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Safe operation of a rotary blast hole drill promotes personal safety and minimizes delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to help prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon a good sense of judgement and alertness on the part of the entire mining crew.
The following is a list of some important safety rules relating to prestart and operation of the (iO Gl-R drill. The safety instructions gi ven in this manual cover normal daily operations of the machine. Additional precautions may be necessary to cover un usual circumstances. Be constantly alert for any potentially dangerous conditions and take action as necessary to correct the conditions immediatl'l,v.
• Wear hard hat, safety shoes and safety glasses at all times.
When operating or performing maintenance functions. wear snug fitting clothing. l,oose clothing can be caught on controls or in moving parts. !{emove all jewelry.
Keep the operator's cab, ladders. walkways and steps free of materials which cause slippery conditions or obstacles which create tripping hazards.
Use proper interior and exterior Iigh ting·.
Do not allow unauthorized personnel on board the machine while in operation.
Do not begin operation until all persoIl!wl an' clear of the machine or in a safe position on the machine.
Use audible signals to warn of machine movements. A signal horn button is provided for th is purpose.
Do not propel until the travel route has I)('en cleared of obstructions,
• Ensure that all personnel are clear of the machine when propelling.
• • •
Do not propel the machine on a slope greater than specified in the stability limits in appendix.
Do not lea ve the rotary gearbox suspended in the air when leaving the machine unattended.
Always wear approved rubber gloves, and use insulated hooks or tongs when handling trail cable.
Install and maintain proper grounding and ground fault protection systems.
Allow electrical inspection and maintenance to be performed only by a qualified electriClan.
Prevent trail cable from being dragged on the ground for long distances or at high speeds.
Limit the amount of cable being dragged by the machine. Pulling too much cable will damage both the cable and the machine.
Use extreme caution when working around loaded blast holes.
*Permission to reproduce the following material has been granted by the Construction Industry Manufacturers Association (eIMA). eIMA assumes no responsibility for the accuracy of this reprod llction.
AC.'AUTION: The following precautions shall be complied with whenever operating near electrical transmission lines.
Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual you arc considered to be working in the vicinity of power lines when the machine, in any position, can reach to within the minimum distance specified by local, state and federal regulations.
Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.
Be certain to comply with all local, state and federal regulations regarding working in the vicinity of power lines.
Before working in the vicinity of power lines, always take the following precautions:
1. Always contact the owners of the power lines or the nearest electric utility before beginning work.
2. You and the electric utility representative must jointly determine what specific precautions must be taken to insure safety.
i). It is the responsibility of the user and the electric utility to see that the necessary precautions are taken.
4. Consider all lines to be power lines and treat all power lines as energized even though it is known that the power is shut off and the line is visibly grounded.
;). Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.
G. Caution all ground personnel to stand clear of the machine at all times.
7. Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.
h CAUTION: Death or serious injury could result should any part of the drill come within the minimum distance specified of an energized power line.
Before starting the drill, inspect it to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example, an undetected oil leak could result in a dry gear case, which would lead eventually to excessive gear wear or destruction, seized bearings, or other problems. A few minutes spent inspecting the machine often
results in considerable savings in time and machine efficiency. This inspection should be performed before each shift.
1. Check areas around and under the machine for signs of oil, water, or grease leaks. If single droplets are noticed, leakage is minimal. Determine the source of the leak and make note of it on the log sheet. If pooling of oil, water, or grease is noticed, determine the source and taKe remedial action immediately.
2. Inspect the crawler belts for broken or cracked pads, missing lock pins, loose track pins, and proper crawler belt tension.
it Inspect the drive chains for missing or broken pins and proper tension. Inspect the sprockets for loose or missing keeper bolts and broken or cracked teeth.
4. Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and bolts.
5. Inspect the dust enclosure for loose or broken cables. Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or covered with cuttings.
G. Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp rocks. Have an electrician inspect the strain relief device and thecondition of the cable where it enters the machine.
h CAUTION: The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with approved rubber gloves and insulated hooks or tongs.
7. Inspect the dust hoppers and ducts of the dust control unit. All seals and doors should be intact. Empty the dust hoppers and clean the ducts if necessary.
8. Drain both air receivers of condensation. It is necessary to go underneath the machine to do this. At this time inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or da mage. lfloose wires are noted do not touch them but notify an electrician imme>elia
FIGURE 1
the jack spuds covering. for cracks, hroken or missing dirt locking ers for uhrication or
.............. 14
.............. 14
3
defective components immediately. Verify that all adjusting bolts are properly adjusted.
h CA UTION: Use a safety belt and .. lanyard to protect against falls when climbing on the back braces or working on the machinery house roof.
immediately. Verify CA belt and .. lanyard to when climbing on the roof.
I:!. nsped mast ng keepers or bol ts. dam-
I:!. I nsped the mast hinge pi ns for loose or missi ng keepers or bolts. ]{eplace missi ng or dam-
9. Inspect the leveling jack spuds for proper grease covering. Inspect the leveling jack pads for cracks, hroken or missing pins, or excessive dirt accumulation.
10. Inspect the mast locking wedges and cylinders for proper I uhrication or damage.
11. On machines equipped with hack braces inspect the hack braces, locking pins, retainer pins and cotter pins. Heplace missing or
hack hack braces, retainer cotter missing
agee! parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.
(Figures 2, a, 4, 5, 6)
sary.
1:3. Inspect the mast hoist cylinders for loose or missing pins or keepers, oil leaks, damaged hoses or structural damage. Repair or replace any missing or damaged components immediately.
missing pins keepers, damaged any missing or damaged imme-
14. Inspect the mast structure for bent or broken chords or plates, loose or broken parts, proper rack lubrication or excessive rack wear. Inspect ladders, handrails and platforms for broken or missing parts. Repair or replace broken or missing parts immediately.
15. Check the main air flex hose, grease lines, and electric lines running from the mast to the rotary drive unit for interference with the mast or excessive wear or leaks.
16. Check the safety restraint cables on the mast. Be certain that the cables and supports are in good repair with no cracks, missing or loose hardware or any damage that could affect their effecti veness.
14. the mast structure for bent or broken broken or missing Repair or replace mast to the drive unit for interference with the or excessive wear or leaks. supports hardware or any damage that could affect upper sprockets auxiliary
17. Every 160 hours inspect and lubricate the upper chain sprockets and auxiliary reel sheaves. All pins, keepers and hardware should be secured tightly.
1. Check the oil levPl in the auxiliary air compressor. Add oil to the proper level if necessary. Check the drive belts for proper tension, excessive wear or broken belts. Verify proper adjustment when new belts have been installed.
auxiliary sary. Check the drive belts for proper tension, proper
h. CAUTION: Do not remove the belt guard unless the air compressor switch in the operator's cab has been turned off and the breaker on the control cabinet in the machinery house has been turned off, locked out and tagged. Serious injury could result if the compressor should start while servicing the compressor belts.
the compressor belts.
2. During freezing weather add alcohol to the antifreezer (if equipped).
/") CAUTION: Serious personal injury will result if the fill plug of the antifreezer is removed with pressure in the system. Relieve all pressure from the air system and shut off the air compressor before servicing this unit.
tem. Relieve from the system air
ON-BOARD INSPECTION
(TYPICAL PLAN WITH VANE COMPRESSOR) DRIVE
(TYPICAL DECK PLAN WITH VANE COMPRESSOR) ELECTRIC DRIVE FIGURE 2
h CAUTION: Alcohol is flammable. Do .. not use alcohol while smoking or near possible ignition sources. Consult the alcohol distributor for specific safl·ty precautions. Store alcohol in an approved metal container outside of the machinery house.
CAUTION: not use alcohol while smoking or near possible ignition distributor specific safl,ty precautions. approved metal container outside house.
:i. Check the tension on tlw drive belts of the malI1 aIr compressor. Check the belts for cracks or wear.
Check the tension drive belts of the malI1 compressor. Check the belts for wear.
h CAUTION: Donotremoveguardunless .. the control power breaker in the machinery house has been locked in an offposition and the compressor test started to verify that the compressOl' will not start. Serious personal injury will result if the compressor starts while the drive helts are heing serviced.
the control power breaker in the malocked test started will not start. Serious personal injury will result if the compressor heing viced.
4. Inspect the main air compressor lubricaiton lines for leaks. ('orrect an:,' leaks found immediately.
4. Inspect compressor lines leaks. ('orrect immediately.
i). Check the oil level in the main aircompressor lubricator. Fill the lubricator to the top of the upper window with an appro\·f·d oil. Hand crank the I ubrica tor to veri fy 0 [wra tion ofthe injectors. (vane compressor)
lubricator. Fill the of apprO\·(·d Hand crank lubricator to verify o[wration injectors. (vane compressor)
G. Check the condition of the main ;Iir COlnpresSOl' intake filter. Heplace til(' Ciltt'l' cdrt ridgf' if
G. Check of ;Iir COlnpresSOl' intake Ciltt'l' ridg('
the red nag is visible in the service indicator . Empty the dust hopper and clean the precleaner element. Inspect the housing and ductwork for damage or IPaks. Hepair or replace leaking components.
the nag in dust hopper and clean the precleaner element. Inspect and ductwork damage or IPaks. Hepair or replace leaking components.
,. Check the oil level in the hydraulic tanks. Fill the tanks to the proper as described on the instruction plate on the tank.
Check the oil level in the hydraulic tanks. Fill the tanks to as the instruction plate on the tank.
('heck the hydraulic system for leaks. Correct all leaks immediatel:,' ,md clean up all oil spills immedial('/y .
('heck the hydraulic system for leaks. all leaks immediatel:,' ,md clean up all oil immedial('/y
is with:l tor for main ;lir lubricator is full. lIand crank the lubricator to verify oper;ltiotl central pumping for prop(']' operation. the or refill
If til(' machine is equipf'IHj with:l bit lubricator for the main ;lir system, check that the lubricator is full. lIand crank the lubricator to verify oper;ltiotl of the injector.
!O. Inspect the ,1ll!Otrl;ltic lubrication central pumping stations for propN operation. Check the supply of lubric,mt and change or refill drums as Iwcess:I/'Y.
I!. Close and lock all deetrical cabinet doors.
h CAUTION: Assume all parts inside of the electrical cabinets to be energized. All electrical components should he serviced by qualified dedl'jcal personnel only.
I!. Closp lock all parts the components dedl"jcal personnel only.
12. Inspect the compressor radiator and fan. C:heck for signs of deterioration or damage to hoses, valves, fitting, etc. Check for leaks at all joints. Check the radiator core for blockage by dust, dirt, leaves, paper, etc. and dean as necessary.
to
all joints. Check the radiator core for blockdust, dirt, leaves, 1:). service before the
1:). Check the phase sequence indicator light. If the lamp is not lit contact qualified electrical service personnel before starting the machine.
14. For diesel powered machines conduct the prestart inspections as required by the engine manufacturer.
if). Inspect the machinery house for general cleanliness. Clean all dirt and debris from the machinery house.
WARNING: Do not to clean the house. air will only move the dirt around. a vacuum
house will cause to of the com-
WARNING: Do not use compressed air to clean the machinery house. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the machine. Failure to clean the inside of the machinery house will cause damage to many of the components located there.
Check the coolant level in the air tor. t to
16. Check the coolant level in the air compressor radia tor. Add coolan t as req uired to fill the radiator.
CA.UTION: Remove the radiator cap slowly and use suitable protection against escaping steam to prevent serious injury.
the radiator cap
steam to prevent nspect auxiliary auxiliary and auxiliary reel line.
17. I nspect the auxiliary reel, auxiliary reel brake and auxiliary reel line.
1K. in
1K. Check the oil level in the hoist-propel gear case. Fill with recommended oil to the proper level.
19. Inspect ment,
19. Inspect the hoist brake for proper adjustment, excessive band wear, proper band alignment, loose or broken linkage, missing keeper pins, etc. Repair or replace missing or damaged parts immediately.
20. Inspect the pulldown chains and sprockets for bent or missing links, proper lubrication, proper timing and excessive wear or dirt buildup.
21. Inspect the intermediate propel chains for proper adjustment, bent or broken links, or excessive wear or dirt buildup. Inspect the propel brakes for proper adjustment, excessive band wear, loose or broken linkage, missing keeper pins, etc. Repair or replace missing or damaged parts immediately.
20. the pulldown chains and sprockets the intermediate propel chains for buildup. the propel brakes for proper adjustment, wear, parts
ON-BOARD INSPECTION
(TYPICAL DECK PLAN WITH SCREW COMPRESSOR)
DI=lIVE
ELECTRIC DI=lIVE FIGURE 4
2:L rnspect the area around the hoist-propel gear case for oiL grease or air leaks or other missing or damaged equipment.
2cL Inspect the pulldown chain equalizer cylinder for leaks or damage. Make sure that the ram has not extended to the maximum stroke oUi inches. If the ram is bottomed out, the pulldown chains will have to be shortened before starting the drill.
2:L around the hoist-propel gear or air or damaged the chain equalizer cylinder for damage. Make that not to of(i If the bottomed the to the
2:-). I nspect the area behind the operator's pamd for oil. air or leaks.
2(j. Check all controls for free operation. [{eturn all controls to the "off' or "set" position.
27. Inspect the operator's cab for housekeeping and cleanliness. Clean dirt and debris from the cab. Clean the windows to give full visibility for proper operation.
2:-). the the or Check controls for operation. all to the "off' the for housekeeping Clean dirt debris operation.
WAHNING: Do not use the will dirt cleaner to the the tool wrenches missing parts, oil or accumulation.
WAHNING: Do not use compressed air to clean the operator's cab. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the cab.
28. Inspect the tool wrenches for free operation, broken or missing parts, proper lubrication, oil leaks or dirt accumulation. H.epair or rep!:lce parts m; !wcessary and clean the drilling platform.
Before working under the rotary drive unit, make sure the off and brake prevent movement injury or should the rotary unit fall personnel
h CAUTION: Before working near or under the rotary drive unit, make sure all of the operator's controls are off and tagged and the hoist brake set to prevent movement ofthe unit. Serious personal injury or death could result should the rotary drive unit fall when personnel are working near or under it.
29. the tong proper oil or dirt accumulation. necessary.
cylinder is properly way of t he case Be certain tong is
29. Inspect the casing tong and breakout cylinder for free operation, broken or missing parts, proper lubrication, oil leaks or excessive dirt accumulation. Repair or replace parts as necessary. Be certain that the breakout cylinder is stored properly out of the way of t he rotary gear case and fully retracted. Be certain that the casing tong is secured out of the way.
:50. Inspect the tool racks for broken or missing parts, proper operation, dirt accumula tion, or oil leaks. Be certain' that the pipe gate is closed and that the rack is in retracted position and locked.
:\1. Inspect tlw guide bushing for excessive wear or dirt accum ula tion. Also inspect the retainer Iugs to be sure they are intact. Do not operate
broken dirt tion, oil Be that closed is position til(' guide excessive or tion. the retainer Iugs operate
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