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49HR Blast Hole Drill
April 2008 49HR Blast Hole Drill 1 Manual No. 10623 Bucyrus International, Inc.
Operator’s Manual Manual No. 10623 sn: 141290 Lot 91 Table of Contents GENERAL INFORMATION ............................................................................................................3 SAFETY PRECAUTIONS ........................................................................................................4 FIRE PREVENTION CONSIDERATIONS.....................................................................................7 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS..............................8 WARNING SIGNS AND DECALS................................................................................................10 Stored Energy Signs ..................................................................................................................12 OPERATION NEAR ELECTRICAL TRANSMISSION LINES.................................................13 MACHINE OVERVIEW ................................................................................................................14 PROPEL MACHINERY ..........................................................................................................15 MAIN FRAME AND DECKS ...................................................................................................16 MACHINERY HOUSE ............................................................................................................17 MAIN AIR SYSTEMS ..............................................................................................................18 Air Compressor ..........................................................................................................................18 HYDRAULIC SYSTEM ...........................................................................................................19 OPERATOR’S CAB..............................................................................................................20 MAST .....................................................................................................................................20 Mast/Machinery ..........................................................................................................................21 ROTARY GEARCASE...........................................................................................................22 PULLDOWN GEARCASE.....................................................................................................23 DRILL TOOL STRING ASSEMBLY........................................................................................24 BREAKOUT WRENCH.........................................................................................................25 CABLE REEL........................................................................................................................25 CONTROLS - LOCATION AND FUNCTION..............................................................................26 OPERATOR’S CONTROL CONSOLE.......................................................................................27 OPERATOR’S CONTROL CONSOLE - OVERVIEW ..................................................................27 MAIN CONTROL PANEL .......................................................................................................27 MAIN CONTROL PANEL - OVERVIEW.....................................................................................28 HOIST/PULLDOWN RHEOSTAT....................................................................................28 ROTARY RHEOSTAT.....................................................................................................29 DRILL/PROPEL CONTROLS ON AND OFF PUSH-BUTTON.......................................29 HOIST/PULLDOWN SPEED SELECTOR SWITCH......................................................30 ROTARY SPEED SELECTOR SWITCH........................................................................30 HOIST BRAKE SWITCH.................................................................................................31 PIPE RACK SELECTOR SWITCH.................................................................................31 PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL)...................................................31
NOTE
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. © 2008 Bucyrus International, Inc. All Rights Reserved. BI619434
IMPORTANT
This
Manual No. 10623 49HR Blast Hole Drill 2 April 2008 Bucyrus International, Inc. WINCH/MAST SELECTOR SWITCH..............................................................................32 MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL)..............................................32 TOOL WRENCH SWITCH..............................................................................................33 DUST CURTAIN SWITCH...............................................................................................33 BIT VIEW HATCH SWITCH.............................................................................................33 PROPEL CONTROL PANEL................................................................................................34 PROPEL CONTROL PANEL - OVERVIEW...............................................................................34 EMERGENCY STOP PUSH-BUTTON (OPTIONAL)......................................................34 PROPEL SPEED SELECTOR SWITCH........................................................................35 COMPRESSOR STOP PUSH-BUTTON........................................................................35 COMPRESSOR VENT/DRILL SWITCH.........................................................................35 HEATER/VENT/AIR CONDITIONER CONTROLS..........................................................35 OPERATING MODE SELECTOR SWITCH....................................................................35 PROPEL JOYSTICKS.....................................................................................................36 SELECTOR SWITCH PANEL...............................................................................................36 SELECTOR SWITCH PANEL - OVERVIEW.............................................................................36 BREAKOUT WRENCH SWITCH....................................................................................37 PIPE POSITIONER SWITCH (OPTIONAL)....................................................................37 DUST SEAL SWITCH (OPTIONAL)................................................................................37 A-FRAME LOCK SWITCH (OPTIONAL).........................................................................37 MAST BRACE LOCK SWITCH.......................................................................................37 MAST LOCK SWITCH....................................................................................................38 BOARDING STAIRS SWITCH.........................................................................................38 PEDESTAL HEATER SWITCH (OPTIONAL)..................................................................38 FIRE SUPPRESSION SYSTEM INDICATORS (OPTIONAL)..........................................38 RADIO (OPTIONAL) ........................................................................................................38 LEVELING CONTROL PANEL ..............................................................................................39 LEVELING CONTROL PANEL ...................................................................................................39 MANUAL LEVELING JOYSTICKS ....................................................................................40 AUTOMATIC LEVELING SWITCH ...................................................................................40 WATER INJECTION ON/OFF SWITCH (OPTIONAL).....................................................40 WATER INJECTION FLOW CONTROL (OPTIONAL)....................................................40 HORN PUSH-BUTTON...................................................................................................41 DEPTH INDICATOR RESET PUSH-BUTTON................................................................41 PROGRAMMED DRILL CONTROL SWITCH.................................................................41 EMERGENCY STOP PUSH-BUTTON (OPTIONAL)......................................................41 OPERATOR’S DISPLAY TERMINAL.....................................................................................42 OPERATOR’S DISPLAY PANEL ................................................................................................42 MACHINERY HOUSE CONTROLS ......................................................................................43 LIGHTING LOAD CENTER ..............................................................................................43 LIGHTING LOAD CENTER ........................................................................................................43 CONTROLS LOCATED ON LOW VOLTAGE START CABINET....................................44 TYPICAL LOW VOLTAGE START CABINET............................................................................44 CONTROLS LOCATED ON LOW VOLTAGE CABINET.................................................44 TYPICAL LOW VOLTAGE CABINET .........................................................................................44 CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET.....................45 TYPICAL PROGRAMMABLE CONTROL CABINET ...................................................................45 HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS...............................45 TYPICAL HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS...........................45 BI619434
April 2008 49HR Blast Hole Drill 3 Manual No. 10623 Bucyrus International, Inc. MISCELLANEOUS CONTROLS.....................................................................................46 PORTABLE REMOTE PROPEL STATION (OPTIONAL)................................................46 PORTABLE REMOTE PROPEL STATION .................................................................................46 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL......................................47 HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ...................................................47 LUBE CONTROL PANEL................................................................................................47 LUBE CONTROL PANEL ...........................................................................................................47 PRESTART CHECKS.................................................................................................................48 EXTERNAL INSPECTION .....................................................................................................48 ONBOARD INSPECTION.....................................................................................................50 PRESTART LUBRICATION.........................................................................................................52 START-UP...................................................................................................................................53 MACHINE START UP............................................................................................................53 MACHINERY CHECK ......................................................................................................54 BREAK-IN OF NEW COMPONENTS.............................................................................54 ROTARY DRIVE UNIT BREAK-IN.............................................................................54 HOIST/PULLDOWN GEARCASE BREAK-IN...........................................................54 ELECTRIC MOTOR BREAK-IN................................................................................54 OPERATION ...............................................................................................................................55 PROPELLING .......................................................................................................................55 DEFINITIONS ..................................................................................................................55 PROPEL PROCEDURE .................................................................................................56 PROPEL CONTROLS - OVERVIEW .........................................................................................57 STRAIGHT PROPEL .................................................................................................................58 GRADUAL RIGHT HAND TURN .................................................................................................58 GRADUAL LEFT HAND TURN ...................................................................................................59 COUNTER-ROTATION LEFT HAND TURN ................................................................................60 ENSURE GRADUAL TURNS ARE MADE - 15O INCREMENTS ...............................................60 TOWING PROCEDURE.................................................................................................62 TOWING PROCEDURE .............................................................................................................62 CABLE REEL OPERATION..................................................................................................64 CABLE REEL............................................................................................................................64 LEVELING .............................................................................................................................65 LEVELING CONTROLS .............................................................................................................66 MAST RAISING AND LOWERING .........................................................................................67 MAST RAISING ................................................................................................................67 MAST RAISING/LOWERING CONTROLS .................................................................................68 MAST LOWERING ..........................................................................................................69 MAST CONTROLS TO ADJUST FOR ANGLE DRILLING ..........................................................69 PULLDOWN MACHINERY OPERATION..............................................................................71 HOIST/PULLDOWN CONTROLS ...............................................................................................71 AUXILIARY WINCH OPERATION ..........................................................................................72 WINCH OPERATION CONTROLS .............................................................................................72 PIPE RACK OPERATION...............................................................................................73 PIPE RACK OPERATING CONTROLS ......................................................................................73 PIPE RACK OPERATION..........................................................................................................74 TOOL HANDLING ..................................................................................................................76 PIPE LOADING AND UNLOADING ..................................................................................76 DRILL TOOL STRING ASSEMBLY..................................................................................78 BI619434
Manual No. 10623 49HR Blast Hole Drill 4 April 2008 Bucyrus International, Inc. TOOL STRING ..........................................................................................................................78 STABILIZER INSTALLATION .....................................................................................................79 DRILL PIPE INSTALLATION CONTROLS ..................................................................................79 BREAKOUT WRENCH OPERATION...................................................................................82 DRILL TOOL STRING DISASSEMBLY..................................................................................84 ADDING ADDITIONAL DRILL PIPE ..................................................................................86 REMOVAL OF MULTIPLE SECTION DRILL PIPE...........................................................87 ANGLE DRILLING .................................................................................................................88 ANGLE DRILLING EQUIPMENT ................................................................................................88 PIPE POSITIONER ...89 JIB CRANE ................................................................................................................................90 DUST SUPPRESSION SYSTEM OPERATION....................................................................91 WATER INJECTION SYSTEM..................................................................................................92 DRILLING ..............................................................................................................................93 VERTICAL DRILLING ......................................................................................................93 CONTROLS UTILIZED WHILE DRILLING .................................................................................93 STARTING THE HOLE (COLLARING)......................................................................94 NORMAL DRILLING ...................................................................................................96 ENDING THE HOLE..................................................................................................97 ENDING THE HOLE (MULTIPLE PIPE SECTIONS).................................................98 DRILLING DIFFICULT FORMATIONS .............................................................................98 UNCONSOLIDATED MATERIALS ...................................................................................99 WET OR STICKY FORMATIONS.......................................................................................101 ANGLE DRILLING ...............................................................................................................102 PROGRAMMED DRILL CONTROL DRILLING ...................................................................103 PROGRAMMED DRILL CONTROLS UTILIZED .......................................................................103 PREPARING TO MOVE................................................................................................104 MACHINE SHUTDOWN ......................................................................................................106 SHUT DOWN PROCEDURE.................................................................................106 SHORT TERM STORAGE......................................................................................107 LONG TERM STORAGE.........................................................................................108 ATTENDED LONG TERM STORAGE....................................................................109 UNATTENDED LONG TERM STORAGE................................................................109 TOOL RECOVERY...................................................................................................................110 DRILL STABILITY CHARTS .................................................................................................112 TYPICAL MACHINE SPECIFICATIONS .....................................................................................114 GENERAL ESTIMATED COMPONENT WEIGHTS..................................................................116 BI619434
49HR 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. 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.
April 2008 49HR Blast Hole Drill 5 Manual No. 10623 Bucyrus International, Inc.
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SAFETY PRECAUTIONS
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 man 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.
•Perform functional tests of all safety circuits.
•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.
•Always have a second person to monitor the lifeline when working in confined spaces.
•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 chisels 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.
April 2008 49HR Blast Hole Drill 7 Manual No. 10623 Bucyrus International, Inc.
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Operating Precautions:
•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 unauthorized personnel on board the machine while in operation.
•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 specified in the stability limits shown on the STABILITY CHART at the end of this section.
•Do not leave the rotary gearbox suspended in the air when leaving the machine unattended.
•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.
Manual No. 10623 49HR Blast Hole Drill 8 April 2008
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FIRE PREVENTION CONSIDERATIONS
Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.
DO NOT smoke while handling flammables or when near batteries.
Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 of this manual for the Scheduled Maintenance recommendations and the Walk Around Inspection procedure.
Repair or replace loose or damaged lines, tubes, and hoses as soon as possible.
Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.
DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.
DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.
Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.
Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.
NEVER weld, burn, or perform service on the machine alone.
April 2008 49HR Blast Hole Drill 9 Manual No. 10623 Bucyrus International, Inc.
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STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS
These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to the signaling used in communication between maintenance personnel and crane operators during the maintenance cycle.
HOIST Extend forearm upward, keeping forefinger extended and pointing up, make small circular movements with hand.
LOWER Extended arm downward, keeping forefinger extended and pointed down, make small circular movements with hand.
MAIN HOIST Tap fist on head until signal received by operator, then use standard signals.
USE WHIP LINE (Auxiliary Hoist) Tap elbow with open hand until signal received by operator, then use standard signals.
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RAISE BOOM Extend arm fully with fingers closed and thumb pointing upward.
STOP Extend arm fully with fingers extended and palm facing down.
EMERGENCY STOP With arm fully extended, fingers fully extended and palm facing down, move arm rapidly along a horizontal plane.
TRAVEL With arm extended forward, hand open and raised at wrist, make a pushing motion in the desired direction of movement.
DOG EVERYTHING Clasp hands together in front of body.
TRAVEL (both tracks) With both fists clenched in front of body, make a circular motion with the desired direction of motion (forward or reverse) duplicated with fists.
LOWER BOOM Extend arm fully with fingers closed and thumb pointing down.
MOVE SLOWLY While giving any motion signal, hold other hand motionless in front of desired signal hand. (Hoist slowly is example provided.)
April 2008 49HR Blast Hole Drill 11 Manual No. 10623 Bucyrus International, Inc.
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RAISE BOOM AND LOWER LOAD Extend arm horizontally with fingers extended and thumb pointing upward, alternately open and close fingers for the duration of the desired movement.
LOWER BOOM AND RAISE LOAD Extend arm horizontally with fingers extended and thumb pointing downward, alternately open and close fingers for the duration of the desired movement.
SWING Extend arm horizontally with index finger extended in desired direction of swing.
TRAVEL (Single Track) Use a raised fist on the side that remains locked and make a vertical circular motion in front of chest for the direction and side of desired movement.
EXTEND BOOM (Telescoping Booms) Place both hands in front of body with palms upward, fingers clenched, and thumbs extending outward.
RETRACT BOOM (Telescoping Booms) Place both hands in front of body with palms upward, fingers clenched, and thumbs extending inward.
EXTEND BOOM (Telescoping Booms) With fingers clenched and thumb extended toward body, use a single hand motion to tap on chest with thumb of hand.
RETRACT BOOM (Telescoping Booms) With fingers clenched and thumb extended away from body, use a single hand motion to tap on chest with heel of hand.
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WARNING SIGNS AND DECALS
The placards depicted below are mounted on the machine as delivered from Bucyrus International, Inc. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.
April 2008 49HR Blast Hole Drill 13 Manual No. 10623 Bucyrus International, Inc.
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Manual No. 10623 49HR Blast Hole Drill 14 April 2008 Bucyrus International, Inc.
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Stored Energy Signs
