CAT BUCYRUS R20 Hydraulic Track Drill Operation and Maintenance Manual 426689 – PDF DOWNLOAD

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PARTS ORDERINGAND PRODUCT SUPPORT

Use only genuineBucyrus parts in the maintenance, rebuild or repair of these machines.The manufacturer shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also not obligated or liable for any machines or parts that have been improperly handled; that have not been operated, maintained or repaired according to furnished manuals or other written instructions, and that have been operated with other than genuineBucyrus parts or authorized OEM components.

IDENTIFICATION OF THE MACHINE

Always furnish the Model Number and Serial Number when ordering parts.This information is found on the machine nameplate.

PART NUMBERAND DESCRIPTION

In addition to the Model and Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensioned sketch or return the part to be replaced, transportation charges prepaid.Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.

SHIPMENT

Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our accounting department.

PARTS ORDERING

In NorthAmericaTelephone 1-800-854-9030

orTelefax 1-800-582-6570

Telephone (903) 786-2981

Telefax (903) 786-6407

PRODUCT SERVICEANDWARRANTY

In NorthAmericaTelephone 1-800-258-0009

Telephone (903) 786-2981

Telefax (903) 786-6408

Bucyrus Mining Equipment, Inc.

3501 S. FM Hwy 1417, Denison,TX 75020 www.bucyrus.com

© 2010Bucyrus International, Inc. All Rights Reserved

Intended Use

This machine and its approved attachments are designed to drill blast holes for surface and underground quarry, mining and construction applications. Use of this machine in any other way is prohibited and contrary to its intended use.

This safety alert symbol indicates important SAFETY MESSAGES in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

DO NOT weld on any part of this machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. Disconnect the connections to the Electronic Control Module (ECM) on the engine before welding.

Before Starting Engine, Study Operator's Manual

* Read and understand the warnings and cautions shown in Section 1

* Practice All Safety Precautions

* Make Pre-Operations Check

* Learn Controls Before Operating

It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws and regulations.

California Proposition 65 Warnings

The following warning applies to equipment supplied with lead-acid batteries:

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Drill Serial No. :

Date Drill Delivered : Dealer : Customer :

The descriptions and specifications contained in this manual were in effect at the time of printing. We reserve the right to make changes at any time without notice or obligation.

09/2010

Glossary of Terms

The following is a list of terms commonly used in the mining and construction industry. This list is not exhaustive, but pertains primarily to surface track drills as discussed in this manual.

Anti-Jam .........................A hydraulic system that senses a change in drill rotation and automatically retracts and extends drill steel to get through “bad ground” and prevent steel from getting stuck.

Belleville Washer .............Another name for “Spring Washer”.

Bleed(ing) .......................A procedure to remove trapped air from a fluid.

Boom ............................Horizontal structure that supports and positions the feed. One end attaches to a pivot at the boom bulkhead at the front of the machine, the other end attaches to the positioner. Some booms are extendable, others are fixed (non-extendable).

Centralizer .....................A device used to keep the drill steel centered with respect to the centerline of the feed. An end centralizer is located at the bottom end of the feed. It has jaws that open and close around the drill steel, but allow the drill steel to pass through and rotate freely. The jaws are also used to clamp around the drill steel coupling and hold it tight for threading and unthreading of drill steel. A midpoint or travelling centralizer is used on long feeds to support the mid-point of the drill steel.

Collar(ing) ......................A term referring to starting a hole, whereby reduced hammer and feed pressure is used to get a hole started straight.

Detergent Tank ...............A holding tank for water and detergent solution that is sometimes pressurized, or used in conjunction with a pump. It is part of a system used to suppress dust from the hole by means of injecting water into the hole while drilling is in progress.

Drill Rod .........................Another name for “drill steel”.

Drill Steel .......................A specially made length of steel with threads on both ends to allow coupling together and to the drill shank and drill bit. The drill steel transfers energy from the drill to the bit and is also used to convey air or water for hole cleaning.

Drill Steel Coupling..........A devise used to join two pieces of drill steel together and to join the drill steel to the drill shank, by means of female threads or sometimes male and female threads.

Drill String ......................Refers to multiple pieces of drill steel joined together. Dump ............................Term used to describe the position of the feed relative to the centerline of the boom. Dump UP tilts top of feed towards boom, dump DOWN tilts top of feed away from boom.

Dust Collector ................A device used to collect dust and cuttings from the hole by means of vacuum, while drilling is in progress.

Extend ...........................To move object OUT or AWAY from machine in the horizontal plane, or to move object TOWARD the ground in the vertical plane.

Glossary of Terms

Feed ..............................Structure used to support the rock drill, drill steel and rod changer. The rock drill moves up and down the feed by means of a chain drive system, or in some cases a cable or hydraulic cylinder drive system. Feeds come in various lengths, depending on length of drill steel required.

Feed Mounting ................Another name for “Feed Table”

Feed Table .....................A device that attaches to the positioner by means of a pin and hydraulic cylinder, and is used to support the feed.

Hammer(ing) ..................A term used to describe the action of the drill hammer or piston striking the drill shank, thus transferring the blow energy through the drill steel to the bit.

Oscillation ......................Refers to the up and down movement of the tracks. During tramming the track oscillation cylinders are unlocked to allow the tracks to move up and down according to the terrain. During drilling the track oscillation cylinders are locked, to prevent the tracks from moving.

Pickup Pot......................A device that can be hydraulically raised or lowered over the hole and provides a means of attaching the dust collector hose to remove dust and cuttings from the hole.

Positioner ......................A device attached to the end of the boom, that allows the feed to pivot and be positioned at various angles.

Pre-Cleaner ....................A device used in conjunction with the dust collector, that removes large particles before they reach the dust collector.

Rattle .............................A term used to describe loosening the drill string joints by “hammering” the drill steel, by using short bursts of the hammer with no feed pressure on the drill bit.

Retract ..........................To move object IN or TOWARDS the machine in the horizontal plane, or to move object AWAY from the ground in the vertical plane.

Rock Drill .......................The device that provides the percussive and rotation forces for drilling. Sometimes referred to as the “hammer” or “drifter”.

Shank ............................A specially made short length of steel with splines at one end and threads at the other end. The splined end is inserted into the rock drill and engages the splines of the chuck end of the drill. The drill steel attaches to the other end by means of a coupling.

Spring Washer ................A cup shaped washer that, when compressed provides a “spring like” action. Also called "belleville washer".

Sting..............................To apply pressure to the ground by extending the feed to prevent the feed from moving while drilling.

Stinger...........................A device attached to the end of the feed which contacts the ground to stabilize the feed while drilling.

Swing ............................Term used to indicate movement of a component to right or left, relative to machine as viewed from rear.

Tram ..............................To move and steer the machine from the tram station or operator’s cab.

Hazard Classification

The Track Drill is a heavy moving machine with a boom capable of extending its reach vertically and horizontally. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly operated, inspected, and maintained. The operator's must read this manual and have been trained to use the machine in an appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer at 1-800-258-0009.

Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Hazard Classification

A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. All are used as attention-getting devices on decals and labels fixed to the machine to assist in potential hazard recognition and prevention.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property or equipment damage.

Safety Alert Symbol

Potential Hazards

Potential Hazard Prevention

Safety Alert Symbol. Used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Entanglement Hazard. Death or serious injury can result from contact with rotating drill steel and drivelines.

Entanglement Hazard. Rotating parts can cause personal injury.

See Operator's Manual for instructions. If you do not understand the information the manuals, consult your supervisor, the owner, or the manufacturer.

Keep clear of rotating drill steel and drivelines. Switch off engine before performing service.

Keep away from fan and belt when engine is running. Stop engine before servicing.

Explosion / Burn Hazard. Will cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.

Keep all open flames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt.

READ MANUALS

Read all manuals prior to operation.

Explosion Hazard. Death or serious injury can result from the use of ether or other high energy starting aids.

Do not use ether or other high energy starting aids. Engine equipped with grid heating system.

Explosion Hazard. Death or serious injury can result from the use of ether or other high energy starting aids.

Do not use ether or other high energy starting aids in compressor.

Burn Hazard. Death or serious injury can result from release of hot pressurized liquids.

Keep away from flames.

Relieve all pressure.

Allow to cool before performing service on compressor.

Potential Hazards

Potential Hazard Prevention

Flying Object & Spray Hazard. Death or serious injury can result from release of pressurized liquids.

Shut off live air at source, and relieve all pressure before removing filler plug.

Flying Object Hazard. Serious injury or death can occur if drill is operated without guards in place.

Use guards. Keep in place.

Flying Object Hazard. Serious injury or death can occur if track tension is adjusted improperly.

Read and understand the procedures in the Operation and Maintenance Manual before adjusting track tension

Electrocution Hazard. Death or injury can result from contacting electric power lines.

Maintain required clearance.

See Table 1-1 in this manual.

Burn Hazard. Hot fluid under pressure can scald.

Allow to cool before opening.

Trip & Fall Hazard. Death or serious injury can result from tripping and falling.

Keep off top of machine.

Flying Object Hazard. Feed can contact cab and break glass. Broken and flying glass can result in serious injury or death.

Keep feed away from cab. Read manual for operating instructions.

Potential Hazards

Potential Hazard Prevention

Inhalation Hazard. Compressor discharge air is hazardous if inhaled. Death or serious injury may result.

Keep clear of compressor air discharge area.

Injection Hazard. Escaping fluid under pressure can penetrate skin, causing serious injury.

Relieve pressure before disconnecting hydraulic lines. Keep away from leaks and pin holes. Use a piece of cardboard or paper to search for leaks. Do not use hand.

Crush Hazard. Death or serious injury can result from contact with moving centralizer.

Keep clear of moving centralizer. Do not actuate centralizer until personnel are clear.

Crush Hazard. Death or serious injury can result from contact with moving machine.

Keep clear of moving machine.

Crush Hazard. Death or serious injury can result from contact with moving feed mast.

Read and understand operator's manual and all safety signs before attempting to remove feed mast swing pin.

Drill Feed And Table Can Fall causing serious injuries or death.

Always raise the drill feed and feed table clear of all obstacles before moving the machine. Raise them high enough to allow for rough ground or small hills.

Caution. Do not use high pressure spray by electrical connections.

Do Not allow anyone under the drill feed or feed table unless machine parts are not moving and are supported.

Do Not attempt to repair a pivot pin that has failed or has been sheared.

Safety Information

Before Operation

• Do study this manual and fully understand the controls.

• Do be sure all safety guards are securely in place. Replace any damaged or missing guards.

• Do be sure all nameplates and decals pertaining to safety, operation, and maintenance are in place and not damaged. Replace any damaged or missing nameplates or decals. Refer to decal locator drawings in this section.

• Do be sure all personnel are clear of the machine and work area before starting the engine or operating the machine.

• Do be sure drill area is clear of all obstructions before operating machine.

• Do attach safety chain when using towbar.

• Do wear safety helmet, glasses and hearing protection when operating or working on machine.

• Do Not operate machine with:

• Hydraulic or air leaks.

• Damaged hydraulic hoses or fittings.

• Broken or damaged electrical wiring.

• Damaged or missing guards and shields.

• Damaged structural members.

• Worn or damaged mechanical parts.

• Damaged or missing fasteners.

• Broken, damaged, or malfunctioning controls.

Operation

• Do examine the surface before drilling to determine the possible presence of unfired explosives.

• Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gases contain carbon monoxide, a deadly poison, which is colorless and odorless.

• Do keep work area clean and clear of mud, snow, ice, fluids, hand tools and other objects.

• Do raise the drill feed before moving the machine. Raise it high enough to allow for rough ground or small hills. Drill feed can fall causing serious injury or death.

• Do wear seat belt and operate machine with door closed on cab machines.

• Do maintain minimum clearance from high voltage wires (see Table 1-1). Check with power company and local regulations for specific guidelines and safety information.

• Do Not use the machine for any other purpose than what it was designed for.

• Do Not wear loose clothing or jewelry; keep clothing and hands clear of moving parts.

• Do Not travel on steep inclines, soft or unstable ground, or close to unsupported excavations.

• Do Not move boom or machine if it is in a potentially unstable position.

• Do Not stand directly under a boom or feed.

• Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.

Safety Information

After Operation

• Follow Shutdown Procedures given in Section 4 of this manual.

Maintenance

• Two people shall be present when performing service work, both being fully trained on safety issues. One person shall supervise from the operator's position and have immediate access to an emergency stop in all situations. Visual, audible or verbal communication signals shall be established and understood by both persons.

• Do relieve pressure in the hydraulic or pneumatic systems before loosening connections or parts.

• Do use only proper tools to make repairs or adjustments.

• Do be sure of adequate lighting when performing service work at night.

• Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank. This will prevent sparks and the possibility of explosion.

• Do be sure each person is adequately trained to perform service and maintenance procedures.

• Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.

• Do be sure machine and components are well supported before servicing or replacing parts.

• Do Not service, or perform maintenance, while machine is running, or capable of being started.

• Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments.

• Do Not weld or grind near oil, air, fuel lines, or batteries.

• Do Not smoke or use an open flame near batteries. Batteries can give off hydrogen which is a highly explosive gas.

Equipment Transfer

If all or part of the equipment is shipped to a new destination, always include a complete Operator's Manual or a copy of the following topics:

• Safety Section

• Operation Instructions including:

• Do Not direct high pressure cleaning agents or water on electrical connections. Clearances

Pre-Start Checks Start-up

After Start Checks

Shutdown Procedure

Tramming Machine

Lines

Table 1-1 Minimum safe distances from high voltage lines.

Refer to Figures 1-1 to 1-3 for locations

Fig. 1-1 Rear and Top of Machine

VIEW D-D

VIEW E-E

Fig. 1-2 Right Side of Machine

VIEW C-C ROTATED FOR CLARITY

VIEW F-F

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.