION.............................................................77 TOOL HANDLING ........................................................................................................................77 TOOL WRENCH...................................................................................................................78 BREAKOUT WRENCH.........................................................................................................79 BI616951
39HR Blast Hole Drill Bucyrus International, Inc. Feb. 2007 3 Manual No. 10395 DRILL TOOL STRING ASSEMBLY..............................................................................................81 ADDING ADDITIONAL DRILL PIPE .......................................................................................87 MULTIPLE SECTIONED DRILL PIPE DISASSEMBLY ..........................................................89 TOOL HANDLING FOR ANGLE DRILLING PROCEDURES................................................90 DRILLING ....................................................................................................................................91 VERTICAL DRILLING ............................................................................................................91 STARTING THE HOLE (COLLARING)............................................................................92 NORMAL DRILLING .........................................................................................................94 ENDING THE HOLE (SINGLE PASS DRILLING) ............................................................96 ENDING THE HOLE (MULTIPLE PASS DRILLING) ........................................................96 DRILLING DIFFICULT FORMATIONS .............................................................................97 UNCONSOLIDATED MATERIALS ...................................................................................97 WET OR STICKY FORMATIONS...................................................................................99 ANGLE DRILLING ...............................................................................................................100 MOVING TO THE NEXT HOLE LOCATION..................................................................101 DRILL STABLILITY CHART .......................................................................................................102 MACHINE SHUTDOWN ............................................................................................................103 NORMAL SHUTDOWN .......................................................................................................103 MACHINE STORAGE ................................................................................................................105 SHORT TERM STORAGE..................................................................................................105 LONG TERM STORAGE....................................................................................................106 ATTENDED LONG TERM STORAGE................................................................................106 UNATTENDED LONG TERM STORAGE...........................................................................107 TYPICAL OPERATING SPECIFICATIONS ................................................................................108 TYPICAL MACHINE SPECIFICATIONS .....................................................................................109 GENERAL ESTIMATED COMPONENT WEIGHTS..................................................................111 SAMPLE DISPLAY SCREENS............................................................................................ (insert) FAULT CODES................................................................................................................... (insert) BI616951
39HR Blast Hole Drill Bucyrus International, Inc. Manual No. 10395 4 Feb. 2007 BI616951
39HR Blast Hole Drill Operator’s Manual
GENERAL INFORMATION
This manual is designed to assist the owner in the operation and preventive 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. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.
RIGHT and LEFT refer to machine locations as viewed by the operator with the mast as the rear of the machine and the engine on the left side.
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 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, the 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 direct to you 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 53172-0500, USA
Telephone (414)-768-4000Fax: (414) 768-4210
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 it’s machines at any time. This will be without incurred obligation 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.
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SAFETY
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 there are questions or concerns on safely performing 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 or assets, or 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 be alert, and must have 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.
Safety must always be paramount!
Consult your supervisor when safety is in doubt.
39HR Blast Hole Drill Bucyrus International, Inc. Manual No. 10395 6 Feb. 2007
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SAFETY PRECAUTIONS
Following the precautions listed below will help to safely maintain or operate any equipment in general.
General Precautions:
•The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment.
•Keep hands, feet and clothing away from rotating parts.
•Wear a hard hat, safety shoes and protective lenses at all times.
•Replace any and all safety and warning placards if they are defaced or removed from the machine.
•Think before you act. Carelessness is one luxury the service person cannot afford.
•Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.
•Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if they are not functioning properly.
•If a heavy item begins to fall, let it fall, don’t try to catch it.
•Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.
•Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.
•Electrical cords and wet metal floors make a dangerous combination.
•Regularly inspect for any loose bolts or locking devices and properly secure them.
•Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified.
•Check limit switches for proper operation.
•After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area.
•Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only.
•Use proper interior and exterior lighting.
•Install and maintain proper grounding and ground fault protection systems.
•Allow electrical inspection and maintenance to be performed only by a qualified electrician.
•Use extreme caution when working around drilled holes.
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Maintenance Precautions:
•Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.
•Always wear a safety belt or harness when the danger of falling exists.
•Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.
•Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance.
•Equipment should be parked on level ground at all times during machine servicing and periods of idleness.
•Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, pipe arms, etc.) Always work within the limitations of the equipment being utilized.
•Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.
•Utilize guide lines or ropes to minimize the swing of suspended heavy components.
•Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.
•Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.
•When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.
•When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.
•Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and drifts only when absolutely necessary. Always be sure to wear safety glasses.
•Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.
•Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.
•Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.
•Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.
•Always wear approved rubber gloves and use insulated hooks or tongs when handling trail cable.
39HR Blast Hole Drill Bucyrus International, Inc. Manual No. 10395 8 Feb. 2007
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Operating Precautions:
NOTE: Permissible Noise Exposure (OSHA Standard 1910.95)
•Wear hearing protection when exposed to the following noise levels in excess of the period indicated:
8 hours at 90 dBa
4 hours at 95 dBa
2 hours at 100 dBa
1 hour at 105 dBa
30 minutes at 110 dBa
15 minutes at 115 dBa
•When in doubt about the noise level, wear approved hearing protection.
•Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine.
•Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine.
•Do not allow personnel on board the machine while it is in operation.
•Do not operate the machine with personnel on the deck or within 5 feet of the machine.
•Use audible signals to warn of machine movements. A signal horn button is provided for this purpose.
•Do not propel until the travel route has been cleared of obstructions.
•Do not propel the machine on a slope greater than that specified in Section 2 ~ OPERATION in this manual.
39HR Blast Hole Drill Bucyrus International, Inc. Feb. 2007 9 Manual No. 10395
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• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
