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Technical Manual

BI616836

BUCYRUS

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BI616836

Bucyrus International Inc.

BI616836

49RIII Blast Hole Drill

DANGER

THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHNNE. 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.

Bucyrus International, Inc. 49RIII Blast Hole Drill

BI616836

Bucyrus International Inc.

BI616836

49RIII Blast Hole Drill

49RIII Blast Hole Drill

IMPORTANT NOTE

This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

Mar. 2001 49RIII Blast Hole Drill 1 Manual No. 10107 BUCYRUS INTERNATIONAL, INC. Table of Contents GENERAL INFORMATION ............................................................................................................5 SAFETY ........................................................................................................................................6 SAFETY PRECAUTIONS .....................................................................................................7 FIRE PREVENTION ...........................................................................................................10 SPECIFICATIONS ..............................................................................................................12 Machine Dimensions ............................................................................................................................13 MACHINE OVERVIEW ................................................................................................................14 PROPEL MACHINERY ................................................................................................................14 Propel Machinery .................................................................................................................................14 MAINFRAME AND DECKS ..........................................................................................................15 Mainframe ............................................................................................................................................15 Deck Plan .....................16 MAST ...........................................................................................................................................17 Mast and Mast Machinery ....................................................................................................................17 MAIN AIR SYSTEMS ....................................................................................................................18 Air Compressor ....................................................................................................................................18 HYDRAULIC SYSTEM .................................................................................................................19 OPERATOR’S CAB....................................................................................................................20 Operator’s Cab ....................................................................................................................................20 MACHINE PLACARDS ................................................................................................................21 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS............................23 OPERATION NEAR ELECTRICAL TRANSMISSION LINES ..............................................26 PRESTART CHECKS.................................................................................................................27 EXTERNAL INSPECTION ..................................................................................................27 ONBOARD INSPECTION..................................................................................................30 PRESTART LUBRICATION................................................................................................32

Operator’s Manual Manual No. 10107 sn: 141128

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Manual No. 10107 49RIII Blast Hole Drill 2 Mar. 2001 BUCYRUS INTERNATIONAL, INC. CONTROLS - LOCATION AND FUNCTION..............................................................................33 OPERATOR’S CONTROL CONSOLE..............................................................................33 MAIN CONTROL PANEL ....................................................................................................34 HOIST/PULLDOWN RHEOSTAT..............................................................................34 ROTARY RHEOSTAT................................................................................................35 DRILL/PROPEL CONTROLS ON / OFF PUSH-BUTTON........................................35 HOIST/PULLDOWN SPEED SELECTOR SWITCH................................................35 ROTARY SPEED SELECTOR SWITCH..................................................................36 HOIST BRAKE SWITCH...........................................................................................36 PIPE RACK SELECTOR SWITCH...........................................................................37 PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL).............................................37 WINCH/MAST SELECTOR SWITCH........................................................................37 MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL)........................................38 TOOL WRENCH SWITCH........................................................................................38 DUST CURTAIN SWITCH.........................................................................................38 BIT VIEW HATCH SWITCH.......................................................................................39 PROPEL CONTROL PANEL.............................................................................................39 EMERGENCY STOP PUSH-BUTTON......................................................................39 PROPEL SPEED SELECTOR SWITCH..................................................................40 COMPRESSOR STOP PUSH-BUTTON..................................................................40 COMPRESSOR VENT/DRILL SWITCH....................................................................40 HEATER/VENT/AIR CONDITIONER CONTROLS....................................................40 OPERATING MODE SELECTOR SWITCH..............................................................40 PROPEL JOYSTICKS...............................................................................................41 SELECTOR SWITCH PANEL............................................................................................42 MAST BRACE LOCK SWITCH.................................................................................42 MAST LOCK SWITCH...............................................................................................43 BOARDING STAIRS SWITCH...................................................................................43 PEDESTAL HEATER SWITCH..................................................................................43 FIRE SUPPRESSION SYSTEM INDICATORS.........................................................43 RADIO .......................................................................................................................43 LEVELING CONTROL PANEL ...........................................................................................44 MANUAL LEVELING JOYSTICKS ..............................................................................44 AUTOMATIC LEVELING SWITCH .............................................................................45 WATER INJECTION ON/OFF SWITCH (OPTIONAL)...............................................45 WATER INJECTION FLOW CONTROL (OPTIONAL)..............................................45 HORN PUSH-BUTTON.............................................................................................45 DEPTH INDICATOR RESET PUSH-BUTTON..........................................................46 PROGRAMMED DRILL CONTROL SWITCH...........................................................46 EMERGENCY STOP PUSH-BUTTON......................................................................46 OPERATOR’S DISPLAY TERMINAL..................................................................................47 MACHINERY HOUSE CONTROLS ...................................................................................48 Lighting Load Center ............................................................................................................................48 Low Voltage Start Cabinet ...................................................................................................................48 Low Voltage Cabinet ............................................................................................................................49 Programmable Controller Cabinet ........................................................................................................49 Hoist/Pulldown and Rotary Drive Control CABINETS ............................................................................50 Air Compressor Controls ......................................................................................................................50 BI616836

Mar. 2001 49RIII Blast Hole Drill 3 Manual No. 10107 BUCYRUS INTERNATIONAL, INC. MISCELLANEOUS CONTROLS...............................................................................51 Portable Remote Propel Station (Optional) ....51 Hydraulic Reservoir Remote Fill Control Panel ...51 Lube Control Panel .................52 MACHINE START-UP ..................................................................................................................53 MACHINERY CHECK ................................................................................................53 BREAK-IN OF NEW COMPONENTS.......................................................................54 ROTARY DRIVE UNIT BREAK-IN....................................................................54 HOIST/PULLDOWN GEARCASE BREAK-IN...................................................54 ELECTRIC MOTOR BREAK-IN.......................................................................54 MACHINE OPERATION ...............................................................................................................55 PROPELLING ....................................................................................................................55 Propel Controls ....................................................................................................................................56 Propel - Forward or Reverse .................................................................................................................57 Propel - Gradual Right Turn ..................................................................................................................58 Propel - Gradual Left Turn....................................................................................................................58 Propel - Counter-Rotation Left Turn ..........59 Gradual Turns - 15° Increments...........................................................................................................59 TOWING THE MACHINE ...........................................................................................61 CABLE REEL OPERATION...............................................................................................62 MACHINE LEVELING ..........................................................................................................63 Machine Orientation .............................................................................................................................63 Leveling Controls .................................................................................................................................65 MAST RAISING AND LOWERING ......................................................................................65 MAST RAISING ..........................................................................................................65 Mast Raising/Lowering Controls ...........................................................................................................66 MAST LOWERING ....................................................................................................67 PULLDOWN MACHINERY OPERATION...........................................................................69 Controls for Hoist/Pulldown ..................................................................................................................69 AUXILIARY WINCH OPERATION .......................................................................................70 Controls for Operating the Winch .........................................................................................................70 PIPE RACK OPERATION.........................................................................................71 Controls for Operating the Pipe Racks.................................................................................................71 TOOL HANDLING ...............................................................................................................74 PIPE LOADING AND UNLOADING ............................................................................74 DRILL TOOL STRING ASSEMBLY............................................................................75 Stabilizer Installation ...........................................................................................................................77 Controls for Drill Pipe Installation ..............77 BREAKOUT WRENCH OPERATION................................................................................81 DRILL TOOL STRING DISASSEMBLY...............................................................................82 ADDING ADDITIONAL DRILL PIPE ............................................................................84 REMOVAL OF MULTIPLE SECTION DRILL PIPE.....................................................85 DUST SUPPRESSION SYSTEM OPERATION.................................................................86 Water Injection System.......................................................................................................................87 BI616836

Manual No. 10107 49RIII Blast Hole Drill 4 Mar. 2001 BUCYRUS INTERNATIONAL, INC. VERTICAL DRILLING .........................................................................................................88 Controls for Drilling ....................88 STARTING THE HOLE (COLLARING).............................................................89 NORMAL DRILLING ..........................................................................................90 ENDING THE HOLE ~SINGLE PIPE SECTION...............................................91 ENDING THE HOLE ~MULTIPLE PIPE SECTIONS.........................................92 DRILLING DIFFICULT FORMATIONS .......................................................................93 UNCONSOLIDATED MATERIALS .............................................................................93 WET OR STICKY FORMATIONS......................................................................................96 PROGRAMMED DRILL CONTROL DRILLING ...................................................................97 Controls for Programmed Drill Control ..................................................................................................97 PREPARING TO MOVE THE MACHINE ....................................................................98 MACHINE SHUTDOWN ..............................................................................................................99 SHORT TERM STORAGE...............................................................................................100 LONG TERM STORAGE.................................................................................................101 ATTENDED LONG TERM STORAGE.............................................................................102 UNATTENDED LONG TERM STORAGE........................................................................102 TOOL RECOVERY..........................................................................................................103 Drill Stability Chart.............................................................................................................................105 BI616836

49RIII Blast Hole Drill Operator’s Manual Introduction

GENERAL INFORMATION

This manual is designed to assist the owner in the operation and maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. When a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, your machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative.

Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed directly from the factory. Should you require additional information or factory service assistance contact your regional service representative or:

Bucyrus International, Inc.

1100 Milwaukee Avenue

P.O. Box 500

South Milwaukee, Wisconsin, USA53172-0500

Telephone (414)-768-4000

It is Bucyrus International’s policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligations to install such changes on machines sold previously.

Due to this ongoing program of product research and development some procedures, specifications and parts may be altered in a constant effort to improve our machines.

Mar. 2001 49RIII Blast Hole Drill 5 Manual No. 10107 BUCYRUS INTERNATIONAL, INC.

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The safety alert symbols displayed here, and throughout this manual, call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all CAUTION and DANGER placards mounted at various locations on the machine.

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definition. In the event you question your ability to safely perform any of the enclosed maintenance and operational procedures contact your regional Bucyrus service representative or the factory.

The following defines distinctions between safety instructions. In all these definitions the safety alert symbols is used.

NOTE: Denotes required information pertaining to the equipment. A loss of time and assets, or a minor injury can result if the appropriate action is not taken.

CAUTION: Serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury.

DANGER:Denotes an imminently dangerous hazard which could result in death, bodily injury, or serious damage to equipment if appropriate action is not taken.

DANGER:Denotes an imminently dangerous electrical hazard which can result in death, bodily injury, or serious damage to equipment if appropriate action is not taken.

Operating, maintaining or servicing this machine can be dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert and has the necessary skills, knowledge, tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Bucyrus International Customer Service representatives and/or factory specialists are also available to provide additional information or technical assistance. In addition, the operator must be alert, physically fit, and free from the influence of alcohol, drugs, or any medications that might impair a person’s eyesight, hearing or reaction time.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

Manual No. 10107 49RIII Blast Hole Drill 6 Mar. 2001 BUCYRUS INTERNATIONAL, INC.

SAFETY

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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.

Mar. 2001 49RIII Blast Hole Drill 7 Manual No. 10107 BUCYRUS INTERNATIONAL, INC.

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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.

Manual No. 10107 49RIII Blast Hole Drill 8 Mar. 2001

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.

Mar. 2001 49RIII Blast Hole Drill 9 Manual No. 10107 BUCYRUS INTERNATIONAL, INC.

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FIRE PREVENTION

•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 ~ PREVENTIVE MAINTENANCE for the scheduled maintenance recommendations.

•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.

Manual No. 10107 49RIII Blast Hole Drill 10 Mar. 2001 BUCYRUS INTERNATIONAL, INC.

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Mar. 2001 49RIII Blast Hole Drill 11 Manual No. 10107 BUCYRUS INTERNATIONAL, INC. BI616836