Technical Manual
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SAFETY PRECAUTIONS AND PRESTART CHECKS
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 judgment and alertness on the part of the entire mining crew.
SPECIFIC SAFETY RULES
The following is a list of some important safety rules relating to prestart and operation of the 49RIII drill. The safety instructions given in this manual cover normal daily operations of the machine. Additional precautions may be necessary to cover unusual circumstances. Be constantly alert for any potentially dangerous conditions and take action as necessary to correct the conditions immediately.
• Wear hard hat, safety shoes and safety glasses at all times.
• When operating or performing maintenance functions, wear snug fitting clothing. Loose clothing can be caught on controls or in moving parts. Remove 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 lighting.
• Do not allow unauthorized personnel on board the machine while in operation.
• Do not begin operation until all personnel are 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 this purpose.
• Do not propel until the travel route has been 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 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.
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 electrician.
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 blast holes.
OPERATION NEAR ELECTRICAL TRANSMISSION LINES
Permission to reproduce the following material has been granted by the Construction Industry Manufacturers Association (CIMA). CIMA assumes no responsibility for the accuracy of this reproduction.
CAUTION: 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 are 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 utility before beginning work.
2. You and the electric utility representative must jointly determine what specific precautions must be taken to insure safety.
3. 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.
5. Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.
6. 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.
CAUTION:
DEATH OR SERIOUS INJURY GOULD RESULT SHOULD ANY PART OF THE DRILL COME WITHIN THE MINIMUM DISTANCE SPECIFIED OF AN ENERGIZED POWER LINE.
PRESTART CHECKS
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 mechanical 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.
EXTERNAL INSPECTION
1. Check areas around and under the machine for signs of water or lubricant leaks. If single droplets of water or lubricant are noticed, leakage is minimal. Determine the source of the leak and make note of it on the log sheet. If pooling of water or lubricant 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.
3. Check the drive tumbler gearcase, hydraulic motor and hoses for leaks. Check the lubricant level in the drive tumbler gearcase.
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. Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or covered with cuttings.
6. Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. sure the cable is kept out of water and away from sharp rocks. Have an electrician inspect the strain relief device and the condition of the cable where it enters the machine.
CAUTION: THE MACHINE TRAIL CABLE GARRIES A LETHAL VOLTAGE. HANDLE THE CABLE IN AN APPROVED MANNER WITH APPROVED RUBBER GLOVES AND INSULATED HOOKS OR TONGS.
7. Inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or damage. If loose wires are noted, do not touch them but notify an electrician immediately.
8. Inspect the leveling jack spuds for proper lubricant covering. Inspect the leveling jack pads for cracks, broken or missing pins, or excessive dirt accumulation.
9. Inspect the mast braces and locking pins. Replace missing or defective components immediately. Verify that all adjusting bolts are properly adjusted. Check all hoses and cylinders for leaking.
ACAUTION: USE A SAFETY BELT AND LANYARD TO PROTECT AGAINST FALLS WHEN CLIMBING ON THE MAST BRACES OR WORKING ON THE HOUSE ROOF.
10. Inspect the mast hinge pins for loose or keepers or bolts. Replace missing or damaged parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.
Inspect the mast hoist cylinders for loose or missing pins or keepers, oil leaks, damaged hoses or structural damage. Hepair or replace any missing or damaged components immediately.
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.
Check the main air flex hose, lubrication lines, and electric lines running from the mast to the rotary drive/pulldown unit for interference with the mast or excessive wear or leaks.
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 effectiveness.
Every 160 hours inspect the upper auxiliary winchsheaves. All pins, keepers and hardware should be secured.
Check the machinery house air filtering fan duct to see that it is clear of obstructions.
ONBOARD INSPECTION
1. Inspect the air compressor lubrication lines for leaks. Correct any leaks found immediately.
2. Check the condition of the air compressor intake filter. Replace the filter cartridge if the red flag is visible in the service indicator. Empty the dust hopper and clean the pre-cleaner element. Inspect the and ductwork for damage or leaks. Repair or replace leaking components.
3. Check the oil level in the hydraulic tank. Fill the tank to the proper level as described on the instruction plate on the tank.
4. Check hydraulic system for leaks. Correct all leaks immediately and clean up all oil spills immediately.
5. If the machine is equipped with a bit lubricator for the main air system, check that the lubricator is full.
6. Inspect the automatic lubrication central pumping stations for proper operation. Check the supply of lubricant and or refill drums as necessary.
7. Close and lock all electrical cabinet doors.
CAUTION: 82_02 ASSUME ALL PARTS INSIDE OF THE ELECTRICAL CABINETS ARE ENERGIZED. ALL ELECTRICAL COMPONENTS SHOULD BE SERVICED BY QUALIFIED ELECTRICAL PERSONNEL ONLY.
8. Inspect the compressor radiator and fan. Check for signs of deterioration or damage to hoses, valves, fittings, etc. Check for leaks at all joints. Check the radiator core for blockage by dust, dirt, leaves, paper, etc. and clean as necessary
9. Check the operator's display terminal for any faults.
1O. Inspect the machinery house for general cleanliness. Clean all dirt and debris from the machinery house.
NOTE: DO NOT USE COMPRESSED AIR TO CLEAN THE MACHINERY HOUSE. COMPRESSED AIR WILL ONLY MOVE THE DIRT 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.
11. Inspect the auxiliary winch and auxiliary winch line.
12. Check the oil level in the pump drive gearbox. Fill with recommended oil to the proper level.
Check all controls for free operation. Return all controls to the OFF or SET position.
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.
NOTE: 00 NOT USE COMPRESSED AIR TO CLEAN THE OPERATOR'S CAB. COMPRESSED AIR WILL ONLY MOVE THE DIRT AROUND. USE A VACUUM CLEANERTOREMOVE THE DIRT FROM THE CAB.
15. Inspect the tool wrenches for free operation, broken or missing parts, proper lubrication, lubricant leaks or dirt accumulation. Repair or replace parts as necessary and clean the drilling platform.
ACAUTION: BEFORE WORKING NEAR OR UNDER THE ROTARY DRIVEl PULLDOWN UNIT, MAKE SURE ALL OF THE OPERATOR'S CONTROLS ARE OFF AND TAGGED AND THE HOIST BRAKE SET TO PREVENT MOVEMENT OF THE UNIT. SERIOUS PERSONAL INJURY OFt DEATH COULD RESULT SHOULD THE ROTARY DRIVE/PlJLLDOWN UNIT FALL WHEN PERSONNEL ARE WORKING NEAR OR UNDER IT.
16. Inspect the automatic breakout wrench for free operation, broken or missing parts, proper lubrication, lubricant leaks or excessive dirt accumulation. Repair or replace parts as necessary. Be certain that the breakout wrench is retracted.
17. Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or lubricant leaks. Be ce!rtain that the upper gate is closed and that the rack is in the stored position.
18. Inspect the guide bushing for excessive wear or dirt accumulation. Also inspect the retainer lugs to be sure they are intact. Do not operate the machinewithout both retainer lugs intact and securely welded to the deck.
19. Inspect the tool string for excessive wear, dirt accumulation, bent pipe and secure joints. The bit cones and bearingshould be in good condition. Manually turn the cones to make sure they turn freely.
20. Inspect the rotary gear case for lubricant leaks, damaged lines, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearbox. Fill to the recommended level with an approved gear lubricant. Check the rotary motor ventilation inlets for leaves, paper, rags, etc. blocking the flow of air.
21. Inspect the rotary drive unit for excessive wear or dirt accumulation. Inspect the guide rollers for proper adjustment and excessive wear. Check for loose or missing bolts and bent or cracked structural members.
22. Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper adjustment and excessive wear.
23. Inspect the pulldown gearcase for lubricant leaks, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearbox. Fill to recommended level with an approved gear lubricant. Check the pulldown motor ventilation inlets for leaves, papers, rags, etc. blocking the flow of air.
24. Check the hoist brake for proper operation.
25. Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation. The deflector should seal around the drill pipe securely.
26. If the machine is equipped with a fire suppression system, perform any applicable checks or inspection as described in the fire suppression system owner's manual.
PRESTART LUBRICATION
Lubrication of the 49RIII blasthole drill is an extremely important job. Most drills come equipped with automatic lubrication systems that lubricate most of the points at regular intervals. These systems, although automatic, are not foolproof. Broken lines, dirty lubricant, faulty feeders, and a whole range of other problems can cause wearing parts to loose lubrication. Forthis reason, it is important that all lubrication points be inspected every shift to verify that they are receiving lubrication. Also, there are several points for lubrication that either need lubrication very infrequently, or are not possible to pipe into the automatic system. These points will need lubrication applied manually.
The lube charts in Appendix 3 gives the location and frequency of lubrication.
The lubricant used should be kept clean. If possible the lubricant should be supplied from a bulk lube truck. Be careful when adding lubricant to the automatic system to keep the pump and drum cover and fill points clean.
When using a manual gun wipe each fitting and thegrease gun fitting before injecting the lubricant. Use clean containers and funnels for lubricant for transferring to the gear cases or reservoirs. Do not allow water to enter any gear case, reservoir or container. Wipe off all fill caps before removing them.
CONTROLS - LOCATION AND FUNCTION
Regardless of previous experience, the new operator of any machine must become familiar with the location and function of all of the operating controls before he can begin to operate the machine. Since this manual covers all possible controls that could be used on the 49RIII Electric Blasthole drill, he should familiarize himself with both this manual and the particular machine being operated.
For the purpose of this manual, the operating controls have been divided into three groups, depending upon their location. These three groups are!:
1. Operator's Console Controls
2. Machinery House Controls
3. Miscellaneous Controls
ACAUTION: READ AND BECOME FAMILIAR WITH THIS MANUAL BEFORE ATTEMPTING TO OPERATE ANY OF THE MACHINE CONTROLS. PAY PARTICULAR ATTENTION TO THE CAUTION AND WARNING STATEMENTS, AND ANY FEDERAL, STATE, LOCAL OR COMPANY SAFETY RULES RELATING TO THE MACHINE. FAILURE TO BE AWARE OF AND UNDERSTAND THE HAZARDS ASSOCIATED WITH THE OPERATION OF THE CONTROLS MAY LEAD TO DEATH, PERSONAL INJURY OR SERIOUS MACHINE DAMAGE.
OPERATOR'S CONTROL CONSOLE
NOTE: THE CONTROLS ON THE OPERATORS CONSOLE ARE ALL ELECTRIC. THE SWITCHES OPERATE ELECTRIC CONTROLS, ELECTROMECHANICAL OR ELECTROHYDRAULIC VALVES ON THE MACHINE. FOR PURPOSE OF DESCRIBING THE CONTROLS, THE CONSOLE WILL BE BROKEN DOWN INTO PANELS AND THE CONTROLS ON EACH PANEL DESCRIBED. THE PANELS OF THE CONSOLE ARE: MAIN CONTROLS, PROPEL CONTROLS, SELECTOR SWITCHES, LEVELING CONTROLS AND OPERATOR'S DISPLAY TERMINAL.
OPERATOR'S CONTROL CONSOLE - OVERVIEW
NOTE: THE PANELS WITH CONTROLS AS SHOWN ON THE FOLLOWING PAGES ARE TYPICAL OF WHAT COULD BE INCLUDED ON A CONSOLE.
• 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
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