CAT BUCYRUS-ERIE 47-R Blast Hole Drill OPERATORS MANUAL BI005457 - PDF DOWNLOAD

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© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

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OPERATOR1S MANUAL

BUCYRUS-ERIE

Blast Hole Drill

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FOREWORD This manual establishes guidelines and furnishes general instructions for the operation of the BucyrusErie® 47-R Rotary Blast Hole Drill.

This drill can be powered either by a diesel engine or an electric trail cable. In either case, all motions are fully electric. The drill consists of three major units; the lower works, the mainframe, and the mast.

The lower works provides a foundation for the mainframe and contains most the necessary components to propel the drill.

The mainframe is mounted upon the lower works and contains the bailing air compressor, hoist machinery, and all controls to operate the drill. The machinery hou'se encloses most of the mainframe. The operator's cab is located at the rear of the mainframe and contains the operator's station.

The mast is mounted to the rear of the mainframe and contains the machinery required for rotation and handling of the tool string.

This manual is divided into seven sections: SECTION 1 - Safety Precautions and Prestart Checks SECTION 2 - Controls-Function and Location SECTION 3 - Start-Up SECTION 4 - General Operation SECTION 5 - Drilling SECTION 6 - Shut Down APPENDICES

A ~AUTION:

Before attempting to operate the drill, read this manual completely.

Familiarize yourself with the contents of this manual so that you can easily locate particular information when you need it.

Throughout this manual the words CAUTION, WARNING and NOTE appear in bold face type.

CAUTION is preceded by the safety alert symbol and indicates that injury to personnel could occur if the proper procedures are not followed during operation or maintenance. Always read the CAUTION note carefully and use extreme care while performing that particular function.

A

WARNING indicates a possible hazard to the machine or its components ifthe proper procedures are not followed. Whenever the word WARNING appears, special attention should be given to prevent possible equipment damage.

NOTE is used to stress a point or to give additional information concerning the procedure being discussed.

These CAUTION's and WARNING's are not all-inclusive. It is impossible for Bucyrus-Erie Company to know, evaluate, and advise maintenance and service personnel in every conceivable way a service operation might be performed and of the resulting possible hazardous consequences of each method. It is therefore extremely important that anyone who uses a service procedure or tool which is not recommended

by Bucyrus-Erie Company to first satisfy himself that the service procedure or tool he chooses will not jeopardize his own safety, the safety of others, or cause machine or component dam'1ge.

Every effort has been made to make this manual as complete and accurate as possible at the time of publication. Bucyrus-Erie Company reserves the right, however, to continually improve its products.

Therefore changes to the equipment described herein may have been made that are not reflected in this manual.

MACHINE SERIAL NUMBER

_ BUCYRUS-ERIE COMPANY General Offices: South Milwaukee, Wisconsin, U.S.A. .1M SPS 384 ·SJ BUCYRUS-ERIE COMPANY, 1984

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TABLE OF CONTENTS PAGE Section 1 - SAFETY PRECAUTIONS AND PRESTART CHECKS 1 Safety 1 General 1 1 Specific Safety Rules Operation Near Electrical Transmission Lines , " 1 Prestart Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 Outside Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 On-Board Inspection 4 Prestart Lubrication 7 Section 2 - CONTROLS-LOCATION AND FUNCTION Introduction Operator's Console Controls Machinery House Controls Miscellaneous Controls

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9 9 , 9 17 20

Section 3 - START-UP 25 Introduction 25 Electric Machine Start-Up 25 Diesel Machine Start-Up 27 Cold Weather Start-Up 27 Machinery Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 Break-In of New Components 29 Main Air Compressor (Vane Type) 29 Rotary Drive Gearcase 29 Hoist-Propel Gearcase 29 Electric Motors .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 Section 4 - OPERATION-GENERAL 31 Introduction 31 Propelling " 31 Straight Propel-Forward or Reverse " , 31 Steering " ::>3 Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35 Mast Raising and Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37 Mast Raising Standard Mast 37 Mast Lowering Standard Mast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39 Mast Raising with Back Braces 40 Mast Lowering with Back Braces 41 Hoist Machinery Operation 42 Hydraulic Mode 42 Electric Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43 Auxiliary Reel Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43 Hydraulic Mode 43 Electric Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Tool Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45 General Operating Procedure 45 Pipe Loading and Unloading 45 Drill Tool String Assembly 46 Casing Tong Operation 51 Drill Tool String Disassembly 53

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Adding Additional Drill Pipe Removal of Multiple Section Drill Pipe Center Guide Operation Dust Suppression System Operation Pipe Positioner and Casing Tong Crane Operation

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55 56 56 57 58

61 Section 5 . DRILLING Vertical Drilling : 61 General Operating Procedures 61 Beginning the Hole (Collaring) " , 61 Normal Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 63 Ending the Hole (Reaming) 64 Ending the Hole (Multiple Pipe Sections) 64 Drilling Difficult Formations , 65 Unconsolidated Materials 65 67 Wet or Sticky Formations Angle Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67 67 General Operating Procedures Preparing to Move . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68 Section 6 . MACHINE SHUT DOWN General Considerations Shut Down Procedure Short Term Storage Long Term Storage Attended Long Term Storage Unattended Long Term Storage

69 69 69 69 70 70 71

APPENDICES Appendix 1 Appendix 2 Appendix 3 Appendix 4 Appendix 5 -

1A 3A 5A 7A 9A

Tool Recovery Static Condition Stabilities Pipe Size Limitations Pipe Loading and Unloading Alternate Procedure Lube Charts

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SECTION 1 - SAFETY PRECAUTIONS AND PRESTART CHECKS SAFETY GENERAL Safe operation of a rotary blast hole drill promotes personal safety and minimizes delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to help prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon a good sense of judgement and alertness on the part of the entire mining crew.

SPECIFIC SAFETY RULES The following is a list of some important safety rules relating to prestart and operation of the 47-R drill. The safety instructions given in this manual cover normal daily operations of the machine.

Additional precautions may be necessary to cover un us ual circums tances. Be cons tan tly alert for any potentially dangerous conditions and take action as necessary to correct the conditions immediately.

•

Wear hard hat, safety shoes and safety glasses at all times.

•

When operating or performing maintenance functions, wear snug fitting clothing. Loose clothing can be caught on controls or in moving parts. Remove all jewelry.

•

Keep the operator's cab, ladders, walkways and steps free of materials which cause slippery conditions or obstacles which create tripping hazards.

• •

Use proper interior and exterior lighting.

Do not allow unauthorized personnel on boarq. the machine while in operation.

•

Do not begin operation until all personnel are clear of the machine or in a safe position on the machine.

•

Use audible signals to warn ofmachine movements. A signal horn button is provided for this purpose.

•

Do not propel until the travel route has been cleared of obstructions.

•

Ensure that all personnel are clear of the machine when propelling.

•

Do not propel the machine on a slope greater than specified in the stability limits in appendix.

•

Do not leave the rotary gearcase suspended in the air when leaving the machine unattended.

•

Always wear approved rubber gloves, and use insulated hooks or tongs when handling trail cable.

•

Install and maintain proper grounding and ground fault protection systems.

•

Allow electrical inspection and maintenance to be performed only by a qualified electrician.

•

Prevent trail cable from being dragged on the ground for long distances or at high speeds.

•

Limit the amount of cable being dragged by the machine. Pulling too much cable will damage both the cable and the machine.

•

Use extreme caution when working around loaded blast holes.

OPERATION NEAR ELECTRICAL TRANSMISSION LINES* *Permission to reproduce the following material has been granted by the Construction Industry Manufacturers Association (CIMA). CIMA assumes no responsibility for the accuracy of this reproduction.

A. CAUTION: The following precautions . . shall be complied with whenever operating near electrical transmission lines.

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual you are considered to be working in the vicinity of power lines when the machine, in any position, can reach to within the minimum distance specified by local, state and federal regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.

" BUCYRUS-ERIE COMPANY, 1984

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Be certain to comply with all local, state and federal regulations regarding working in the vicinity of power lines.

OUTSIDE INSPECTION (Figure 1) 1.

Check areas around and under the machine for signs of oil, water, or grease leaks. If single droplets are noticed, leakage is minimal.

Determine the source of the leak and make note of it on the log sheet. If pooling of oil, water, or grease is noticed, determine the source and take remedial action immediately.

2.

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

3.

Inspect the drive chains for missing or broken pins and proper tension. Inspect the sprockets for loose or missing keeper bolts and broken or cracked teeth.

4.

Inspect the erawIer frames for cracks and dirt or ice buildup. Check the rollers and tumblers for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and bolts.

5.

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

6.

Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp rocks. Inspect the strain relief device and the condition of the cable where it enters the machine.

Before working in the vicinity of power lines, always take the following precautions: 1.

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

2.

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

3.

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

4.

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

5.

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

6.

7.

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

Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.

h CAUTION: Death or serious injury . . could result should any part ofthe drill come within the minimum distance specified of an energized power line.

h 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.

7.

Inspect the dust hoppers and ducts ofthe dust control unit. All seals and doors should be intact. Empty the dust hoppers and clean the ducts if necessary.

8.

Drain both air receivers of condensation. It is necessary to go underneath the machine to do this. At this time inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or damage.

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 gearcase, 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.

2

h CAUTION: I£loose wires are noted do . . not touch -them but notify an electrician immediately.

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9

OUTSIDE INSPECTION FIGURE 1

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10.

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

climbing on the back braces or working on the machinery house roof.

12.

Inspect the mast locking wedges and cylinders for proper lubrication, wear, and damage.

11. On machines equipped with back braces inspect the back braces,locking pins, retainer pins and cotter pins. Replace missing or defective components immediately. Verify that all adjusting bolts are properly adjusted.

h CAUTION: Use a safety belt and . . lanyard to protect against falls when

Inspect the mast hinge pins for loose or missing keepers or bolts. Replace missing or damaged parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.

13. 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.

14.

Inspect the mast structure for bent or broken chords or lacings, loose or broken parts,

• BUCYRUS-ERIE COMPANY, 1984

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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.

Verify that the mast stops on the mainframe are in place.

15. Check the main air flex hose, grease lines, and electric lines running from the mast to the rotary drive unit for interference with the mast or excessive wear or leaks.

16. Check the safety restraint cables on the mast.

Be certain that the cables and supports are in good repair with no cracks, missing or loose hardware or any damage that could affect their effectiveness.

17.

Every 160 hours inspect and lubricate the upper chain sprockets and auxiliary reel sheaves. All pins, keepers and hardware should be secured tightly.

ON-BOARD INSPECTION (Figures 2, 3,) 1.

Check the oil level in the auxiliary air compressor. Add oil to the proper level if necessary. Check the drive belts for proper tension,

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excessive wear or broken belts. Verify proper adjustment when new belts have been installed.

/). CAUTION: Do not remove the belt . . guard unless the air compressor switch in the operator's cab has been turned off and the breaker on the control cabinet in the machinery house has been turned offand tagged.

Serious injury could result ifthe compressor should start while servicing the compressor belts.

2.

During freezing weather add alcohol to the antifreezer (if so equipped).

/). CAUTION: Serious personal injury . . will result if the fill plug of the antifreezer is removed with pressure in the system. Relieve all pressure from the air system and shut off the air compressor before servicing this unit. /). CAUTION: Alcohol is flammable. Do . . not use alcohol while smoking or near possible ignition sources. Consult the alcohol distributor for specific safety precautions.

Store alcohol in an approved metal container outside of the machinery house.

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3.

Check the tension on the drive belts of the main air compressor. Check the belts for cracks or wear.

7.

Check the oil level in the hydraulic tank. Fill the tank to the proper level as described on the instruction plate on the tank.

/). CAUTION: Donotremoveguardunless . . the control power breaker in the machinery house has been locked in an offposition and the compressor test started to verify that the compressor will not start. Serious personal injury will result if the compressor starts while the drive belts are being serviced.

8.

Check the hydraulic system for leaks. Correct all leaks immediately and clean up all oil spills immediately.

9.

If the machine is equipped with a bit lubricator for the main air system, check that the lubricator is full. Hand crank the lubricator to verify operation of the injector.

10.

Inspect the automatic lubrication central pumping stations for proper operation. Check the supply of lubricant and change or refill drums as necessary.

11.

Close and lock all electrical cabinet doors.

4.

Inspect the main air compressor lubricaiton lines for leaks. Correct any leaks found immediately.

5.

Check the oil level in the main air compressor lubricator. Fill the lubricator to the top of the upper window with an approved oil. Hand crank the lubricator to verify operation ofthe injectors. (vane compressor)

6.

Check the condition of the main air compressor intake filter. Replace the filter cartridge if the red flag is visible in the service indicator.

Empty the dust hopper and clean the precleaner element. Inspect the housing and ductwork for damage or leaks. Repair or replace leaking components.

/). CAUTION: Assume all parts inside of . . the electrical cabinets to be energized.

All electrical components should be serviced by qualified electrical personnel only.

12. Inspect the compressor radiator and fan.

Check for signs of deterioration or damage to hoses, valves, fitting, etc. Check for leaks at all joints. Check the radiator core for blockage by dust, dirt, leaves, paper, etc. and clean as necessary.

~ BUCYRUS-ERIE COMPANY, 1984

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13. Check the phase sequence indicator light. If the lamp is not lit contact qualified electrical service personnel before starting the machine.

14. For diesel powered machines conduct the prestart inspections as required by the engine manufacturer.

15. Inspect the machinery house for general cleanliness. Clean all dirt and debris from the machinery house.

WARNING: Do not use compressed air to clean the machinery house. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the machine.

Failure to clean the inside of the machinery house will cause damage to many ofthe components located there.

16. Check the coolant level in the air compressor radiator. Add coolant as required to fill the radiator.

A. CAUTION: Due to the location of the . . radiator compartment handrails can not be placed on the compartment roof. Use a safety belt and lanyard to protect against falling from the compartment roof. Remove the radiator cap slowly and use suitable protection against escaping steam to prevent serious injury.

17. Inspect the auxiliary reel, auxiliary reel brake and auxiliary reel line.

18. Check the oil level in the hoist-propel gearcase. Fill with recommended oil to the proper level.

19. Inspect the hoist brake for proper adjustment, excessive band wear, proper band alignment, loose or broken linkage, missing keeper pins, etc. Repair or replace missing or damaged parts immediately.

20. Inspect the pulldown chains and sprockets for bent or missing links, proper lubrication, proper timing and excessive wear or dirt buildup.

21. Inspect the intermediate propel chains for proper adjustment, bent or broken links, or excessive wear or dirt buildup.

22. Inspect the propel brakes for proper adjustment, excessive band wear, loose or broken linkage, missing keeper pins, etc. Repair or replace missing or damaged parts immediately.

6

23. Inspect the area around the hoist-propel gearcase for oil, grease or air leaks or other missing or damaged equipment.

24. Inspect the pulldown chain equalizer cylinder for leaks or damage. Make sure that the ram has not extended to the maximurn stroke of 6 inches. If the ram is bottomed out, the pulldown chains will have to be shortened before starting the drill.

25. Inspect the area behind the operator's panel for oil, air or water leaks.

26. Check all controls for free operation. Return all controls to the "off' or "set" position.

27. Inspect the operator's cab for housekeeping and cleanliness. Clean dirt and debris from the cab. Clean the windows to give full visibility for proper operation.

WARNING: Do not use compressed air to clean the operator's cab. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the cab.

28. Inspect the tool wrenches for free operation, broken or missing parts, proper lubrication, oil leaks or dirt accumulation. Repair or replace parts as necessary and clean the drilling platform.

A. CAUTION: Before working near or . . under the rotary drive unit, make sure all of the operator's controls are off and tagged and the hoist brake set to prevent movement ofthe unit. Serious personal injury or death could result should the rotary drive unit fall when personnel are working near or under it.

29. Inspect the casing tong and breakout cylinder for free operation, broken or missing parts, proper lubrication, oil leaks or excessive dirt accumulation. Repair or replace parts as necessary. Be certain that the breakout cylinder is stored properly out of the way of the rotary gearcase and fully retracted. Be certain that the casing tong is secured out of the way.

30. Inspect the tool racks for broken or missing parts, proper operation, dirt accumulation, or oil leaks. Be certain that the pipe gate is closed and that the rack is in the retracted position and locked.

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31. Inspect the guide bushing for excessive wear or dirt accumulation. Also inspect the retainer lugs to be sure they are intact. Do not operate the machine without both retainer lugs intact and securely welded to the deck.

32. Inspect the tool string for excessive wear, dirt accumulation, bent pipe and secure joints.

The bit cones and bearing should be in good condition. Manually turn the cones to make sure they turn freely.

33. Inspect the rotary gearcase for oil leaks, damaged lines, dirt accumulation and other damaged or missing parts. Check the oil level in the gearcase. Fill to the recommended level with an approved gear oil. Check the rotary motor ventilation inlets for leaves, paper, rags, etc. blocking the flow of air.

34. Inspect the rotary drive unit for excessive wear or dirt accumulation. Also inspect the pulldown sprockets for excessive wear.

Inspect the rack pinions for excessive wear, proper lubrication, and tight retainer bolts.

Inspect the slide shoes for proper adjustment and excessive wear. Check for loose or missing bolts and bent or cracked structural members.

35. Inspect the equalizer sprockets for free operation, proper lubrication, excessive wear, and loose or missing hardware.

36. Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation. The deflector should seal around the drill pipe securely.

PRESTART LUBRICATION Lubrication of the 47-R blast hole drill is extremely important. Most drills come equipped with automatic lubrication systems that lubricate most of the necessary points at regular intervals. These systems, although automatic, are not foolproof.

Broken lines, dirty lubricant, faulty feeders, and a whole range of other problems can cause wearing parts to loose lubrication. For this reason, it is important that all lubrication points be inspected every shift to verify that they are receiving lubrication. Also, there are several points for lubrication that either need lubrication very infrequently, or are not possible to pipe into the automatic system. These points will need lubrication applied manually.

The lube charts in the appendix give the location and frequency of lubrication.

The lubricant used should be kept clean. If possible the lubricant should be supplied in unopened containers. Be careful when changing containers on the automatic system to keep the pump and drum cover clean.

When using a manual gun wipe each fitting and the grease gun fitting before injecting the lubricant. Use clean containers and funnels for oils and grease for transferring to the gearcases or reservoirs. Do not allow water to enter any gearcase, oil reservoir or container. Wipe off all fill caps before removing them.

., BUCYRUS-ERIE COMPANY, 1984

7 (8 blank)

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SECTION 2 - CONTROLS - LOCATION AND FUNCTION INTRODUCTION Regardless of previous experience, the new operator of any machine must become familiar with the location and function of all of the operating controls before he can begin to operate the machine.

Since this manual covers all possible controls that could be used on the 47-R drill, he should familiarize himself wi th both this manual and the particular machine being operated.

For the purpose of this manual, the operating controls have been divided into three groups, depend· ing upon their location. These three groups are: 1.

Operator's Console Controls

2.

Machinery House Controls

3.

Miscellaneous Controls

h CAUTION: Read and become familiar . . with this manual before attempting to operate any of the machine controls. Pay particular attention to the caution and warning statements, and any federal, state, local or company safety rules relating to the machine. Failure to be aware of and understand the hazards associated with the operation of the controls may lead to death, personal injury or serious machine damage.

OPERATOR'S CONSOLE CONTROLS (Figures 4 and 5) WARNING: All of the hydraulic controls (1 through 13), with the exception of the hoistpulldown selector (5), will automatically return to the neutral position when released.

This is a safety feature and should not be used during normal operation. The controls should be moved from and returned to the neutral position slowly. Failure to operate the controls smoothly will lead to machine damage.

1,2,3,4. LEVELING JACK CONTROLS The leveling jack controls are used to raise or lower the leveling jacks at the four corners of the machine. There are four controls, one for each leveling jack. No.1 lever controls the left-hand rear jack, No.2 lever controls the left-hand front jack, No.3 lever controls the right-hand front jack, and No.4 lever con· troIs the right-hand rear jack.

Pulling the control toward the operator will lower the jack, raising the machine. Pushing the control away from the operator will raise the jack, lowering the machine. Returning the control to neutral will stop all motion.

Full forward or rearward positions provide the fastest motion.

5. HOIST-PULLDOWN SELECTOR The hoist-pulldown selector is used to hydraulically hoist or lower the rotary drive unit or auxiliary reel line.

This control is a full flow locking type in that it cannot be feathered like the other hydraulic controls. Detents will lock the spool in push (pulldown), pull (hoist) or neutral positions.

This feature allows the operator to have the control activated without having to continuously hold it in the activated position.

Pushing the control away from the operator will lower the rotary drive unit or auxiliary reel line. Pulling the control toward the operator will hoist the rotary drive unit or auxiliary reel line.

6,7,8. TOOL RACK CONTROLS The tool rack controls are used to raise or lower the tool racks. The number of tool rack controls is determined by the number of tool racks on the machine. There is a separate control for each rack. All of the controls operate identically. No. 6 lever controIs the center rack, No. 7 lever controls the right-hand rack, and No.8 lever controls the left-hand rack.

Pulling the control toward the operator will raise the tool rack while pushing the control away from the operator will lower the tool rack. Full forward or rearward positions will provide the fastest motion.

9. CASING TONG CONTROL The casing tong control is used to extend or retract the casing tong breakout cylinder.

Pulling the control toward the operator will extend the casing tong breakout cylinder.

Pushing the control away from the operator will retract the casing tong cylinder. Full forward or rearward positions will provide the fastest motion.

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• JUCYRUS-ERIE COMPANY, 1984

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10. TOOL WRENCH CONTROL

The tool wrench control is used to clamp or release the tool wrench from the tool string.

Pushing the control away from the operator will extend the wrench, clamping the tool string. Pulling the control toward the operator will retract the tool wrench, releasing the tool string. Full forward or rearward positions provide the fastest motion.

11. DUST CURTAIN CONTROL (Hydraulic)

On machines equipped for angle drilling this control is used to raise or lower the dust curtains. On standard vertical drilling machines the curtains are controlled by air valve 21A. Pushing the control away from the operator will lower the dust curtain. Pulling the control toward the operator will raise the dust curtain. Full forward or rearward positions will provide the fastest motion.

12. MAST HOIST CONTROL WARNING: To eliminate shock loading on the mast structure the mast hoist control should be moved away and returned to the neutral position slowly.

The mast hoist control is used to raise or lower the mast.

Pulling the control toward the operator will raise the mast. Pushing the control away from the operator will lower the mast. Full forward or rearward positions provide the fastest motion.

13. MAST LATCH CONTROL

The mast latch control is used to secure the mast in the raised vertical position or release the mast so that it can be lowered.

Pushing the control away from the operator will unlatch the mast allowing it to be lowered.

Pulling the control toward the operator will move the latch to lock the mast in the vertical position. Full forward or rearward positions provide the fastest motions.

14. CENTER GUIDE CONTROL

The center guide control is used to open or close the center guide jaws around the pipe.

Pushing the control away from the operator will close the jaws around the drill pipe.

12

Pulling the control toward the operator will open the jaws. Full forward or rearward positions provide the fastest motion.

15. DOWNFEED PRESSURE CONTROL The downfeed pressure control regulates the pressure in the pulldown hydraulic circuit.

The pulldown force is determined by how far the control knob is turned. Turning the knob fully to the left (counter-clockwise) will relieve the pressure in the circuit, resulting in no pulldown force. As the knob is turned to the right (clockwise) the pulldown force will increase to the maximum at the full clockwise position of the knob.

NOTE: In order to turn the knob it is necessary to first pull the knob out slightly to unlock it. Releasing the knob will return it to the locked position.

16. HOIST BRAKE CONTROL

The hoist brake control is used to set or release the hoist brake.

Pulling the control lever fully toward the operator will completely set the hoist brake preventing movement of the rotary drive unit. As the control is pushed away from the operator, the brake is gradually released until it is fully released at the full forward position.

When in the lowering mode, the lowering speed of the rotary drive unit is determined by how far the control lever is pushed forward from the set position. Full forward will release the brake fully, resulting in the fastest lowering speed.

WARNING: The hoist brake must be fully released when hoisting or lowering the rotary drive unit with power. Partial releasing of the brake is allowed only when lowering under gravity.

17. AUXILIARY REEL BRAKE CONTROL The auxiliary reel brake control is used to set or release the auxiliary reel brake.

Pulling the control lever fully toward the operator will completely set the brake, preventing movement of the auxiliary reel line.

As the control is pushed away from the operator, the brake is gradually released until the brake is fully released at the full forward position.

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The lowering speed of the auxiliary reel line when in the gravity lowering mode is determined by how far the control is pushed forward from the set position. Full forward position will result in the fastest lowering speed.

WARNING: The auxiliary reel brake should be fully released when hoisting or lowering under power. Partial releasing of the brake is allowed only when lowering the auxiliary line under gravity.

18. DOWNFEED CLUTCH CONTROL The downfeed clutch control is used to engage or disengage the hydraulic pulldown motor jaw clutch. This allows the operator to use hydraulic power for hoist and pulldown while drilling.

This control is a two-position lever operated valve. Placing the lever in the forward position will disengage the pulldown motor jaw clutch. Placing the lever in the rear postion will engage the jaw clutch.

WARNING: Always disengage the clutch when using the electric hoist or propelling.

Failure to do so will result in damage to the hydraulic motor.

Pulling the lever to the rear to the first position (next to "off') will engage the right-hand clutch and release the right-hand brake, allowing the right crawler to move.

Pushing the lever forward to the first position (next of "off') will engage the left-hand clutch and release the left-hand brake allowing the left crawler to move.

Placing the control in either the full forward or full rearward position will engage both clutches and release both brakes, allowing both crawlers to move.

21A. DUST CURTAIN CONTROL (Air) This control is used to raise and lower the dust curtains or standard vertical drilling machines. For machines equipped for angle drilling the curtains are controlled by hydraulic lever 11.

This valve is a two-position lever-operated air valve. Pushing the lever forward will raise the dust curtains, while pulling the lever to the rear will lower the curtains. The machine can not propel ifthe controllever is in the rear position (curtains lowered).

22,23,24. TOOL RACK LOCK CONTROLS

19. MAIN AIR CONTROL The main air control is a two-position lever operated valve. Pushing the lever to the forward position will allow the main air stream to flow to the tool string. Pulling the lever to the rear position stops the flow of air to the tool string and unloads the compressor.

20. HOIST-AUXILIARY REEL SELECTOR The hoist-auxiliary reel selector is a lever operated three-position valve. Pushing the lever to the forw~rd position will shift the jaw clutch to couple the auxiliary reel to the hoistpropel gearcase. Placing the lever in the center position will disengage the jaw clutch completely, allowing the machine to be propelled. Placing the lever in the rear postion will shift the jaw clutch to couple the hoist gear train to the hoist-propel gearcase.

21. PROPEL STEERING SELECTOR The propel steering selector is a five-position lever operated valve. In the center position both propel clutches are disengaged and both propel brakes are set.

§

The tool rack lock control is used to release the tool rack lock which in turn releases the tool rack from the stored position. The tool rack lock is spring closing, requiring no operator action to lock the tool rack in the stored position. There may be one to three controls, depending upon the number of tool racks on the machine. No. 22 control is for the center rack lock, No. 23 control is for the right-hand rack lock, and No. 24 control is for the lefthand rack lock.

The control is a spring returned pushbutton activated air valve. Depressing the pushbutton releases the tool rack lock so that the tool rack may be lowered. As soon as the tool rack clears the lock, the pushbutton may be released.

25. PIPE POSITIONER CONTROL The pipe positioner control is a two-position lever operated air valve. Pushing the control to the forward position will swing the positioner into place. Placing the control in the rear position will retract the positioner to the stored position.

BUCYRUS·ERIE COMPANY. 1984

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26. PIPE POSITIONER JAW CONTROL The pipe positioner jaw control is a twoposition lever operated air valve. Pushing the control to the forward position will close the pipe positioner jaws around the drill pipe.

Pulling the control to the rear position will open the positioner jaws, releasing the drill pipe.

27. RETRACTABLE STAIRWAY CONTROL The retractable stairway control is a twoposition lever operated valve. Pulling up on the lever will raise the stairway. Pushing down on the lever will lower the stairway. A similar valve is located near the stairway.

28. HYDRAULIC CYLINDER CIRCUIT PRESSURE GAUGE The hydraulic cylinder circuit pressure gauge monitors the pressure in the hydraulic circuit containing the hydraulic cylinders. The gauge is specially calibrated in both english and metric units.

29. PULLDOWN HYDRAULIC CIRCUIT PRESSURE GAUGE The pulldown hydraulic circuit pressure gauge monitors the pressure on the hydraulic pulldown circuit. The calibration on the gauge is in english and metric units and the gauge is also calibrated to measure the load on the drill bit.

30. MAIN AIR PRESSURE GAUGE The main air pressure gauge is specially calibrated in both english and metric units and is used to monitor the pressure in the main air system (bailing air).

31. AUXILIARY AIR PRESSURE GAUGE The auxiliary air pressure gauge is specially calibrated in both english and metric units and is used to monitor the pressure in the auxiliary air system.

33,34,35. WATER INJECTION SYSTEM CONTROLS As an option the 47-R may be equipped with one of two water injection systems which are used to inject water into the main (bailing) air stream to reduce the dust generated during drilling. A blowdown feature is used during freezing weather to remove standing water from the water lines when the system is not in use.

In both systems a handwheel (33) is used to control the amount of water used. Turning the handwheel fully to the right will shut off the water flow. Turning the handwheel to the left will increase the water flow.

The rate of flow is monitored either on a flowmeter (34) or specially calibrated gauge (34) depending upon which type of system is used on the machine.

The blowdown control (35) is a push to operate valve. The control applies air to the water lines to remove water from these lines to prevent freezing. The control is operated by depressing the pushbutton. The control will automatically return to the closed position when released.

36. HOIST/PROPEL RHEOSTAT The hoist/propel rheostat controls the speed and direction of the hoist/propel motor for hoisting or lowering the rotary drive unit or auxiliary reel line or for propelling the machine.

Turning the rheostat to the right (clockwise) from the "off' position will hoist the rotary drive unit or auxiliary reel line or propel the machine in the forward direction. Maximum speed and torque is available at full clockwise position.

Turning the rheostat to the left (counterclockwise) from the "off' position will lower the rotary drive unit or auxiliary reel line or propel the machine in reverse. Maximum speed and torque is available at full clockwise position.

32. AIR HORN CONTROL The air horn control is a pushbutton air valve. The air horn is sounded by depressing the control pushbutton. The horn will stop sounding when the control is released.

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NOTE The rheostat utilizes a referenceplate andpointer. When the rheostat is turned, the pointer indicates, on the referenceplate, the relativepercentage offull power being used.

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37. ROTARY RHEOSTAT

41. RPM METER

The rotary rheostat controls the speed and direction of the rotary motor.

The rheostat is activated by turning the control handwheel. Rotating the control to the extreme left (counterclockwise) position stops the rotary motion. The speed of the motor is increased by turning the control to the right (clockwise) position. Full rotary speed is achieved at the full clockwise position.

NOTE: The rheostat utilizes a plate and pointer. When the rheostat is turned, the pointer indicates, on the referenceplate, the relative percentage offull power being used.

38. ROTARY MASTER SWITCH The rotary master switch is a handle operated five-position switch. The center or off position of the switch stops rotary motor rotation. Turning the switch to the right (clockwise) to the second position (maximum clockwise position) will result in the motor turning in the forward direction.

Turning the control to the left (counterclockwise) to the second position (full counterclockwise position) will result in the motor turning in the reverse direction. The two positions nearest "off' are not used during drilling.

39. RPM METER SWITCH This two-position switch determines which rotary motor speed is being monitored. If the switch is turned to the left #1 rotary motor is being monitored. Ifit is turned to the right #2 rotary motor is being monitored.

40. LOAD AMMETER #1 ROTARY MOTOR The load ammeter monitors the electrical current flowing in the #1 rotary motor. The ammeter is specially calibrated to show the operating range of the motor, normal range (green band), caution range (yellow band), and overload range (red band).

40A. LOAD AMMETER #2 ROTARY MOTOR This load ammeter monitors the electrical current flowing in the #2 rotary motor. The ammeter is specially calibrated to show the operating range of the motor, normal range (green band), caution range (yellow band), and overload range (red band).

@

The RPM meter monitors the speed of the rotary motors and therefore, the tool string.

The meter is specially calibrated to show the revolutions per minute of the tool string.

Which rotary motor is being monitored is determined by the position ofthe RPM switch.

42. HOURMETER - OPTIONAL The hourmeter monitors the hours of operation of the main air compressor or diesel engine. The meter is calibrated in hours and tenths of hours.

43. CONTROL ON PUSHBUTTON The control on pushbutton, when depressed, activates the control circuitry for the rotary and hoist/propel motions and starts the hoist/ propel motor blower.

44. CONTROL OFF PUSHBUTTON The control off pushbutton, when depressed, deactivates the control circuitry of the rotary and hoist/propel motions, sets the brakes on these motions and releases the propel clutches.

Depressing the pushbutton will not stop the main air compressor or the diesel engine.

This control may be used as an emergency stop control for the hoist, propel, auxiliary reel and rotary motions.

45. AIR COMPRESSOR STOP CONTROL (Electric Machines Only) The air compressor stop control is a spring return pushbutton switch. Depressing the pushbutton stops the main air compressor motor. The pushbutton will spring return when released. There is an identical control on the high voltage cabinet in the machinery house. This control is used on electrically driven machines only.

46. OIL PUMP START PUSHBUTTON The oil pump start pushbutton, when depressed, starts the oil pump motor. The pushbutton will spring return when released and the motor will continue running.

47. OIL PUMP STOP PUSHBUTTON The oil pump stop pushbutton is a spring return pushbutton. Depressing the pushbutton will stop the oil pump motor.

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48. HYDRAULIC OIL TEMPERATURE INDICATOR The hydraulic oil temperature indicator is used to monitor the temperature of the oil in the reservoir. The indicator is lit when the oil temperature is in the operating range. The indicator will go out when the temperature of the oil exceeds the operating range.

49. HIGH AIR TEMPERATURE INDICATOR The high air temperature indicator is used to monitor the temperature of the main air compressor discharge air. The indicator is lit when the temperature is in the operating range. The indicator will go out and the compressor will shut down when the main air stream exceeds the normal operating range.

50. GROUND FAULT INDICATOR The ground fault indicator monitors ground faults on the machine. The light will go out if a ground fault condition exists on the machine.

h CAUTION: Activation of the ground . . fault circuit indicates that a ground fault exists. Cease operation of the machine immediately and have a qualified electrician remedy the ground fault before returning to work. Death or serious injury can result from contact with a part that has become energized due to a ground fault.

51. AUXILIARY AIR COMPRESSOR CONTROL The auxiliary air compressor control is a two position rotary switch. Turning this switch to the right position, turns the auxiliary air compressor on, while turning the switch to the left will turn the compressor off.

52. FILTER FAN CONTROL The filter fan control is a two-position switch.

Turning the switch to the right position turns the filter fan on, while turning the switch to the left will turn the fan off.

53. AIR CONDITIONER AND/OR CAB HEATER CONTROL This switch controls the temperature and air in the operator's cab. If the machine is equipped with a heater/ventilator unit, the switch will have three positions (off, heat,

16

vent). If the machine is equipped with a heater/air conditioner unit, the switch has four positions (off, heat, vent, cool). Turning the switch to a particular position will activate that system of the unit.

54. FILTER CLOGGED INDICATOR The filter clogged indicator is used with the heater/ventilator or air conditioner unit mounted atop the operator's cab. When the indicator is lit the filter in the unit is clogged and must be changed. When the indicator is off the filter is clean.

55. WATER PUMP CONTROL (Optional) The water pump control is a two-position rotary switch. Turning the switch to the right will start the pump, while turning it to the left will stop the water pump.

56. RADIATOR FAN/WATER PUMP CONTROL (Electric Machine with Vane Compressor) The radiator fan/water pump control is a two-position rotary switch. Turning the switch to the right position turns the fan and pump on. Turning the switch to the left position turns the fan and pump off.

57. BAG-TYPE DUST CONTROL UNIT (Optional) The control is a two-position rotary switch.

Turning the switch to the right starts the intake fan, while turning it to the left will stop the fan.

58. WATER TEMPERATURE INDICATOR (Vane Compressor) The water temperature indicator is used to monitor the temperature ofthe main air compressor. The indicator is lit when the coolant temperature is in the operating range. The indicator will go out when the temperature of the coolant exceeds the operating range.

59. LUBE LEVEL INDICATOR The lube level indicator is used to monitor the level of oil in the main air compressor lubricator (vane compressor) or oil level (in screw compressor). The indicator is lit when the oil level is in the operating range. The indicator will go out and the compressor will shut down when the levei of the oil falls below the operating range.

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60. FUSE FAILURE MONITOR The fuse failure monitor is used to monitor the condition of the main output fuses in the hoist-propel motor control circuitry. Normal state of the monitor is with the indicator lamp on. If the indicator lamp is off, one of the fuses in the hoist-propel circuitry has blown and must be replaced.

61. DEPTH INDICATOR (Optional) There may be one of several different types of depth indicators used on a machine. Regardless of the type used the main purpose of the indicator is to monitor the depth of the hole being drilled. The meter is typically calibrated in feet or meters. The meter is usually reset to zero with a ratchet thumbwheel on the meter body.

62. EMERGENCY STOP PUSHBUTTON (Optional) The emergency stop pushbutton, when depressed, will shut down the machine completely, de-energize all controls and set all brakes.

WARNING: This pushbutton should be used only during an emergency as the motors will be stopped while under load which could possibly damage the units.

63. AUTOLUBESYSTEMREMOTEPANEL For machines equipped with an automatic lubrication system, some type of remote control panel is usually mounted on the upper right side of the operator's console about eye level.

the engine. This control will not return to the reset position automatically. To reset the control, the pushbutton must be pulled up.

The diesel engine may be started after resetting the control and following the manufacturers recommendations.

WARNING: This pushbutton should only be used in an emergency. Shutting the engine down with this switch can damage the engine as the engine most likely will be under load when it is stopped.

65,66,67,68. DIESEL ENGINE GAUGES The typical diesel engine gauges are the battery charging circuit ammeter (65), the engine coolant temperature gauge (66), the engine oil pressure gauge (67), and the engine fuel level gauge (68). Each ofthese gauges is marked as to its function. Refer to the engine manufacturer's manual for exact operating ranges.

MACHINERY HOUSE CONTROLS LIGHTING LOAD CENTER (Figure 6) The lighting load center is located on the front wall of the operator's cab, just to the left of the front door.

The lighting load center contains all the circuit breakers necessary to control the ,interior and exterior lights of the drills.

Each breaker is labeled as to its particular function on any particular machine.

A typical panel would include: a pushbutton to activate the system, a red indicator which will light if a fault occurs, a green indicator, which when lit indicates normal operation and another indicator which when lit indicates a lube cycle in process.

The following switch and gauges are provided only when the machine is equipped with a diesel engine.

64. DIESEL ENGINE EMERGENCY STOP CONTROL The diesel engine emergency stop control is used to shut down the diesel in an emergency.

The control is a two-position pushbutton switch. Depressing the pushbutton will stop

TYPICAL LIGHTING LOAD CENTER

• BUCYRUS-ERIE COMPANY, 1984

FIGURE 6

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The controls are three-position lever operated circuit breakers. Moving the lever in one direction (on) will close the circuit, while moving it in the opposite direction (off) will open the circuit. The center position is the tripped position. The breaker may be reset by moving the lever to the "off' position and then back to the "on" position.

LUBRICATION SYSTEM CONTROLS (Optional) If a particular machine is equipped with an automatic lube system, the control panel will be located typically just inside the machinery house front door.

The controls found on a typical lube system control panel are as shown on figure 7.

CONTROLS LOCATED ON LOW VOLTAGE CABINET

1.

2.

3.

4.

5.

6.

The low voltage cabinet contains most of the breakers for the auxiliary equipment on the drill.

Because of the variations of equipment supplied on a particular drill, figure 8 illustrates typical controls which might appear on the low voltage cabinet.

12

SIGNAL HORN ON/OFF SWITCH START PUSHBUTTON INDICATOR (GREEN) INDICATOR (GREEN) INDICATOR (RED)

TYPICAL LUBRICATION SYSTEM CONTROLS FIGURE 7

8.

9.

10.

11.

12.

1. AUXILIARY POWER BREAKER 2. RADIATOR FAN BREAKER 3. HOIST BLOWER BREAKER 4. MAIN CONTROL BREAKER 5. LUBE SYSTEM BREAKER 6. OIL PUMP RESET BUTTON 7. FILTER FAN RESET BUTTON AUXILIARY COMPRESSOR RESET BUTTON RADIATOR FAN RESET BUTTON (VANE COMPRESSOR) WATER PUMP RESET BUTTON (VANE COMPRESSOR) COMPRESSOR LUBE RESET BUTTON (VANE COMPRESSOR) HOIST BLOWER RESET BUTTON

TYPICAL LOW VOLTAGE CABINET CONTROLS FIGURE 8

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CONTROLS LOCATED ON RESISTOR AND DC CABINET The typical resistor and DC cabinet contains controls as shown on figure 9.

"-_ _"""":,,,,~_1 A~~_l

2 3 4

2 3 4

5

1.

2.

3.

4.

5.

6.

7.

ROTARY BREAKER HOIST BREAKER AIR CONDITIONER OR CAB HEATER BREAKER LIGHTING BREAKER CHAIN EQUALIZER RESET BUTTON ROTARY RESET BUTTON HOIST RESET BUTTON

1.

2.

3.

4.

5.

MAIN AIR COMPRESSOR BREAKER MAIN AIR COMPRESSOR START PUSHBUTTON MAIN AIR COMPRESSOR STOP PUSHBUTTON PHASE SEQUENCE INDICATOR MAIN AIR COMPRESSOR RESET BUTTON

TYPICAL LOW VOLTAGE START CABINET CONTROLS

TYPICAL RESISTOR AND DC CABINET CONTROLS

FIGURE 10

FIGURE 9

CONTROLS LOCATED ON LOW VOLTAGE START CABINET 2

The typical low voltage start cabinet contains controls as shown on figure 10.

3

CONTROLS LOCATED ON HIGH VOLTAG:E CABINET The typical high voltage cabinet contains controls as shown on figure 11.

CONTROLS LOCATED ON OR NEAR VANE TYPE MAIN AIR COMPRESSOR Figure 12 shows controls, monitors and indicators located on or near a typical vane type main air compressor.

1.

2.

3.

MAIN AIR COMPRESSOR START PUSHBUTTON MAIN AIR COMPRESSOR STOP PUSHBUTTON PHASE SEQUENCE INDICATOR

TYPICAL HIGH VOLTAGE CABINET CONTROLS

., BUCYRUS-ERIE COMPANY, 1984

FIGURE 11

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CONTROLS LOCATED ON OR NEAR SCREW TYPE MAIN AIR COMPRESSOR A typical set of controls, monitors and indicators loacted on or near a screw type main air compressor are shown on figure 13.

NOTE: For the exact controls located on a screw type main air compressor on aparticular machine refer to the compressor manufacturer's manual.

DIESEL ENGINE CONTROL Figure 14 shows controIs and gauges typical of the controls which might be located at the diesel engine. Refer to the engine manufacturer's manuals for the exact controls on a particular machine.

On some machines there is an additional set of gauges on the operator's console.

MISCELLANEOUS CONTROL 1.

2.

3.

4.

5.

INTAKE FILTER INDICATOR COMPRESSOR AIR DISCHARGE THERMOMETER COMPRESSOR DRIP TYPE LUBRICATOR COMPRESSOR COOLANT THERMOMETER COMPRESSOR COOLANT FLOW METER

Located about the machine are various miscellaneous controls and monitors which would be used with optional equipment or do not fit in the previously described groups.

FIGURE 12

4

3.

4.

5.

6.

7.

AIR PRESSURE CONTROL VALVE OIL INJECTION TEMPERATURE GAUGE DISCHARGE AIR TEMPERATURE GAUGE DISCHARGE AIR PRESSURE GAUGE BEARING OIL FILTER MAlNT. INDICATOR ROTOR OIL FILTER MAINT. INDICATOR HOURMETER

TYPICAL SCREW COMPRESSOR CONTROLS FIGURE 13

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264

1

CABLE REEL CONTROLS (Figure 16) The cable reel is driven by a hydraulic motor. The direction and speed of the motor is determined by the position of the valve bank lever. Pushing the lever forward will wind up the trail cable, as the machine moves toward the cable, while pulling the lever to the rear will unwind the trail cable.

WARNING: The cable reel should not be used to pull the cable onto the reel but only wind the cable onto the reel as the machine moves toward the cable. Attempting to pull 50 feet or more cable, layed on a straight line, onto the reel without moving the machine toward the cable, will damage or possibly break the cable.

1.

2.

3.

4.

S. 6.

The winding mode is tied into the propel mode of the machine. When the propel control is in the farthest forward or rearward position and the hoist/propel rheostat is turned in the propel forward direction, an air cylinder connected to the valve bank lever will be activated and move the lever forward, winding up the trail cable.

OIL PRESSURE GAUGE WATER TEMPERATURE GAUGE AMMETER TACHOMETER STARTING SWITCH FUEL GAUGE

TYPICAL DIESEL ENGINE CONTROLS FIGURE 14

CLINOMETERS (Figure 15) The clinometers are angle indicators used to monitor the angle at which the machine is resting.

There are two clinometers. One for side-to-side angle measurement and one for end-to-end angle measurement. The clinometers are mounted to the ceiling in the right-hand corner of the operator's cab.

When the propelling mode is stopped the air to the cylinder will be cutoff and the valve bank lever will return to the neutral position.

The cable reel is so adjusted that the trail cable will unwind without activation of the valve bank when the machine is propelled in reverse. The unwinding of the trail cable can be speeded up by manually moving the valve bank lever to the rear.

The hydraulic pressure should be adjusted to a minimum of 250 PSIG, maximum 400 PSIG.

UNWIND TRAIL CABLE

~

t

WINDUP TRAIL CABLE

VALVE BANK LEVER VALVE BANK

AIR CYLINDER

CLINOMETERS

TYPICAL CABLE REEL CONTROLS

FIGURE 15

FIGURE 16

~ BUCYRUS-ERIE COMPANY, 1984

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-1 HANDLE SUPPORT

('

PROPEL BRAKE

/

\..·v' BRAKE RELEASE HANDLE SHOWN IN SUPPORTBRAKE SET

TYPICAL PROPEL BRAKE RELEASE CONTROL FIGURE 17

MANUAL PROPEL BRAKE RELEASE (Figure 17)

CASING TONG HOLDBACK CONTROL (Figure 18)

The manual propel brake release is a mechanical linkage connected to the propel brakes that allows the brakes to be released manually. Normally it is necessary to have power to the machine and the propel system activated before the propel brakes can be released. The manual release is used when towing the machine.

The casing tong holdback control is an air pressure regulator mounted on the drill deck near the casing tong holdback equipment. Turning the control to the right (clockwise) will retract the casing tong to the stored position. Turning the control to the left (counterclockwise) will lower the casing tong into position around the drill pipe.

The control handle is located near the door leading from the drilling deck to the operator's cab. The propel brakes are set and in the normal operating mode when the handle is in the maximum upward position and resting in the handle support. To release the brakes, move the handle out of the support and push the handle downward to the maximum position. The handle will remain in this position. To reset the brakes, lift the handle up and secure it in the support.

TO CASING TONG

CAUTION: Useextremecautionwhen . . using the manual propel brake release.

Always have the drill well secured, either by blocking or with a suitable towing vehicle before releasing the propel brakes. Releasing the propel brake without the machine being secured may cause the machine to run away on a grade.

22

r

rf;

h

AIR PRESSURE REGULATOR

II·

~} <:/

CASING TONG HOLDBACK CONTROL FIGURE 18

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RETRACTABLE STAIRWAY CONTROL

HOIST LIMIT BELL The hoist limit bell is used to warn the operator when the rotary drive unit approaches the top of the mast. The hoist limit bell is activated by a limit switch mounted approximately 10 feet from the top of the mast. When the rotary drive unit passes this limit the bell will sound once. When the rotary drive unit reaches approximately 5 feet from the top of the mast, the electric hoist controls will be disabled.

WARNING: The hydraulic hoist is not connected to the hoist limit switch. Operating the hydraulic hoist near the upper limits of the mast is not recommended since the rotary drive unit may be pulled into the top of the mast, doing damage to the mast and drive unit. Do not rely on the limit switches alone to warn ofthe drive unit approaching the top of the mast. Always visually observe the rotary drive unit and operate slowly when near the top of the mast.

HYDRAULIC MOTOR PINION SHIFTER This is a manual shifter located on the hoist/propel gearcase (figure 20). It is used to change the speed ofthe hydraulic hoist or pulldown. The high speed position is used when drilling soft material, the low position is used when drilling hard material. To operate the shifter, lift the plunger knob and move the lever to the forward position for high speed or to the rear position for low speed. Be sure the plunger is seated in the hole in the shifter cover.

WARNING: Be sure the machinery is stopped before shifting from one speed to the other. Shifting while the machinery is in motion will damage the splines of the motor shaft.

=1

~~j~

AIR CYUNDER

The retractable stairway control is located on the mainframe next to the stairway (figure 19). The control is a two-position lever operated valve.

Pulling up on the lever will raise the stairway.

Pushing down on the lever will lower the stairway.

A similar valve is located on the operator's console.

o

o

II

o

HIGH SPEED POSITION

\

/

--

o

~

o LOW SPEED POSITION

RETRACTABLE STAIRWAY CONTROL

HYDRAULIC MOTOR PINION SHIFTER

FIGURE 19

FIGURE 20

< BUCYRUS-ERIE COMPANY, 1984

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SECTION 3 - START-UP

INTRODUCTION

4.

Return to the machinery house. After verifying that personnel are in the clear and again verifying that the phase sequence indicator is lit, depress the main air compressor start pushbutton. Hold the pushbutton in until the motor comes up to speed (5-10 sec.) and then release it. On machines equipped with the optional low voltage air compressor motor, close the air compressor breaker before pressing the main air compressor start pushbutton.

5.

Verify the operation of the compressor lubrication and coolant pump. Listen for unusual noises and look for oil leaks or other problems.

Start-up ofthe drill is not a difficult operation, but it is very important. Improper start-up could cause various safety and operating difficulties as well as damage to the machine. Following the step-bystep procedure listed below to start the machine will help reduce the possibility of accidental injury or machine damage.

ELECTRIC MACHINE START-UP (Figure 21)

NOTE: The machine is to be started only after the prestart inspection and lubrication, as detailed in Section 1, have been completed.

1.

Go into the operator's cab and verify that all controls on the operator's console are in the off or neutral position.

NOTE: On some machines equipped with screw type air compressors, it is necessary to hold the start button depressed until the lubricating oil pressure reaches normal levelse In cold weather this time span might reach 8-10 seconds. Do not try to pump start an air compressor.

2.

Return to the machinery house. Verify that the phase sequence indicator is lit, then turn on all circuit breakers except the main air compressor breaker. Verify that the electrical cabinet ventilation fans are running.

6.

3.

Return to the operator's cab and turn the auxiliary air compressor switch to the "on" position. Check the auxiliary air pressure gauge to verify that the air compressor shuts off at the proper pressure. Turn the fan/pump switch to the "on" position.

Return to the operator's cab. Start the filter fan, hydraulic pumps, and any other auxiliary equipment necessary.

WARNING: Refer to the cold weather startup procedure before starting the hydraulic pumps ifthe temperature is below 32°F (O°C).

Failure to follow this procedure will cause serious damage to the hydraulic pumps.

• BUCYRUS-ERIE COMPANY. 1984

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MAIN AIR COMPRESSOR START PUSHBUTTON PHASE SEQUENCE INDICATOR

TYPICAL OPERATOR'S CONSOLE TYPICAL HIGH VOLTAGE CABINET

MAIN AIR COMPRESSOR START PUSHBUTTON MAIN AIR COMPRESSOR BREAKER

TYPICAL RESISTOR AND DC CABINET

PHASE SEQUENCE r--"i-~~~e~" INDICATOR

CIRCUIT BREAKERS

ELECTRIC MACHINE START-UP FIGURE 21

26

TYPICAL LOW VOLTAGE START CABINET

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DIESEL MACHINE START-UP (Figure 22) Start-up of a diesel driven machine is essentially the same as the start-up of an electrically driven machine with the exceptions of the added procedures for starting the diesel engine and the alternator/generator and main air compressor.

NOTE: The machine is to be started only after the prestart inspection and lubrication as detailed in Section 1, have been completed. Also, the inspection and lubrication of the diesel engine, as described in the engine manufacturer's manual, must have been completed.

1.

Go to the operator's cab and verify that all of the controls on the operator's console are in the "off' or neutral position. Be sure the engine emergency stop pushbutton is in the up position.

2.

Return to the machinery house. Verify that all circuit breakers are in the "off' position.

Verify that the engine clutch is in the disengaged position. Start the diesel engine. Refer to the engine manufacturer's manual for the exact start-up procedure.

3.

After the engine is warmed up, bring it up to operating speed. Allow the engine to operate at this speed until the auxiliary air pressure is iIi the operating range.

4.

While the air system is charging and if the machine is equipped with a vane type main air compressor, hand crank the compressor lubrication 15-20 cycles (revolutions of hand crank). This gives the compressor lubrication for initial start-up.

5.

After the compressor has been prelubed and the auxiliary air pressure has reached the operating range, engage the engine clutch.

Engaging the clutch will start the main air compressor and alternator/generator. Immediately after engaging the clutch, turn on all the el'ectrical circuit breakers. This starts the compressor lubrication and applies power to all the control and auxiliary circuits.

WARNING: Do not allow the compressor to run for more than 10-20 seconds without the lubricator operating. Failure to lubricate the

compressor will result in serious damage to the compressor.

6.

After the engine has been started, the compressor and alternator/ generator started and the circuit breakers turned on, check for any unusual noises, oil leaks or other operational problems. Check the diesel engine per engine manufacturer's manual.

7.

Return to the operator's cab. Start the filter fan, hydraulic pumps, and any other auxiliary equipment necessary.

WARNING: Refer to the cold weather startup procedure before starting the hydraulic pumps ifthe temperature is below 32°F (O°C).

Failure to follow this procedure will cause serious damage to the hydraulic pumps.

COLD WEATHER START-UP Additional precautions are necessary during the start-up of the hydraulic pumps during cold weather, below 32°F (O°C). These precautions are necessary due to the fact that as the hydraulic oil gets colder, it looses the ability to flow easily.

Starting the hydraulic pumps with cold oil may cause the pumps to cavitate, or in other words, pump air into the system. This cavitation can be heard as a loud knocking when the pumps are started. If this knocking is heard immediately depress the pump stop pushbutton.

If the pumps are cavitating it will be necessary to jog the pumps a few revolutions at a time until the cold oil starts flowing. This is done by depressing the pump start pushbutton and then immediately depressing the stop pushbutton. Repeat this procedure of starting and then immediately stopping the pumps 6-8 times. Depress the start pushbutton and listen for cavitation. If no cavitation is heard, the system is ready for operation. If cavitation continues, immediately depress the stop pushbutton and repeat the jogging procedures until the cavitation stops.

WARNING: If the jog and test start procedure is repeated more than 3-4 times the cause may be other than cold oil. Have a qualified mechanic check the inlet piping to the pumps for air leaks.

~ BUCYRUS-ERIE COMPANY, 1984

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ENGINE EMERGENCY STOP PUSHBUTTON

TYPICAL DIESEL ENGINE

TYPICAL OPERATOR'S CONSOLE

TYPICAL RESISTOR AND DC CABINET

DIESEL MACHINE START-UP FIGURE 22

28

TYPICAL LOW VOLTAGE CABINET

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MACHINERY CHECKS The following is a list of points and equipment that should be checked for proper operation immediately following start-up of the drill. If operating difficulties are not found during this procedure, they probably will not be noticed until some point in time at which the system or component will cease to function and cause serious damage to the machine.

1.

Check the compressor lubricator for proper flow rate. (Vane. Type Compressor) For bearings: 3 drops per minute For cylinder: 6-8 drops per minute For inlet quill: 8-10 drops per minute

2.

Check for oil leaks in the piping from the lubricator to the injection points on the compressor.

3.

Check the main air system for leaks. On machines equipped with a vane air compressor air leaks can easily be spotted by an accumulation of oil near the leaking point.

4.

Verify that the main air compressor coolant pump and radiator fan are operating correctly. Check the coolant system for leaks.

5.

Check for leaks in the auxiliary air system.

6.

Check for leaks in the hydraulic system.

The prestart lubrication is required only once, immediately before the initial startup of a new, rebuilt compressor, or a compressor returned to service after a long term storage. This lubrication consists of flooding the vanes with oil before applying load. To do this, adjust the lubricator to deliver the maximum amount of oil per cycle.

Hand crank the lubricator 25 times then rotate the compressor 1/4 turn by hand. Repeat this procedure for each 1/4 turn of the compressor until the compressor has been rotated a full 360 0 • Also, during this time carefully monitor the discharge air and coolant temperatures. Problems caused by insufficient clearances or damage components will be indicated by a drastic increase in temperatures. Monitoring the temperatures frequently will allow the problem to be spotted and corrected before damage to the compressor can take place.

ROTARY DRIVE GEARCASE Break-in ofthe rotary gearcase is limited to reduced loading during the first 100 hours of operation and a complete oil change at the end of the break-in period.

This break-in period applies only to a new gearcase or gearcase in which a new gear has been installed.

HOIST-PROPEL GEARCASE

BREAK-IN OF NEW COMPONENTS When a machine is new, is returned to service after a long period of storage, or is returned to service after major repairs, certain precautions must be taken upon initial start-up and for a time following the start-up. These precautions are necessary to insure that the full service life of the components is realized.

MAIN AIR COMPRESSOR (Vane Type)

Break-in of the compressor (vane type) is limited to prestart lubrication and during the first 16 hours of operation increased lubrication at a flow rate of double the normal drops per minute as listed under Step 1 of the topic MACHINERY CHECKS. After the 16 hour break-in period return the lubricator to the normal flow rate.

Break-in for the hoist-propel gearcase is limited to reduce loading during the first 200 hours of operation and a complete oil change at the end of the break-in period.

The break-in period applies only to a new gearcase or gearcase in which a new gear has been installed.

ELECTRIC MOTORS Break-in of the rotary and hoist/propel motors is limited to reduced loading and inspection for the first 8 hours of operation. This break-in period is intended to spot any problems in the motors before they lead to serious damage to the motors or the machine. Inspection should include monitoring the motor temperature and listening for unusual noises which might indicate a problem. Inspection should also include verifying that all blower vents and intake openings are clear.

e BUCYRUS-ERIE COMPANY, 1984

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SECTION 4 - OPERATION - GENERAL INTRODUCTION Operation ofthe 47-R drill is, in principle, the same as the operation of any other blasthole drill. But just because the machines operate the same in principle does not mean they operate the same in all respects. For this reason itis important that the operator becomes familiar with the particular machine that is being operated.

The purpose of this section of the operator's manual is to detail the procedures involved in operating many of the major components and preparing to drill a hole. The actual drilling procedure is detailed in Section 5 of this manual.

Become familiar with the controls and learn to operate at reduced speeds. As the machine and drilling cycle become more familiar, increase speeds gradually to the full operating capability of the machine.

Inspect the trail cable layout on the drill pattern.

Be certain that the trail cable is in such a position so as not to be run over by the drill or dragged through water or around or over large sharp rocks.

L). CAUTION: The trail cable carries high . . voltage AC power. Handle the cable with approved tongs and gloves. Follow all recommended safety procedures when working with or around the trail cable.

Once it has been verified that the travel route is in good condition and the trail cable is out of danger, the machine is now ready to propel.

STRAIGHT PROPEL - FORWARD OR REVERSE (Figure 23) To propel straight: 1.

The most important reason to operate slowly at first is safety. Operating at full speed means that things happen quickly, perhaps more quickly than expected. This unexpected operation ofequipment can very easily lead to an accident.

This section of the 47-R operator's manual describes the various functions of the machine. Some parts are for machines equipped with special equipment. Read and understand the procedures for the particular machine being operated, paying close attention to the CAUTION, WARNING, and NOTE statements.

For the purpose of this manual, we will assume that the drill has been left in the proper condition for operating. If this is not the case, complete the prestart checks as listed in Section 1 and start the machine using the procedures as outlined in Section 3.

PROPELLING Before beginning the propel operation, the operator should first inspect the travel route for large rocks, deep ruts or uneven contour. When working on a grade, verify the angle of the slope before propelling.

L). CAUTION: During the propel opera. . tion the machine will be propelled in the forward direction. Visibility in this direction is limited. Have a helper assist in the propel operation.

Verify that the hoist and auxiliary reel brakes are set. Verify that the tool string is clamped with the tool wrenches to prevent the tools from moving during the propel operation.

Also, verify that the tool string is hoisted to a position to avoid striking the ground when the machine is propelled. Verify that the leveling jacks are fully retracted and that the dust curtains are fully raised. If the machine is equipped with retractable stairway, be sure the stairway is in the raised position.

NOTE: For a long move of1,000 feet or more or if the machine is to be propelled over areas where machine stability may enter into the operation, the tool string may have to be disassembled and the rotary drive unit lowered and possibly the mast lowered.

2.

Place the hoist/auxiliary reel selector in the "off' position.

3.

Place the downfeed clutch control in the "off' position.

4.

Verify that the hoist-propel rheostat and the propel steering selector are in the "neutral" or "off' positions.

5.

Depress the control on pushbutton. The hoistpropel motor blower will start running.

6.

Place the propel steering selector in either the full forward or full rearward positions to engage the propel clutches and disengage the propel brakes. These positions are marked

,~ BUCYRUS-ERIE COMPANY, 1984

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7.

"LH & RH CLUTCH" on the control label plate.

neutral position to full speed at the full right position.

The speed and direction of straight propel is determined by the direction and distance the hoist-propel rheostat is turned from the "neutral" or "off' position. Turning the control to the right will propel the drill in the forward direction. The speed is varied from zero at the

Propelling straight to the rear is the same as propelling straight ahead except that the hoist-propel rheostat is turned to the left from neutral. Speed control is the same as forward propel, zero speed at neutral, full speed at full left position.

DUST CURTAIN CONTROL (ANGLE DRILLING)

PROPEL STEERING SELECTOR HOIST/AUXILIARY REEL SELECTOR DUST CURTAIN CONTROL DOWNFEED CLUTCH CONTROL AUXILIARY REEL BRAKE CONTROL HOIST BRAKE CONTROL

RETRACTABLE STAIRWAY CONTROL

STRAIGHT PROPEL FORWARD OR REVERSE FIGURE 23

32

REVERSE

FORWARD

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WARNING: Propelling in reverse is not recommended except when maneuvering over the hole or out of tight spots. Propelling in reverse places additional strain on the crawler links and drive tumblers which causes additional wear. Always try to propel in the forward direction.

WARNING: Do not propel for more than 5 minutes at less than 25% offull propel speed.

The dead slow range of the propel motion is for maneuvering around and in tight spots or lining up for the next hole. The dead slow range is not meant for use on long moves.

Overheating of the electrical system will occur if the control is at less than 25% for more than 5 minutes.

STEERING Steering on the 47-R is accomplished by disengaging the power to one crawler, setting the brake for that crawler, and then applying power to the other crawIer in either the forward or reverse directions.

To steer to the right when propelling forward or in reverse, place the steering selector in the LH clutch position (figure 24). This disengages the right propel clutch and sets the right propel brake.

The machine, by means of the left crawler, is then pushed to the right when going forward or pulled to the right when going in reverse.

To steer to the left when propelling forward or in reverse, place the steering selector in the RH

RIGHT TURN FORWARD

PROPEL STEERING SELECTOR

t

RIGHT TURN REVERSE

STEERING - RIGHT TURN FIGURE 24

" BUCYRUS·ERIE COMPANY, 1984

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clutch position (figure 25). This will disengage the left clutch and set the left brake. The machine, by means of the right crawler, is then pushed to the left when going forward or pulled to the left when going in reverse.

Steering should be done in steps of 15 degrees each (figure 26). After turning the machine a maximum of 15 degrees, the machine should be propelled straight for about one-half of the machine length to clear the crawler belts of dirt and rocks. Trying to turn the drill in more than 15 degree increments

will subject the crawler belts to severe strain.

Steering may be done while the machine is moving at less than 1/3 maximum speed. Steering should not be attempted at speeds over 1/3 maximum since this will place unacceptable shock loads on the propel system. Changing directions while still moving is not allowed. To change from forward to reverse or reverse to forward directions, the hoist/propel rheostat should be brought to the oor neutral position, and then after movement has stopped, turned in the opposite direction.

LEFT TURN FORWARD

PROPEL STEERING SELECTOR

LEFT TURN REVERSE

STEERING - LEFT TURN FIGURE 25

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LEVELING (Figure 27) The purpose for leveling the drill is to insure that the drill tool string is properly aligned, that the weight of the machine is off the crawler pads, and that the machine remains stable and level during the drilling operation.

The following points should be noted when leveling the drill: 1.

The drill should be raised on the leveling jacks only high enough so that the crawler lower rollers are not resting on the crawler pads (about 1 inch).

2.

The leveling jack pads should rest solidly on the ground. Cut, fill or reposition as necessary to achieve a solid footing.

3.

The clinometers or indicators used to gauge the levelness of the drill should be checked periodically to assure that they are accurate.

4.

When leveling the drill or lowering the drill back onto the crawler pads, care must be exercised in order to maintain stability ofthe machine and to avoid a binding action in the leveling jacks.

5.

When leveling a drill on an inclined surface care must be exercised to assure a stable machine once the machine is leveled. When drilling on an inclined surface, it is recommended to keep some weight of the machine on part of the crawler pads.

To level the machine proceed as follows: 1.

Depress the hydraulic pump start pushbutton.

WARNING: Refer to cold weather start-up procedures if ambient temperature is 32°F (0° C) or below. Improper cold weather startup ofthe hydraulic system will cause damage to the system.

2.

TURNING FIGURE 26

Lower all four jacks until the pads are resting firmly on the ground.

NOTE: For the following steps the leveling jack controls will be worked in pairs (i.e., front and rear left side or two front leveling jack controls, etc.). This will reduce the load deflection on the main frame. ~ BUCYRUS-ERIE COMPANY, 1984

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LOW SIDE

.-~"':;'-+--OILPUMP START

PUSHBUTTON

LEVELING JACK

LOW END

_1~~~~~~~~~~:~ L1

L

6"

LEVELING FIGURE 27

3.

Starting with the lowest side or end (front end, rear end, right side or left side) of the drill, raise that side or end ofthe machine, by operating both controls for the jacks on that side or end of the machine, to the level position. As an example if the lowest side is the left side, then actuate the left front and left rear jack 'controls.

4.

Next raise the second lowest point of the machine if required to the level position by actuating the two jack controls for that side of the machine.

5.

Finally, trim the machine to the level position using the individual controls to either raise or lower a specific point.

36

WARNING: When using the individual controls to raise or lower a specific point, do so in increments of no more than four inches.

Exceeding this causes excessive main frame deflection that could possible result in main frame or mast failure.

6.

The clinometers (figure 28) located in the right rear comer of the operator's cab near the ceiling, are used to indicate the levelness of the machine. The side-to-side clinometer is mounted parallel to the back wall of the cab while the end-to-end clinometer is mounted parallel to the right wall of the cab.

7.

Reverse the leveling procedure to lower the drill back onfo the crawler pads. Be sure to use the controls in pairs.

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MAST RAISING - STANDARD MAST (Figure 29)

h CAUTION: Raising or lowering the . . mast is a two-person job. Do not attempt to raise or lower the mast without the assistance of a helper familiar with the procedures involved.

CLINOMETERS FIGURE 28

NOTE: The following is a list of DON'TS to remember when lowering the drill.

1.

Don't lower the machine with the tool string in the drilled hole. The tool string must be out of the drilled hole and high enough so that it will not touch the ground when the machine is lowered onto the crawler pads.

2.

Don't attempt to retract the leveling jacks unless the hydraulic pump is running. The hydraulic pump must be running to maintain proper control of the leveling jacks.

3.

Don't move the leveling jack controls in short, quick movements. The controls are to be moved slowly and smoothly.

4.

Don't propel the machine unless the leveling jacks are fully retracted. Propelling with the jack partially raised can cause the jacks to hit ground obstructions and damage the jacks.

h CAUTION: During the mast raising . . procedure personnel should be kept clear of the machine and the area immediately surrounding the machine, especially the front of the machine. No one is to be allowed on the mast, operator's cab roof, or machinery house roof while the mast is in the air. Failure to heed this caution may result in the death or serious injury of personnel struck by the mast. h CAUTION: Limitations exist as to the . . length, diameter, wall thickness and number of drill pipes that may be stored in the tool racks when raising or lowering the mast. Refer to the pipe size limitation chart in the appendix before attempting to raise or lower the mast. Failure to comply with these limitations will overload the mast, mast support and hydraulic system possibly causing loss of control of the mast.

1.

Inspect the mast and machine exterior to ensure that all wires, hoses, cables, etc. are clear of the machine to prevent damage to the machine or equipment during the raising procedure.

2.

Depress the control on pushbutton and place the hoist/auxiliary reel selector in the "hoist" position. Release the hoist brake.

This allows the hoist shaft to turn as the mast pivots about the hinge pins, preventing the rotary drive unit from moving during the raising process. Slowly raise the mast by gently pulling the mast hoist control lever to the rear. As the mast reaches an angle of about 70 degrees it will begin to go over center and tend to come into the vertical position by itself. Care should be used once the mast has gone over center since the speed of the mast will increase sharply.

MAST RAISING AND LOWERING The mast on the 47-R is normally left in the raised position for most situations. The mast need not be lowered to propel from hole to hole on a blast pattern as long as the stability limitations for the mast up condition are not exceeded during the move. Lowering the mast is necessary under three conditions: 1.

maintenance work not possible or too dangerous to perform with the mast up,

2.

long moves (over 1,000 feet) where the drill will be towed into position or propelled at high speed and

3.

any situation when the stability limitations in the mast up condition will be exceeded and the limitations in the mast down condition will not.

h CAUTION: The mast hoist control . . should be moved away from and returned to the neutral position very slowly.

., BUCYRUS-ERIE COMPANY. 1984

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OIL PUMP START PUSHBUTTON CONTROL ON PUSHBUTTON

HOIST/AUXILIARY REEL SELECTOR

HOIST BRAKE CONTROL

MAST RAISING FIGURE 29

Sudden starts and stops can be damaging to the mast and hydraulic system. Be extremely cautious as the mast approaches 70 degrees as once the mast goes over center only a very slight movement of the control is necessary to cause motion in the mast.

cylinders to make the mast go up. Failure to move the controller far enough will allow the mast to lower slowly. Do not allow the mast, especially if near horizontal to fall quickly. Damage may result from the mast hitting the mast rests too hard.

WARNING: Pay close attention to the hoses, wires and cables that run between the mast support and the mast to prevent damage to the machine as the mast is being raised.

Have a helper watch from a safe position on the left side of the machine as the mast is going up.

3.

WARNING: If the raising or lowering procedure is halted before the mast has gone over center it will be necessary to move the control lever to almost the maximum position to supply enough pressure to the hoist

38

Once the mast is vertical, move the latch control lever rearward to lock the mast in the vertical position. Return the lever to the neutral position when the latch is in position.

The helper can verify that the latch is engaged.

MAST LOWERING - STANDARD MAST (Figure 30)

h CAUTION: Refer to cautionary state. . ments at tlie beginning of the standard mast raising procedure.

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To lower the mast: 1.

2.

Remove the drill pipe from the rotary drive unit and store it in the tool racks. Remove the bit and stabilizer from the machine. Clear the drill deck of all tools and materials which could fall off during the lowering procedure.

Secure the casing tongs and auxiliary reel hook. Raise the dust curtains. Place 20 feet of slack in the auxiliary reel line to allow the sliding hood to move without damage. Lower the rotary drive unit to its lowest position.

Verify that the machine is level.

3.

Move the latch control lever forward to release the mast latch. Have the helper verify that the latch has released, then return the lever to the neutral position.

4.

Slowly lower the mast by pushing the mast hoist control forward. As the mast moves away from the vertical position, its speed will increase. Gently reduce the lowering speed by moving the mast hoist control toward neutral. Continue lowering the mast until it is in place on the mast rest.

/). CAUTION: The mast hoist control . . should be moved away from and returned to the neutral position very slowly.

Sudden starts and stops can be damaging to the mast hydraulic system. Be extremely cautious as the mast approaches the mast rests, as only a slight movement of the control is necessary to cause motion in the mast.

Release the hoist brake so that the hoist shaft is allowed to turn while the mast is pivoting about the hinge pins, reducing the chances of overloading the pulldown chains or the mast machinery. Check the condition of the mast hinge pins, lugs and cylinder pins and that the pin retainers are in place.

OIL PUMP START PUSHBUTTON CONTROL ON PUSHBUTTON

HOIST BRAKE CONTROL

MAST LOWERING FIGURE 30

., BUCYRUS-ERIE COMPANY, 1984

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Lay the mast in the mast rests gently to prevent damage to the mast or machine house.

WARNING: Pay close attention to the hoses, wires and cables that run between the mast support and the mast to prevent damage to the machine as the mast is being lowered.

Have the helper observe the machine from a safe position on the left side of the machine as the mast is coming down. Also pay close attention to the sliding hood as the mast is coming down. Do not allow the hood to catch on the machinery house roof or allow the curtains to be damaged.

machines without back braces. Additional effort is necessary to attach the back braces, but the basic procedure remains the same.

h CAUTION: During this procedure it . . will be necessary that personnel be on the machinery house roof to gain access to the back braces. Be sure to follow all safety measures to prevent personal injury.

To raise the mast on machines equipped with back braces: 1.

MAST RAISING WITH BACK BRACES (Figure 31) The mast raising procedure on machines equipped with back braces is similar to the procedure for

Refer to caution statements at the beginning ofstandard mast raising procedure. Complete step 1 of the standard mast raising procedure. The back brace lower lock pins should be stored separately from the back braces. If not, remove the pins at this time.

OIL PUMP START PUSHBUTTON CONTROL ON PUSHBUTTON

BRACE LOWER LOCK PIN MAST HOIST CONTROL MAST LATCH CONTROL

HOIST BRAKE CONTROL

MAST RAISING OR LOWERING WITH BACK BRACES FIGURE 31

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2.

Slowly raise the mast as detailed in step 2 of the standard mast raising procedure. When the mast reaches a 30 degree angle the lower lock pins may be inserted in the back braces.

It may be necessary to insert one pin and then raise or lower the mast slightly to insert the other pin. If the lower lock pins will not line up with slight movement of the mast, it will be necessary to raise or lower one or more of the leveling jacks to align the pin bores.

MAST LOWERING WITH BACK BRACES (Figure 31) To lower the mast on machines equipped with back braces: 1.

Refer to caution statements at the beginning of standard mast lowering procedure and complete steps 1 and 2 of the standard mast lowering procedure.

2.

After the brace lower lock pins have been inserted, remove the telescoping lock pins to allow the back braces to telescope. If the mast is to be raised to the vertical position for vertical drilling, proceed to step 4. If the mast is to be set up for angle drilling proceed to step 5.

If the mast is at an angle for angle hole drilling, remove the back brace telescoping pins.

Slowly lower the mast to a 30 degree angle, by gently pushing the mast hoist control forward, then proceed to step 4 below. If the mast is in the vertical position remove the back brace telescoping pins and move the latch control lever forward to unlatch the mast. Have the helper verify that latch has released, then return the lever to the neutral position. It may be necessary to raise or lower one or more of the leveling jacks in order to remove the pins.

3.

Complete the mast raising procedure as detailed in step 3 of the standard mast raising procedure. After the mast is locked into position with the mast lock pins, the telescoping lock pins may be installed in the ba'ck braces. It may be necessary to raise or lower one or more of the leveling jacks slightly to allow the pins to be inserted.

Once the telescoping lock pins have been removed and the mast unlatched, the mast may be slowly lowered to a 30 degree angle by slowly pushing the mast hoist control forward.

4.

Once the mast is at a 30 degree angle, the back brace telescoping lock pins may be reinserted. It may be necessary to raise or lower the mast slightly to make insertion of the pins possible. When the telescoping pins have been inserted, the lower lock pins may be removed. Remove these pins and store in a safe place on the machine.

5.

After removal of the lower lock pins is complete the mast may be lowered to the mast rests. Follow the procedures detailed in step 4 of the standard mast lowering procedure to complete the mast lowering procedure.

WARNING: Do not adjust the back braces without following the adjustment procedure in the Mechanical Maintenance Manual. Adjusting the braces arbitrarily will place undue strain on the mast structure, causing eventual machine damage.

NOTE: As the lower end of the mast brace approaches the anchor lug on the machinery house, it may be necessary to guide the end of the brace onto the anchor lug.

3.

4.

NOTE: If the machine is equipped with mast latches, move the latch control lever rearward to latch the mast in the vertical position. Return the lever to the neutralposition when the latch is in position. The helper can verify that the latch is engaged.

5.

Continue raising the mast to the desired angle and insert the telescoping lock pins into the back braces at the desired location.

WARNING: The mast back braces must be adjusted to remove all clearances in the pins and braces. Failure to remove clearances can cause mast cracking.

NOTE: During step 5 of the lowering procedure the back braces will slide along the back brace support mounted to the front of the machinery house. Be sure that the back braces slide along this support.

" BUCYRUS-ERIE COMPANY. 1984

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HOIST MACHINERY OPERATION

2.

(Figure 32)

The hoist machinery supplies power to the hoist chains which either raise or lower the rotary drive unit. Power is supplied to the hoist gearcase by either an electric motor or a hydraulic motor. The electric motor is used for high speed hoisting or lowering of the rotary drive unit while there is no load on the tool string. The hydraulic motor is used when fine control of the rotary drive unit is required, or when there are loads on the tool string such as when drilling or removing a stuck tool string.

HYDRAULIC MODE To operate the hydraulic hoist, proceed as follows: 1.

Place the hoist-auxiliary reel selector in the "hoist" position.

Place the downfeed clutch control in the "on" position. This connects the hydraulic pulldown motor to the hoist-propel gearcase.

Depress the control on pushbutton to supply control power to the hoist brake.

/').. CAUTION: Depress the control off . . pushbutton to set the hoist brake. Depressing the control off pushbutton does not disable the hydraulic hoist. To stop in an emergency it is necessary to both set the hoist brake and return the hoist-pulldown selector to the neutral position.

WARNING: Do not operate the electric hoist motor with the downfeed clutch engaged. To do so will overspeed the hydraulic motor and possibly overload the hoist-propel motor and cause serious damage to the hoist-propel gearcase.

HOIST

• •

LOWER DOWNFEED PRESSURE CONTROL

HOIST/AUXILIARY REEL SELECTOR DOWNFEED CLUTCH CONTROL HOIST BRAKE CONTROL

HOIST MACHINERY OPERATION FIGURE 32

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3.

4.

To hoist the rotary drive unit hydraulically, simultaneously place the hoist-pulldown selector in the hoist (forward) position and release the hoist brake. To stop the drive unit, simultaneously return the selector to neutral and set the hoist brake.

To lower the rotary drive unit, simultaneously place the hoist-pulldown selector in the lower (rear) position and release the hoist brake. Control the speed and down pressure with the downfeed pressure control. To stop the drive unit, simultaneously return the selector to neutral and set the hoist brake.

NOTE: When the hoisting or lowering ofthe drive unit is complete always set the hoist brake and depress the control off pushbutton to prevent movement of the drive unit.

lower direction. To stop the rotary drive unit, return the rheostat to the neutral position and set the hoist brake.

NOTE: When the hoisting or lowering operation is complete always set the hoist brake and depress the control stop pushbutton.

AUXILIARY REEL OPERATION HYDRAULIC MODE (Figure 33) To operate the auxiliary reel in the hydraulic mode proceed as follows: 1.

Depress the control on pushbutton. Place the hoist-auxiliary reel selector in the auxiliary reel position.

2.

Place the downfeed clutch control in the "on" position. This connects the hydraulic motor to the gearcase.

3.

To hoist the auxiliary reel line hydraulically, simultaneously place the hoist-pulldown selector in the hoist mode and release the auxiliary reel brake. To stop the line, simultaneously place the hoist-pulldown selector in the "neutral" position and set the auxiliary reel brake.

4.

To lower the reel line one of two operations may be done. If fine control of the load is necessary, the hoist-pulldown selector may be placed in the neutral position and the load lowered by releasing the auxiliary reel brake.

With the brake in the set position, the load is held from moving. As the brake is gradually released, the load will start lowering. Maximum speed is obtained when the brake is fully released. The speed of the load may be varied by releasing or setting the brake slightly.

ELECTRIC MODE To operate the electric hoist proceed as follows: 1.

Place the hoist-auxiliary reel selector in the "hoist" mode.

2.

Place the downfeed clutch control in the "off' position. This disconnects the hydraulic pulldown motor from the hoist-propel gearcase. Depress the control on pushbutton to supply control power to the hoist controls.

3.

To hoist the rotary drive unit electrically, simultaneously release the hoist brake and turn the hoist rheostat in the hoist direction.

Control the hoist speed with the rheostat. To stop the rotary drive unit, simultaneously set the hoist brake and return the rheostat to neutral.

NOTE: Depress the control off pushbutton to disable the hoist controls and to stop in an emergency. Depressing the control offpushbutton will set the hoist brake.

4.

Lowering the rotary drive unit can be done two ways. If a sufficient enough load is on the rotary drive unit (usually a complete tool string), the drive unit will lower under gravity when the hoist rheostat is in neutral and the hoist brake released. Lowering under gravity is the preferred method when a tool string is attached to the drive unit. To regulate the speed use the hoist brake. If the load on the rotary drive unit is not sufficient, the unit may not lower under gravity or may lower too slowly. In this case the unit may be lowered by simultaneously releasing the hoist brake and turning the hoist rheostat in the

If a fast lowering speed is desired or if the load is not sufficient enough to lower under gravity, the reel may be powered down. To lower the load in this manner, the hoistpulldown selector is placed in the pulldown position and the auxiliary reel brake released fully. Speed of the line is controlled by the downfeed pressure control. Maximum speed is obtained when the control is rotated to the full clockwise position, while speed is a minimum when the control is rotated fully counterclockwise. The load is stopped by simultaneously placing the hoist-pulldown selector in the neutral position and setting the auxiliary reel brake.

" BUCYRUS-ERIE COMPANY, 1984

43

BI005457 AUXILIARY REEL LINE

HOIST

•

LOWER DOWNFEED PRESSURE CONTROL

HOISTI AUXILIARY REEL SELECTOR DOWNFEED CLUTCH CONTROL AUXILIARY REEL BRAKE CONTROL

AUXILIARY REEL OPERATION FIGURE 33

WARNING: The auxiliary reel brake control should be moved from and returned to the set position gradually. Setting the brake quickly places severe shock loads on the auxiliary reel and reel line. Control of the load speed should be maintained so that sudden stops are not necessary. Do not release the brake quickly as the load may move faster than expected and a quick stop may be necessary.

ELECTRIC MODE To operate the auxiliary reel in the electric mode proceed as follows: 1.

44

Depress the control on pushbutton. Place the hoist-auxiliary reel selector in the auxiliary reel position.

2.

To hoist the auxiliary line, simultaneously release the auxiliary reel brake and turn the hoist-propel rheostat clockwise (to the right).

3.

To stop the load, reduce the hoisting speed to a minimum, then simultaneously apply the auxiliary reel brake and return the hoistpropel rheostat to the neutral position.

WARNING: The auxiliary reel brake should be moved from and returned to the set position gradually. Setting the brake rapidly will shock load the auxiliary reel line.

Smooth control of the load is mandatory.

4.

Lowering of the load may be done one of two ways, either by gravity or under power. Both methods are acceptable as long as control of the load is maintained and the system is not subjected to shock loading.

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Lowering by gravity in the electric mode is accomplished by placing the hoist-propel rheostat in the neutral position, then gradually releasing the auxiliary reel brake. Control of the load is maintained by gradually setting or releasing the brake. Full lowering speed will be realized by releasing the brake fully, while the load will be stopped completely by setting the brake completely. Lowering speed is determined by the weight of the load and the amount the brake is released.

Lowering under power is accomplished by simultaneously releasing the auxiliary reel brake and turning the hoist-propel rheostat counterclockwise (to the left). The lowering speed is determined by the weight and rheostat position. Maximum speed will be reached when the rheostat is rotated fully counterclockwise while the load will be lowered by gravity alone when the controller is in neutral.

WARNING: The auxiliary reel brake must be fully released whenever the hoist-propel motor is activated. Do not attempt to control the lowering speed with the brake while in the power lowering mode. If the lowering speed becomes excessive, return the rheostat to the neutral position and control the speed with the brake alone.

or when the pipe has been removed for changeout or for maintenance to the mast. The procedure in this manual, unlike some more commonly used procedures requires that the mast be in the horizontal or lowered position to load the drill pipe.

This procedure, while not the most expedient for machines requiring pipe changeout while the mast is in the drilling position, is quite efficient while the mast is in the stored position. Proper scheduling of maintenance and production requirements against pipe life will allow using this procedure while reducing the downtime of the machine.

h CAUTION: Limitations exist as to the . . length, diameter, wall thickness and number of drill pipes that may be stored in the tool racks when raising or lowering the mast. Refer to the pipe size limitation chart in the appendix of this manual before loading pipe onto the machine with the mast down and before raising or lowering the mast. Failure to comply with these limitations will overload the mast, mast support and hydraulic system possibly causing loss of control of the mast. Refer to the appendix of this manual for an alternate method of loading and unloading pipe from the machine in order to comply with the mast raising and lowering limitations.

To load drill pipe onto the drill, proceed as follows:

To stop the load in the power lowering mode, simultaneously set the auxiliary reel brake and return the hoist-propel rheostat to the neutral position.

1.

tion, lower the mast and store it in the mast rests. Refer to the appropriate topic in this manual for the exact operating procedures.

2.

TOOL HANDLING GENERAL OPERATING PROCEDURE This section in the 47-R Operator's Manual describes the procedures necessary to load, unload, handle, assemble and disassemble the drill tools.

The procedures detailed in this section are intended to be as universally applicable as possible.

It is, however, impossible to prepare a procedure that will take into account every possible machine option or tool vendors products. For this reason it is important that the operator not only become familiar with these procedures, but with the machine and the particular tools being handled.

PIPE LOADING AND UNLOADING Loading pipe onto the drill is necessary when the drill is new and has not yet had the pipe installed

If the mast is in the vertical or drilling posi-

Obtain a crane with suitable capacity and reach to place the drill pipe into the pipe racks with the mast in the stored position. Normal placement ofthe crane is on the left side of the drill since this allows the shortest reach and greatest boom angle.

h CAUTION: Followallapplicablesafety . . measures when working with cranes and rigging.

3.

Position the pipe to be installed in such a position so as to be accessible to the crane.

Normal placement of the drill pipe is on the left side of the machine, laying at right angles to the machine. This allows the crane to lift the pipe and swing without excessive boom hoisting and lowering. The pipe may be stored on suitable blocking on the ground, or on a truck or trailer.

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h CAUTION: Make sure the drill pipe is . . secured against unwanted or unexpected movement.

4.

Manually open the pipe gate on the pipe rack and block the gate open to allow the pipe to be installed.

DRILL TOOL STRING ASSEMBLY The tool string consists of one or more sections of drill pipe, a stabilizer (drill collar) and a bit (figure 34). In assembling the tool string, the stabilizer is the first item installed, then comes the drill pipe and finally the bit.

h CAUTION: Care should be exercised . . when climbing on the mast. No normal accessway exists to the position of the pipe gates. Personnel should be protected by safety belts or temporary walkways if necessary.

ROTARY COUPLING OR OPTIONAL SHOCK COUPLING (shown)

h CAUTION: The pipe gate is spring . . loaded to snap shut without air pressure being supplied to the opening air ram. Personnel should exercise caution while opening the gate that they are not in a position to be struck by the gate should it snap shut.

5.

Using suitable rigging, attach the crane to the drill pipe. The pipe should be rigged so that it will remain horizontal while being lifted. Attach suitable tag lines to the pipe.

Remove the thread protectors and clean and lubricate the threads and shoulders on each end of the pipe. Install an approved lifting bell to the pin (upper) end of the pipe. Lift the pipe into position over the mast.

6.

Using a tag line guide the pipe into the desired pipe rack. Place suitable blocking beneath the pipe to allow the slings to be removed from the pipe.

DRILL PIPE

STABILIZER (DRILL COLLAR)

h CAUTION: Block the pipe $ecurely to . . prevent it from moving unexpectedly.

7.

Remove the slings from the pipe. Attach a sling to the lifting bell on the pin end of the pipe and lift the pipe sufficiently to remove the blocking.

8.

Slide the pipe down the pipe rack until it rests on the bottQm of the pocket. Lay the pipe in the pipe rack and remove the sling and lifting bell.

9.

Remove the blocking holding the pipe gate open. Verify that the gate is completely closed.

10.

Repeat the procedure for additional lengths of pipe.

Unloading the pipe is the reverse of the procedure used for loading the pipe.

46

~DAILLBIT FIGURE 34

To install the stabilizer proceed as follows: 1.

Remove the guide bushing from the hole in the drill deck. Place the stabilizer to be installed in a position so as to be accessible to the auxiliary reel line. Clean and lubricate the threads and shoulders on each end of the stabilizer. Install a lifting bell on the pin (upper) end ofthe stabilizer and lift it onto the drilling deck and set it in the guide bushing

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hole with the auxiliary reel line. Securely block the stabilizer horizontally on blocking sufficient enough to place the stabilizer 8-10 inches above the drill deck. Remove the auxiliary reel line.

2.

Place the guide bushing on the upper end of the stabilizer with the tapered end of the bushing toward the lower (box) end of the stabilizer. Reattach the auxiliary reel line to the lifting bell.

3.

Install the stabilizer and guide bushing in the hole in the drill deck (figure 35). Make sure the guide bushing is seated properly.

Lower the stabilizer until the slots in the stabilizer are aligned with the tool wrenches.

Extend the tool wrenches to hold the stabilizer in place.

AUXILIARY REEL LINE

To install a single section of drill pipe proceed as follows: 1.

WARNING: Use only drill pipe thread compound on the pipe threads. Drill pipe thread compound contains material that will prevent the threads from seizing and galling under the severe pressure encountered on the pipe threads.

2.

Depress the control on pushbutton. Raise the rotary drive unit to a position on the mast so as to clear the tool rack as it comes into place.

3.

Raise the selected pipe rack slightly to remove pressure on locking arms by moving the corresponding tool rack control in the raise direction (pull toward operator).

4.

Return the pipe rack control to the neutral position. Depress the tool rack lock control to unlock the tool rack. While holding the tool rack lock control down, lower the tool rack by moving the tool rack control in the lower direction (push away from the operator).

After the tool rack has cleared the locking arms, the lock control may be released.

5.

Slowly lower the tool rack until it is resting firmly on the lower stops. Once the rack is resting on the stops, return the pipe rack COlltrol to the neutral position.

--_-II

GUIDE BUSHING

FIGURE 35

4.

Remove the auxiliary reel line from the stabilizer and secure it out of the way. Remove the lifting bell from the stabilizer and store it.

WARNING: The use of stabilizers that have been modified or that do not allow this procedure to be used should be avoided. The use of non-standard stabilizers will make assembly and disassembly of the tool string difficult and dangerous.

Lower the rotary drive unit until the pipe coupling on the unit can be reached from the drill deck. Set the hoist brake and depress the control off pushbutton. Tag the controls to prevent unauthorized operation. Clean the inside threads on the coupling to remove any dirt or old lubricant. Apply a coat of drill thread compound to the threads and shoulder of the coupling.

WARNING: Do not allow the tool rack to descend too quickly that it hits the bottom stop hard. This will shock load the hydraulic ram and possibly do damage to the ram and the tool rack and mast structures. Operate the tool rack slowly. Do not apply pressure to the bottom stop.

6.

Lower the rotary drive unit until it is approximately 1 foot above the upper end of the drill pipe (figure 36). Turn the rotary master switch clockwise to the run position.

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7.

Turn the rotary rheostat clockwise until the rotary drive unit coupling begins to turn at approximately 5 RPM. Carefully lower the rotary drive unit until the coupling contacts the drill pipe. Release the hoist brake completely and allow the rotary drive unit to lower under gravity while the coupling is threading onto the pipe.

WARNING: Do not use pulldown power to force the rotary drive unit down onto the drill pipe. Doing so will make the joint harder to make up and may cause it to cross-thread.

8.

together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the pipe is removed from the rack.

h CAUTION: The threads on the drill . . pipe are tapered to make assembly and disassembly of the pipe easier. The threads are designed to disengage after only a few revolutions of the pipe. Failure to have the pipe shoulders contacting may result in the pipe joint uncoupling and the pipe falling from the rotary drive unit.

When the drill pipe begins to turn with the rotary drive unit coupling, check the joint between the coupling and the pipe. The shoulders on the pipe and coupling must be

There is no provision made for holding the pipe stationary in the rack while the joint is tightened. If the joint does not tighten using the above procedure it may be necessary to

ROTARY DRIVE UNIT

ROTARY COUPLING

DRILL PIPE I .....,.........""_

L-'r7"'Zi~;W!-L....~_ROTARY MASTER SWITCH

TOOL RACK GATE

TOOL RACK LHTOOLRACK LOCK CONTROL

FIGURE 36

48

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apply a small amount of hoist power to the rotary drive unit to lift it slightly to remove the pressure from the drill threads. Use the hydraulic hoist to gently raise the rotary drive unit slightly.

A CAUTION: Do not lift the drill pipe. . . Lift the rotary drive unit only enough to relieve the pressure on the threads. Lifting the drive unit enough to lift the pipe will not only put pressure on the other side of the threads, but may also allow the tool rack gate to open. Should the joint uncouple at this point, the drill pipe may fall out of the rack, causing death, serious injury or serious machine damage.

If the pipe joint does not make up by relieving the weight of the drive unit from the threads it will be necessary to inspect and/or repair the threads on the rotary drive unit coupling and the drill pipe. Inspect the threads for rough surfaces and burrs and apply a liberal coat ofthread compound to them. The threads should have a smooth finish and no burrs or dirt that will hinder joint make-up. The joint shoulders should also be clean and smooth and should have compound applied.

9.

WARNING: Make sure that the tool rack is in the locked position before continuing.

Should the tool rack lower itself while drilling and contact the rotary drive uni t, damage will be done to both the rack and the drive unit.

11. Once the tool rack has been stored the pipe should be cleaned out using the bailing air.

Remove all personnel from the area and turn on the bailing air for a moment. After cleaning the pipe, clean and lubricate the threads and shoulder on the lower end of the pipe and the upper end of the stabilizer.

A CAUTION: Before working around the . . tool string set the hoist brake. Depress the control off pushbutton, tag the operator's controls.

12. Lower the rotary drive unit until the drill pipe is approximately 1 foot about the upper end of the stabilizer (figure 37).

After cleaning and repairing the threads, try making the joint again. If the joint cannot be made, either the drill pipe or the coupling is defective. Replace the pipe or coupling as necessary.

13. Turn the rotary rheostat clockwise until the drill pipe begins to turn at approximately 5 RPM. Carefully lower the rotary drive unit until the drill pipe contacts the stabilizer.

Release the hoist brake completely and allow the rotary drive unit to lower under gravity while the drill pipe is threading onto the stabilizer.

Once the joint is made up between the coupling and the pipe, the pipe is now ready to be lifted out of the tool rack pocket. Use the hydraulic or electric hoist to lift the pipe approximately three feet above the top ofthe pocket to allow the tool rack to be raised. Set the hoist brake.

WARNING: Do not use pulldown power to force the drill pipe down onto the stabilizer.

Doing so will make the joint harder to make up and may cause it to cross-thread.

10. Once the pipe has been lifted clear of the tool rack, raise the tool rack to the stored position by p~lling the tool rack control to the raise position.

WARNING: Verify that the pipe gate on the tool rack is open before retracting the tool rack. Retracting the tool rack with the gate closed will cause damage to the tool rack.

14. When the stabilizer begins to turn with the drill pipe, check the joint between the stabilizer and the pipe. The shoulders on the pipe and stabilizer must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the stabilizer is released. If the shoulders of the pipe and stabilizer are contacting, the joint is made up.

NOTE: It is not necessary to depress the tool rack lock control when storing the tool rack.

Installation of the drill bit is the last step in preparing the tool string.

" BUCYRUS-ERIE COMPANY, 1984

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BI005457

ROTARY RPM METER DRILL PIPE

~__~~__~r--ROTARYRHEOSTAT

HOIST BRAKE CONTROL

FIGURE 37

To install the bit, proceed as follows: 1.

Hoist the completed drill pipe/stabilizer assembly 2-3 feet off of the drill deck. Place the bit basket into the hole left by the guide bushing in the drill deck. Remove all personnel from the drilling deck and the immediate area. Turn 'on the main air stream to blow any contaminants from the drill pipe and stabilizer.

2.

Place the bit into the bit basket (figure 38).

Coat the threads and shoulders of the bit and stabilizer with drill pipe thread compound.

3.

Turn the rotary master switch to the right to the run position.

50

4.

Turn the rotary rheostat to the right until the tool string begins to turn at approximately 5 RPM. Slowly lower the rotary drive unit and tool string by gravity onto the bit. Lower the drive unit in small increments until the threads catch and the stabilizer starts to thread itself onto the bit. As soon as the bit starts to move, set the hoist brake and let the stabilizer screw itself onto the bit.

5.

When the joint is tight the rotary drive unit will slow down and the rotary load meter will show an increased load. Return the rotary rheostat to the "off' position when the rotary loadmeter starts to show an increase in load.

6.

After making the bit to stabilizer joint, hoist

BI005457

ROTARY RHEOSTAT

STABILIZER

ROTARY MASTER SWITCH

BIT BASKET

HOIST BRAKE CONTROL

FIGURE 38

the rotary drive unit to allow the bit basket to be removed. Remove the bit basket and store it in a safe place.

7.

Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck. Set the hoist brake and depress the control off pushbutton. The tool string is now complete for single pass drilling or for the first pass of multiple pass drilling.

CASING TONG OPERATION Operation of the casing tong is necessary anytime a pipe joint, except the joint on the rotary drive unit, must be broken. This includes removing the bit or stabilizer, or separating two sections of pipe.

To break a joint with the casing tong proceed as follows (figure 39): ~ CAUTION: When working with the . . casing tong it is important that the hoist brake be set, the control off pushbutton be depressed and the control tagged to prevent operation of the hoist or rotary controls.

1.

If a pipe joint between pipe sections or between the stabilizer and the pipe is to be broken, align the slots in the lower tool to be broken with the tool wrench jaws. Close the tool wrench by pushing the tool wrench control forward. Make sure the lower tool is held securely by the tool wrench and that the slots in the tool are aligned with the tool wrench Jaws.

• BUCYRUS-ERIE COMPANY, 1984

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DRILL PIPE CASING TONG OR AUXILIARY REEL LINE

CONTROL ON PUSHBUnON

TOOL WRENCHES

HOIST BRAKE CONTROL

FIGURE 39

2.

3.

If the casing tong is not supported by a separate cable, support it with the auxiliary reel line. Operate the auxiliary reel in the hydraulic mode to give the best control of the casing tong.

Attach the handle end ofthe tong to the breakout cylinder with the pin provided. Open the jaws of the tong (or if optional chain type tong is used, unlatch the chain) and verify that the hardened jaw inserts are in place and in good condition, and that the jaws or chain works freely. Retract the breakout cylinder fully by pushing the casing tong control forward.

tion of the tong should be so that the entire tong/breakout cylinder assembly is horizontal. Make sure that the jaws are clamped as tightly as possible around the upper tool.

5.

h CAUTION: All personnel should be . . removed from the drill deck when operating the casing tong cylinder.

6.

4.

52

Swing the tong into position and close the jaws or chain around the upper tool. The posi-

To break the joint, extend the breakout cylinder by pulling the casing tong control rearward. The jaws of the tong should grip the upper tool and turn it while the lower tool is held stationary by the tool wrench.

Once the joint has broken, repeat the cycle 2-3 times to loosen the joint sufficiently to allow the rotary drive unit to finish disassembly.

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7.

8.

Retract the breakout cylinder and remove the casing tong from the tool string. Disconnect the tong from the breakout cylinder and store the pin in a safe place. Return the casing tong to the stored position and secure it to prevent movement during drilling.

STABILIZER

Using the rotary drive unit, continue disassembly of the joint. Refer to the appropriate topic for exact operating procedures.

n..

CAUTION: The joint must uncouple . . freely while using the rotary drive unit.

If the joint does not uncouple freely, repeat the procedure using the casing tong until it does. Constantly observe the joint between the rotary drive unit coupling and the first section of pipe when running the rotary motion in reverse. If this joint begins to uncouple, stop the rotary motion immediately and retighten the joint. If this joint uncouples the pipe will fall, possibly causing death or serious injury to personnel.

9.

If the lower tool is the bit, secure the bit with the bit basket as described in the topic BIT REMOVAL. Operate the casing tong as described above, except that the lower tool (bit) is secured by the bit basket, not the tool wrench.

FIGURE 40

5.

To remove the drill pipe from the rotary drive unit, proceed as follows: 1.

Depress the control off pushbutton and set all brakes. Tag the operator's controls to prevent operation. Go to the drill deck and clean the pocket of the tool rack to be used of dirt, cuttings or any material that will interfere with the entrance ofthe pipe or the operation ofthe tool rack gate controls. Verify that the gate controls are intact. After performing this function, return the controls to operating condition.

2.

Raise the rotary drive unit until the lower end of the pipe is 4-6 feet off of the drill deck.

Depress the control off pushbutton and tag the controls. Clean and lubricate the threads and shoulder on the lower end of the pipe.

This is to prevent rusting while stored in the tool rack.

3.

Raise the tool rack slightly to remove the weight ofthe rack from the lock arms by pulling the appropriate pipe rack control rearward.

4.

Depress the tool rack lock control to release the tool rack. Lower the tool rack until it rests on the lower stops. When the tool rack is lowered, return the tool rack control to the neutral position.

DRILL TOOL STRING DISASSEMBLY The tool string is disassembled in reverse of assembly, that is the bit is removed first, then the drill pipe and lastly the s~abilizer.

To remove the bit from the tool string, proceed as follows: 1.

Raise the tool string 2-3 feet above the drill deck. Install the bit basket in the hole in the drill deck.

2.

Lower the bit into the bit basket. Attach the casing tong to the stabilizer just above the bit (figure 40).

3.

4.

Using the casing tong, break the joint between the stabilizer and the bit. After breaking the joint, use rotary power to disassemble the joint. Use a slight amount of hoist power to lift the tool string off ofthe bit to facilitate the disassembly.

Hoist the tool string 2-3 feet off of the drill deck. Secure the rotary drive unit and controls. Attach a lifting bell to the bit. Attach the auxiliary reel line to the lifting bell and lift the bit out the bit basket.

After removing the bit, the bit basket may be removed, allowing removal of the drill pipe.

NOTE: The tool rack lock control may be released after the rack has cleared the lock arms.

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5.

Slowly lower the rotary drive unit and place the lower end of the pipe into the tool rack pocket. Make sure that the pipe is seated firmly on the bottom of the pocket.

6.

Turn the rotary master switch counterclockwise to the run position. Turn the rotary speed/torque selector to the low speed/high torque position.

7.

Quickly turn the rotary rheostat to approximatelyone-halfpower. Thejointshould break at the rotary drive unit. If the joint does not break immediately, return the rotary rheostat to the "off' position.

8.

Gently raise the rotary drive unit under the hydraulic hoist as the joint is unthreading.

9.

When the joint completely unscrews, the pipe

will drop to the bottom ofthe tool rack pocket.

When the joint is completely unscrewed, raise the rotary drive unit until it is in a position so as not to be struck by the tool rack when it is raised. Set the hoist brake.

10. Raise the tool rack into the stored position by pulling the appropriate tool rack control rearward. When the tool rack is in the stored position, gently lower it slightly to verify that the lock is secured.

To remove the stabilizer, proceed as follows: 1.

Lower the tool string until the slots on the upper end of the stabilizer are aligned with the tool wrench. Clamp the stabilizer in the tool wrench. Break the joint between the stabilizer and the drill pipe (figure 41), lower the tool rack and store the drill pipe.

DRILL PIPE CASING TONG OR AUXILIARY REEL LINE

CONTROL OFF PUSHBUTTON

TOOL WRENCHES HOIST BRAKE CONTROL

FIGURE 41

54

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2.

Attach a lifting bell to the upper end of the stabilizer. Attach the auxiliary reel line to the lifting bell and lift the stabilizer and guide bushing and block the assembly in a horizontal position.

3.

Remove the auxiliary reel line from the stabilizer. Remove the guide bushing from the stabilizer and replace the auxiliary reel line.

4.

Using the auxiliary reel line, remove the stabilizer from the drill. Replace the guide bushing in the deck.

allow the rotary drive unit to build up speed before stopping the drill pipe. This is done by rotating the drill pipe in the forward direction until the slots in the pipe are almost aligned with the tool wrenches. This allows the drill pipe to rotate almost one-half turn before being stopped by the tool wrenches. The spring loaded inserts in the tool wrench allow the pipe to rotate while being clamped by the wrench.

After indexing the pipe to allow the one-half turn rotation, repeat step 3 above to break the joint.

Repeat this procedure as many times as is necessary to break the joint.

ADDING ADDITIONAL DRILL PIPE Installation of additional sections of drill pipe is necessary when the depth of the hole is to be greater than the total length of one section of pipe.

Installation of the second and third sections of pipe is essentially the same procedure as installation of the first. The rotary drive unit is raised above the tool racks, a tool rack with pipe lowered, the rotary drive unit threaded to the pipe, and the pipe removed from the rack and the rack stored.

5.

When the joint breaks, apply enough hoist power (hydraulic mode) to raise the rotary drive unit as the joint is unthreading. Do not apply enough power to lift the tool wrench and cause it to loose it's grip on the pipe. Once the joint is completely disassembled, raise the rotary drive unit to a position to make the coupling accessible from the drill deck. Set the hoist brake, depress the control off pushbutton and tag the controls to prevent operation. Clean and lubricate the threads and shoulder of the rotary drive unit coupling.

Use an approved drill thread compound on the threads and shoulder. After cleaning and lubricating the coupling, remove the locks and tags and raise the rotary drive unit to a position above the tool racks so as not to be struck by the pipe or rack as the rack descends.

6.

Lower the tool rack and install the new section of pipe to the rotary drive unit.

7.

Once the new section of pipe is attached to the rotary drive unit and the tool rack stored, lower the pipe until it is approximately 3 feet above the drilling deck. Set the hoist brake and tag and lock the controls. Place a cover over the threads on the pipe held by the tool wrench. Clear all personnel from the area and turn the main air stream on to blow away any dirt from inside of the pipe attached to the rotary drive unit. After turning off the main air stream, remove the cover from the lower pipe and clean and lube both the pin threads on the lower pipe and the box threads on the upper pipe.

8.

After cleaning and lubricating the threads, turn the rotary rheostat until the drill pipe is

To add an additional section of drill pipe, proceed as follows: 1.

The first part of the hole should be drilled as deep as possible with the first section of pipe.

The hole should be drilled deep enough to place the joint between the rotary drive unit and the top ofthe first section of the pipe even with the top ofthe tool wrench. After completing this section of the hole turn the main air stream off.

2.

Raise the tool string until the slots in the top of the first section of pipe are aligned with the tool wrench. Clamp the tool wrench firmly around the drill pipe.

3.

Turn the rotary master switch to the far left position. Turn the rotary speed/torque selector to the low speed/high torque position.

Quickly turn the rotary rheostat to approximately one-half offull speed. The rotary drive unit coupling should turn, breaking the joint between the pipe and the coupling.

WARNING: If the joint does not break immediately, return the rotary rheostat to the o position to reduce the chance of damaging the motor by stalling it.

4.

If the joint does not break, it will be necessary to index the slots on the drill pipe so as to

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rotating at approximately 5 RPM. Lower the rotary drive unit slowly by gravity until the threads begin to contact. Once the threads begin to join the two pipes, attempt to minimize the pressure on the threads by allowing the joint to close slightly while holding the upper pipe in position with the hoist brake, then allowing the upper pipe to descend slightly to keep the tool wrench from loosing it's grip on the lower pipe. Once the joint is tight stop the rotary motion.

WARNING: Be sure that the joint is made properly before attempting to unclamp the lower pipe. Should the joint not be made properly and fail, the lower pipe will fall into the hole and be difficult to recover.

9.

Unclamp the tool wrench and retract it fully.

The second section of pipe is now installed.

FIGURE 42

To install the third section of pipe, follow the procedure for installation of the second section of pipe, except that the third section of pipe is now installed between the rotary drive unit and the second section of pipe.

REMOVAL OF MULTIPLE SECTION DRILL PIPE Disassembly of multisection pipe strings is essentially the same as disassembly of a single section of pipe. The difference is that instead of the stabilizer being held by the tool wrench, it is the first or second section of pipe.

The tool string is disassembled in reverse order of assembly. First, the last section of pipe to be installed is removed, followed by the second section of pipe installed, and then the first. In each case the lower section of pipe is held by the tool wrench while the joint is broken by the casing tong (figure 41). The joint is then disassembled by the rotary motion and the pipe stored in the tool rack. The procedure is then repeated as necessary to remove all, or part, of the tool string.

NOTE: For normal operation it is not necessary to completely disassemble the tool string to move from hole-to-hole within the drill pattern as long as the stability limitations are not exceeded. Do not disassemble the tool string more than necessary.

56

CENTER GUIDE OPERATION Some machines are equipped with a center guide which is used to guide the drill pipe as the hole is being drilled. A center guide is used when deep holes are being drilled or with small diameter pipe.

As the diameter of the pipe decreases or as the length ofthe pipe increases the possibility ofbending the pipe become greater.

The center guide is clamped around the drill pipe prior to beginning drilling the hole. As the hole is drilled and the rotary drive unit descends, the center guide will remain halfway between the drive unit and the drill deck. As the center guide approaches the drill deck support is no longer necessary and the center guide jaws will automatically open. The jaws cannot be closed once the center guide passes the set limit on the mast. This is to prevent the jaws and rotary drive unit coupling from being damaged should the jaws close around the coupling.

The center guide jaws are controlled by the center guide jaw control located on the operator's console (figure 42). Pushing the control forward will close the jaws when the center guide is above the limit switch. Pulling the control rearward will open the jaws at any time.

Always close the jaws around the drill pipe before starting to collar the hole and during the drilling procedure. The jaws will open automatically when the limit switch is- passed so no operator action is necessary.

BI005457 WATER TANK

DUST SUPPRESSION SYSTEM OPERATION Most 47-R drills are equipped with some sort of dust control system. This system may be either a bag type filter or a water injection system. Dust control is necessary to contain the dust generated by drilling from escaping to the environment. All machines are equipped with dust control curtains (figure 43) to contain the dust around the drill hole as standard equipment.

WATER LINES

WATER PUMP

MAIN AIR ' - - ' . J 4 . - - PRESSURE

SENSING LINE

WATER INJECTION W/WATER PUMP

f VERTICAL DRILLING DUST CURTAINS

AIR LINES MAIN AIR PRESSURE SENSING LINE WATER LINE

TO AUXILIARY AIR LINE WATER INJECTION W/AIR PRESSURIZED TANKS

WATER INJECTION FIGURE 44

ANGLE DRILLING DUST CURTAINS

DUST CURTAINS FIGURE 43

There are two ways to suppress dust generation or prevent the escape of the dust to the atmosphere.

The two methods cannot be used at the same time as they are not compatible. One method to suppress the generation of dust is to inject water into the main air stream as it passes to the bit (figure 44).

The water serves to conglomerate the dust particles into larger particles that may be treated as cuttings. The other method to suppress the dust is to contain the dust in the dust curtain enclosure then draw off the lighter particles and filter them out of the air before returning the air to the atmosphere. The filtering can be done by a filter bag unit, which forces the dust laden air through filters where the dust is removed (figure 45), or by a centrifugal filter where dust particles are forced out of the air by centrifugal force. In both systems, either the bag filter or the centrifugal filter, the dust must remain dryas wet material will plug the filters.

• BUCYRUS·ERIE COMPANY, 1984

57

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PIPE POSITIONER AND CASING TONG CRANE OPERATION (Figure 46) The pipe positioner and the casing tong crane are two additional options that must be present, along with the back braces, in order to drill an angle hole. The pipe positioner is used to hold the drill pipe in position while joints are assembled or disassembled. The casing tong holdback is used with the casing tong to break the joints.

The pipe positioner is operated by two air controls located on the operator's control panel with the other air controls. The pipe positioner is moved into position with the pipe positioner operating control. Moving the control to the in position will allow for the positioner to swing into operating position. Moving the control to the out position will retract the positioner to the stored position.

The pipe positioner jaws are opened and closed with the pipe positioner jaw control. Placing the control in the open position will open the positioner jaws and allow the positioner to be placed in the operating position. Placing the control in the closed position will lock the jaws around the pipe and hold it in position.

BAG FILTER DUST SUPPRESSION SYSTEM FIGURE 45

To operate the water injection system turn the water on when starting to drill. The dust curtains should be lowered to contain any dust that escapes being trapped by the water. Vary the amount of water injected into the air stream to keep the dust at an acceptable level. Using excessive water will not suppress the dust any better and will necessitate filling the water tank more often. When wet material is being drilled, shut off the water injection system to conserve water.

To operate the filter system lower the dust curtains and start the blower units before beginning to drill. Keep the filter units running as long as the main air stream is flowing. When wet material is being drilled, shut off the units to prevent wet material from being drawn into the units, plugging the filters. When operating the filter units, do not operate the water injection unit (ifthe machine is equipped with both) as this will plug the filters.

Empty the dust hoppers frequently ifnot equipped with automatic dust bin doors.

Maintain the dust control systems in good working order to prevent the escape of dust into the atmosphere.

58

WARNING: Do not operate the rotary machinery except at low speeds to make and break joints while the jaws are closed around the pipe. Operating the rotary machinery at high speeds or drilling while the pipe positioner jaws are closed around the pipe will damage the jaws and positioner structures.

To make a joint with the pipe positioner, proceed as with normal joint assembly. When the pipe rack has been lowered into position, swing the positioner into place and lock the jaws around the pipe.

Proceed as normal to make the joint. Once the joint is made, open the positioner jaws and retract the positioner to the stored position.

To break a joint both the pipe positioner and the casing tong crane are utilized. The pipe positioner is used to hold the pipe in position to be loaded into the tool rack. The casing tong crane is used to hold the casing tong in position to break the joint.

To break a joint, proceed as normal with joint disassembly. The casing tong is now suspended with auxiliary reel line and is held away from the mast with the holdback cable. By adjusting the pressure regulator on the holdback cylinder, the

BI005457

(f'

t II

PRESSURE

REGULATOR ~b

v TYPICAL CASING TONG PULLBACK

\1\\ 1\

PIPE POSITIONER CONTROL

\1\

PIPE POSITIONER JAW CONTROL

\\ \

TYPICAL PIPE POSITIONER

PIPE POSITIONER AND CASING TONG PULLBACK OPERATION FIGURE 46

position ofthe casing tong is lowered into position around the drill pipe. Proceed as normal with joint disassembly and retract the casing tong by adjusting the holdback regulator. Before breaking the joint completely, clamp the pipe with the pipe posi-

tioner. After breaking the joint, hoist the drill pipe and lower the pipe rack into position. Lower the pipe into the tool rack, release the jaws and retract the positioner. Proceed as normal with the pipe joint disassembly procedure.

., BUCYRUS-ERIE COMPANY, 1984

59 (60 blank)

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SECTION 5 - DRILLING VERTICAL DRILLING

To begin, or collar the hole, proceed as follows:

GENERAL OPERATING PROCEDURES (Figure 48) Once the drill has been inspected and started, positioned, leveled, and the tool string assembled, it is now ready to begin drilling. There are two methods of drilling, vertical drilling and angle drilling. Vertical drilling is, as the name implies, drilling a vertical hole. Angle drilling is drilling the hole at some angle from vertical (up to 30 degrees).

The actual drilling procedure involves three main sections: 1.

starting the hole (collaring),

2.

drilling the hole, and

3.

cleaning or reaming the hole.

1.

Verify that the tool wrench is retracted fully and that the casing tong is secured out of the way. Clear the drill deck of personnel and material which is not necessary for the drilling procedure.

NOTE: If drilling is to be done in soft material with a fairly fast penetration rate move the hydraulic motor pinion shifter, on the hoist!propel gearcase, to the high speed position (figure 47). If drilling is to be done in hard or difficult material, the shifter should be placed in the low speed position.

o

o

HIGH SPEED POSITION

o

Many types of formations are found in mining areas. Formations that are drilled may range from a wet clay to solid taconite. Each formation, and the parts of the hole within each formation, requires drilling techniques expressly for that formation. A hole drilled through fragmented limestone is not drilled the same way that a hole is drilled through consolidated taconite. For this reason it is important that the operator not only become familiar with the basic drilling procedures and the specific machine being operated, but that he also become familiar with the formation being drilled.

For the purpose of this manual it is assumed that the hole will be drilled in a consolidated rock formation. This is probably the simplest formation to drill in. Special circumstances will be taken into account in the DRILLING IN DIFFICULT FOR· MATI a NS topic ofthis manual. It is also assumed that the operator is familiar with the location and operation of all of the controls on the machine and that the machine is in good repair.

BEGINNING THE HOLE (COLLARING) (Figure 48) Since the first few feet of a hole are usually in unconsolidated material, the procedure for drilling through this material will be different than for the remainder of the hole. This procedure is commonly referred to as collaring the hole.

o

o

HYDRAULIC MOTOR PINION SHIFTER FIGURE 47

If the shifter is in the high speedposition and drilling pressure starts to increase, it may be necessary to stop the drill and move the shifter to the low speed position.

WARNING: Do not attempt to move the shifter with the machinery running as the splines on the shaft could possibly be damaged.

2.

Place the hoist-auxiliary reel selector in the hoist position. Depress the control on pushbutton. Lower the drill string so that the guide bushing is firmly seated in the hole in the drill deck. Make sure that the slots in the bushing align with the lugs on the drill deck.

3. Turn the rotary master switch to the far right position. Turn the rotary rheostat to the right until the rotary RPM meter indicates that the tool string is turning at approximately 25 RPM.

~ BUCYRUS-ERIE COMPANY, 1984

61

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DEPTH L~~_--INDlcATOR

ROTARY LOAD AMMETER NO.2 MOTOR - - ; -

I

ROTARY LOAD _ AMMETER ,--NO.1 MOTOR _

I

HOIST/PROPEL] RHEOSTAT CONTROL ON PUSHBUTTON --;-----:""~...,L~~

...

FIGURE 48

4.

Lower the dust curtains and turn on the dust control system. Place the main air control in the "on" position to supply bailing air to the bit.

NOTE: While the bit is passing through the unconsolidated material laying on the top of the formation the downpressure applied to it will be provided by the weight of the tool string and the rotary drive unit alone.

5.

Slowly release the hoist brake and allow the drill bit to contact the ground. Monitor the vibration coming from the tool string. To reduce vibration either slow the rotary speed with the rotary rheostat or reduce the downpressure by setting the hoist brake, or both.

Keep the vibration to a minimum. As the vibration lessens, increase the rotary speed and the downpressure (releasing the hoist brake) while monitoring the rotary loadmeter and the main air pressure gauge.

The objective is to penetrate the formation as

62

fast as possible without damaging the machine or plugging the hole with cuttings.

Monitoring the rotary loadmeter, and keeping the load in the green band will eliminate damage to the rotary motor. Reducing the load on the motor is accomplished by reducing the downpressure on the bit. Setting the hoist brake will, in most instances, accomplish this. In some cases it may even be necessary to hoist the tool string slightly to reduce the loading. Monitoring the main air pressure gauge will indicate the condition of the hole. If penetration is too fast and the bailing air cannot remove the cuttings as fast as they are generated, the hole will plug and the main air pressure will rise. Varying the penetration rate (setting or releasing the hoist brake) will vary the main air pressure.

Keep the main air pressure in the working range (below 30 psi) by increasing or reducing the penetration rate. Keep the vibration levels to a minimurn by varying the rotary speed and the downpressure.

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6.

When the bit passes through the fragmented material (approximately 3'-5') and into the consolidated material underneath, the vibration and loading will reduce drastically. When this occurs, the hole has been collared and normal drilling may commence.

NORMAL DRILLING (Figure 48) After the bit has passed through the unconsolidated material at the top of the hole, it is no longer necessary to reduce the load on the bit to reduce vibration and rotary motor loading. More rapid penetration and increased downpressure may now be used to complete the hole as fast as possible with minimum vibration. This is the normal drilling condition for the machine.

Normal drilling follows the same guidelines as collaring the hole. Penetration is increased to the maximum determined by the rotary motor load, the vibration of the tool string, and the main air pressure. By keeping the penetration at or slightly below the optimum, the hole can be completed in the shortest possible time.

the green band. It is permissible for the load to increase momentarily into the yellow band, but continuous running in the yellow or red bands will cause rotary motor damage.

NOTE: To monitor the load in both rotary motors it will be necessary to turn the RPM meter switch to the right to monitor #1 rotary motor and to the left to monitor the #2 rotary motor.

3.

WARNING: Excessive or prolonged vibration of the tool string and machine will cause eventual damage to the machine.

Monitor the main air pressure. Keep the pressure below 30 psi. Pressures above 30 psi indicate that the hole is starting to plug with cuttings.

After the bit passes through the unconsolidated portion of the hole and the vibration is reduced, the normal drilling procedure begins.

1.

2.

When normal drilling is desired it is necessary to add pressure to the bit in addition to the dead weight of the tool string and rotary drive unit. This pressure is furnished with the hydraulic pulldown motor and hoist-propel gearcase. To activate the hydraulic pulldown motor, place the downfeed clutch control in the "on" position and push the hoist-pulldown selector forward until it locks. Adjust the pulldown pressure with the downfeed pressure control. Turning the control to the right will increase the pressure on the bit, while turning it to the left will decrease the pressure.

Apply enough downpressure to allow the bit inserts to chip the material being drilled, rather than pulverizing it. If the downpressure is not sufficient enough, the bit will ride over the top of the material being drilled and will not create chips. This condition can be observed by monitoring the cuttings. If the cuttings are finely pulverized material, the downpressure is not enough. Another cause of poor cutting is a worn bit. If downpressure is high, but the cuttings are fine and penetration is slow, change the bit.

Monitor the rotary motor load and adjust the pulldown pressure to keep the loadmeter in

Monitor the vibration of the tool string and the machine. Keep the vibration to a minimum by varying the pulldown pressure and the rotary speed. If vibration increases, reduce the rotary speed first. If this does not reduce the vibration to an acceptable level, reduce the pulldown pressure until the vibration is acceptable.

NOTE: With a screw compressor the 30 psi limitation is not the determining factor. For screw compressors the pressure is determined by the bit orifices and the bailing requirements. Only a sizeable increase in pressure, ofperhaps 5 psi, above determined pressure is significant.

Stop the downfeed by returning hoist-pulldown selector to neutral and setting the hoist brake. Wait a moment and if the pressure starts to decrease, let the hole clear before returning to drilling. If the pressure does not start to decrease it will be necessary to hoist the tool string to clear the hole. To do this place the hoist-pulldown selector in the hoist position and release the hoist brake. Hoist the tool string until the hole is cleared. Leave the rotary motion activated since this will help clear the hole. If the pressure is noticed slowly rising during drilling, reducing the penetration rate momentarily may eliminate the need to cease downfeed and hoist the tool string.

4.

Continue normal drilling until the hole is at the desired depth. It may be necessary to add drill pipe to complete the hole. Refer to the appropriate sections in this manual for the procedures necessary for adding drill pipe.

., BUCYRUS-ERIE COMPANY, 1984

63

BI005457

Determining the depth of the hole may be done a number of ways. The most desirable and fastest way is to use a depth indicator if the drill is equipped with one. Reset the indicator to zero when starting the hole and the indicator will continuously show the depth of the hole. Another method is to paint gauge marks on the drill pipe every 5 feet and count the marks visible on the drill pipe out of the hole. Subtracting the amount ofpipe from the total length of the tool string will give the hole depth. Unfortunately, this method requires that the paint stripes be repainted every couple of holes.

5.

increases, reduce the rotary speed and return the hoist-pulldown selector to neutral while setting the hoist brake. Allow the obstruction to be removed by the bit before continuing. If the hole is very crooked (indicating a worn stabilizer) it may be necessary to repeat this procedure of hoisting, then stopping and allowing the bit to clear, many times before reaching the top of the hole. This procedure straightens the hole and allows the tool string to be removed.

3.

Once the finished hole depth is reached it is necessary to clean or ream the hole before it is completed.

ENDING THE HOLE (Reaming) (Figure 48) Once the finished hole depth is reached normal drilling ceases. It is now necessary to ream the hole before preparing the drill to move to the next hole. Reaming the hole removes cuttings that have fallen to the bottom of the hole and also straightens and increases the diameter of the hole.

As the bit and tool string are cutting through the formation, the bit may tend to wander slightly.

This wandering is due to the fact that the stabilizer cannot be exactly the same diameter ofthe bit or it would wear out quickly and create operational problems. The stabilizer tends to keep the bit on course, but it cannot keep the hole exactly straight.

Reaming the hole straightens the hole and therefore increases the diameter of the hole slightly.

Reaming the hole also removes any cuttings that are lodged in the hole. These cuttings must be removed or they will eventually fall to the bottom of the hole, reducing the drilling depth.

To complete the drilling procedure the hole is reamed as follows: 1.

When the hole is drilled to the finished depth, leave the main air stream on and the rotary motion activated. Return the hoist-pulldown selector to the neutral position and set the hoist brake. Allow the tool string to rotate and the main air to bail the hole for a moment. This removes all of the cuttings in suspension in the hole from the hole.

2.

Place the hoist-pulldown selector in the hoist position by pulling the control to the rear while simultaneously releasing the hoist brake. Slowly hoist the tool string out of the hole. If resistance is met, or if vibration

64

Once the tool string has been removed and the hole reamed, it must now be cleaned out.

Reaming the hole loosens cuttings that have become lodged in the side of the hole. These cuttings, and most of the cuttings generated during reaming will fall to the bottom of the hole. This filling of the hole may reduce the actual depth ofthe hole significantly, so it is necessary to remove these cuttings from the hole. To do this, return the hoist-pulldown selector to the neutral position and set the hoist brake.

Once the hoist-pulldown selector is in the neutral position, the tool string may be lowered by gravity to the bottom of the hole by releasing the hoist brake. Leave the main air on and the tool string turning at 25-30 RPM. When the bit reaches the point where the cuttings have accumulated on the bottom ofthe hole, these cuttings will be forced out of the hole. When the cuttings have been cleaned out of the bottom of the hole, the bit will contact the undrilled formation at the bottom of the hole and stop penetrating. Once the flow of cuttings out of the hole stops and the tool string stops penetrating, the hole is clean.

4.

After cleaning the hole the tool string may be raised to the top using either hydraulic or electric hoist. To remove the tool string with the electric hoist disengage the downfeed clutch control and turn the hoist rheostat control to the right. If resistance is encountered while hoisting, return the hoist rheostat to the neutral position. Do not use the electric hoist if resistance is encountered. Switch to the hydraulic hoist by engaging the downfeed clutch and pulling the hoist-pulldown selector to the rear until it locks.

ENDING THE HOLE (Multiple Pipe Sections) Reaming the hole with multi-section tool strings is the same as reaming with single pipe section

BI005457

strings. The reaming procedure must be done in stages as the pipe sections are removed.

While removing the drill pipe the cuttings dislodged from the sides of the hole and the cuttings generated by reaming will fall to the bottom of the hole. To effectively clean the hole, it would be necessary to reassemble the tool string and lower it to the bottom ofthe hole. This is not desirable as it is time consuming. One method to eliminate the need to clean the hole is to overdrill the depth and allow cuttings to fill the hole to the desired finishing depth. Experience in this area will show how much to overdrill the hole. A good practice is to overdrill the hole by 1-2 feet over the estimated finished hole depth. This way, if the estimate is wrong, the hole will be 1-2 feet too deep. This can easily be corrected by a few shovels full of cutting thrown into the hole. Under estimating, on the other hand will require that the tool string be reassembled and the hole cleaned.

DRILLING DIFFICULT FORMATIONS For the purpose of explanation, the drilling procedure given in the topic DRILLING ofthis manual assumes that drilling takes place in consistant, consolidated rock formations. Unfortunately, not all drilling is in this type of formation. This portion of the Operator's Manual will detail l in general, some typical drilling difficulties encountered.

The main cause of difficult drilling are unconsolidated material or wet sticky material. Unconsolidate material causes vibration far greater than experienced in consolidated formation, and if severe enough, may also decrease the bailing velocity of the main air stream. Wet, sticky material causes problems with cleaning the hole since the material may coat the hole and the drill pipe, increasing the main air pressure above the working range. Wet material may also plug the bit orifices, freeze the bit cones, or compact into balls that refuse to be bailed out of the hole.

The general procedure for drilling in difficult formations is the same as the procedure for drilling in good formations. The hole is collared, drilled, reamed, and cleaned using the standard operating procedures. Monitoring of the machine is however, critical while drilling in difficult formations.

NOTE: When drilling in difficult formations the hydraulic motor pinion shifter should be in the low speed position.

WARNING: Failure to closely monitor the machine and it's gauges and meters will result in damage to the machine or a stuck drill pipe.

UNCONSOLIDATED MATERIALS Drilling unconsolidated materials may present two problems. The first, and most severe, is the vibration encountered ifthe penetration rate is too fast. As the bit rotates the cones pass over the material and the teeth or inserts chip away at the material being drilled. Unconsolidated material, however, has voids in it. When the bit passes over a void in the material it only contacts part of the bottom of the hole. As each roller passes through the void, the tool string moves down, as the roller falls into the void, and then back up as the roller climbs out. This continual up and down motion results in shock loads being transmitted from the bit, through the tool string, to the machine.

NOTE: When drilling in unconsolidated materials the hydraulic motor pinion shifter should be in the low speed position.

To drill through an unconsolidated formation it is necessary to reduce the load on the bit as it is passing over the voids. It is also helpful to isolate the shock loading to the tool string. This is accomplished by first reducing the downfeed pressure. If reducing the downfeed pressure does not reduce the vibration to the machine to an acceptable limit, it is then necessary to reduce the pressure even more by disengaging the pulldown motor and allowing the tool string to penetrate by gravity. This also tends to isolate the vibration in the tool string, since the tool string is no longer connected to the hoist-propel gearcase and may rise or fall as necessary without transmitting the shock to the machine. If the void is extensive it may even be necessary to hoist the bit above the void and then lower the bit a small amount at a time so as to chip away at the sides ofthe void a little at a time.

Reduction ofthe rotary speed will also help reduce the vibration of the tool string. This is the last procedure that should be tried since if the downfeed pressure is left high and the rotary speed diminished, the vibration will be just as severe, only at a different frequency.

Unconsolidated material presents another problem due to the fact that the voids in the material may allow the bailing air to escape through the sides of the hole, rather than passing along the drill pipe and exiting through the top of the hole.

This loss of air reduces the volume of air available to bail the hole, causing the cuttings to fall to the bottom ofthe hole and be reground by the bit. This further reduces the penetration rate since these cuttings must be ground up by the bit and bailed out of the hole or they will plug the hole. Unconsol-

.~ BUCYRUS-ERIE COMPANY, 1984

65

BI005457

idated material may also cause the hole to cave in.

This creates problems due to the sudden addition of material into the hole and the resultant loss of bailing velocity due to the increased diameter of the hole.

If unconsolidated material is causing the loss of bailing air volume or caving ofthe hole itis necessary to continually clean the hole as the recycled cuttings or the caved material will plug the hole.

Closely monitor both the bailing air pressure and the flow of cuttings from the hole. If the air is being lost the air pressure will remain constant but the flow of cuttings will stop or drastically decrease while penetration does not decrease. Continue drilling for a few feet to try and get past the leak. If the bailing air pressure starts to rise, the hole is plugging. Immediately hoist the tool string until the pressure drops and allow the drill string to rotate for a few moments to clear itself. Then lower the tool string to the bottom ofthe hole and clean it out. It may be necessary to regrind the cuttings to make them small enough to seal the leak and be bailed out of the hole by reduced air volume. Once the hole is clean, repeat the hoisting and lowering procedure ever 2-3 feet to keep it so.

If the material tends to cave in from the sides of the hole, the tool string can become stuck in the hole quickly. If the caved material is small, it will fit between the cones of the roller and fall to the bottom of the hole. The hole can then be cleaned out using the same procedure as for a leaky hole. If the caved material is large it will be necessary to pull the tool string out of the hole and then redrill the caved material.

NOTE: Be very cautious when drilling in formations which tend to cave in easily, especially if the material caves in large blocks. Should the material that caves into the hole be too large to lift with the rotary drive unit or too hard to break with the top of the bit, the tool string will have to be abandoned in the hole.

Experience will dictate what procedure to follow when encountering material which tends to cave in. When the formation is unfamiliar always be cautious. Caution may result in lower production, but it could save a great amount of work and a complete tool string should the tool string become stuck. Always clean the hole often and monitor the air pressure constantly. If the air pressure starts to climb, hoist the tool string immediately - do not wait to see if the pressure will level off or not. By the time it is determined what the air pressure will

66

be, the hole is plugged. Cleaning the hole often accomplishes two things.

First, it removes the caved in materials from the hole. Second, it loosens any potentially hazardous material and causes it to cave in while the tool string is being hoisted. If the hole caves in while in the hoist mode there is a better chance of recover· ing from the cave in.

If the hole should become plugged there are two ways to recover the tool string. Each method depends upon what type of material has plugged the hole. If the material that is plugging the hole is small (less that 6 inches square), it is possible to grind the material sufficiently to allow it to pass between the lobes ofthe bit and fall to the bottom of the hole. This condition can be observed if the bailing air pressure increases over 30 psi working range. Large, chunky material will let the bailing air through, while fine material won't. Also, when attempting to hoist out of the hole the tool string will not vibrate greatly, due to the small size ofthe material. Large material will cause the tool string to be shocked every time a lobe on the bit strikes the block. To recover the tool string from a hole plugged with smaller material, put the rotary drive unit in the hydraulic hoist mode and hoist the bit until it runs into the plug and stops hoist· ing. With rotary motion turning at approximately 50-60 RPM keep 300-500 psi of hoist loading on the bit and allow the bit to work its way through the plug. Monitor the rotary motor loading and reduce the hoist loading to keep the load in the green band. Once the plug is passed, clean the hole and return to drilling. The main air pressure mayor may not exceed the safety valve setting and cause the safety valve to open and it mayor may not cause the main air compressor to overheat. If the safety valve opens wr~ en the hole is plugged, continue to attempt to free the tool string. The safety valve will close when the plug has been removed.

If the compressor overheats and shuts down continue to attempt to free the tool string without the compressor. Allow the compressor to cool for a few minutes and restart it. Continue this procedure until the tool string is free.

If the material plugging the hole is large it will be necessary to try and force the material back into position enough to let the bit go past, and then try and redrill through the plug. Large material is indicated when the tool string experiences severe vibration when being hoisted. To free the tool string under this condition slow the rotary speed to 20-30 RPM and apply maximum hydraulic hoist power. If the plug does not clear itself within a few

BI005457

moments lower the tool string a few feet if possible and try again.

If the plug does not clear itself after repeated attempts at clearing it, there are two options available. The tool string can be abandoned immediately without further trial or an attempt to drill through the plug using the top of the bit can be made. In either case the hole being drilled will have to be abandoned. In the first case the cost of the abandoned tool string is known, while in the second case a gamble is being taken as the bit and stabilizer will almost certainly have to be scrapped and there is no guarantee that the rest of the drill pipe will be recovered. If it is decided to abandon the tool string, attempt to unscrew a section of pipe to recover some of the tool string. If this cannot be done, lower the tool string to the bottom of the hole and then using a suitable burning torch cut the drill pipe at ground level. It will be necessary to move over an existing hole to remove the stub of pipe from the rotary drive unit.

A. CAUTION: Before cutting the drill pipe . . verify that the main air compressor is shut down. Burning the pipe with the main air compressor running may cause a fire or explosion as hot slag is introduced to the main air steam or may cause hot material to be blown back onto the torch operator.

If an attempt is to be made to free the drill string by drilling with the top of the bit, place the rotary drive unit in hydraulic hoist and apply only enough hoist pressure to keep the vibration and rotary motor load levels in an acceptable range.

Vary the hoist pressure by alternately placing the hoist-pulldown selector in the hoist and neutral positions. Vary the rotary speed to help reduce vibration. Drilling through a large block with the top of the bit can be a lengthy procedure and it is important to prevent damage to the rest of the machine. Once the tool string is free, check the bit and stabilizer as well as the drill pipe for damage.

Replace components and move to a new location for the hole. Do not try and drill the same hole again as this will almost certainly cause the tool string to become stuck again.

WET OR STICKY FORMATIONS Drilling in wet or sticky formations presents three possible problem areas. The three problems that may be encountered are coating of the hole and pipe with material, conglomeration of the material into pieces too large to remove with the bailing air stream, and caving of the hole. Either of these problems may be present, or any combination of the three may be present at the same time.

NOTE: When drilling in wet or sticky formations the hydraulic motor pinion shifter should be in the low speed position.

Drilling in wet formations follows the same practices as drilling any other formation. Drilling wet formations, however, requires that particular attention be paid to the bailing air pressure and penetration rates. Wet formations are more susceptible to plugging the hole, but recovering the tool string from the plugged hole is easier than with unconsolidated material.

In the ~ase where the material is adhering to the drill pipe and coating the sides of the hole it is necessary to ream and clean the hole every 5-10 feet to remove the offending material. It is also necessary to clean the drill pipe periodically to remove the caked on material. This can be accomplished by removing the tool string from the hole and allowing the material to be scraped offby the guide bushing. It is important then, if the guide bushing is to be used to clean the tool string, that the bushing be kept in good repair.

In the case where the material is conglomerating into large pieces, these pieces fall back down to the bottom ofthe hole and are recycled through the bit to be broken up. If the amount ofrecycled material is too great it will accumulate at the bottom of the hole and restrict the main air stream. To keep this material at a minimum clean the hole periodically.

When hoisting the tool string allow the material to be ground by the bit and fall to the bottom of the hole before cleaning the hole.

In the case where the material is caving in from the sides of the hole, treat the formation as unconsolidated and drill according to the procedure detailed in this manual for unconsolidated material.

It is important when drilling through difficult formations to constantly monitor the machine and tool string. Allowing the tool string to become stuck is an expensive mistake and can be avoided by cautious drilling practices. Reaming and cleaning the hole may only take a few moments, but it could be the difference between an abandoned hole and tool string and a successfully completed hole.

ANGLE DRILLING GENERAL OPERATING PROCEDURES (Figure 48) Angle drilling follows the same general drilling procedures as vertical drilling. The main differ-

~ BUCYRUS-ERIE COMPANY, 1984

67

BI005457

ence in the drilling procedures, besides the fact that the hole is at an angle, is the need to monitor, the condition of the different systems more closely while angle drilling. The differences in the operating procedures for the different systems on the machine are limited to handling the tool string and raising and lowering the mast to the proper drilling angle.

When drilling an angle hole, monitoring of the system indicators such as the drilling air pressure, the rotary load and the machine vibration, becomes more critical than when drilling a vertical hole.

The reason these monitors become more important is the fact that an angle hole will tend to wander downward as the hole is being drilled.

This wandering is due to the drill steel assuming a natural camber as it is being extended past the guide bushing. This camber is unavoidable and becomes worse as the angle of the hole approaches 30 degrees.

The force of gravity continually acts upon the tool string causing it to bend downward. This downward bending is known as the camber of the drill pipe. This camber causes the hole to be drilled with a gradual bend in it. This causes the drill pipe to contact the side of the hole, increasing the load on the rotary motor. This also tends to inhibit the bailing of the hole since the cuttings are not flowing vertically. The flow of the bailing air (and suspended cuttings) must be diverted around the points that the drill pipe is resting on the side of the hole. This contributes to the increased air pressures needed to drill an angle hole. The vibration of the tool string will be increased while drilling at an angle, due to the tool string resting on the side of the hole, rather than on the bottom.

PREPARING TO MOVE Once the hole has been completed and the tool string removed from the hole it is necessary to move the drill to the next hole location to prepare to drill the next hole. Preparing to move the drill consists of proper storage of the tool string, lowering the machine'to the ground, and inspection of the machine and travel route prior to propelling.

To prepare the drill to move, proceed as follows: 1.

68

Upon completion of the current hole, hoist the tool string from the hole. If using multiple pipe sections, remove and store all pipe necessary to remove the entire tool string from the hole. Turn off the dust control system and raise the dust curtains.

2.

Determine the maximum grade to be propelled over while moving to the next hole.

Refer to the MACHINE STABILITY LIMITS in appendix for the maximum allowable grades under different circumstances. If it is necessary to remove and store the entire tool string, do so at this time. Be certain to lower the rotary drive unit to it's lowest position if dictated by the stability limits. If the tool string is to remain in place, clamp the stabilizer with the tool wrench to prevent movement of the tool string during propel.

WARNING: Do not propel with the tool string in a position where it will be struck against the ground while propelling. Should the tool string hit the ground while propelling, damage to the machine and tool string will result.

3.

Using the leveling jack controls, lower the machine so that it remains level, but is touching the ground. Use the leveling jack controls in pairs (Le., either both side controls, or both end controls simultaneously) to reduce the bending loads on the drill frame.

4.

Once the machine is touching the ground, it may be lowered completely. To lower the machine completely, first lower the uphill side or end of the machine to the ground, then lower the downhill side or end to the ground.

It is important that the machine be lowered in stages to minimize both the angle of the machine and the bending stresses placed on the machine.

WARNING: While lowering the machine to the ground it is imperative that the machine be kept as level as possible. It may be necessary to lower the machine in stages to keep it as level as possible.

5.

Once the machine is completely lowered, retract the leveling jacks to the maximum retracted position.

WARNING: Be sure that the leveling jacks are fully retracted before propelling the machine. Propelling the machine with a leveling jack not fully retracted will result in serious damage to the jack and machine structures.

6. Inspect the machine, travel route and trail cable as outlined in the PROPELLING topic in this manual. If equipped with retractable stairway raise the stairway. After completing the inspections and raising the stairway the machine is ready to propel.

BI005457

SECTION 6 - MACHINE SHUTDOWN

GENERAL CONSIDERATIONS

5.

Shutting down the machine is necessary any time that the operator must leave the machine, either at the end of the shift, of for a period of time during the shift. Machine shut down is also necessary for most maintenance work to be performed.

Following the procedures in the PREPARING TO MOVE topic in this manual, lower the drill to the ground. Place the leveling jack pads on the ground, but do not place any weight on them.

6.

Shut off the main air compressor. Place all controls in the off or neutral position.

7.

Go the the machinery house and turn off all breakers. If the machine is to be shut down for a short period oftime and it is necessary to leave the lights on, it is permissible to leave the lighting breaker and lights on.

8.

Inspect the machine for obvious damage or wear. Make note of any operating difficulties discovered while drilling and any problems discovered during this inspection. Report the difficulties to the appropriate personnel.

9.

Close all doors and windows tightly.

Shutting down the machine is essentially the reverse of starting it up. The degree of work to be done is determined by the length of time the machine will be shut down. Shut down for a short period involves little extra work, while shutting the machine down for a lengthy period will involve considerable effort.

SHUT DOWN PROCEDURE To shut down the machine, proceed as follows: 1.

2.

Complete the hole, if any, currently being drilled. If the hole is not completed before the machine is shut down, it will be necessary to abandon the hole and drill another in its place. Do not try and redrill a hole that has been left unfinished as releveling and placing the drill in the exact same position is extremely difficult.

Remove the tool string from the hole. If multiple pipe sections are used, remove and store pipe sections as necessary to remove the entire tool string from the hole.

WARNING: Do not shut the machine down with the tool string in the hole. To do so may cause damage to the drill pipe and may lead to the abandonment ofthe tool string and the hole.

3. Determine the length of time the drill is to be idle. Refer to the appropriate storage topic in this manual for the degree to which the tool string must be disassembled. If necessary, disassemble and store the tool string at this time.

4. If possible lower the rotary drive unit to its lowest position and set the hoist brake. If the tool string is not to be removed, clamp the stabilizer with the tool wrench and set the hoist brake.

SHORT TERM STORAGE If the machine is to be shut down for more than 3 eight hour shifts, but less than 3 weeks, short term storage precautions are necessary. These precautions are necessary to insure that the machine is not damaged or does not deteriorate during the storage period.

Short term storage is primarily concerned with placing all components in a safe position and providing additional protective lubrication to normally lubricated components.

To store the machine for a maximum of3 consecutive weeks, proceed as follows: 1.

If not already done so previously, complete all shut down procedures as detailed in the MACHINE SHUT DOWN topic in this manual. During the shut down procedure it is necessary to remove and store the complete tool string. Remove the bit from the stabilizer and store it in a protected place. Coat the bit with a suitable oil to prevent rusting while stored. As the drill pipe is being disassembled, clean and lubricate the threads on each end of the pipe before storing in the pipe racks.

• BUCYRUS·ERIE COMPANY, 1984

69

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2.

Coat the pulldown chains with a suitable oil to prevent rusting while stored.

3.

Lower the rotary drive unit to the lowest position and set the hoist brake. Inspect the rotary drive unit for damage or wear and note any problems discovered. Cover the rotary motor with a waterproof tarp or cover. If equipped, turn on the anti-condensation heater for the rotary motor. If the drill is not equipped with an anti-condensation heater, have a qualified electrician install one or a suitable substitute. Raise the dust curtains.

Retract the breakout cylinder.

4.

5.

6.

7.

11. Drain and refill the auxiliary air compressor oil sump.

12.

Close and lock all electrical cabinet doors.

13. Check the coolant level in the main air compressor radiator. Fill the radiator to the top with anti-freeze solution.

Check the oil level in the rotary drive unit.

Check the case to see if there is water in the oil. If there is water in the case, drain and refill the case with suitable oil. If no water is present, fill the case to the proper level.

14. Manually cycle the auto lube system to verify that all points on the machine are receiving lubricant. Repair the system as necessary to lube all points.

Manually cycle the lube system and verify that all points on the mast are receiving lubricant. If the auto lube system is not functioning properly, repair or replace components as necessary.

16. Clean the dust hoppers on the dust control system if required.

Lower the leveling jacks until the jack pads are resting on the ground, but no machine weight is on them.

Inspect the hoist-propel gearcase for wear or damage. Make note of any problems discovered. Check the gearcase for water in the oil. If water is found, drain and refill the gearcase with an approved oil. If none is found, fill the gearcase to the recommended full level.

8.

If the hoist-propel motor is equipped with anti-condensation heaters, turn them on at this time. If the motor is not equipped with heaters, have a qualified electrician install heaters or a suitable substitute. Cover the motor with a waterproof tarp or covering.

9.

Inspect the main air compressor for signs of wear or damage. Make note of any damage discovered. Manually cycle the compressor lubricator 25 turns, then manually rotate the compressor rotor one-quarter turn and cycle the lubricator 25 more times. Repeat this procedure twice more to ensure that the compressor rotor is lubricated with oil every 90 degrees.

This will prevent rust from forming on the rotor or cylinder bore.

70

10. If the main air compressor motor is equipped with anti-condensation heaters, turn them on at this time. If the motor is not equipped with heaters, have a qualified electrician install heaters or a suitable substitute. Cover the motor with a waterproof tarp or cover.

15. Lube all manual lube points.

17. Close and lock all windows and doors.

LONG TERM STORAGE Long term storage procedures are necessary any time the machine is to be left idle for a period exceeding 3 weeks. Long term storage includes all procedures necessary for short term storage, and depending on the situation, some additional precautions.

There are two procedures involved in long term storage of the drill, the choice of which depends upon whether the machine can be attended to while in storage. If the machine can be started and the majority of the machinery operated once a month during the storage period, much less protective work is necessary. If the machine must remain unattended, special precautions are necessary to prevent damage to the machine.

NOTE: If the machine is to be unattended during the storageprocedure the procedures necessary to store the machineproperly will take considerable time and restoring the machine to production will take even longer.

Do not utilize the unattended long term storage procedure unless absolutely necessary.

ATTENDED LONG TERM STORAGE The attended long term storage procedure combines the short term storage procedure with monthly start-up and running periods. To store

BI005457

the machine for a long period of time it is necessary to complete the procedures listed in the SHORT TERM STORAGE topic in this manual.

Then, once a month for the duration ofthe storage period, complete all start-up inspection and lubrication procedures listed in this manual and start the drill. Run all of the gear trains for 10-20 minutes to distribute the oil over the gears and bearings. Hoist and lower the rotary drive unit the full length of the mast 4-6 times to distribute lubrication to the mast and rotary drive unit components.

Cycle the tool racks 2-3 times. Run the main air compressor for 1 hour. Propel the drill at least 6 times the length of the machine. After running the machine components, follow the short term storage procedure once again and store the machine for another month. Repeat this procedure every month until the machine is returned to service.

Loosen the sliding shoes on the rotary drive unit frame to provide one-halfinch clearance between the shoes and the mast.

5.

Remove the auxiliary reel line.

6.

Cover the rotary gear case and hoist-propel gear cases with a waterproof tarp.

7.

Completely disassemble the main air compressor. Store the rotor, shaft and heads in a heated building. Remove the bearings and store in a suitable manner. Heavily grease the compressor cylinder bore. Remove the discharge elbow and cover the compressor opening. Remove the filter box and cover the compressor opening. Alternately it is permissible to completely remove the main air compressor from the machine and store in an attended heated building.

8.

Close and completely seal all electrical cabinets.

9.

Close and completely seal the operator's cab.

UNATTENDED LONG TERM STORAGE It is not within the scope of this manual to detail the procedures involved in the long term storage of a drill. These procedures will involve disassembly of the main air compressor and the two gear cases on the drill, duties that are not usually performed by operating personnel.

10. Close and completely seal the machinery house. Completely seal the filter fan unit.

To store the unattended machine for an extended period of time, proceed as follows:

11. Completely drain the compressor coolant system.

1.

Complete all short term storage procedures.

2.

If power is to be left on the machine, cover the rotary, hoist-propel and main air compressor motor and install anti-condensation heaters.

If power is to be removed from the drill, remove the motors from the drill and store in a heated building.

12. Remove the auxiliary air compressor from the machine and store in an attended building or alternately, completely drain and refill the entire compressor with a suitable oil. It will be necessary to remove the heads to accomplish this.

3.

4.

Completely fill the rotary and hoist-propel gearcases with an approved oil. Both cases can be filled completely by adding the oil through the breather openings. Remove all water from the cases.

Protect the pulldown chains with a suitable asphaltic base compound or remove them from ,the drill and store in a covered area.

13. Propel the machine onto blocks to prevent the crawler belts from rusting. Coat the entire crawler belts with a rust preventative oil.

Coat the propel chains with a rust preventative oil.

14. Block the leveling jacks in the full retracted position.

15. Manually grease every lube point (including auto lube points).

© BUCYRUS-ERIE COMPANY. 1984

71 (72 blank)

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APPENDIXl

TOOL RECOVERY Normally the drill tools are always either connected to the rotary drive unit or are held by the tool wrench. Mistakes, however, do happen and the drill tools may be dropped down the hole. Tool recovery (or tool fishing) is the procedure used to recover these tools.

There are two situations where the tool recovery procedures are necessary and each situation dictates the procedure to be used. The first situation is when the tools have been uncoupled and have fallen below the guide bushing. It is possible in this situation to recover the drill string and, if no damage was done, return to drilling. The other situation is where the drill pipe has broken and has either fallen below the guide bushing or cannot be handled normally.

If the tools have uncoupled and the upper end of the tool string is still above the guide bushing, recouple the tools as would normally be done for tool joint make-up. Clamp the tool string with the tool wrench to aid in making the joint. When the tools are coupled, remove the tool string from the hole, remove the bit and turn the main air on momentarily to clean the inside of the drill pipe.

Clean and reinstall the bit and return to drilling.

If the tools have uncoupled and the upper end of the tool string is below the guide bushing but still above ground level, recouple the tool string as would normally be done to tool joint make-up, except use caution when making the joint. Caution is necessary when making the joint as the tools in the hole will now be at an angle with respect to the tools on the drill. Cross threading of the joint is possible in this situation and should be avoided since it will not only damage the threads but result in an unreliable joint. One method to realign the tools would be to attach a suitable pulling device to the tools in the hole and center the tools with blocking (make sure it doesn't fall down the hole). This would allow normal joint make-up without abandoning the hole. If this is not possible, the leveling jacks may be adjusted to align the tools. Be sure that the stability limits of the machine are not exceeded. It will be necessary to abandon the hole since the drill cannot be repo-

sitioned in the exact same orientation as before losing the tools. When the tools are recovered, clean the pipe and bit as detailed in the first procedure of this section and return to drilling.

If the tool string has uncoupled and the upper end of the lost tool string is below ground level, there are two methods of recovering the lost tools. One method is to attempt to make the joint using the drill pipe still connect to the rotary drive unit. The other method is to use special equipment (not supplied by B-E) to recover the tools.

If the top of the lost tool string is not reachable from ground level, very gently lower the remaining tool string until it contacts the tools in the hole.

Using very slow rotary speed and low torque, attempt to re-make the joint. If the joint can be made very gently raise the tools to a position where the top ofthe recovered tools can be clamped in the tool wrench. Rebreak the joint and inspect the threads on both sections of pipe. Repair the threads if necessary before continuing. When the tool string is repaired, remove the bit and clean both it and the drill pipe to remove any dirt that may have entered while the joint was uncoupled.

If the joint cannot be made using the above procedures, or if the pipe has been broken or been damaged to an extent that it cannot be handled normally, it will be necessary to use special equipment and techniques to continue drilling or recover the lost tools. It is not within the scope of this manual to detail the procedures necessary to handle broken tools or tools that are unrecovered with the procedures detailed herein. Many of the major tool manufacturers offer equipment that can be used to recover broken or lost tools, and the use of these tools should be described by the manufacturer.

h CAUTION: When performing special . . procedures not detailed in this manual, always follow the recommendations of the tool manufacturer and prudent safety guidelines. Failure to follow safe procedures may result in the death or serious injury of personnel or serious damage to the machine.

" BUCYRUS-ERIE COMPANY, 1984

IA (2A blank)

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APPENDIX 2 47-R STATIC CONDITION STABILITIES MACHINE SET-UP

MACHINE SET-UP

Mast up; Rotary head up supporting one full length of drill pipe; One pipe rack empty, remaining pipe racks containing full length drill pipe.

Mast down; Rotary head down; Pipe racks full of full length pipe; Full cable reel on front end.

F = FRONT OF MACHINE

F = FRONT OF MACHINE

W = WORST CASE INTERMEDIATE POSITION

W = WORST CASE INTERMEDIATE POSITION

TIPPING 0 LISTING 0

TIPPING 0 NOT APPLICABLE

19.4°

17.2°

NOT APPLICABLE

LISTING 0

NOT APPLICABLE

FIGURE 50

8.6°

7.6°

12.8° NOT APPLICABLE

FIGURE 49

h CAUTION: Stability angles shown in figure 49 and 50 are for static conditions only. . . Dynamic action is not accounted for, therefore caution must be exercised while propelling over rough terrain.

DEFINITIONS Tipping: Tipping is defined as the point of incipient overturning.

Listing: Listing is a phenomenon which can occur with tracked vehicles which utilize pivotable front crawler axles.

Listing occurs when the center of gravity ofthe upper works falls outside of a triangle formed by the two mainframe/rear axle attachment points and the equalizer axle pivot point.

When the extent of the center of gravity shift overcomes the lower works weight the listing phenomenon is manifest by the lifting of the rear end of one of the crawlers.

No particular danger to the machine or operator results unless the free travel of the equalized axle permits the listed angle to exceed the tipping angle. In any case, the "listed" position is NOT an ACCEPTABLE practical working position.

NOTE: % grade = 100 (tangent of grade angle).

~ BUCYRUS-ERIE COMPANY, 1984

3A (4A blank)

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APPENDIX 3

PIPE SIZE LIMITATIONS Machines with the capability to drill 60 foot single pass holes are subject to limitations as to the length, diameter, wall thickness and number of drill pipes that may be stored in the tool racks when raising or lowering the mast. Machines with standard (34 foot) through intermediate (44 foot) masts are not subject to limitations other than use of industry standard pipes in unmodified tool racks.

Before raising or lowering the mast always determine the pipe diameter, wall thickness and length and compare the results against the above table. If the pipe on the machine falls within the limitations set forth in the table the mast may be raised or lowered following the procedures detailed in this manual. If the pipe on the machine falls outside of these limitations do not raise or lower the mast. Either remove the pipe from the machine or consult with the Bucyrus-Erie Company Service Department before raising or lowering the mast.

These limitations (table 1) are necessary to prevent overloading of the mast and mast support structures as well as the machine hydraulic system by long, heavy drill pipe.

A

CAUTION: Failure to comply with these limitations will result in overloading of the mast, mast support and hydraulic system possibly causing serious machine damage and possibly resulting in loss of control of the mast.

Pipe Length* Less than 45 feet 45 feet to 60 feet

60 feet

CAUTION: Always remove all drill pipe from the rotary drive unit and store it in the tool racks before lowering the mast. Always lower the rotary drive unit to its lowest position and rest it on the lower stops before raising or lowering the mast.

A

Maximum Wall Thickness

Maximum Number of Pipes

Determined by tool rack (unmodified)

Any industry standard pipe

3

9-1/4"

linch

3

10-3/4"

linch

2

less than 7-3/4"

Any industry standard pipe

3

7-3/4"

linch

3

8-5/8"

linch

3

10-3/4"

linch

2

Diameter

PIPE SIZE LIMITATIONS TABLE 1

"BUCYRUS-ERIE COMPANY, 1984

5A (6A blank)

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APPENDIX 4 PIPE LOADING AND UNLOADING ALTERNATE PROCEDURE Certain unusual circumstances may arise when it is not possible to raise or lower the mast with the drill pipe stored in the tool racks. If such a situation occurs it will be necessary to load and unload the pipe using a procedure which is different than the one detailed under the PIPE LOADING AND UNLOADING topic in this manual. The procedure detailed below will allow pipe loading and unloading with the mast in the vertical position.

NOTE: Use this procedure only in the event that the drill pipe cannot be loaded or unloaded from the drill using the normal procedure detailed under the PIPE LOADING AND UNLOADING topic in this manual. /').. CAUTION: Follow the procedures . . detailed in this discussion exactly as stated. Use of procedures other than described here is I1Dt recommended. If the procedures detailed in this discussion must be modified always follow prudent safety guidelines to reduce the chances of an accident. /').. CAUTION: The procedures detailed in . . this discussion require the use ofcranes and rigging. Always follow all applicable safety guidelines when working with cranes and rigging.

There are some conditions that must be assumed to exist in order to utilize this procedure. These conditions are: 1.

The machine has 2 or 3 working tool racks.

2.

The machine is capable of drilling 1 to 2 holes.

3.

The machine may be propelled.

If these conditions cannot be met this procedure cannot be used.

For the purpose of this procedure it is assumed that there will be three drill pipes on the machine, each pipe being made up of 2 - 30 foot sections welded together. There are three parts to this procedure. These are 1) Initial loading of6 -30 foot sections and assembly of the 3 - 60 foot sections, 2) Unloading of the 60 foot sections and 3) Reloading of the 60 foot sections.

To load the 6 - 30 foot sections proceed as follows: 1.

If the mast is in the vertical position, lower it to the horizontal position and rest it in the mast rests. Following the standard pipe loading procedures load 3 short sections of pipe into the tool racks. Raise the mast to the vertical position.

2.

Propel to a suitable location and drill down one section of pipe. Add another section of pipe and continue drilling so as to put the joint between pipes approximately 3 feet above ground level.

3.

Hoist the tool string until the joint between pipes is at a comfortable working position and weld the pipes together. Store the assembled pipe in a tool rack.

4.

Propel the drill off of the hole and to a safe location. Using a suitable crane and rigging lower one short section of pipe down the hole.

Disconnect the crane from the rigging and restrain the rigging from falling down the hole.

5.

Propel the drill back over the hole and level the drill. Thread the rigging attached to the pipe up through the guide bushing and attach it to the crane.

6.

Lift the pipe enough to clamp it with the tool wrench. Remove the crane and rigging and couple the rotary drive unit to this pipe. Store the pipe in a tool rack.

7.

Propel to a suitable location and once again drill a hole of sufficient depth to put the joint between pipes 3 feet from the ground. Hoist the tool string, weld the joint and store the completed pipe in a tool rack.

8.

Propel the machine off of the hole and again lower one section of pipe down the hole with the crane. Propel the machine back over the hole, pick up the pipe with the crane and secure it with the tool wrench.

9.

Lower the rotary drive unit and couple the pipe to it. Store the pipe in the remaining tool rack.

., BUCYRUS-ERIE COMPANY. 1984

7A

BI005457

10.

Propel the drill off of the hole and lower the last section of drill pipe down the hole with the crane. Propel the machine over the hole, pick the pipe up with the crane and clamp it with the tool wrench.

11. Assemble the pipe in the pipe rack to the rotary drive unit, then connect this pipe to the pipe in the tool wrench. Hoist the assembly, install the bit and stabilizer.

12.

Move to a new location, drill a hole and weld the joint between pipes. This completes the initial pipe loading procedure.

2.

Lower the pipe back down the hole and clamp it with the tool wrench. Disconnect the rotary drive unit from the pipe. Using a suitable crane and rigging lower the pipe until it rests on the bottom of the hole. Disconnect the crane and propel the machine off of the hole.

3.

Using the crane remove the pipe from the hole. Propel the machine back over the hole and level it.

4.

Lower the second section of pipe down the hole and clamp it with the tool wrench. Lower the pipe to the bottom of the hole with the crane. Disconnect the crane and propel off of the hole.

5.

Lift the pipe out of the hole with the crane. If necessary repeat for the third section of pipe.

To unload 2 - 60 foot sections of pipe proceed as follows:

NOTE: It is assumed for this procedure that one 60 foot section ofpipe may remain in the tool rack while raising or lowering the mast.

Refer to the PIPE SIZE LIMITA TION topic in this manual to verify ifthis is allowable. If it is necessary to remove all of the pipe from the machine, it will be necessary to have on hand three additional 30 foot sections of pipe in order to reload the pipe onto the machine.

1.

SA

Drill a hole as deep as possible with one section of pipe. Add a second section of pipe and continue drilling so as to place the joint between pipes 3 feet above ground level.

Remove the second section of pipe and store in a tool rack. Hoist the first section of pipe out of the hole and remove the bit and stabilIzer.

To load 60 foot sections of pipe on the machine, it is necessary to drill a hole 60 feet deep. To do this requires either 3 - 30 foot sections of pipe or 1 - 60 foot section and 1- 30 foot section. Ifit is permissible to have 1 - 60 foot section in a tool rack while raising and lowering the mast, the procedure is to drill a 30 foot hole then load a 30 foot section of pipe, then drill a 60 foot hole. Unload the 30 foot section and load the 2 - 60 foot sections of pipe.

If it is not permissible to have a 60 foot section of pipe on the machine while raising or lowering the mast, it will be necessary to load 3 -30 foot sections of pipe on the machine, then drill the 30 foot and 60 foot holes, unload the 30 foot pipe and load the 60 foot pipe.

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APPENDIX 5

HYDRAULIC RESERVOIR FOR ENGINE RADIATOR FAN DRIVE 25 GAL. (HYDO)

o

o DIESEL ENGINE (SEE VENDOR MANUAL)

o

LUBRICATOR FOR VANE COMPRESSOR 3.9 GAL. (MPO)

[[~,III~~ I

[I§

SCREW COMPRESSOR ALLIS-CHALMERS MODEL KS 27 LU 55 GAL.

o

o

CJ

~

Q

I

BIT LUBRICATION 3.9 GAL. (MPO) HYDRAULIC RESERVOIR " - - - - - - - - - - + 1 1 0 GAL. (HYDO)

HOIST/PROPEL GEARCASE "'-----' APPROX. 15 GAL. (RGL)

ROTARY GEARCASE APPROX. 19 GAL. (RGL)

TYPICAL ELECTRIC MACHINE WITH SCREW COMPRESSOR

TYPICAL DIESEL MACHINE WITH VANE COMPRESSOR

GEAR CASE AND RESERVOIR CAPACITIES FIGURE 51

9A