Operator and Maintenance Manual Model SCH5000 Hydraulic Track Drill P/N 343654 3rd Edition Bucyrus Mining Equipment, Inc. 3501 S. FM Hwy 1417 Denison, Texas 75020 USA BI615874
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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 a 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
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WARNING:
BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1.
Failure to do so may result in dangerous practices which can cause equipment damage, serious personal injury or death.
BOTH operator and service personnel must read this manual, particularly the warnings and cautions listed in Section 1.
This manual contains instructions regarding operation of the Model SCH5000 Hydra-Trac® track drill carrier. It is intended to help you understand how the system operates and the precautions that should be observed. Read and understand this manual before operating or servicing this unit. This manual must be read and interpreted to non-English speaking personnel. Keep it handy for future reference.
For maximum utilization and efficiency in operating this equipment, we urge you to thoroughly read the entire contents of this manual before you begin to drill or service this machine.
CAUTION:
DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) from the engine before welding.
Specifications are subject to change without notice. Information contained in this manual was up to date at the time of printing.
Introduction i Introduction
Fig. i-1Caterpillar C10 Engine
1.Electronic Control Module (ECM)
2.Plug-Ins - Disconnect from ECM BEFORE welding.
Fig. i-1aCaterpillar C11 Engine
1.Electronic Control Module (ECM)
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2.Plug-Ins - Disconnect from ECM BEFORE welding.
ii Introduction
General Information
Fig. i-3 SCH5000CL - Right Side View
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Fig. i-2 SCH5000CL - Left Side View
The SCH5000 series Hydra-Trac and HPR518 (HPR2-C1) drill make an ideal drilling package for a wide range of mining and construction applications. The SCH5000 Hydra-Trac is easy to operate, maneuverable, and efficient. A fully self-contained drill carrier, the Hydra-Trac consists of the following main components:
1.D-4 type track assemblies with 15 inch triple-bar grousers.
2.Prime mover - Caterpillar model C11 ACERT, Tier 3 electronic diesel engine rated at 325 B.H.P. @ 1800RPM.
3.Hydraulic system, consisting of three (3) hydraulic pumps driven by the prime mover thru an elastic coupling to the pump drive gearbox.
4.Drill/right-hand tram pump - Rexroth A11VLO. Compressor/left-hand tram pump - Rexroth A11VLO. Drill rotation pump - Vickers PVE-19
5.400 C.F.M. compressor driven by a piston hydraulic motor provides plenty of blowing air for large hole sizes.
6.A 12' chain feed (20' Model SCH5000CL) powered by a hydraulic piston motor, complete with a hydraulic powered, scissors type centralizer, an automatic linear rod changer, rack, and hose reel system.
7.Model HPR5128 (HPR2-C1) hydraulic percussion drill complete with nitrogen charge kit. The HPR5128 Hydra-Drill is a high performance hydraulic rock drill that produces 3 1/2 inch (8.9 cm) and larger holes in medium to hard rock.
The SCH5000C/SCH5000CL operator cab is sound suppressive pressurized, with air conditioning. The cab encloses control consoles for tramming, drilling, and positioning, and is mounted on the left side of the carrier. The SCH5000 (non-cab machine) is equipped with a drill console mounted on a hydraulically movable arm for safety and comfortable operation.
Machines equipped with optional dust collector incorporate an additional pump dedicated for operation of the dust collector fan.
The heavy duty 3' extendable telescoping boom is installed on all SCH5000/5000C model machines. The boom has large wear pads and all externally mounted cylinders, which combine for long component life and easy access for service areas. The combination of the telescoping boom and the 12' feed system provide accurate and fast set-up for all drilling functions. A massive non-extendable boom is provided on SCH5000CL machines. This boom system combines with a 20' feed system that can satisfy all high production demands.
The heavy duty construction and low center of gravity make this self contained carrier a highly stable drilling platform.
Overlapping track pads and track frame with + 8% oscillation provide positive ground contact when tramming over rough terrain.
SCH5000 Model machines are equipped with an automatic engine throttle system which provides full engine power only at drilling operation for energy saving and economic operation.
Introduction iii General Information
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iv Introduction
SECTION 1 SAFETY Overview of Potential Hazards..............................................................................................1-2 Before Operation.................................................................................................................1-3 Clearance from High Voltage Lines.......................................................................................1-3 Operation and After Operation..............................................................................................1-4 Maintenance and Equipment Transfer....................................................................................1-5 Stability Limits.....................................................................................................................1-6 SECTION 2 OPERATOR CONTROLS Tram / Drill Positioning Controls...........................................................................................2-2 Instrument Panel - Non-Cab with 3306 Engine........................................................................2-4 Instrument Panel - Non-Cab with C11 Engine..........................................................................2-6 Drilling Controls - Non-Cab Machine.......................................................................................2-8 Instrument Panel - Cab Machine.......................................................................................... 2-12 Drilling Controls - Cab Machine........................................................................................... 2-14 Tramming Controls - Cab Machine...................................................................................... 2-16 Drill Positioning Controls - Cab Machine.............................................................................. 2-18 Air Ride Seat Adjustment....................................................................................................2-20 SECTION 3 OPERATING PROCEDURES Personal Safety...................................................................................................................3-2 Walk-Around Checks............................................................................................................3-3 Pre-Start Checklist...............................................................................................................3-4 Engine and Gearcases........................................................................................................3-5 Pneumatic System .............................................................................................................3-5 Feed Table Pivot Pin........................................................................................................... 3-6 Weekly Checks...................................................................................................................3-6 Boom, Feed and Drill..........................................................................................................3-7 Drill Accumulators..............................................................................................................3-7 Daily Maintenance Checklist..................................................................................................3-8 Mounting & Dismounting Machine.........................................................................................3-9 Start-Up Procedure............................................................................................................3-10 Cold Weather Starting...................................................................................................... 3-11 Tramming-Preliminary Checks and Warnings........................................................................ 3-12 Tramming from Operator's Cab.......................................................................................... 3-13 Tramming from Tram Station............................................................................................. 3-14 Shutdown Procedure ..........................................................................................................3-16 SECTION 4 DRILLING PROCEDURES Loading Drill Steel................................................................................................................4-2 Drill Positioning Procedure...................................................................................................4-4 Position Feed for Vertical Drilling.........................................................................................4-6 Vertical Indicator (optional).................................................................................................. 4-6 Position Feed for Angle Drilling...........................................................................................4-7 Repositioning Feed or Lowering Feed to Horizontal Position.................................................4-7 BI615874
Table of Contents
Introduction v SECTION 5 PREVENTIVE MAINTENANCE Hydraulic Oils for Percussion Drills........................................................................................5-2 Lubrication and Inspection....................................................................................................5-3 Engine Oil............................................................................................................................5-3 Bolt Maintenance.................................................................................................................5-4 Bolt Torque Specifications....................................................................................................5-5 Preventive Maintenance Chart...............................................................................................5-6 SCH5000 Grease Points - Overall Machine.............................................................................5-8 Grease Point Chart..............................................................................................................5-9 Grease Points - Drill & Centralizer...................................................................................... 5-10 Grease Points - Feed & Feed Drive.................................................................................... 5-11 Grease Points - Lower Rod Rack & Rod Wrench................................................................. 5-12 Grease Points - Rod Rack Driveline.................................................................................... 5-13 Grease Points - Upper Rod Rack & Hose Reel.................................................................... 5-14 Grease Points - Feed Table................................................................................................ 5-15 Grease Points - Positioner (12 Ft. Feed)............................................................................ 5-16 Grease Points - Positioner (20 Ft. Feed)............................................................................ 5-17 Grease Points - Boom Assembly....................................................................................... 5-18 Grease Points - Drill Console Boom (non-cab)..................................................................... 5-19 Grease Points - Cab Mounting........................................................................................... 5-20 Grease Points - Track Assembly........................................................................................ 5-21 Grease Points - Headrest for 20 Ft. Feed.......................................................................... 5-22 Grease Points - Fan Drive, Caterpillar C10 & 11 Engine...................................................... 5-22 Maintenance Record..........................................................................................................5-23 Table of Contents SECTION 4 DRILLING PROCEDURES Final Checks......................................................................................................................4-9 Drilling Procedure..............................................................................................................4-10 Collaring the Hole............................................................................................................4-10 Collaring Circuit...............................................................................................................4-13 Normal Drilling...................................................................................................................4-13 Drilling Practices................................................................................................................4-14 Collaring 4-14 Hole Deviation..................................................................................................................4-14 Feed Pressure.................................................................................................................4-14 Drill Pressures.................................................................................................................4-14 Adjusting Drill Pressure and Monitioring the Machine.......................................................... 4-14 Plugged Bit and Stuck Drill Steel........................................................................................ 4-14 Anti-Jam System (optional)..................................................................................................4-16 Reverse Percussion (optional)............................................................................................. 4-18 Adding and Removing Drill Steel.......................................................................................... 4-20 Adding Drill Steel..............................................................................................................4-20 Removing Drill Steel.........................................................................................................4-21 Drill Shank Replacement.....................................................................................................4-23 Indexing the Swing Cylinder................................................................................................ 4-24 BI615874
vi Introduction SECTION 6 DRILL MAINTENANCE Charging the Accumulators..................................................................................................6-2 Requirements....................................................................................................................6-2 Procedure .........................................................................................................................6-3 Checking the Accumulator Charge Pressure..........................................................................6-4 Accumulator Charge Kit.......................................................................................................6-6 Drill Lubrication....................................................................................................................6-7 Grease Lubrication with a Hand Grease Gun........................................................................6-7 Grease Specifications.........................................................................................................6-7 Automatic Lubrication.........................................................................................................6-7 Automatic Grease Lubricator Operation...............................................................................6-8 SECTION 7 DUST CONTROL Health Hazard Warning.........................................................................................................7-1 Dust Collector Assembly......................................................................................................7-2 Function of Dust Collector..................................................................................................7-3 Detailed Function of Components........................................................................................7-3 Initial Start-up and Tuning.................................................................................................... 7-4 Dust Collector Valve Adjustment (3306 engine)....................................................................7-5 Dust Collector Valve Adjustment (C10 & C11 engine)............................................................7-6 Air Pressure Regulator Adjustment......................................................................................7-7 Timer Adjustment............................................................................................................... 7-8 Fan Speed Adjustment ........................................................................................................7-8 Filter Elements.................................................................................................................7-10 Dust Collector Efficiency.................................................................................................. 7-10 Operational Variables........................................................................................................7-11 Fine Tuning.......................................................................................................................711 Manometer Setup Instructions.......................................................................................... 7-13 Timer Installation............................................................................................................. 7-14 To Set Timer................................................................................................................7-14 Control Circuit (Hydraulic, Electric and Air)......................................................................... 7-15 Fan Removal and Installation............................................................................................. 7-16 Troubleshooting Hints ...................................................................................................... 7-17 SECTION 8 GLOSSARY Table of Contents BI615874
Safety 1-1 Safety Section 1 BI615874
Overview of Potential Hazards
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 inspected and maintained. The operators should read this manual and have been trained to use the machine in an appropriate and safe manner. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer at 1-800-258-0009.
In this section and those that follow, the word:
DANGER - means that severe injury or death will result from failure to follow instruction.
WARNING - means that severe injury or death can result from failure to follow instruction.
CAUTION - means that minor injury or property damage can result from failure to follow instruction.
NOTE - means that special attention should be given to the instruction.
POTENTIAL HAZARD
Electrical Contact
EFFECTPREVENTION
DANGER: Will cause serious injuryMaintain minimum clearance from or death.high voltage power lines (refer to table 1-1). Do Not drill near underground power lines. Machine is NOT insulated.
Contaminated Air
DANGER: WILL cause serious injuryDo Not run machine in an area or death.without good ventilation.
Silica Dust WARNING: Health Hazard Always use dust collector or Can cause silicosis, as serious andwater suppression to control dust. sometimes fatal disease.
Unit OverturnWARNING: Can cause serious injuryDo Not travel on steep inclines or or death.tram crosswise to grades. Do Not travel on soft or unstable ground, or close to unsupported excavations.
Moving Boom or Parts WARNING: Can cause serious injuryDo Not operate machine or boom or death.until all people are clear of the area. Do Not lubricate or service while machine is running.
High Pressure Air WARNING: Can cause serious injuryRelieve pressure on hydraulic and or Fluid or death.pneumatic systems before loosening hoses or connections.
1-2 Safety
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Safety Instructions
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 gasses contain carbon monoxide, a deadly poison, which is colorless and odorless.
• Do keep work areas clean and clear of cuttings, hand tools and other objects.
• Do place feed in horizontal position with feed resting on feed rest (if equipped) when tramming over rough ground or during long moves. When moving from hole to hole, be sure feed is high enough to clear ground obstacles. If feed hits something while tramming, feed can fall causing serious injury or death.
• Do Not use the machine for any other purpose than what it was designed for. This machine is designed for blasthole drilling operations only.
• Do Not wear jewelry or loose fitting clothing when working on machinery. 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.
After Operation
•Follow Shut Down Procedures as listed in Operator's Manual.
1-4 Safety
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Safety Instructions
Maintenance
• Do have two people present when performing service work, both being fully trained on the 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 must be established and understood by both persons.
• Do make 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 have adequate lighting when performing service work at night.
• Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.
• Do make sure machine and components are well supported before servicing or replacing parts.
• 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 an explosion.
• Do make sure no tools or other loose objects are left on the engine or drive mechanisms. They could be thrown by this equipment with a powerful force.
• Do Not service or perform maintenance while machine is running.
• Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can give off hydrogen which is a highly explosive gas.
• Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments.
• Do Not weld or grind near oil lines.
• Do Not attempt to remove radiator cap when engine is hot or has overheated.
Equipment Transfer
If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics:
• Safety Section
• Operation Instructions including:
•Pre-Start Checks
• Start-up
• After Start Checks
•Shutdown Procedure
•Tramming Machine
Safety 1-5
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