CAT BUCYRUS 49RIII ELECTRIC BLAST HOLE DRILL MAINTENANCE & OPERATION MANUAL BI005588 - PDF DOWNLOAD

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Technical Manual

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BI005588
BUCYRUS

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DANGER: I

THIS MANUAL IS INTENDED TO PROVIDE INFORMATION AND DATA FOR THE ANCE AND OPERATION OF THIS MACHINE. THE ELECTRICAL EQUIPMENT INVOLVED SHOULD BE SERVICED ONLY BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS AND PWM AC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER:

DO NOT ATTE MPT ANY MAINTENANCE, MECHANICAL OR ELECTRICAL, ON THIS WITHOUT A FULL UNDERSTANDING OF THE COMPONENT I OPERATION P NO INTERNAL PARTS. COMPONENTS UTILIZING ELECTRICAL

tOWER, PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSlC N SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.

,

The FEEDER CA13LE must contain a provision for ground connection, especially where 2,300 Volts and apove are utilized. The power line end must attach (see paragraph on ground circuits) tc a suitable permanent ground. The machine end must securely attach through a bolted ( onnection to ground the machine frame. This provides a constant ground for the maiChine and electrical equipment. Failure to provide this adequate ground endanger employees and equipment.

A POWER LINE CIRCUIT THAT IS ADEQUATE FOR THE MACHINE CANNOT BE OVE R-EMPHASIZED. Without a good grounding system, high voltage exists between th 3 machine and ground. The portable cable and power lines supplying the machine must ha\ ea ground wire, ample in capacity, running parallel to the main wires over the entire dis ance from the transformer to the machine. A suitable grounding system must be u sed at the transformer. Consult the local electric supplier for details.

DANGER:

DUE TO THE IN -1ERENT DANGERS IN THE OPERATION OF ANY HIGH VOLTAGE ELECTRICAL QUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE GROUNC CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOH, AND RELATED RELAYS AND SWITCH GEAR. A GROUND COr-. TINUITY CHECK SYSTEM IS ALSO RECOMMENDED. ;

BI005588
BI005588

Bucyru International Incorporated

1100 Mil aukee Avenue

P.O. Box 500

South M Iwaukee, WI 53172-0500, USA

Phone: ( 14) 768-4000

Fax: (41 ) 768-4210

This anual is divided into eight major sections covering the various s rvicable components of the 49RIII Blast Hole Drill. These sections are listed below.

Thi

BI005588
BUCVRUS
1- Introduction/Machine Familiarization ction 2- Machine Operation ction 3- Lubrication ction 4- Scheduled Maintenance 5- Major Maintenance S ction 6- Brakes and Couplings ction 7- Compressed Air ction 8- Heating, Ventilation and Air Conditioning
ction
IMPORTANT NOTE
document is protected under applicable copyright right laws to the extent available. Any un uthorized and unlawful reproduction, distribution, or other use shall be subject to liability.
1999 Bucyrus International, Inc. All rights reserved.
®
BI005588
BI005588
BI005588 · BUCYRUS ''''''lO BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077 SECTION 1- INTRODUCTION FORWARD 3 SAFETY PRECAUTIONS/HAZARDS 4 IN-OPERATION MAINTENANCE 4 PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK 5 GENERAL SAFETY CONSIDERATIONS 7 FIRE PREVENTION CONSIDERATIONS 10 STANDARD SIGNALS FOR CONTROLLING CRANE OPERATIONS 11 SAFETY SYM OLOGY 16 MACHINE P CARDS 17 OPERATION EAR ELECTRICAL TRANSMISSION LINES 18 PRESTART C ECKS 19 EXTE NAL INSPECTION 19 ONBO RD INSPECTION 22 PRESTART L BRICATION 25 MACHINE OV RVIEW 26 SPEC I (CATIONS TABLE OF YOUR 49RIII: 26 PROPEL MACHINERY 30 MAIN FRAME DECKS 31 MAST 1 32 MAIN AIR SYSTEMS 35 HYDRAULIC SySTEM 34 OPERATOR'S CAB 35 MANUAL NO. 10 6, SEPTEMBER 99 SECTION 1, INTRODUCTION - 1
BI005588 BUCYRUS INTERNATI?NAL INC. I CaMPANIA MINERA A TAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 14106011410681141077 BUCYRUS LIST OF IMAGES SUGGESTED EXTERN L INSPECT/ON 19 SUGGESTED ONBOA D INSPECT/ON PROCEDURE 22 RH PROFILE - DIMENS,/ONS 27 REAR PROFILE - DIMeNSIONS 28 PROPEL MACHINERY OVERVIEW 30 MAINFRAME OVERVIEW 31 MAST/MACHINERY OVERVIEW 32 AIR COMPRESSOR OVERVIEW 33 HYDRAULIC OVERVIEW 34 OPERATOR'S CAB OVfRVIEW 35 49RIII- COMPANIA MIN,ERAANTIMINA S.A. - DECKPLAN FO-1 2- SECT/ON 1, INTRO UCT/ON MANUAL NO. 10046, SEPTEMBER 99

This manual is! designed to assist you as 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. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result.

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

Sucy us International, Inc.

1100 ilwaukee Avenue

P.O. ox 500

Sout Milwaukee, Wisconsin, USA (414)-768-4000

53172-0500

It is Bucyrus In ernational's policy to improve its products whenever possible and practical to do so. The comp ny reserves the right to make changes or add improvements to it's machines at any time. This will e without incurred obligationsto install such changes on machines sold previously.

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

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 forTHIS SPECIFIC MACHINE. Order parts in the exact quantity needed. Parts ordered by mistake and returned ate subject to a re-handling charge. RIGHT HAND (RH) and LEFT-HAND (LH) parts correspond to _he operator's hands at the controls when operating the machine. Please state the correct maChiniSERIAL NUMBER (Serial Nos.141060, 141068 and 141077) when corresponding or contacting te factory service or parts departments. Records on each machine are filed by serial number nd when given this number, your machine's specific design and original equipment is accessed q ickly by theBucyrus International's parts representative.

BI005588 BUCYRUS
BUCYRUS INTERNATIONAL INC. OMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
FORWARD
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 3

The importance of overall safety in the maintenance of mining equipment should always be emphasized. Many cdtical components are subject to wear and other deterioration that limits their useful life and makes expendable. When new, all such parts have a built-in reserve strength against these factors reasonable loss of durability from gradual wear. If, however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the machine also cotlstitutes a safety problem. Study this manual carefully and follow all recommended to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of the e procedures. Supervisors, operators and maintenance personnel should continuously follow sa e practices.

IN-OPERATION MAl TENANCE

Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. In-operation deficiencies should be carefully investigated. It should be determined if a safety problem exists. Remember that maintenance is vital to safe operation. It should be performed systematically by competent personnel.

From an economic it is advisable to perform as much of the upkeep as can be safely accomplished while machine is running. Obviously, there are some maintenance procedures, such as gear tooth and compressor maintenance, which require machine shut down. However, many supp<l>rt duties can be safely and effectively handled at shift change when the machine is still activated.

Some parts of the machinery may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator's hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

DANGER: MAKE SURE ALL GUARDS, COVERS OR OTHER SAFETY DEVICES ARE PROPERLY INSTALLED BEFORE OPERATING THIS EQUIPMENT AFTER PERFORMING MAINTENANCE OR REPAIRS. FAILURE TO HEED, COULD RESULT IN SERIOUS INJURY OR DEATH. A REPAIR OR MAINTENANCE TASK IS NOT COMPLETE UNTIL ALL GUARDS, COVERS OR OTHER SAFETY DEVICES REMOVED TO PERFORM THE TASK HAVE BEEN PROPERLY REINSTALLED.

BI005588 BUCYRUS INTERNATI NAL INC.
CaMPANIA MINERA A TAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 14106011410681141077
. BUCYRUS '''''lO
SAFETY PRECAUTI NS/HAZARDS
4- SECT/ON 1, INTRa VCT/ON MANUAL NO. 10046, SEPTEMBER 99

PRECAUTIO S BEFORE AND DURING MAINTENANCE WORK

The operator must be sure the equipment is in a safe position before repairs or adjustments are made. The should not be endangered by falling rock or a yielding support surface.

Before beginning repair or adjustment, the operator shall:

the rotary drive unit and tool string.

*Oe-en rgize and tag control functions.

*00 w atever else is necessary to prevent accidental movement of the machine.

AD4 NGER: I !

ALL PERSONNEL MUST BE CLEAR OF ELECTRICAL, MECHANICAL AND HYDRAULIC COMPONENT HAZARDS IF IT IS NECESSARY TO RUN THE MACHINE, OR CONTROLS DURING A REPAIR ACTIVITY.

Prior to beginnIng any work, maintenance personnel must notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the engine must be shut off, the engine key in the "OFF" position with the key removed, and the controls should be tagged. The machine should only be returned to service when the maintenance personnel have completed all maintenance and have notified the appropriate personnel.

Approved protection equipment such as hard hats, gloves and safety glasses should always be worn around the machine. When the engine is running, hearing protection should be worn.

While performil1g maintenance, the awkward positions encountered often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical lifting and handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing materials, ladders and scaffolding. Service crews should have a fundamental knowledge of lIfting practices so their knees and legs are used rather than their backs.

BI005588 BUCYRUS BUCYRUS INTERNATIONAL INC CaMPANIA MINERA ANTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 5

DANGE :

MANY OF THE COMPONENTS OF THE 49RIII DRILL ARE HEAVY, BULKY ITEMS. EXTREME CAUTION SHOULD BE USED WHEN LIFTING. PERSONNEL SHOULD BE CERTAIN OF THE WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT THEM, EITHER MANUALLY OR WITH SOME LIFTING DEVICE. FOLLOW ALL APPLICABLE SAFETY RULES WHEN USING CRANES OR OTHER LIFTING EQUIPMENT. BE SURE OF THE LOAD, LIFTING HEIGHT AND RADIUS, AND CAPACITY OF THE LIFTING DEVICE BEFORE LIFTING. FAILURE TO FOLLOW ALL APPLICABLE SAFETY RULES WHEN LIFTING CAN CAUSE SERIOUS INJURY OR DEATH.

CAUTIO,:

WHEN REMOVING CERTAIN MACHINE PARTS FOR MAINTENANCE OR REPLACEMENT PURPOSES, IT MAY BE A PRACTICE TO LOOSEN THESE PARTS BY STRIKING THEM WITH A SLEDGE-HAMMER. USE EXTREME CAUTION WHEN STRIKING METAL PARTS AS CHIPS MAY FLY OFF WITH GREAT FORCE AND POSSIBLY CAUSE SERIOUS INJURY. WEAR ADEQUATE PROTECTIVE CLOTHING TO INCLUDE A FACE SHIELD. ALTERNATE METHODS OF REMOVAL MIGHT INVOLVE USING A DUCTILE METAL HAMMER OR A HYDRAULIC JACK WITH SUITABLE FIXTURES.

BI005588 BUCYRUS INTERNATlbNAL INC. CaMPANIA MINERA A TAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 14106011410681141077 BUCYRUS ''''''lO
I
6- SECT/ON 1, INTRa VCT/ON MANUAL NO. 10046, SEPTEMBER 99

GENERAL SAFETY CONSIDERATIONS

The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way;to minimize machine downtime and maximize productivity of equipment.

All personnel should be familiar with the location, usage, and operation of all onboard First-Aid kits, fire extinguishers, and other safety/emergency equipment.

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

l15 minutes at 115 dBa

When i 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.

Keep hands, feet, and clothing away from rotating parts.

Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury.

Wear a hardhat, safety shoes and protective lenses at all times.

Do not move or operate the machine without first knowing the location and purpose of all p¢rsonnel, test or support equipment, on or near the machine.

Always wear a safety belt or harnesswhen the danger of falling exists.

BI005588 · BUCYRUS BUCYRUS INTERNATIONAL INC. OMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 7

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Always have a second person to monitor the lifeline when working in confined spaces.

Replace any and all safety and warning placards if they are defaced or removed from the machiine.

Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation.

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 of skin contact refer to the Material Safety Data Sheet (MSDS) for that materipl and the suggested method of cleanup.

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 sh<l>uld 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, Pi,' e 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.

Inspect safety !catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off oIf the hook if they are not functioning properly.

If a heavy iteITl begins to fall, let it fall, don't try to catch it.

When disasse bling a machine, be sure to use safety stands and adequate cribbing to pre ent tipping or rollover of components.

BI005588 BUCYRUS INTERNATIONAL INC.
CaMPANIA MINERA MJTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
BUCYRUS
8- SECT/ON 1, INTR DUCT/ON MANUAL NO. 10046, SEPTEMBER 99

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.

Check all wire ropes for telltale signs of premature wear or failure. Refer to the topic in Section 5 of this manual "Wire Rope Care and Maintenance" for more information.

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.

When Ulsing 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. Alwaysbe 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 to promptly reinstall safety devices, guards or shields after adjusting and/or the machine.

After s rvicing, be sure all tools, parts or servicing equipment are removed from the machin ,and secured in an appropriate storage area.

Protect ve eye goggles should be worn at all times when working on the airconditi ning system. Work on the air conditioning system only in a well ventilated area.

BI005588 .. BUCYRUS '''''l" BUCYRUS INTERNATIONAL INC CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 9

Wipe away ex¢ess lubricants around bearings and gears. Never lubricate parts in motion.

Mechanical Brakes are designed for use as static. holding brakes only. Use as a motion (dynaniic) brake in emergency situations only.

FIRE PREVENTION aONSIDERATIONS

Always have a "charged" fire extinguisher on hand and know how to use it. Inspect and service th extinguisher as indicated on its instruction plate.

DO NOT smo e while handling flammables or when near batteries.

Inspect all line ,tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 of this manual for the Scheduled Maintenance and the Walk Around Inspection procedure.

Repair or replClce loose or damaged lines, tubes, and hoses as soon as possible.

Make certain tlhat all clamps, guards, and shields are replaced correctly so as to prevent vibrati¢>n and the chafing of parts during operation.

DO NOT carrylflammable 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 reSlidue.

NEVER weld, urn, or perform service on the machine alone.

BI005588 BUCYRUS INTERNATIONAL INC. CaMPANIA
- 49RIII
141060/1410681141077 BUCYRUS
MINERA AIVTAMINA S.A.
ELECTRIC BLAST HOLE DRILL -
10 - SECT/ON 1, INTR DUCT/ON MANUAL NO. 10046, SEPTEMBER 99

STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to the signalling used in communication between maintenance personnel and crane operators during the maintenance cycle.

HOIST

Extend forearm upward, keeping forefinger extended and pointing up, make small circular movements with hand.

LOWER

Extended arm downward, keeping forefinger extended and pointed down, make small circular movements with hand.

MAIN HOIST

Tap fist on head until signal received by operator, then use standard signals.

USE WHIP LINE

(Auxiliary Hoist) Tap elbow with open hand until signal received by operator, then use standard signals.

BI005588 BUCYRUS '''''lO BUCYRUS INTERNATIONAL INC CaMPANIA MINERA ANTAMINA S.A. - 49RI/1 ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 11

RAISE BOOM STOP

Extend arm fully with fingers closed and thumb pointing upward.

Extend arm fully with fingers extended and palm facing down.

EMERGENCY STOP With arm fully extended, fingers fully extended and palm facing down, move arm rapidly alonga horizontal plane.

TRAVEL

With arm extended forward, hand open and raised at wrist, make a pushing motion in the desired idirection of movement.

BI005588 BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077 BUCYRUS ,"'
12 - SECTION 1, INTR DUCT/ON MANUAL NO. 10046, SEPTEMBER 99

DOG EVERYTHING Clasp hands together in front of body.

TRAVEL (both tracks) With both fists clenched in front of body, make a circular motion with the desired direction of motion (forward or reverse) duplicated with fists. (crawler cranes only)

LOWER BOOM

Extend arm fully with fingers closed and thumb pointing down.

MOVE SLOWLY

While giving any motion signal, hold other hand motionless in front of desired signal hand. (Hoist slowly is example provided)

BI005588 BUCYRUS BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 13

RAISE BOOM AND LOWER LOAD Extend arm horizontally with fingers extended and thumb pointing upward, alternately open and close fingers for the duration of the desired movement.

LOWER BOOM AND liSE LOAD Extend arm with fingers extended and thumb pointing downward, alternately open and close fingers for the duration of the desired movement.

SWING

Extend arm horizontally with index finger extended in desired direction of swing.

TRAVEL

(SingleITrack) Use a raised fist on the side that remains locked and make a vertical circulan motionin front of chest for the directin and side of desired movement.

(crawler cranes only)

BI005588 BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077 BUCYRUS
i
14 - SECT/ON 1, INTR DUCT/ON MANUAL NO. 10046, SEPTEMBER 99

EXTEND BOOM

(Telescoping Booms) Place both hands in front of bodywith palms upward, fingers clenched, and thumbs extending outward.

EXTEND BOOM

(Telescoping Booms) Place both hands in front of bodywith palms upward, fingers clenched, and thumbs extending inward.

(Telescoping Booms) With fingers clenched and thumb extended toward body, use a single hand motion to tap on chest with thumb of hand.

RETRACT BOOM (Telescoping Booms) With fingers clenched and thumb extended away from body, use a single hand motion to tap on chest with heel of hand.

BI005588 BUCYRUS BUCYRUS INTERNATIONAL INC . CaMPANIA MINERA ANTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
I MANUAL NO. 10q46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 15

SAFETY SYMBOLOGY A

The safety alert symbCl>ls displayed here, and throughout this manual, is used to call your attention to instructions concerrning your personal safety. Carefully read and follow these instructions and observe all NOTE, CAUTION and DANGER graphics mounted on various areas of 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 signal is used.!

NOTE: THIS J/GNAL WORD DENOTES AN ITEM OR REQUIRED INFORMA TlON TO THE EQUIPMENT. A LOSS OF TIME, ASSETS, OR MINOR INJURY MAY RESULT IF THE APPROPRIATE ACTION IS NOT TAKEN.

ACAUTION.:

THIS SIGNAL WORD SERVES AS A REMINDER OF SAFETY PRACTICES, OR DIRECTS ATTENTION TO SPECIFIC SAFETY PRACTICES WHICH COULD PREVENT POSSIBLE INJURY IF PRECAUTIONS ARE NOT ADHERED TO.

ADANGER:

THIS SIGNAL WORD DENOTES AN IMMINENTLY DANGEROUS HAZARD WHICH COULD RESULT IN DEATH, GRIEVOUS BODILY INJURY, OR SERIOUS DAMAGE TO EQUIPMENT IF NOT ACKNOWLEDGED AND THE APPROPRIATE ACTION TAKEN.

DANGER:

THIS SIGNAL WORD DENOTES AN IMMINENTLY DANGEROUS ELECTRICAL HAZARD WHICH WILL RESULT IN DEATH, GRIEVOUS BODILY INJURY, OR SERIOUS DAMAGE TO EQUIPMENT IF NOT ACKNOWLEDGED AND THE APPROPRIATE ACTION TAKEN.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy hit!l1self and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that and that all the methods used are safe and correct. Fact· ry service representatives and specialists are available to provide additional information or technic I assistance. The operator must be alert, physically fit, and free from the influence of alcohol, dr g5, or any medications that might impair his eyesight, hearing or reactions.

Safety must always b paramount! Consult your supervisor when safety is in doubt.

BI005588 BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077 BUCYRUS ''''''lO
MANUAL NO. 10046, SEPTEMBER 99

MACHINE PLACARDS

The image below depicts only an example of the warning placards mounted on your machine as it was delivered from Bucyrus International. These hazard warning placards convey information to operator's, maintenance personnel, and anyone who will be on, or near, the machine. The information is designed to help prevent situations which will terminate in injury or damage to personnel, or the machine.

Please ensure that these placards remain undamaged and intact!

BI005588 · BUCYRUS BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
FOR MINIMUM CLEARANCES OF HIGH VOLTAGE LINES IN EXCESS OF SUII VOLTS SEE YOUR LOCAL, STATE AND FEDERAL REGULATIONS, DO NOT DEFACE OR REMOVE THIS SIGN FROM THE MACHINE, "w""
OR INJURY MAY RESULT FROM DEATH CONTACTING ELECTRIC LINES. TO PLACE ANY PART OF THIS UNLA 'AIFUL MACHINE OR LOAD WITHIN 10 "I FEET OF HIGH VOLTAGE LINES OF 50,000 VOLTS OR LESS.
MANUAL NO, 10q46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 17

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 p'IJrposes of this manual you are considered to be working in the vicinity of power lines when the rJ1achine, in any position, can reach to within the minimum distance specified by local, state and 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:

Always contact the owners of the power lines or the nearest utility before beginning work.

You and the electric utility representative must jointly determine what specific precautions must be taken to insure safety.

It is the responsibility of the user and the electric utility to see that the necessary precautions are taken.

Consider to be power lines and treat all power lines as energized even though it is known that power is shut off and the line is visibly grounded.

Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.

Caution all ground personnel to stand clear of the machine at all times.

Use a signal p$rson to guide the machine into close quarters. The sole responsibility of the signal person lS 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 signals.

BI005588 BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA AfrJlTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
BUCYRUS
I I
1. 2. 3. 4. 5. 6. 7.
18 - SECTION 1, INTRPOUCTION MANUAL NO. 10046, SEPTEMBER 99

DANGER: DEATH OR SERIOUS INJURY COULD 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.

SUGGESTED EXTERNAL INSPECTION

BI005588 .. BUCYRUS '",". BUCYRUS INTERNATIONAL INC CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10 46, SEPTEMBER 99 SECTION 1, INTRODUCTION - 19

9.

Inspect the crawler belts for broken or cracked pads, missing lock pins, loose track pins, and proper crawler belt tension.

Check the drive tumbler gearcase, hydraulic motor and hoses for leaks. Check the lubricant level in the drive tumbler gearcase.

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.

Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or covered with c\.Jttings.

Inspect the trajl cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make 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 CARRIES A LETHAL VOLTAGE. HANDLE THE CABLE IN AN APPROVED MANNER WITH APPROVED RUBBER GLOVES AND INSULATED HOOKS OR TONGS.

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.

Inspect the leveling jack spuds for proper lubricant covering. Inspect the leveling jack pads for qracks, broken or missing pins, or excessive dirt accumulation.

Inspect the mtt braces and locking pins. Replace missing or defective components immediately. erify that all adjusting bolts are properly adjusted. Check all hoses and cylinders for Ie king.

ACAUTION!: USE A SAFETY BELT AND LANYARD TO PROTECT AGAINST FALLS WHEN CLIMBING ON THE MAST BRACES OR WORKING ON THE MACHINERY HOUSE ROOF.

10. Inspect the m st hinge pins for loose or missing keepers or bolts. Replace missing or damaged p rts immediately. Check the pins for sufficient lubrication and lubricate if necessary.

BI005588 BUCYRUS INTERNATIONAL INC. CaMPANIA MINERA ANTAMINA S.A. - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077 BUCYRUS
2. 3. 4. 5. 6. 7. 8.
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20 - SECT/ON 1, INTR DUCT/ON MANUAL NO. 10046, SEPTEMBER 99

11. Inspect the mast hoist cylinders for loose or missing pins or keepers, oil leaks, damaged hoses or structural damage. Repair or replace any missing or damaged components immediately.

12. 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.

13. 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.

14. Check the safety restraint cables on the mast. Be certain that the cables and supports are in goodl repair with no cracks, missing or loose hardware or any damage that could affect their

15. Every 1160 hours inspect the upper auxiliary winch sheaves. All pins, keepers and hardware should be secured.

16. Check the machinery house air filtering fan duct to see that it is clear of obstructions.

BI005588 .. BUCYRUS '","'lO BUCYRUS INTERNATIONAL INC CaMPANIA MINERA ANTAMINA SA - 49RIII ELECTRIC BLAST HOLE DRILL - 141060/1410681141077
MANUAL NO. 10046, SEPTEMBER 99 SECTION 1, INTRODUCTION - 21

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