CAT Bucyrus 49HR Blast Hole Drill Maintenance & Operation Manual BI619426 - PDF DOWNLOAD

49HR Blast Hole Drill

Maintenance and Operation Manual

Manual No. 10576

sn: 141287, Lot 89

sn: 141288, Lot 90

sn: 141291, Lot 92

–Table of Contents–

This manual is divided into major sections covering the various serviceable components and systems of the 49HR Blast Hole Drill. These sections and their contents are organized as shown below.

Section 1 - INTRODUCTION

Section 2 - OPERATION

Section 3 - LUBRICATION

Section 4 - PREVENTIVE MAINTENANCE

Section 5 - SERVICE PROCEDURES

Section 6 - BRAKES AND COUPLINGS

Section 7 - MAIN AIR SYSTEM

Section 8 - AIR FILTRATION

Section 9 - ENGINEERING DATA

IMPORTANT NOTE

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

© 2008 Bucyrus International, Inc. All Rights Reserved.

2008 Manual No. 10576

DANGER:

THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/ OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER:

DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY.

The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

THE NEED FOR A POWER LINE GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltages exist between the machine and the ground. The portable trail cable and power lines supplying electric energy to the machine must have a ground wire, ample in capacity, running parallel to the main wires over the entire distance from the transformer to the machine. A suitable grounding system must be used at the transformer. Consult your local electrical supplier for details.

DANGER:

DUE TO THE INHERENT DANGERS IN THE OPERATION OF HIGH VOLTAGE ELECTRICAL EQUIPMENT, A SAFE GROUNDING SYSTEM IS REQUIRED THAT INCLUDES GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING RESISTOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.

Section 1 Introduction

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

GENERAL INFORMATION

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

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

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

Bucyrus International, Inc.

1100 Milwaukee Avenue

P.O. Box 500

South Milwaukee, Wisconsin, USA53172-0500

Telephone (414)-768-4000

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

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

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

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

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

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

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

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

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

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

CAUTION: STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/ordamage to the front-end of the machine.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

SAFETY PRECAUTIONS

General Precautions:

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

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

•Wear a hard hat, safety shoes and protective lenses at all times.

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

•Think before you act. Carelessness is one luxury the service man cannot afford.

•Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup.

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

•If a heavy item begins to fall, let it fall, don’t try to catch it.

•Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.

•Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up.

•Electrical cords and wet metal floors make a dangerous combination.

•Regularly inspect for any loose bolts or locking devices and properly secure them.

•Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified.

•Check limit switches for proper operation.

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

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

•Use proper interior and exterior lighting.

•Install and maintain proper grounding and ground fault protection systems.

•Perform functional tests of all safety circuits.

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

•Use extreme caution when working around drilled holes.

Maintenance Precautions:

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

•Always wear a safety belt or harness when the danger of falling exists.

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

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

•Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance.

•Equipment should be parked on level ground at all times during machine servicing and periods of idleness.

•Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, pipe arms, etc.) Always work within the limitations of the equipment being utilized.

•Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine.

•Utilize guide lines or ropes to minimize the swing of suspended heavy components.

•Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times.

•Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail.

•When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components.

•When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart.

•Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses.

•Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area.

•Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine.

•Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.

•Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion.

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

Operating Precautions:

•Wear hearing protection when exposed to the following noise levels in excess of the period indicated:

8 hours at 90 dBa

4 hours at 95 dBa

2 hours at 100 dBa

1 hour at 105 dBa

30 minutes at 110 dBa

15 minutes at 115 dBa

•When in doubt about the noise level, wear approved hearing protection.

•Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine.

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

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

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

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

•Do not propel the machine on a slope greater than specified in the stability limits shown on the STABILITY CHART at the end of this section.

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

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

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

FIRE PREVENTION

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

•DO NOT smoke while handling flammables or when near batteries.

•Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 ~ PREVENTIVE MAINTENANCE for the scheduled maintenance recommendations.

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

•Make certain that all clamps, guards, and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation.

•DO NOT carry flammable fluids such as gasoline or solvents on board the machine.

•DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately.

•DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.

•Keep all cleaning rags properly stored. DO NOT discard them into a pile on board.

•Keep all structural frame compartments, walkways, and work areas clean and free of lubricant residue.

•NEVER weld, burn, or perform service on the machine alone.

WARNING SIGNS AND DECALS

The placards depicted below are mounted on the machine as delivered from Bucyrus International, Inc. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.

Stored Energy Signs

STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

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

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

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

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

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

RAISE BOOM Extend arm fully with fingers closed and thumb pointing upward.

STOP Extend arm fully with fingers extended and palm facing down.

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

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

DOG EVERYTHING Clasp hands together in front of body.

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

LOWER BOOM Extend arm fully with fingers closed and thumb pointing down.

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

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

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

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

TRAVEL (Single Track) Use a raised fist on the side that remains locked and make a vertical circular motion in front of chest for the direction and side of desired movement.

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

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

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

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

PROPEL MACHINERY

The propel system is a chainless hydraulic drive system which will allow the separate tracks to counter-rotate. This capability provides the machine with the capacity to turn completely around within its own length, but it is not a normal recommended operating procedure. Each track is driven by a hydraulic motor and a planetary gearcase equipped with a hydraulically-released, springactivated brake. The machine is capable of 2 different propel speed ranges. The lower speed range is used for maneuvering in close spaces while the high speed range is used for tramming in open areas, over long distances.

Propel Machinery

MAINFRAME AND DECKS

The mainframe is of welded box type construction with integrally placed mast supports and jack towers.

Mainframe

Machinery House

The mast is a fabricated structure made up of steel tubes and formed plates. The major structure is composed of 4 main cord sections connected by both horizontal and diagonal lacings. The mast recieves support from two braces that connect the mast to the top of the front jack towers. The function of the mast is to provide adequate mounting and guidance for the head machinery that operates the primary drilling function of the machine. The mast is typically setup to drill 90 degree holes and with the addition of the angle hole option is capable of being positioned at any 5 degree increment within its operating range from 65 degree through 90 degree (vertical). The mast can be raised and lowered by 2 large hydraulic cylinders.

Mast and Mast Machinery

MAIN AIR SYSTEMS

The screw compressor is located within the machinery house just forward of the hydraulic pump gearbox. The rotary screw compressor is an oil flooded, single stage twin screw type compressor which has a nominal rating of 3,000 cfm (84.9m3/min), @ 65 psi (74.7 m3/min) and a maximum operating pressure of 65 psi.

Air Compressor

HYDRAULIC SYSTEM

Hydraulic pressure for operation of the 49HR is provided by five main pumps. These pumps are driven by a gearbox coupled to one end of the motor. The pumps are located in the machinery house, forward of the hydraulic reservoir.

The machine has 2 separate, though not completely independent, hydraulic systems. These are the OPEN and CLOSED circuits. Both draw fluid from a common reservoir.

OPERATOR’S CAB

The sound insulated operator’s cab of the 49HR provides a sealed, comfortable enclosure from which the operator can perform the tasks involved with the operation of the machine. The location and design of this compartment have been structured to provide the optimum viewing angles with immediate accessibility. The swivel mounted chair provides easy access to all required controls. The cab is provided with two doorways to the main deck.

Operator’s Cab

TYPICAL MACHINE SPECIFICATIONS

Refer to the images on the following page.

Machine Dimensions

GENERAL ESTIMATED COMPONENT WEIGHTS

CAUTION:These are estimated weights only. Contact your Bucyrus International service representative for the exact weight of components on your specific machine before rigging and lifting.

Section 2 Operation

Section 2 Operation

GENERAL INFORMATION

This section is designed to assist the owner in the operation of this machine. It provides the operator with the location and explanation of the controls, instructions for machine operation, and certain maneuvering techniques. Throughout this section, and the remainder of the manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

Safe operation of this machine 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 judgment and alertness on the part of the entire mining crew. Refer to Section 1 in this manual for specific safety precautions.

OPERATION NEAR ELECTRICAL TRANSMISSION LINES

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

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

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For 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. Be certain to comply with all local, state and federal regulations regarding working in the vicinity of power lines.

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

1.Always contact the owners of the power lines or the nearest 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.Caution all ground personnel to stand clear of the machine at all times.

7.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.

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

PRESTART CHECKS

Before starting the drill, inspect it to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example, an undetected oil leak could result in a dry 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. SECTION 4 OF THIS MANUAL CONTAINS REPRODUCIBLE CHECKLISTS TO ASSIST IN RECORD KEEPING AND INSURE THAT ADEQUATE INSPECTION STANDARDS ARE MET.

EXTERNAL INSPECTION

1.Check areas around and under the machine for signs of water or lubricant leaks. If single droplets of water or lubricant are noticed, leakage is minimal. Determine the source of the leak and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine the source and take corrective action immediately.

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

3.Check the propel gearcase, hydraulic motor and hoses for leaks. Check the lubricant level in the propel gearcase.

4.Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers for proper lubrication, free operation, and dirt or ice buildup. Check equalizer axle pins for cracks and lost or missing retainers.

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. Have an electrician inspect the strain relief device and the condition of the cable where it enters the machine.

CAUTION:The machine trail cable carries a lethal voltage. Handle the cable in an approved manner with approved high voltage gloves and insulated hooks or tongs.

7.Inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or damage. If loose wires are noted, do not touch them but notify an electrician immediately.

8.Inspect the leveling jack spuds for proper lubricant coverage. Inspect the leveling jack pads for cracks, broken or missing hardware, or excessive dirt accumulation.

9.Inspect the mast braces and locking pins. Replace missing or defective components immediately. Verify that all adjusting bolts are properly adjusted. Check all hoses and cylinders for leaking.

CAUTION:Use an approved safety harness to protect against falls when climbing on the mast braces or working on the machinery house roof.

10.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.

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

12.Inspect the mast structure for bent or broken chords, lacings or plates; loose or broken components; proper rack lubrication or excessive rack wear. Inspect ladders, handrails and platforms for broken or missing parts. Repair or replace broken or missing components immediately.

13.Check the main air flex hose, lubrication lines, and electric lines running from the mast to the rotary drive/pulldown unit for damage, excessive wear or leaks.

14.Check the safety restraint device on the mast. Be certain that the cable or rod and supports are in good repair with no cracks, missing or loose hardware or any damage that could reduce their effectiveness.

15.Every 160 hours inspect the upper auxiliary winch sheaves. All pins, keepers and hardware should be resecured.

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

ONBOARD INSPECTION

1.Inspect the air compressor lubrication lines for leaks. Correct any leaks found immediately.

2.Check the condition of the 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 pre-cleaner element. Inspect the housing and ductwork for damage or leaks. Repair or replace leaking components.

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

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

5.If the machine is equipped with a bit lubricator for the main air system, check that the lubricator is full.

6.Inspect the automatic lubrication central pumping station for proper operation. Check the supply of lubricant and refill as necessary.

7.Close and lock all electrical cabinet doors.

CAUTION:Assume all parts inside of the electrical cabinets are energized. All electrical components should be serviced by qualified electrical personnel only.

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

9.Check the operator’s display terminal for any faults.

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

CAUTION: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 of the components located there.

11.Inspect the auxiliary winch and auxiliary winch line.

12.Check the oil level in the pump drive gearcase. Fill with recommended oil to the proper level.

13.Check all controls for free operation. Return all controls to the OFF or SET position.

14.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.

CAUTION: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.

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

CAUTION:Before working near or under the rotary drive/pulldown unit, MAKE SURE ALL OF THE OPERATOR’S CONTROLS ARE OFF AND TAGGED AND THE HOIST BRAKE SET TO PREVENT MOVEMENT OF THE UNIT. Serious personal injury or death could result should the rotary drive/pulldown unit fall when personnel are working near or under it.

16.Inspect the automatic breakout wrench for free operation, broken or missing parts, proper lubrication, hydraulic leaks or excessive dirt accumulation. Repair or replace parts as necessary. Be certain that the breakout wrench is retracted.

17.Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or hydraulic leaks. Be certain that the racks are in the stored position. If a drill steel is in the pipe rack ensure the upper gate is closed.

18.Inspect the guide bushing for excessive wear or dirt accumulation.

19.Inspect the tool string for dirt accumulation, excessive wear, secure joints and bent pipes. The bit cones and bearing should be in good condition. Manually turn the cones to make sure they turn freely.

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

21.Inspect the rotary drive unit for excessive wear or dirt accumulation. Inspect the guide rollers for proper adjustment and excessive wear. Check for loose or missing bolts and bent or cracked structural members.

22.Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper adjustment and excessive wear.

23.Inspect the pulldown gearcase for leaks, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearcase. Fill to recommended level with an approved gear lubricant. Check the pulldown motor ventilation inlets for leaves, papers, rags, etc. blocking the flow of air.

24.Check the hoist brake for proper operation.

25.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.

26.If the machine is equipped with a fire suppression system, perform any applicable checks or inspection as described in the fire suppression system owner’s manual.

PRESTART LUBRICATION

Most machines are 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 Section 3 ~ LUBRICATION give the location and frequency of lubrication.

The lubricant used should be kept clean. If possible the lubricant should be supplied from a bulk lube truck. Be careful when adding lubricant to the automatic system to keep the pump and fill points clean.

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

CONTROLS - LOCATION AND FUNCTION

The operator must become familiar with the location and function of all of the operating controls. The operating controls have been divided into three groups, depending upon their location, as follows:

1.Operator’s Console Controls

2.Machinery House Controls

3.Miscellaneous Controls

CAUTION:Become familiar with the controls on this machine before operating it. Pay particular attention to 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 CONTROL CONSOLE

NOTE: The switches on the operator’s console operate electromechanical or electrohydraulic valves on the machine. The panels of the console are: main controls, propel controls, selector switches, leveling controls and operator’s display terminal.

HOIST/PULLDOWN RHEOSTAT

The Hoist/Pulldown rheostat controls the speed and direction of the hoist-pulldown motor for hoisting or lowering the rotary drive unit.

Turning the rheostat in the hoist direction from the “0” position will raise the mast machinery. Maximum speed is available at full clockwise position.

Turning the rheostat in the pulldown direction from the “0” position will lower the mast machinery. Maximum speed is available at full counterclockwise position.

NOTE: The rheostat utilizes a reference scale and pointer. When the rheostat is turned, the pointer indicates the relative percentage of full speed being set on the reference scale.

ROTARY RHEOSTAT

The Rotary rheostat controls the speed and direction of the rotary motor which drives the rotary machinery.

Turning the rheostat clockwise from the “0” position will turn the tool string in a clockwise direction. Maximum rotary speed is achieved at full clockwise position.

Turning the rheostat counterclockwise from the “0” position will turn the tool string in the reverse direction. Maximum rotary speed is achieved at full counterclockwise position.

NOTE: The rheostat utilizes a reference scale and pointer. When the rheostat is turned, the pointer indicates, on the reference scale, the relative percentage of full speed being set.

DRILL/PROPEL CONTROLS ON / OFF PUSH-BUTTON

The Drill/Propel controls on and off push-buttons are used to energize or de-energize the control devices of the machine.

When the operating mode selector switch is in the DRILL position, pressing the ON push-button will energize the hoist/pulldown and rotary drives if all appropriate circuit breakers are closed; no drive or power system faults exist, and master switches are in NEUTRAL.

When the operating mode selector switch is in the PROPEL position, pressing the ON push-button will enable the propel controls if all appropriate circuit breakers are closed, compressor motor is operating normally, and no power system faults exist.

When the operating mode selector switch is in the REMOTE position the ON and OFF pushbuttons are not functional.

HOIST/PULLDOWN SPEED SELECTOR SWITCH

The Hoist/Pulldown speed selector switch is located above the hoist/pulldown rheostat and is used to determine the speed range of the hoist/pulldown rheostat. The switch is a four-position switch with the following designations: PULLDOWN, HOIST HIGH, HOIST LOW, and PIPE RACK/JOINT.

In the PULLDOWN setting, which is used for normal drilling, full pulldown force is available but the speed range for both pulldown and hoisting is limited to about 25 FPM (7.62 MPM).

The HOIST HIGH and HOIST LOW settings are used for pipe raising and lowering at high speeds.

In the HOIST LOW position full hoisting and lowering force is allowed, but the speed is capable of reaching a higher level (typically about 65 FPM [19.8 MPM]).

In the HOIST HIGH position maximum head speed capability is allowed for both hoisting and lowering. However, force capability in the lowering direction is limited to the weight of the rotary head/pipe combination. No additional drive downforce is allowed, which reduces the chance of equipment damage during the lowering operation.

As a result of obtaining a higher speed, the hoist force is limited compared to what is obtainable in the HOIST LOW position.

In the PIPE RACK/JOINT position, the hoisting and lowering force capabilities are the same as those when the switch is in the HOIST HIGH position. However, the speed limit is reduced to 25-35 FPM (7.62-10.67 MPM).

NOTE: Pipe rack operation also requires the rotary head assembly to be above the pipe rack limit before operation is allowed.

ROTARY SPEED SELECTOR SWITCH

The Rotary speed selector switch is a three-position switch located above the rotary rheostat. This switch determines the speed/torque range of the rotary motor. In the LOW position, the motor has the highest torque capability, but the speed is limited to 100 RPM at the bit. In the MEDIUM position the motor provides an operational range of 0-117RPM with 84% of the torque developed in low speed. In the HIGH position, the motor has a higher speed capability range of 0-140 RPM but motor torque will be limited with 73% of the torque developed in low speed.

The switch should be set to the range that most closely matches the desired bit speed range. The LOW setting is sufficient for most conditions. If more speed is desired, select the desired range as needed.

HOIST BRAKE SWITCH

The Hoist brake switch is a two-position switch. It is used to set or release the hoist brake.

This switch must be in the RELEASE position before the hoist/pulldown drive is allowed to move the mast machinery. Placing the switch into the SET position during machine operation immediately disables hoist/pulldown drive operation.

Under normal operating conditions, the hoist/pulldown speed rheostat should be set to “0” before setting the brake.

PIPE RACK SELECTOR SWITCH

The pipe rack selector switch is a four-position switch used to determine which pipe rack will be operated. For machines without a pipe rack or with only one pipe rack, this switch is not used.

PIPE RACK JOYSTICK (Left Crawler Propel)

This joystick will operate the pipe rack or the left crawler (secondary propel control). For the joystick to control the pipe rack, the operating mode selector switch on the propel control panel must be in the DRILL position and the hoist/pulldown speed selector switch in the PIPE RACK/JOINT position.

For the joystick to control the left crawler the operating mode selector switch on the propel control panel must be in the SECONDARY PROPEL position.

Full forward or rearward movement of the joystick will supply the fastest motion.

This switch is equipped with a lock feature. To move the switch out of the NEUTRAL position the switch knob must be lifted.

WINCH/MAST SELECTOR SWITCH

The Winch/Mast selector switch is a two-position switch. Turning the switch to the WINCH position will activate the winch circuit. The right secondary propel joystick can then be used to operate the winch. Turning the switch to the MAST position will activate the mast hoist cylinder circuit and the right secondary propel joystick is used to raise or lower the drill mast.

When the machine is equipped with winch remote control, this switch has four positions. These positions are OFF, REMOTE WINCH, CONSOLE WINCH, and MAST. The REMOTE WINCH and CONSOLE WINCH positions determine whether the winch is controlled at the remote station or the operator’s console.

The switch is operational only when the operating mode selector switch is in the DRILL position, the air compressor motor is running, and no leveling jacks are being operated.

MAST/WINCH JOYSTICK (Right Crawler Propel)

This joystick is used to raise or lower the mast, operate the auxiliary winch or right crawler.

For the joystick to control the mast raising and lowering operation, the operating mode selector switch must be in the DRILL position and the mast/winch selector switch must be in the MAST position.

For the joystick to control the auxiliary winch, the operating mode selector switch must be in the DRILL position and the mast/winch selector switch must be in the WINCH position.

For the joystick to control the right crawler, the operating mode selector switch must be in the SECONDARY PROPEL position.

Pushing the joystick lever forward will either raise the mast, raise the auxiliary winch line or propel the right crawler in the forward direction.

Pulling the joystick lever to the rear will either lower the mast, lower the auxiliary winch line or propel the right crawler in the reverse direction.

Full forward or rearward movement of the joystick will supply the fastest motion. This switch is equipped with a lock feature. To move it out of the NEUTRAL position the switch knob must be lifted.

TOOL WRENCH SWITCH

The tool wrench switch is a three-position spring return switch. Turning the switch to the EXTEND position will cause the tool wrench to extend to clamp the drill pipe. Turning the switch to the RETRACT position will retract the wrench, releasing the drill pipe. This switch is functional only when the hydraulic pumps are running.

DUST CURTAIN SWITCH

The dust curtain switch is a three-position switch. Turning the switch to the UP position will raise the dust curtains. Turning it to the LOWER position will lower the dust curtains.

In the AUTO position, the curtains are raised automatically when the operating mode selector switch is in the PRIMARY PROPEL, SECONDARY PROPEL, or REMOTE PROPEL position. The curtains are not lowered automatically, they must be lowered by moving the switch to the LOWER position.

BIT VIEW HATCH SWITCH

This is a two-position switch that is used to move the hatch for viewing the drill bit on the ground. Moving the switch to the CLOSE position will close the hatch. Turning the switch to the OPEN position will open the hatch.

PROPEL CONTROL PANEL - OVERVIEW

EMERGENCY STOP PUSH-BUTTON (Optional)

The emergency stop push-button (1) on the propel control panel is a large red mushroom head push-button switch. Pressing the emergency stop push-button will shut-down the air compressor, hydraulic systems and shut-off all controls. It will also simultaneously provide electrical and immediate mechanical braking. This button should therefore only be used if the operator intends the harshest braking for all motions.

CAUTION:PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

PROPEL SPEED SELECTOR SWITCH

This two-position switch (2) is used to set the propel speed. In the SLOW position, the propel is in the low speed range (about 30% of maximum). This position is used when maneuvering in tight spots and in drilling patterns. NORMAL position is used when moving from one site to another.

COMPRESSOR STOP PUSH-BUTTON

This push-button (3) is used to shutdown the compressor motor. The compressor will have to be restarted from the machinery house.

COMPRESSOR VENT/DRILL SWITCH

This switch (4) is used to open or close the butterfly valve in the compressor discharge line. In the VENT position, the butterfly valve will close and the compressor will unload and vent air to the atmosphere. In the DRILL position, the butterfly valve will be opened and the air will be routed to the drill bit to bail the hole of cuttings.

HEATER/VENT/AIR CONDITIONER CONTROLS

The heater/vent/air conditioner controls consist of two (2) four-position switches (5 & 6).

One switch (5) selects the mode being used and has the following positions: OFF, FAN, HEAT, and COOL.

The other switch (6) controls fan speed for vented air and circulated air. The four positions are: VENT HIGH, VENT LOW, CIRCULATE HIGH, and CIRCULATE LOW.

OPERATING MODE SELECTOR SWITCH

The operating mode selector switch (7) is a four-position switch. Turning the switch to the DRILL position will allow the drill controls of the machine to be operated. Turning the switch to the PRIMARY PROPEL position will allow the propel joystick controls on this panel to control the propelling motion of the machine. Turning the switch to the SECONDARY PROPEL position will allow the propel joysticks on the Main Control Panel to control the propelling motion of the machine. Turning the switch to the REMOTE PROPEL position enables the optional portable remote propel control function.

PROPEL JOYSTICKS

For the joysticks to control the crawlers, the operating mode selector switch must be in the PRIMARY PROPEL position. When propelling the machine:

•Pushing the RIGHT joystick forward will propel the RIGHT crawler forward. This will steer the machine to the LEFT.

•Pulling the RIGHT joystick to the rear will propel the RIGHT crawler backward. This will steer the machine to the RIGHT.

•Pushing the LEFT joystick forward will propel the LEFT crawler forward. This will steer the machine to the RIGHT.

•Pulling the LEFT joystick to the rear will propel the LEFT crawler backward. This will steer the machine to the LEFT.

•Pushing both controls forward will propel the machine straight forward.

•Pulling both controls to the rear will propel the machine straight backward.

Full forward or rearward movement of the joystick levers will supply the fastest motion. The joysticks are equipped with a lock feature. To move the levers out of NEUTRAL position, the switch knob must be lifted.

MAST BRACE LOCK SWITCH

The Mast brace lock switch is a three-position spring-return switch. Turning the switch to the LOCK position will extend the mast brace lock pin cylinder. Turning the switch to the UNLOCK position will retract the cylinder. For this switch to be operable, the hydraulic pump must be running and the mast/winch selector switch must be in the MAST position. This will allow the switch to function in the LOCK position. To function in the UNLOCK position, the rotary head assembly must be at the lower limit point.

MAST LOCK SWITCH

The Mast lock switch is a three-position spring-return switch. Turning the switch to the LOCK position will extend the mast lock cylinder. Turning the switch to the UNLOCK position will retract the cylinder. Before this switch can become operable the hydraulic pumps must be running and the mast/winch selector switch must be in the MAST position. For the switch to be functional in the UNLOCK position, the rotary head assembly must be at the lower limit point.

BOARDING STAIRS SWITCH

The Boarding stairs switch is a two-position switch. A like switch is located at the stairs. Depending upon the position of the stairs, the switch must be moved from its present position to the opposite position for the stairs to change position.

PEDESTAL HEATER SWITCH (Optional)

The Pedestal heater switch is a two-position switch used to turn the heater ON or OFF.

FIRE SUPPRESSION SYSTEM INDICATORS (Optional)

The fire suppression system indicators show the status of the fire suppression system.

RADIO

The Radio is standard equipment.

BREAKOUT WRENCH SWITCH

The breakout wrench switch (1) is a three-position spring-return switch. Turning the switch to the EXTEND position will cause the breakout wrench to extend, grip the pipe and turn, breaking the pipe joint. Turning the switch to the RETRACT position will retract the breakout wrench arm and then retract the breakout wrench, away from the pipe.

LEVELING CONTROL PANEL

MANUAL LEVELING JOYSTICKS

The four two-directional joysticks are used to manually raise or lower the corresponding leveling jacks. Moving a joystick forward will extend the corresponding jack cylinder and raise that corner of the machine. Pulling the joystick toward the operator will retract the corresponding leveling jack cylinder and lower that corner of the machine. These joysticks are not functional if the automatic leveling switch is being used.

The Leveling portion of the panel consists of four two-directional joysticks, one for each leveling jack cylinder and an automatic leveling switch.

NOTE: The joysticks should be moved in pairs. Single joysticks may be used for the final adjustment of leveling jacks.

AUTOMATIC LEVELING SWITCH

The Automatic leveling switch is a three-position spring return switch. Turning the switch to the EXTEND position will extend the leveling jack cylinders and raise the machine. Turning the switch to the RETRACT position will retract the cylinders and lower the machine. When this switch is being used, the manual leveling joysticks are not functional.

NOTE: The automatic leveling switch is a spring-return switch. The switch must be held until the desired action of the leveling jacks has been achieved. Releasing the switch will allow it to return to the neutral position but the jacks will remain in the position to which they were moved.

WATER INJECTION ON/OFF SWITCH (Optional)

The Water injection on/off switch is a two-position switch used to start-up or shut-off the water injection system. When the switch is turned to the OFF position, it will stop the pump.

When the machine is equipped with a deck washdown system, this switch has an additional position designated WASHDOWN. When the switch is in the WASHDOWN position, water to the main air pipe is shutoff and all water is directed to the washdown system on the deck.

WATER INJECTION FLOW CONTROL (Optional)

The Water injection flow control is a potentiometer used to regulate the water flow. Full counterclockwise rotation of the control will shut-off water flow. Full clockwise rotation of the control will supply maximum flow of water.

HORN PUSH-BUTTON

The Horn push-button is used to sound the warning horn of the machine.

DEPTH INDICATOR RESET PUSH-BUTTON

The Depth indicator reset push-button is used to zero out the depth meter, as shown on the Operator’s display terminal Operator’s Display screen, when one hole is completed and another is to be started. This function can also be performed on the operator’s display terminal keypad.

PROGRAMMED DRILL CONTROL SWITCH

The Programmed drill control switch is used to activate or deactivate the programmed drill control system on the machine. This function can also be performed on the operator’s display terminal keypad.

EMERGENCY STOP PUSH-BUTTON (OPTIONAL)

The emergency stop push-button (11) on the leveling control panel is a large red mushroom head push-button switch. Pressing the emergency stop push-button will shut-down the air compressor, hydraulic systems and shut-off all controls. It will also simultaneously provide electrical and immediate mechanical braking. This button should therefore only be used if the operator intends the harshest braking for all motions.

CAUTION:PRESSING THIS BUTTON WHEN ANY DRIVE IS IN MOTION MAY RESULT IN COMPONENT DAMAGE.

OPERATOR’S DISPLAY TERMINAL

The Operator’s Display Terminal consists of an active matrix display, keypads and industrial computer (PC).

The Operator’s Display Terminal displays status information for all PLC controlled machine functions. Some machine setup parameters may be entered using the keypad. Refer to a separate manual for further operational procedures for the Operator’s Display Terminal.

MACHINERY HOUSE CONTROLS

NOTE: The controls shown on the following illustrations are typical of the controls on a machine. Because of the variations of controls that can be supplied for customers needs, be sure to become acquainted with the controls on the cabinets of your machine. All controls will be identified with nameplates.

LIGHTING LOAD CENTER

The lighting load center is located on the right side of the front wall of the machinery house.

It contains the breakers to control the interior and exterior lights and various auxiliary functions. Each breaker is labeled as to its particular function on any particular machine.

Lighting Load Center

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.

CONTROLS LOCATED ON LOW VOLTAGE START CABINET

The low voltage start cabinet contains the breaker for the main compressor. Turning the breaker to the ON position will activate the compressor circuits, allowing the compressor to be started.

CONTROLS LOCATED ON LOW VOLTAGE CABINET

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, a list of typical controls which might appear on the cabinet is shown in figure.

Low Voltage Start Cabinet

Low Voltage Cabinet

CONTROL LOCATED ON PROGRAMMABLE CONTROLLER CABINET

The typical programmable controller cabinet contains controls as shown.

Programmable Controller Cabinet

HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS

Controls on the Hoist/Pulldown and Rotary Drive Control cabinets are shown in the figure below.

Hoist/Pulldown and Rotary Drive Control Cabinets

AIR COMPRESSOR CONTROLS

The controls, monitors and indicators located on or near a screw type air compressor are shown in the figure below.

Air Compressor Controls

MISCELLANEOUS CONTROLS

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.

HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL

The hydraulic reservoir remote fill control panel is used to monitor the reservoir as it is being filled. The instructions for use of these controls are printed directly below the controls.

LUBE CONTROL PANEL

The Lube control panel is located next to the lube pump station in the machinery house and contains the controls as shown.

Hydraulic Reservoir Remote Fill Control Panel

Lube Control Panel

START-UP

Start-up of the machine 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-by-step procedure listed below to start the machine will help reduce the possibility of accidental injury or machine damage.

MACHINE START-UP

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

1.In the operator’s cab verify that all controls on the operator’s console are in the off or neutral position. Be sure that the EMERGENCY STOP push-button is in the pulled-up position.

NOTE: On some machines there are two or more emergency stop push-buttons. Be sure these push-buttons are in the pulled-up position.

2.In the machinery house, turn on the main compressor breaker on the low voltage start cabinet.

3.On the low voltage cabinet, turn all the breakers to the ON position.

4.On the programmable controller cabinet verify that the lockout control push-button is in the RELEASED position. Turn the house pressurization fan switch to the desired operating position. Verify that the operator’s display terminal power supply, PLC input and PLC output breakers are in the ON position,

5.Press the air compressor start push-button on the programmable controller cabinet to start the main compressor.

NOTE: If the ambient temperature is below 32°F (0°C), the machine will normally use special fluids in the hydraulic system and/or heaters for the system.

When the machine is shutdown, temporarily or for an extended time, power should be left on the machine to maintain heater operation. If power is removed at shutdown, the machine fluids should be warmed to at least 32°F (0°C) before attempting to start the machine.

MACHINERY CHECK

The following is a list of points and equipment that should be checked for proper operation immediately following start-up. Any operating difficulties not found during this procedure may not be noticed until a system or component ceases to function.

1.Check the main air system for leaks.

2.Verify that the air compressor radiator fan is operating correctly. Check the coolant system for leaks.

3.Check for leaks in the hydraulic system.

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 are realized.

ROTARY DRIVE UNIT BREAK-IN

Break-in of the 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 new gearcases or gearcases in which a new gear has been installed.

HOIST/PULLDOWN GEARCASE BREAK-IN

Break-in for the hoist/pulldown 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.

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

ELECTRIC MOTOR BREAK-IN

Break-in of the rotary and hoist/pulldown 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 open.

OPERATION

Operation of this machine is 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 it is 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 later within this section.

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.

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 of equipment can very easily lead to an accident.

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 and start the machine using the procedures as outlined.

PROPELLING

DEFINITIONS:

“Listing” is a condition when the upper works is tilting over onto the pivotal axle, lifting one side of the fixed axle. This can occur on vehicles which have a pivotal axle and a fixed axle.

“Tipping” is defined as the point of impending overturning. A machine can tip to the rear without listing first. Under all other conditions, the machine will “list” before tipping.

“Maneuvering slope” is the grade on which the machine can be propelled in any direction without listing or tipping.

PROPEL PROCEDURE

Before beginning the propel operation, the operator should first inspect the travel route for large rocks, deep ruts, or uneven contours. When working on a grade, verify the slope and compare to the allowable maneuvering slope limits shown at the end of this section.

CAUTION:Do not attempt to maneuver or steer the machine on grades which exceed the allowable maneuvering slopes. (Refer to the end of this section.) Failure to follow these instructions could result in a machine tip-over, damaging the equipment and resulting in possible serious injury or death.

The operator’s display terminal leveling/propel screen should be monitored during propel to make sure the allowable machine stability limits are not exceeded.

Verify that the travel route is in good condition.

NOTE: The machine should only be propelled with the mast fully lowered or fully raised with the mast lock and mast brace pins in locked position.

For long propels of 1,000 feet (304.8 meters) or more, or if the machine is to be propelled over grades which approach the allowable stability limits, the tool string should be disassembled, the mast machinery lowered and the mast lowered. This achieves the most STABLE condition for a machine against tipping and also reduces stresses in the mast structure.

If while propelling with the MAST-DOWN and the HEAD-DOWN the machine starts to list, it will continue to list until the upper works contacts the pivotal axle at which point it will reach equilibrium and WILL NOT TIP OVER. With the mast-down and the head-down, full listing will NOT cause the machine to tip over. The operator should attempt to propel toward a more level area on the bench to correct this condition.

All of the stability values shown at the end of this section are based on a fully loaded machine (i.e. full water tank, cable on cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by the customer and shipped by Bucyrus International, Inc.

This machine is propelled using the controls on the operator’s console in the operator’s cab or radio controlled from the remote propel station outside the machine.

Propel Controls

To propel:

1.Verify the following:

•The hoist brake is set.

•The tool string is clamped with the tool wrenches to prevent the tools from moving during the propel operation.

•The tool string is hoisted to a position to avoid striking the ground when the machine is propelled.

•The leveling jacks are fully retracted and that the dust curtains are fully raised.

•The boarding stair is raised.

2.Move the operating mode selector switch to PRIMARY PROPEL, SECONDARY PROPEL, or to REMOTE PROPEL. The remote propel is radio controlled (if provided).

3.Press the drill/propel control ON push-button. The automatic leveling/propel screen will appear on the operator’s display terminal. If the propelling is being done from the remote propel station, turn the enabling key switch to the ENABLE position.

4.At the control console or remote propel station, turn the propel selector switch to the SLOW SPEED position.

NOTE: There are two propel speeds available to the operator, slow speed and normal. For the inexperienced operator or for maneuvering in tight spots and in drill patterns, the SLOW SPEED setting allows for a more controlled and precise operation.

When the operator becomes more proficient or when moving from one site to another, the increased speed of normal propel is used.

5.To propel straight forward, lift up on both joysticks (to unlatch), which releases the propel brakes, then move both joysticks slowly forward. Speed is increased as the levers are moved farther forward. To propel straight in reverse pull both joysticks slowly to the rear. Speed is increased as the levers are pulled further.

6.To make a gradual forward right turn, leave the right joystick in neutral and operate the left joystick forward.

Propel - Forward or Reverse

Propel - Gradual Right Turn

Propel - Gradual Left Turn

7.To make a gradual forward left turn, leave the left joystick in neutral and operate the right joystick forward.

8.Gradual turns should be done in steps of 15 degrees each. After turning the machine a maximum of 15 degrees, the machine should be propelled straight for about one-half of the length of the machine to clear the crawler belts of dirt and rocks. Turning the machine in more than 15 degree increments will subject the crawler belts to severe strain.

Propel - Counter-Rotation Left Turn

9.To make a sharp right (counter-rotation) turn, push the left joystick forward and pull the right joystick to the rear. To make a sharp left turn, push the right joystick forward and pull the left joystick to the rear.

Gradual Turns - 15° Increments

CAUTION:ENSURE THAT THE TURN IS STOPPED EVERY 15 DEGREES AND THAT THE MACHINE IS PROPELLED FORWARD, OR REARWARD, AT LEAST TEN FEET PRIOR TO RESUMING THE TURN. MAKING GRADUAL TURNS WILL GREATLY EXTEND THE SERVICE LIFE OF THE TRACKS.

NOTES: •When using the counter-rotation method for turning, have a helper watch that the trail cable does not get fouled and/or torn from the main junction box or cable reel.

NOTES:• The ability of the machine to turn sharply is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig in and impede the machine’s progress.

NOTES:• The propel brakes are released when either joystick is lifted from its mechanical neutral detent. The propel brakes are set when both joysticks are returned to their neutral detent and released.

PROPEL BYPASS

This machine has a special feature that allows the operator to bypass the propel limit when the pipe is close to the ground. This feature is used to properly locate the machine when redrilling holes.

Propel the machine to a hole. When near the hole location, lower the drill bit with in a few feet of the ground.

The operator must determine if the machine is exactly over the hole. If required the operator can place the machine into propel mode and press the F11 button to bypass the pipe in hole warning. This allows the machine to propel for 20 seconds to position the machine precisely over the hole.

When the pipe in hole warning is bypassed an active window is shown on all display screens. If required the operator can bypass the pipe in hole warning for another 20 seconds.

TOWING THE MACHINE

CAUTION:Be sure the crawlers are securely blocked before disengaging the gearcase clutch for towing.

1.Secure the machine by blocking the crawlers.

2.Secure the tow bar to the towing vehicle.

3.Fasten a lanyard to the towing safety valve lever. The valve is mounted to the left front jack casing. Run the lanyard down the casing, along the tow bar and secure it to the towing vehicle. If during towing the tow bar should come loose from either the machine or the towing vehicle, the lanyard will trip the safety valve and set the machine’s propel brakes.

4.Disconnect the drive tumbler gearcase from the propel motor as follows:

a.Ensure that the propel pump controls are in neutral position.

b.Loosen the shifter lever lock screw.

c.Pull out the shifter lever to disengage the clutch.

d.Tighten the shifter lever lock screw.

5.Use the hand pump mounted to the right front jack casing. Pump the jack until 1,500 PSI (10,350 kPa) shows on the gauge near the pump.

NOTES: •Anytime pressure drops below 800 PSI (5,520 kPa), the brakes could drag resulting in premature brake failure.

• Do not tow at speeds greater than 1.1 mph (1.8 kph). Excessive planetary gearcase heating can occur.

6.When towing is complete, reverse the above procedure. The hand pump pressure can be released by turning the release valve on the pump.

MACHINE LEVELING

To level the machine, proceed as follows:

1.Place the machine in the proper location to drill the required hole. Verify that the leveling jack pads will rest on solid footing. The maximum angle for a jack pad resting on the ground is 17°.

2.The operating mode selector switch must be in the DRILL position and the main air compressor motor must be energized.

NOTE: Normally the machine will be leveled using the automatic leveling switch, Step 3. For manual leveling use Step 4 through 7.

Machine Orientation

3.To level the machine automatically verify that the operating mode selector switch is in the DRILL mode, then turn the automatic leveling switch to the EXTEND position and hold the switch in that position. The Automatic Leveling/Propel screen will come on automatically on the operator’s display terminal. Use the screen to monitor the machine as it is being leveled. The jack cylinders will extend to raise and level the machine. When the machine is raised and leveled, release the switch and it will spring return to the CENTER or OFF position. This procedure can be performed by the operator while he is seated at the main operator’s console.

4.To level the machine manually, use the four joysticks and the automatic leveling screen on the operator’s display terminal. The operator is seated at the control console as he operates the joystick controls and at the same time observes the operator’s display terminal screen.

5.Lower all four leveling jacks until they are resting on the ground. Then, starting with the low side (left or right) of the machine, slowly lower the jacks until the weight of the machine is resting on them. THE LEVELING JACK CONTROLS SHOULD BE OPERATED IN PAIRS WHILE DOING THIS OPERATION TO REDUCE TWISTING OF THE MACHINERY FRAME. Once the weight of the machine is resting on the downhill side leveling jacks, slowly lower the uphill side leveling jacks until the machine weight is resting on them. The machine does not need to be raised to an excessive height during this operation, since the purpose is only to get the weight of the machine resting on the leveling jacks.

CAUTION:During this and subsequent leveling procedures, it is important that the machine stays as close to level as possible. Care should be taken especially when working on steep grades.

6.Once the machine weight is resting on the leveling jacks it may be leveled. Starting with the downhill side of the machine, lower the two side leveling jacks to bring the machine into side-to-side level as observed on the operator’s display terminal screen. Then, once the machine is level from side-to-side, operate the leveling jack controls for the downhill end of the machine to bring the machine into level end-to-end as observed on the operator’s display terminal screen.

7.Once the machine is level, make sure that the weight of the machine is off of the crawlers. The preferred method of doing this is to raise the machine until the closest point of the lower rollers to the crawler belts is 2" to 7" (5.1 to 17.8 cm). This assures that the machine is resting on the leveling jacks while maintaining a low center of gravity.

Leveling Controls

MAST RAISING AND LOWERING

The mast is normally left in the raised position for most situations, including propelling from hole to hole on a blast pattern. Lowering the mast is necessary under three conditions:

1.Maintenance work is not possible or too dangerous to perform with the mast up.

2.Long moves over 1,000 feet (304 m) where the machine will be towed into position, propelled at high speed, or be loaded onto a trailer.

3.Any situation when steep slopes are encountered. Contact Bucyrus Service Department if unsure of slope limitation for propelling.

MAST RAISING

CAUTION:It is recommended that the mast be raised or lowered with the assistance of a helper familiar with the procedures involved.

CAUTION: During the mast raising procedure personnel should be kept clear of the machine and the area immediately surrounding the machine, especially the front. 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.

CAUTION:Limitations exist as to the length, diameter, wall thickness and number of drill pipes that may be stored in the pipe racks when 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.

To raise 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. Check that the mast cylinder pins, mast hinge pins and mast brace pins are in place and secured. Verify on the operator’s display terminal, pin status screen that the mast lock and mast brace lock pins are in the unlock position. Verify that the operating mode selector switch is in the DRILL mode.

2.The main air compressor motor must be energized. Move the winch/mast selector switch to the MAST position. Slowly raise the mast by lifting and then slowly pushing the mast/winch joystick forward. (The joystick is located on the main control panel.) As the mast reaches an angle of 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.

CAUTION:The mast joystick should be moved away from and returned to the neutral position very slowly. Sudden starts and stops can be damaging to the mast and hydraulic system. Be extremely cautious as the mast approaches 70 degrees - once the mast goes over center only a very slight movement of the joystick is necessary to cause motion in the mast.

Mast Raising/Lowering Controls

NOTE: 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, in view, on the left side of the machine as the mast is going up.

3.Once the mast is vertical, move the mast lock switch to the LOCK position to lock the mast in the vertical position. Return the lever to the neutral position when the latch is in position.When the mast is locked in position the words MAST PINS LOCKED will appear on the operator’s display screen. Turn the mast brace lock switch to the LOCKED position to secure the mast in the vertical position.

NOTE: A visual inspection of the pins is recommended to ensure the pins are fully locked.

MAST LOWERING

CAUTION:It is recommended that the mast be raised or lowered with the assistance of a helper familiar with the procedures involved.

CAUTION: During the mast raising procedure personnel should be kept clear of the machine and the area immediately surrounding the machine, especially the front. 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.

CAUTION:Limitations exist as to the length, diameter, wall thickness and number of drill pipes that may be stored in the pipe racks when 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.

To lower the mast:

1.Remove the drill pipe from the rotary drive unit and store it in the pipe 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 auxiliary winch hook. Be sure the auxiliary winch line is secured to the mast. Raise the dust curtains. Lower the rotary/pulldown unit to its lowest position. Verify that the machine is level.

2.Check the condition of the mast hinge pins, lugs and cylinder pins.

Mast Raising/Lowering Controls

3.If the mast lock pins and/or mast brace lock switch have not been released, turn the switches to the UNLOCK position to release the pins. When the pins are being released the words MAST PINS OUT and MAST BRACE PINS OUT will appear on the operator’s display terminal. On the pin status screen the pins should show unlocked.

4.Slowly lower the mast by lifting and then pulling the joystick to the rear. As the mast moves away from the vertical position, its speed will increase. Gently reduce the lowering speed by moving the joystick toward neutral.

CAUTION:The joystick should be moved very slowly away from and returned to the neutral position. 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. Lay the mast in the mast rests gently to prevent damage to the mast or machine house.

NOTE: 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, in view, on the left side of the machine as the mast is coming down.

NOTE: Do not allow the mast to lower too quickly especially if near horizontal. Damage may result from the mast hitting the mast rests too hard.

5.Once the mast is resting in the mast rests, inspect the mast and the mast support to verify that no hoses, wires or cables are kinked or damaged. Repair any damage found immediately.

PULLDOWN MACHINERY OPERATION

The pulldown machinery is used during the tool handling and the drilling procedures. The pulldown machinery supplies power to either raise or lower the rotary/pulldown unit. Power is supplied to the pulldown gearcase by an electric motor.

To operate the hoist/pulldown machinery proceed as follows;

1.Move the operating mode selector switch to the DRILL position.

2.Turn the hoist/pulldown selector switch to either PULLDOWN, HOIST HIGH, HOIST LOW, or PIPE RACK/JOINT.

For this procedure, turn the switch to the PULLDOWN position.

For a review of each switch position, refer to HOIST/PULLDOWN SPEED SELECTOR SWITCH

Controls for Hoist/Pulldown

3.Press the drill/propel control ON push-button. “Pulldown” readout will show on the operator’s display terminal operator’s display screen.

4.Turn the hoist brake switch to the RELEASE position. “Head Brake Released” will appear on operator’s display terminal operator’s display screen.

5.Rotate the hoist/pulldown rheostat in the hoist direction to hoist the rotary/pulldown unit. The farther the rheostat is turned to the right the faster the unit will be raised.

6.Rotate the pulldown force rheostat in the pulldown direction to lower the rotary/pulldown unit. The farther the rheostat is turned to the left the faster the unit will be lowered.

7.When the hoist/pulldown operations are complete, set the hoist/pulldown speed rheostat to the “0” position and then turn the hoist brake switch to the SET position.

CAUTION:Whenever the hoist/pulldown speed rheostat is in the “0” position, the hoist brake switch must be in the SET position. This will prevent the rotary/pulldown unit from creeping downward due to the weight of the unit.

AUXILIARY WINCH OPERATION

To operate the auxiliary winch proceed as follows:

Controls for Operating the Winch

1.Place the winch/mast control selector switch in the WINCH position.

2.Place the operating mode selector switch in the DRILL position. The main air compressor must be energized.

3.To hoist the auxiliary winch line, lift and move the mast/winch joystick, located on the main control panel, forward. To stop the line, return the joystick to the NEUTRAL position.

4.To lower the winch line, lift and move the joystick rearward. To stop the line, return the joystick to the NEUTRAL position.

PIPE RACK OPERATION

The machine can be equipped with 1 to 4 pipe racks. Depending upon the number of pipe racks the pipe rack configuration and operation will differ.

•With one pipe rack, the rack will be on a swing-out arm and will be in #1 position .

•With two pipe racks, the racks will be on swing-out arms and will be in #1 and #4 positions.

•With three pipe racks, two pipe racks will be located on a carousel that swings out and then is rotated. This carousel houses pipe racks in #1 and #2 positions as shown. The third pipe rack is a swing-out rack that will be in #4 position.

•With four pipe racks, there are two swing-out carousels with two racks in each carousel. The carousels rotate to make each rack available for use. The left carousel houses racks #1 and #2 and the right carousel racks #3 and #4.

Controls for Operating the Pipe Racks

The general method of operating the pipe racks is as follows:

1.Place the operating mode selector switch in the DRILL position. The main air compressor must be energized.

2.Verify that the operating mode selector switch is in the DRILL position and that the hoist/ pulldown speed selector switch is in the PIPE RACK/JOINT position.

3.Select the desired pipe rack.

4.Lift and move the pipe rack joystick, located on the main control panel, out of neutral to perform the desired operation.

The following special sequence is required for each pipe rack configuration.

One-pipe rack configuration:

a.Turn the pipe rack selector switch to the #1 position.

b.Operate the rack as described under general procedure.

Two-pipe rack configuration:

a.If the first pipe rack is to be operated place the selector switch #1 position and operate the rack as described under general procedure.

b.If the second pipe rack is to be operated place the selector switch in the #4 position and operate the rack as described under general procedure.

NOTE: Take extra care to insure that one pipe rack is out of the way and locked in place before operating the second pipe rack.

Three-pipe rack configuration:

a.The first and second pipe racks are part of a carousel and require a special operating sequence. The third pipe rack is a standard swing out rack.

To operate the third pipe rack place the selector switch in the #4 position and operate the rack as described under general procedure.

b.The carousel configuration of pipe racks one and two requires a special sequence. Position #1 of the selector switch will allow, when the joystick is pulled to the rear, the carousel with pipe racks to be swung out over the guide bushing hole.

One of the pipe racks will be over the hole. Position #2 of the selector switch will allow, when the joystick is pulled to the rear or pushed forward, the carousel to rotate to move the other pipe rack over the hole. Returning the selector switch to position #1 and moving the joystick forward will return the carousel to the stored position.

c.Because of the sequence of operation pipes must be removed from pipe rack #1 first and then pipe rack #2. When returning the pipes to the racks return pipe to #2 pipe rack, then #1 pipe rack.

NOTE: Take care to insure that one pipe rack is out of the way and locked in place before operating the other pipe rack.

Four-pipe rack configuration:

a.The four-pipe rack configuration consists of two swing out carousels with two pipe racks to each carousel. Pipe racks #1 and #2 in the left carousel and pipe racks #3 and #4 in the right carousel work and are sequenced the same as the carousel in the three pipe rack configuration. For pipe rack #3 and #4, the #4 position of the selector switch controls the swing out of the right carousel and the #3 position controls the rotation of the carousel.

b.Because of the sequence of operation, pipe must be removed from pipe rack #4 first, then pipe rack #3. When returning the pipes to the racks, return pipe to #3 pipe rack, then #4 pipe rack.

TOOL HANDLING

The following describes the procedures necessary to load, unload, handle, assemble and disassemble the drill tools.

PIPE LOADING AND UNLOADING

Loading pipe is done when the machine is new and has not yet had the pipe installed or when the pipe has been removed for changeout or for maintenance to the mast. This procedure requires that the mast be in the horizontal or lowered position to load the drill pipe for safety.

This procedure is not the most expedient while the mast is in the drilling position. However it 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.

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 proceed as follows:

1.If the mast is in the vertical or drilling position, lower the mast and store it in the mast rests. Refer to the appropriate topic in this manual for the exact operating procedures.

2.Use 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 of the crane is on the left side of the machine since this allows the shortest reach and greatest boom angle.

CAUTION:Follow all applicable safety measures when working with cranes and rigging. Failure to follow safe working procedures can cause an accident, leading to the possible death or injury of personnel.

3.Position the pipe to be installed so that it is 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.

CAUTION:Make sure the drill pipe is secured against unwanted or unexpected movement. Failure to secure the pipe properly may result in the pipe shifting and causing death or serious injury to personnel in the area.

4.The upper gate is open when the pipe rack is empty. This function is controlled by a limit switch in the lower pocket of the pipe rack.

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 sling to be removed from the pipe.

CAUTION:Block the pipe securely 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 bottom of the pocket. Lay the pipe in the pipe rack and remove the sling and lifting bell.

9.When the pipe rest in the bottom of the pocket it will trigger the limit switch and close the upper gate.

10.Repeat the procedure for additional lengths of pipe.

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

DRILL TOOL STRING ASSEMBLY

The tool string consists of one or more sections of drill pipe, a stabilizer (drill collar) and a bit. In assembling the tool string, the stabilizer is the first item installed, then a section of drill pipe and finally the bit.

To install the stabilizer proceed as follows:

1.Place the stabilizer to be installed in a position to be accessible to the auxiliary winch line. Clean and lubricate the threads and shoulders on each end of the stabilizer. Install a lifting bell on the pin (upper) end of the stabilizer and lift it onto the drilling deck with the auxiliary winch line. Securely block the stabilizer horizontally on blocking sufficient enough to place the stabilizer 8-10 inches above the drill deck. Remove the auxiliary winch line.

2.Remove the guide bushing from the hole in the drill deck. 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 winch line to the lifting bell.

3.Install the stabilizer and drill bushing in the hole in the drill deck. Make sure the drill 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.

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

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

Stabilizer Installation

Controls for Drill Pipe Installation

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

1.Lower the rotary/pulldown unit until the pipe coupling on the unit can be reached from the drill deck. Set the hoist brake and press the drill/propel control OFF push-button. 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.

NOTE: 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.Press the drill/propel control ON push-button and release the hoist brake. Raise the rotary/ pulldown unit to a position on the mast so as to clear the pipe rack as it comes into place. Set the hoist brake.

3.Verify that:

•The main compressor/hydraulic pump motor is running,

•The hoist/pulldown speed selector switch is in PIPE RACK/JOINTS position,

•The operating mode selector switch is in DRILL position,

•The head is clear of pipe rack on the operator’s display terminal.

Place the pipe rack selector switch in #1 position. The pipe rack joystick will now control only the #l pipe rack.

4.Lift and move the joystick rearward (OVER HOLE position) to move the pipe rack over the hole. Once the rack is over the hole return the joystick to the NEUTRAL position.

5.Release the hoist brake and lower the rotary/pulldown unit until it is approximately 1 foot above the upper end of the drill pipe. Reset the hoist brake.

6.Turn the rotary rheostat clockwise until the rotary drive unit coupling begins to turn at approximately 35 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and carefully lower the rotary drive unit until the coupling contacts the drill pipe. Allow the rotary/pulldown unit to lower under gravity while the coupling is threading onto the pipe.

7.When the drill pipe begins to turn with the rotary coupling, stop the rotary motion and check the joint between the coupling and the pipe. The shoulders on the pipe and coupling must be 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. If the shoulders of the pipe and coupling are contacting, the joint is made up.

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/pulldown unit.

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 apply a small amount of hoist power to the rotary/pulldown unit to lift it slightly to remove the pressure from the drill threads.

CAUTION:Do not lift the drill pipe. Lift the rotary/pulldown unit only enough to relieve the pressure on the threads. Lifting the unit enough to lift the pipe will not only put pressure on the other side of the threads, but may also allow the pipe rack upper 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 coupling and the drill pipe. Inspect the threads for rough surfaces and burrs and apply a liberal coat of thread 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.

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.

8.Once the joint is made up between the coupling and the pipe, the pipe is now ready to be lifted out of the pipe rack pocket. Lift the pipe approximately a foot above the top of the pocket to allow the pipe rack to swing out of the way. Set the hoist brake.

9.Once the pipe has been lifted clear of the pipe rack, swing the pipe rack to the STORED position by lifting and pushing the joystick forward to the STORED position.

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

10.Once the pipe 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.

CAUTION:Before working around the tool string set the hoist brake. Press the drill/propel control OFF push-button.

11.Release the hoist brake and lower the rotary/pulldown unit until the drill pipe is approximately 1 foot above the upper end of the stabilizer. Reset the hoist brake.

12.Turn the rotary rheostat clockwise until the drill pipe begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and carefully lower the rotary drive unit until the drill pipe contacts the stabilizer. Allow the rotary drive unit to continue to lower under gravity while the drill pipe is threading onto the stabilizer.

13.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.

Installation of the drill bit is the last step in preparing the tool string. To install the bit, proceed as follows:

1.Hoist the completed drill pipe/stabilizer assembly 2 to 3 Ft. (0.6 to 0.9 m) off the drill deck. Place the bit basket (furnished with machine) 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. Coat the threads and shoulders of the bit and stabilizer with drill pipe thread compound.

3.Turn the rotary rheostat clockwise until the tool string begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen. Release the hoist brake and slowly lower the rotary/pulldown unit and tool string 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 threads start to catch, set the hoist brake and let the stabilizer screw itself onto the bit.

4.When the joint is tight the rotary unit will slow down and the rotary load meter will show an increased load. At this point return the rotary rheostat to the neutral position.

5.After making the bit to stabilizer joint, hoist the rotary drive unit to allow the bit basket to be removed. Remove the bit basket and store it in a safe place.

6.Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck. Set the hoist brake and press the drill/propel control OFF push-button. The tool string is now complete for single pass drilling or for the first pass of multiple pass drilling.

BREAKOUT WRENCH OPERATION

CAUTION:When working with the breakout wrench it is important that the hoist brake be set, the drill/propel control OFF push-button be pressed to prevent operation of the hoist or rotary controls. Failure to follow this caution may lead to the controls being energized while personnel are in the area, leading to the death or serious injury of those personnel.

Operation of the breakout wrench is necessary anytime a pipe joint, except the joint at the rotary coupling, must be broken. This includes removing the bit or stabilizer, or separating two sections of pipe.

To break a joint with the breakout wrench, proceed as follows:

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 pipe to be broken with the tool wrench jaws. Close the tool wrench by turning the tool wrench control switch to the EXTEND position. 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.

CAUTION:All personnel should be removed from the drill deck when operating the breakout wrench.

2.To break the joint, turn and hold the breakout wrench switch to the EXTEND position. The jaws of the breakout wrench should grip the upper tool and turn it while the lower tool is held stationary by the tool wrench. Release the breakout wrench switch.

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

4.Turn and hold the breakout wrench switch in the RETRACT position until the breakout wrench releases the upper section of pipe and moves away from the pipe.

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

CAUTION:The joint must uncouple freely while using the rotary unit. If the joint does not uncouple freely, repeat the procedure using the breakout wrench until it does. Constantly observe the joint between the rotary 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.

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

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 stabilizer.

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

1.Raise the tool string 2 to 3 ft (0.6 to 0.9 m) above the drill deck. Install the bit basket in the hole in the drill deck.

2.Using the breakout wrench, 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 of the bit to facilitate the disassembly.

3.Hoist the tool string 2 to 3 ft (0.6 to 0.9 m) off of the drill deck. Secure the rotary/pulldown unit and controls. Attach a lifting bell to the bit. Attach the auxiliary winch line to the lifting bell and lift the bit out of the bit basket.

4.After removing the bit, a new bit may be installed or the bit basket may be removed, allowing removal of the drill pipe.

To remove the drill pipe from the rotary drive unit, 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. Using the breakout wrench to break the joint between the stabilizer and the drill pipe. After breaking the joint, use the rotary unit to disassemble that joint completely. Raise the rotary/pulldown unit and drill pipe 2 to 3 ft (0.6 to 0.9 m).

2.Press the drill/propel control OFF push-button and set hoist brake. Go to the drill deck and clean the pocket of the pipe rack to be used of dirt, cuttings or any material that will interfere with the entrance of the pipe or the operation of the pipe rack gate controls. Verify that the gate controls are intact.

3.Clean and lubricate the threads and shoulder on the lower end of the pipe. This is to prevent rusting while stored in the pipe rack. After performing this function, return the controls to operating condition.

4.After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4, swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.

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

6.Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full speed. The joint should break at the rotary coupling.

NOTE: IF THE JOINT DOES NOT BREAK IMMEDIATELY, RETURN THE ROTARY RHEOSTAT TO THE ZERO POSITION TO REDUCE THE CHANCE OF DAMAGING THE MOTOR BY STALLING IT.

7.If the joint does not break, it will be necessary to index the slots on the drill pipe so as to 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 pawls in the sockets. This allows the drill pipe to rotate almost one-half turn before being stopped by the pawls.

After indexing the pipe to allow the one-half turn rotation, repeat step 6 above to break the joint. Repeat this procedure as many times as is necessary to break the joint.

8.When the joint breaks, gently raise the rotary/pulldown unit as the joint is unthreading.

9.When the joint completely unscrews, the pipe will drop to the bottom of the pipe rack pocket. The upper gate will automatically close around the drill pipe. When the joint is completely unscrewed, raise the rotary/pulldown unit until it is in a position so as not to be struck by the pipe rack when it is moved. Set the hoist brake.

10.Swing the pipe rack into the stored position.

To remove the stabilizer, proceed as follows;

1.With the stabilizer still clamped in the tool wrenches, attach a lifting bell to the upper end of the stabilizer. Attach the auxiliary winch line to the lifting bell and lift the stabilizer and guide bushing from the hole in the drill deck. Block the assembly in a horizontal position.

2.Remove the auxiliary winch line from the stabilizer. Remove the guide bushing from the stabilizer and replace the auxiliary winch line.

3.Using the auxiliary winch line, remove the stabilizer from the drill. Replace the guide bushing in the hole in the deck.

BIT REMOVAL

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

1.Raise the head machinery to position the bit about 18” above the drill deck.

2.Install the bit wrench into the deck opening.

3.Ensure the bit wrench contacts the two square breaking lug that are welded to the drill deck.

4.Turn the rotary machinery until the cones of the bit match the slots in the bit wrench.

5.Lower the mast machinery until the bit is about 2” from the bottom of the bit wrench.

6.Set the head brake.

7.Slowly rotate the drill steel counterclockwise using the rotary machinery until the bit wrench is tight against the breaking lugs.

8.Leave a small amount of counterclockwise reference on the rotary machinery to keep the bit and bit wrench tight to the breaking lugs.

9.Extend the hydraulic breakout wrench.

10.Allow the wrench to extend until the joint between the bit and drill string is broken.

11.If the joint does not break, retract the wrench fully and extend the wrench again.

12.If the area where the hydraulic breakout wrench is contacting the drill string is in poor condition, it may be necessary to reposition the drill string. Retract the hydraulic breakout wrench. Turn the drill string clockwise to allow the bit wrench to loosen from the breaking lugs. Release the head brake and raise the machinery until it clears the bit wrench. Rotate the drill string 1/3 of a turn and lower the bit back into the bit wrench. Set the head brake once the bit is about 2” from the bottom of the bit wrench. Turn the drill sting counterclockwise with the rotary machinery until it is tight against the breaking lugs. Leave a small amount of counterclockwise reference on the rotary machinery to keep the bit and bit wrench tight to the breaking lugs.

13.Extend the breakout wrench. Repeat step 12 if necessary.

14.Once the joint has broken, place the rotary master switch in neutral.

15.Retract the hydraulic breakout wrench.

16.Release the head brake. Rotate the drill string slowly counterclockwise while hoisting the drill string until there is enough clearance to remove the bit and bit basket.

17.Return the master switches to neutral and set the head brake.

18.Install the bit lift adapter and use the winch to remove the bit.

After removing the bit, a new bit may be installed or the bit basket may be removed, allowing removal of the drill pipe.

STABILIZER REMOVAL

To remove the stabilizer, proceed as follows:

1.With the stabilizer still clamped in the tool wrenches, attach a lifting bell to the upper end of the stabilizer. Attach the auxiliary winch line to the lifting bell and lift the stabilizer and guide bushing from the hole in the drill deck. Block the assembly in a horizontal position.

2.Remove the auxiliary winch line from the stabilizer. Remove the guide bushing from the stabilizer and replace the auxiliary winch line.

3.Using the auxiliary winch line, remove the stabilizer from the drill. Replace the guide bushing in the hole in the deck.

DRILL PIPE REMOVAL

To remove the drill pipe from the rotary drive unit, 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. Using the breakout wrench to break the joint between the stabilizer and the drill pipe. After breaking the joint, use the rotary unit to disassemble that joint completely. Raise the rotary/pulldown unit and drill pipe 2 to 3 Ft. (0.6 to 0.9 m).

2.Press the DRILL/PROPEL CONTROL OFF push-button and set hoist brake. Go to the drill deck and clean the pocket of the pipe rack to be used of dirt, cuttings or any material that will interfere with the entrance of the pipe or the operation of the pipe rack gate controls. Verify that the gate controls are intact.

3.Clean and lubricate the threads and shoulder on the lower end of the pipe. This is to prevent rusting while stored in the pipe rack. After performing this function return the controls to continue the operation.

4.After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4, swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.

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

6.Quickly turn the rotary rheostat to the left (counterclockwise) to approximately 1/2 of full speed. The joint should break at the rotary coupling.

NOTE: If the joint does not break immediately, return the rotary rheostat to the zero position to reduce the chance of stalling the motor and thereby damaging it.

7.If the joint does not break, it will be necessary to index the slots on the drill pipe so as to 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 pawls in the sockets. This allows the drill pipe to rotate almost 1/2 turn before being stopped by the pawls.

After indexing the pipe to allow the one-half turn rotation, repeat step 6 above to break the joint. Repeat this procedure as many times as is necessary to break the joint.

8.When the joint breaks, gently raise the rotary/pulldown unit as the joint is unthreading. The drill pipe should remain on the bottom of pip rack pocket when unscrewing to ensure the upper gate is latched.

CAUTION:When breaking a drillstring with multiple sections, verify that the correct joint is broken.

9.When the joint completely unscrews, the pipe will rest on the bottom of the pipe rack pocket. The upper gate should be closed around the drill pipe. When the joint is completely unscrewed, raise the rotary/pulldown unit until it is above the pipe rack clearance limit. Set the hoist brake.

10.Swing the pipe rack into the stored position.

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/pulldown unit is raised above the pipe rack limit, a pipe rack with pipe moved over the hole, the rotary coupling threaded to the pipe, and the pipe removed from the rack and the rack stored.

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 of the first section of the pipe even with the top of the 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.Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half of full speed. The rotary coupling should turn, breaking the joint between the pipe and the coupling.

NOTE: If the joint does not break immediately, return the rotary rheostat to the zero 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 allow the rotary drive unit to build up speed before the tool wrench stops 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.

5.When the joint breaks, apply enough hoist power to raise the rotary/pulldown unit as the joint is unthreading. Do not apply enough power to lift the pipe in the tool wrench which could cause the tool wrench to lose its grip on the pipe. Once the joint is completely disassembled, raise the rotary/pulldown unit to a position to make the coupling accessible from the drill deck. Set the hoist brake, press the drill/propel control OFF push-button to prevent operation. Clean and lubricate the threads and shoulder of the rotary coupling. Use an approved drill thread compound on the threads and shoulder. After cleaning and lubricating the coupling, raise the rotary drive unit to a position above the pipe racks so as not to be struck by the pipe or rack as the rack swings into position over the guide bushing.

6.Position the pipe rack over the hole and install the new section of pipe to the rotary unit.

7.Once the new section of pipe is attached to the rotary unit and the pipe rack stored, lower the pipe until it is approximately 3 feet above the drilling deck. Set the hoist brake. 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 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 rotating at approximately 35 RPM as shown on the operator’s display terminal operator’s display screen. Lower the rotary/pulldown 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 rheostat, then allowing the upper pipe to descend slightly to keep the tool wrench from losing its grip on the lower pipe. Once the joint is tight, stop the rotary motion.

NOTE: 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.

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 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 to reverse order of assembly. First, the last section of pipe 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 breakout wrench. The joint is then disassembled by the rotary motion and the pipe stored in the pipe 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.

DUST SUPPRESSION SYSTEM OPERATION

The dust control system may be either a dry type filter or a water injection system. Dust control is used to prevent the generated drilling dust from escaping to the environment. All machines are equipped with dust seal to contain the dust around the drill hole.

One method to suppress the generation of dust is to inject water into the main air stream as it passes to the bit. The water serves to conglomerate the dust particles into larger particles that may be treated as cuttings.

NOTE: When the machine is equipped with a dry-type dust filter system, the air for cleaning the filters is drawn from the bailing air system. Air pressure to the dry-type dust filter must be maintained at 40 PSI (276 kPa) to insure proper cleaning of the filter elements.

Water Injection System

VERTICAL DRILLING

Once the machine has been inspected, started, positioned, leveled, and the tool string assembled, it is 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). This section details the procedures involved in the drilling of vertical holes.

Controls for Drilling

The actual drilling procedure involves three main sections:

1.Starting the hole (collaring)

2.Drilling the hole

3.Cleaning or reaming the hole

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.

A hole drilled in a consolidated rock formation is the simplest formation to drill in. During the actual drilling the operator’s display terminal should be turned on and the operator display screen shown on the monitor. All of the drilling parameters noted in the following paragraphs will appear on the operator’s display screen.

NOTE: The bar graphs on the operator’s screen on the operator display terminal shows the condition of each function. If a function operates beyond its normal operating range, especially for rotary current and hoist/pulldown force, the bar graph color will change from green to yellow or red when the graph valve raises into that particular range. For details, refer to the Operator Display Manual.

STARTING THE HOLE (COLLARING)

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.

To begin the hole proceed as follows:

1.Verify that the tool wrench and breakout wrench are retracted fully. Clear the drill deck of personnel and material which is not necessary for the drilling procedure (i.e. oil drums, tools, spare bits, etc.).

2.Place the operating mode selector switch in the DRILL position. Press the drill/propel control ON push-button. Release the hoist brake. Place the hoist/pulldown speed selector switch in the PULLDOWN position, allowing the tool string to lower 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. Reset the hoist brake.

3.Turn the rotary speed selector switch to LOW position. Turn the rotary rheostat clockwise until the rotary speed bar graph on the operator’s display terminal screen indicates that the tool string is turning at approximately 45 RPM.

4.Lower the dust curtains and turn on the dust control system. Place the main compressor vent/drill switch in the DRILL 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 pulldown speed sufficient to cause penetration of the bit is provided by turning the hoist/pulldown rheostat slightly in the pulldown direction.

5.Release the hoist brake and allow the drill bit to contact the ground. Monitor the vibration coming from the tool string. To reduce vibration slow the rotary speed with the rotary rheostat. Keep the vibration to a minimum. As the vibration lessens, increase the rotary speed and the pulldown speed while monitoring the rotary current and the air pressure bar graph on the operator’s display terminal screen.

The objective is to penetrate the formation as fast as possible without damaging the machine or plugging the hole with cuttings. Monitoring the rotary current, and keeping the load in the lower portion of the bar graph (green) will eliminate damage to the rotary motor. Reducing the load on the motor is accomplished by reducing the pulldown force on the bit. In some cases it may even be necessary to hoist the tool string slightly to reduce the loading.

Monitoring the air pressure bar graph 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 air pressure will rise. Varying the penetration rate will vary the air pressure. Keep the air pressure in the normal working range (45 PSI for machines with water injection and 50 PSI for machines with dry-type dust control) by increasing or reducing the penetration rate. Keep the vibration levels to a minimum by varying the rotary speed and the pulldown force.

6.When the bit passes through the fragmented material (approximately 3-5 Ft. [0.9-1.5 m]) and into the consolidated material underneath, the vibration and rotary current will reduce drastically. When this occurs, the hole has been collared and normal drilling may commence.

NORMAL DRILLING

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 pulldown force 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 air pressure. By keeping the penetration at or slightly below the optimum, the hole can be completed in the shortest possible time.

To begin normal drilling proceed as follows:

1.Normal drilling requires added pressure to the bit in addition to the deadweight of the tool string and rotary/pulldown unit. This pressure is furnished with the electric motor and pulldown gearcase. To activate the pulldown motor, turn the hoist/pulldown rheostat in the pulldown direction as required for maximum drill rate and pulldown force. Turning the control in the pulldown direction will increase the pressure on the bit by calling for a desired pulldown speed.

Apply enough pulldown force to allow the bit inserts to chip the material being drilled, rather than pulverizing it. If the pulldown force 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 pulldown force is not enough. Another cause of poor cutting is a worn bit. If pulldown force is high, but the cuttings are fine and penetration is slow, change the bit.

2.Monitor the rotary motor load (current) and adjust the pulldown force to keep the bar graph in the lower (green) portion of the graph. It is permissible for the load to increase momentarily into the yellow, but continuous running in the yellow or red portions will cause rotary motor damage.

3.Monitor the vibration of the tool string and the machine. Keep the vibration to a minimum by varying the pulldown speed 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 speed until the vibration is acceptable.

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

Monitor the air pressure. Keep the pressure in normal working range to eliminate compressor overheating. Pressures above normal working range (45 PSI [310.26 kpa] for machines with water injection and 50 PSI [344.74 kpa] for machines with dry-type dust control) indicate that the hole is starting to plug with cuttings. Stop the pulldown by returning the hoist/pulldown rheostat to the “0” position. Set 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 release the hoist brake and turn the hoist/pulldown selector switch to the LOW position and the hoist/pulldown rheostat in the hoist direction. 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 pulldown 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. The operator’s display screen on the operator’s display terminal will show the hole depth in feet.

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

ENDING THE HOLE ~SINGLE PIPE SECTION

Once the finished hole depth is reached, normal drilling ceases. It is now necessary to ream the hole before preparing the machine 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. Wandering is due to the stabilizer being a smaller diameter than the bit to decrease wear and operation 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 rheostat to the MINIMUM position and the motion activated. Return the hoist/pulldown rheostat to the “0” position and set the hoist brake. Allow the tool string to rotate and the air to bail the hole for a moment. This removes all of the cuttings in suspension from the hole.

2.Turn the hoist/pulldown speed selector switch to the LOW HOIST position and the hoist/ pulldown rheostat in the HOIST direction while simultaneously releasing the hoist brake. Slowly hoist the tool string out of the hole. If resistance is met, or if vibration increases, return the hoist/pulldown rheostat to “0” position and set 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 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 of the hole significantly, so it is necessary to remove these cuttings from the hole. To do this, release the hoist brake and turn the hoist/ pulldown rheostat slowly in the pulldown mode.

Leave the 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 of the 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. Turning the hoist/pulldown rheostat control in the HOIST direction and the hoist/pulldown speed selector switch in the HOIST HIGH position will hoist the tool string.

ENDING THE HOLE ~MULTIPLE PIPE

Reaming the hole with multi-section tool strings is the same as reaming with single pipe section 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 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 of the hole. This is not desirable as it is time consuming. One method to eliminate the need to clean the hole is to over-drill the depth and allow cuttings to fill the hole to the desired finishing depth. Experience in this area will show how much to over-drill the hole. A good practice is to over-drill the hole by 1 to 2 feet (0.3 to 0.6 m) over the estimated finished hole depth, which could be corrected by a few shovels full of cutting thrown into the hole. Underestimating, on the other hand will require that the tool string be reassembled and the hole cleaned.

DRILLING DIFFICULT FORMATIONS

Unfortunately, not all drilling is in consistent, consolidated rock formations. The main cause of difficult drilling are unconsolidated or wet, sticky material. Unconsolidated 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 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. However, monitoring of the machine is critical while drilling in difficult formations.

NOTE: Failure to closely monitor the machine and its bar graphs as shown on the operator’s display terminal operator’s display screen 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 if the 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.

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 pulldown speed. If reducing the pulldown speed does not reduce the vibration to the machine to an acceptable limit, 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 of the void a little at a time. Reduction of the rotary speed will also help reduce the vibration of the tool string. This is the last procedure that should be tried since a high pulldown speed with a low rotary speed causes vibration just as severe at a different frequency.

The second problem with unconsolidated material is 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 of the 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. Unconsolidated 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 of the hole it is 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 of the 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 every 2 to 3 feet (0.3 to 0.6 m) 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 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 stool string is being hoisted. If the hole caves in while in the hoist mode there is a better chance of recovering 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 than 6 inches [15.2 cm] square), it is possible to grind the material sufficiently to allow it to pass between the lobes of the bit and fall to the bottom of the hole. This condition can be observed if the bailing air pressure increases over normal 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 of the 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 hoist the bit until it runs into the plug and stops hoisting. With rotary motion turning at approximately 50-60 RPM keep high hoist loading on the bit and allow the bit to work its way through the plug. Monitor the rotary motor loading (current) and reduce the hoist loading (force) to keep the load in the lower portion of the bar graph. Once the plug is passed, clean the hole and return to drilling. The main air pressure may or may not exceed the safety valve setting and cause the main air compressor to overheat. If the safety valve opens when 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 apply maximum hoist power. If the plug does not clear itself within a few 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.

CAUTION: Before cutting an abandoned 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 stream 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, 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:

•Coating of the hole and pipe with material,

•Clumping of the material into pieces too large to remove with the bailing air stream

•Caving of the hole.

Any of these problems may be present, or any combination of the three may be present at the same time.

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 case 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 to 10 feet (1.5 to 3.0 m) to remove the offending material. It is also necessary to clean the drill 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 off by 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 clumping into large pieces, these pieces fall back down to the bottom of the hole and are recycled through the bit to be broken up. If the amount of recycled 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 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.

PROGRAMMED DRILL CONTROL DRILLING

P.D.C. drilling is similar to normal drilling in that the machine must be positioned, leveled and set-up manually by the operator. The actual drilling operation will be controlled by the automated system. To start the automated system use the following start-up sequence.

Controls for Programmed Drill Control

1.Make sure the hoist/pulldown rheostat and the rotary rheostat are in the “0” position.

2.Verify that the desired drilling depths, collaring depth, and wet hole depth have been set per P.D.C. operating parameters screen on operator’s display terminal.

3.Place the hoist/pulldown speed selector switch in the PULLDOWN position.

4.Place the operating mode selector switch in the DRILL position.

5.Press the drill/propel control ON push-button.

6.Place the compressor vent/drill switch in the DRILL position.

7.Verify on the operator’s display terminal that no P.D.C. faults exist. If a fault exits, it must be cleared before the P.D.C. control can be activated.

8.With the operator’s display screen shown in the operator’s display terminal, press the depth indicator reset push-button to reset the hole depth and bit depth indicators to zero.

9.Place the hoist brake control in the RELEASE position.

10.Press the program drill control switch. A readout on the operator’s display terminal will read “PDC on”.

After the above start-up procedure has been initiated, the automatic controls will take over the actual drilling of the hole. Water injection (if so equipped) will be shut off at preset depth. When the total depth of the hole is reached (as preset) the tool string will be automatically hoisted. The operator should now take over control of the machine and start reaming and cleaning the hole as described in ENDING THE HOLE~SINGLE PIPE SECTIONS.

If problems arise in the P.D.C. functions, the system will have to be corrected by a qualified electrician. In most cases, if a malfunction occurs in the automated system, the automated system can be turned off and the drilling completed manually.

PREPARING TO MOVE THE MACHINE

Once the hole has been completed and the tool string is removed from the hole, it is necessary to move the machine to the next hole location. Preparing to move the machine 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 to move, proceed as follows:

1.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.Clamp the stabilizer with the tool wrench to prevent movement of the tool string during propel.

CAUTION: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.Turn the automatic leveling switch to the RETRACT position to raise the jacks and lower the machine. Hold the switch in the RETRACT position until the jacks are fully retracted. Refer to the auto-leveling screen on the operator’s display terminal to verify all four jacks are fully retracted.

NOTE: If the machine is to be lowered manually, refer to steps 4, 5 and 6 and operator’s display terminal auto leveling screen.

4.Using the manual leveling jack controls, lower the machine, so that it remains level, until it is touching the ground. Use the leveling jack controls in pairs (i.e. either both side controls, or both end controls simultaneously) to reduce the twisting loads on the drill frame.

5.Once the machine is touching the ground, 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.

CAUTION:While manually 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.

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

CAUTION:When manually lowering the machine 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.

7.Inspect the machine travel route as outlined in PROPELLING in this manual. After completing the inspections the machine is ready to propel.

MACHINE SHUTDOWN

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

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

SHUT DOWN PROCEDURE

To shut down the machine, proceed as follows:

1.Complete the hole 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 to redrill a hole that has been left unfinished as releveling and placing the drill in the exact position is extremely difficult.

2.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.

NOTE: 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 of the tool string and the hole.

3.Determine the length of time the drill is to be idle. 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.

5.Following the procedures in PREPARING TO MOVE in this manual, lower the machine 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.In the machinery house turn off all breakers. If the machine is to be shut down for a short period of time 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.

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 involves placing all components in a safe position and providing additional protective lubrication to normally lubricated components.

To store the machine for a maximum of 3 consecutive weeks, proceed as follows:

1.If not already done so previously, complete all shutdown procedures. During the shutdown 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.

2.Lower the rotary/pulldown unit to the lowest position and set the hoist brake. Inspect the rotary/pulldown unit for damage or wear and note any problems discovered. Cover the rotary and pulldown motors with waterproof tarps or covers. Raise the dust curtains. Retract the casing tong cylinder.

3.Check the oil level in the rotary/pulldown unit. Check the cases to see if there is water in the oil. If there is water in the cases, drain and refill the cases with suitable oil. If no water is present, fill the cases to the proper level.

4.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.

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

6.Inspect the air compressor for signs of wear or damage. Make note of any damage discovered.

7.If the 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.

8.Close and lock all electrical cabinet doors.

9.If equipped with screw compressors, fill the separator tank to the proper level with the specified oil.

10.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.

11.Lube all manual lube points.

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

13.Close and lock all windows and doors.

LONG TERM STORAGE

Long term storage is required any time the machine is to be left for a period exceeding 3 weeks. Long term storage includes all procedures for short term storage and some additional precautions.

There are two procedures involved in long term storage, depending on 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: Do not utilize the unattended long term storage procedure unless absolutely necessary.

ATTENDED LONG TERM STORAGE

Attended long term storage combines the short term storage with monthly start-up and running periods. Complete the procedures listed in SHORT TERM STORAGE in this manual. Once a month for the duration of the storage period.

1.Complete all start-up inspection and lubrication procedures listed in this manual and start the machine.

2.Run all of the gear trains for 10-20 minutes to distribute the oil over the gears and bearings.

3.Hoist and lower the rotary/pulldown unit the full length of the mast 4-6 times to distribute lubrication to the mast and rotary/pulldown unit components.

4.Cycle the tool racks 2-3 times.

5.Run the air compressor for 1 hour.

6.Propel the machine 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.

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 machine. These procedures will involve disassembly of the major units, duties that are not usually performed by operating personnel.

The procedure listed here is an outline intended only to give a general idea of the effort involved in proper storage of the machine. To store the unattended machine for an extended period of time, proceed as follows:

1.Complete all short term storage procedures.

2.Remove the motors from the drill and store in a heated building.

3.Completely fill the rotary and pulldown 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.

4.Loosen the guide rollers on the rotary/pulldown unit frame to provide one-half inch clearance between the rollers and the mast.

5.Remove the auxiliary winch line.

6.Cover the rotary gearcase and hoist/pulldown gearcase with a waterproof tarp.

7.Remove the 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.

10.Close and completely seal the machinery house. Completely seal the filter fan unit.

11.Completely drain the compressor coolant system.

12.Propel the machine onto blocks to prevent the crawler belts from rusting. Coat the entire crawler belts with a rust preventative oil.

13.Block the leveling jacks in the full retracted position.

14.Manually grease every lube point (including auto lube points).

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 tool 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, re-couple 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 repositioned 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 Bucyrus) 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 of the 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 or lost tools, and the use of these tools should be described by the manufacturer.

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.

Drill Stability Chart~141287 - Part 1

Drill Stability Chart~141287 - Part 2

Drill Stability Chart~141288 - Part 3

Drill Stability Chart~141288 - Part 4

ADDITIONAL LUBRICATION BENCHMARKS:

EGL - ENCLOSED GEARCASE LUBRICANT.................................................................. (insert)

MPG - MULTIPURPOSE GREASE................................................................................... (insert)

OGL - OPEN GEAR LUBRICANT..................................................................................... (insert)

CERTIFIED LISTING FOR OGL, MPG, AND EGL LUBRICANTS...................................... (insert)

LUBRICATION PRINCIPLES

Lubrication may be the most important portion of a preventative maintenance program. Do not interfere with the lubrication of the machine. The amount of lubricant to use at each servicing depends on how hard the machine is being worked, how much the bearing has previously worn, and the grade of lubricant being used. Watch all the bearings closely until enough lubricant remains from one servicing to the next.

Most wearing parts require that lubricant be applied regularly in small quantities, instead of large amounts applied occasionally. Make regular inspections of the machine and watch for signs of improper lubrication such as accumulation of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line or lubricant pipe. Normally, do not pump more lubricant into a plain bearing after the lubricant starts to come out. However, certain bearings, in locations which may collect dirt (such as the lower works) should have extra lubricant added to purge all of the old lubricant which may have collected abrasive dirt.

New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant. It may be necessary to give it more frequent lubrication until it is worked in. Old bushings may overheat because they are so worn that lubricant will not stay in until the next time of servicing. In the case of a worn bushing, it may be necessary to give it more lubricant until it can be replaced.

The most common cause of overheating of an anti-friction bearing is churning of the lubricant. This happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing, it is almost a sure sign that too much lubricant may have been added to the bearing. Continue to lubricate it as often as before but use less lubricant.

AUTOMATIC LUBRICATION SYSTEM

THE AUTOMATIC LUBRICATION SYSTEM IS NOT DESIGNED TO PROVIDE INITIAL COVERAGE. New parts installed or those cleaned during maintenance procedures must be fully lubricated before commencing machine operation. Anti-friction bearings and bushings must be hand packed or thoroughly coated with the correct lubricant. Open gearing and moving contact surfaces must be completely covered with their lubricant. Do not permit the lack of lubricant at start-up to cause you to redo a repair job!

NOTE: The greatest amount of wear to be experienced by any moving part will take place during the first few cycles, or operating hours. A lack of proper lubrication can destroy a new part at a dramatically increased rate over the normal wear patterns experienced.

Enclosed gearcases must have their recommended lubricant level maintained at the prescribed level. Check the lubricant level at the oil level plug or with the dipstick at least once weekly (every 150 hours). Inspect them daily (every 24 hours) for leaks. Change the oil in the gearcase at their recommended intervals while flushing each case with a light lube oil before adding the new gear oil. ALWAYS STORE THE USED OIL IN A SAFE CONTAINER UNTIL PROPERLY DISPOSED. DO NOT POLLUTE THE ENVIRONMENT!

Bucyrus International recommends that scheduled oil samplings from the enclosed gearcases and air compressor crankcase on this machine be taken and tested by an authorized, reputable lab to determine the contamination level of the sump oil. These samples should be obtained and tested every 30 operating days (600 hours). They should be taken when the oil is at its normal operating temperature, and is well mixed in the case, so the samples are representative of actual conditions. This diagnostic maintenance procedure will permit you to determine the condition of internal components within the operating gearcases. Increases in the presence of certain metallic types can be analyzed with the Bucyrus International Service personnel to determine the best time to change the oil, thus obtaining its best service life. This will simultaneously allow you to monitor the condition of the components and address situations in their infancy instead of after a catastrophic breakdown. This program will pay you dividends in the long run.

If a sample diagnostic system is undertaken, it is imperative that adequate records be maintained of the maintenance and component history of the items in question. Without these records there will be no adequate date by which to compare any changes or occurrences and make realistic determinations.

Lubricant Service Life is adversely affected by unusually dusty or dirty environments and atmospheres where extreme high humidity or temperatures exist. It shall, therefore, be the responsibility of the owner/operator of this machine to determine the most effective lubricant and lubrication interval for all the components according to the environmental conditions that prevail.

CAUTION: Contact with or ingestion of petroleum products can be harmful. Automatic lubrication systems operate under pressure. Before opening any lube supply line, relieve the system and that line in particular, of any residual pressure.

Auto Lube Reservoir

Auto Lube Piping ~Mainframe (View #1)

Auto Lube Piping ~Mainframe (View #2)

Auto Lube Piping ~Crawlers

Auto Lube Piping ~Mast (View #1)

Auto Lube Piping ~Mast (View #2)

LINCOLN TYPE SL-1 LUBRICANT INJECTORS

These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted on manifolds or individually. Each injector expels a maximum of .08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lube to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted; however Bucyrus recommends that injectors initially be set and used at their maximum setting.

NOTE :MAXIMUM Operating Pressure: 3,500 PSI

RECOMMENDED Operating Pressure: 2,500 PSI

MINIMUM Operating Pressure: 1,850 PSI

MAXIMUM Recharge Pressure: 600 PSI

To set an injector for maximum output:

1.Loosen locknut.

2.Turn adjusting nut until there is a small gap at the top of the stem.

3.Orient the adjusting nut so that the opening is toward the front of the injector.

4.Tighten the locknut.

To reduce an injector’s output:

1.Loosen locknut.

2.Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This forces the stem into the body, retarding the stem’s movement.

3.Set the locknut.

CAUTION:Do not turn adjusting nut down (clockwise) more than 5 full turns from the maximum discharge setting. Check output flow from injector at this time to ensure it is still operating. If not, back off adjusting nut until injector does consistently operate. Inspect the adjusted injector for operation over 3 or 4 cycles after returning machine to work to make sure it is functioning.

LUBRICANT INJECTOR OPERATION

STAGE 1: The injector piston is in its normal or reset position. The discharge chamber is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to open the passage leading to the piston.

STAGE 2: When the slide valve uncovers the passage, lubricant is admitted to the top of the piston, forcing the piston down. The piston forces lubricant from the discharge chamber through the outlet port to the bearing.

STAGE 3: As the piston completes its stroke, it pushes the slide valve past the passage, cutting off further admission of lubricant to the passage. The piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump.

STAGE 4: After the pressure is relieved, the compressed spring moves the slide valve to the closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber.

NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.

TROUBLESHOOTING

AIR LOCKS:

When the system is not primed properly, air is often trapped in the pump, supply line, injectors, or feed lines. Since the air pockets, with their great compressibility, provide a cushion against the normal rapid rise in supply line pressure, they serve to make the cycling of the system sluggish and erratic. In some extreme cases, particularly when the pump is air locked, they may make the system inoperable.

NOTE: If cycling time of a new installation greatly exceeds the cycling time determined from the system planning, it is an indication of an air lock in the system.

When the pump fails to prime and pump due to air locks, the vent plug located on or near the pump outlet on all Lincoln models should be opened while the pump is in operation and all of the air allowed to escape. The use of oil as an aid to priming is recommended. Air in the supply lines is expelled by loosening pipe plugs at the end of each line (main supply lines, etc.) and allowing generous quantities of lubricant to escape carrying with it the entrapped air. Air locks in the injectors are corrected, in the case of the SL-1 injectors, by opening the lube fitting and allowing the lubricant and air to escape. Air locks in the feed line can be corrected by loosening the feed line connection at the bearing inlet and allowing lubricant and air to escape as the system is cycled repeatedly. Do not loosen any connections which are under pressure.

DIRTY SUPPLY LINES:

This is a preventive maintenance problem and should be thoroughly checked before the system is installed. However, a malfunction of the injectors or the vent valve can usually be traced, by the disassembly of the unit and examination, to foreign material from the supply line inner surfaces preventing proper operation.

After the trouble has been encountered, only the disassembly and complete cleaning of the affected units will restore the system to its original state. Preventively, the supply lines should be thoroughly cleaned and blown out before installation.

ALL INJECTORS DO NOT WORK PROPERLY:

On a newly installed system, the indicator stems on one or more injectors fails to move to the discharge position. As a result, some of the bearings do not receive the measured amount of lubricant.

Those units equipped with a pressure switch must be adjusted to allow a higher developed pressure, at which level all of the injectors will discharge.

3500 PSI maximum for high pressure systems.

1000 PSI maximum for low pressure systems.

(For long life, keep pressure to a minimum permissible for proper injector operation.)

INDICATOR STEMS DO NOT RETURN TO NORMAL:

This condition could be due to the sluggish operation of all new assemblies and after a few operations this stiffness may disappear.

However, it could be an indication that, after venting, the residual supply line pressure is too high to allow the injectors to operate normally. This is due to a restriction in the supply line which hampers the rapid venting pressure. This condition may be the result of many things: notably, lubricants, low temperatures at which lubricants stiffen, or coupled with the above, an extremely short lubrication cycle. This condition is usually encountered when the lubrication cycle is relatively short. In the automatic system, where the cycle can be as low as 3-3/4 minutes, it can be a big problem.

CORRECTIONS:

1.The lubricant should be checked. The use of the centralized system eliminates the need (in most cases) for the heavy soap additive which only lengthens the effective line of the individual lubricant application.

2.The lubricant can be made more resistant to physical change by the use of low temperature additives.

3.The output of lubricant per cycle can be increased and the lubrication interval lengthened.

4.Be sure lubricant used meets requirements of system.

When hand operated systems are being tested after installation, repeated operations can use short intervals between cycles. Under normal conditions, the cycling of a hand operated system will usually be infrequent (once an hour at the most), allowing plenty of time for proper venting.

BIT LUBRICATOR

The Bit Lubricator is located at the right, front of the machine, beneath the house air filter.

GRACO PUMP SERVICING

CAUTION:To reduce the risk of serious bodily injury, including fluid injection, injury from moving parts, and splashing in the eyes or on the skin: always follow the following Pressure Relief Procedure whenever you shutoff the pump; when checking or servicing any part of the spray system; when installing, cleaning or changing dispense valve nozzles; or whenever you stop dispensing.

PRESSURE RELIEF PROCEDURE

1.Close the supply line shutoff valve, and then the return line shutoff valve. Shut off the hydraulic power supply.

2.Open the dispensing valve to relieve pressure.

3.Open the pump outlet drain valve, having a container ready to catch the drainage.

4.Leave the drain valve open until you are ready to spray again.

CAUTION:If you suspect that the nozzle or hose is completely clogged, or that the pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the hose end coupling to relieve pressure. Now clear the obstruction.

NOTE: When refering to the following fugures, numbers in parenthesis (x) refer to items in the figures.

REPLACING THE THROAT SEALS

(Refer to Fig. 1)

NOTE: Replace these seals if fluid leaks excessively through the drain tube. This procedure can be done without disassembling the entire reciprocator.

1.Follow the above Pressure Relief Procedure and the corresponding Caution statements.

2.Disconnect the reciprocator from the pump. See the following procedure and Fig. 2

3.Remove the four capscrews (46, Fig. 3) from the bottom of the adapter (43). Tap the adapter to loosen it and pull off the bottom cap (32).

4.Remove the seals (16 & 44) and guide (19) from the top of the adapter (43).

NOTE: Items 16 & 44 are included in the Reciprocator Repair Kit.

5.Lubricate the guide (19) and install the seals and guide in the adapter (43), one at a time in the order shown in Fig. 3

6.Reassemble. Tighten the capscrews (46) to 28 to 32 ft.lbs. (36 to 43 NM). Install the displacement pump.

DISCONNECTING THE RECIPROCATOR AND DISPLACEMENT PUMP

(Refer to Fig. 2)

NOTE: When displacement pump is purchased separately, it comes with the priming piston and priming cylinder unassembled. Connect the displacement pump to the hydraulic reciprocator before assembling the priming piston and cylinder. Tighten the priming piston to 35 ft.lbs. (47 NM).

WARNING: Keep the hydraulic system clean. It is essential to keep the hydraulic oil system free of contaminants to reduce the risk of damaging the hydraulic reciprocator. Always install a plug in each tube fitting and on each hose end whenever fluid lines are disconnected to prevent contamination.

1.Flush the pump if possible and stop it with the displacement rod in the lowest position.

2.Follow the Pressure Relief Procedure and the corresponding Caution statements.

3.Disconnect the outlet hose from the displacement pump.

4.Slowly loosen the hydraulic supply and return fittings to relieve any pressure, and then remove the hoses. Install plugs on the tube fittings and in the hose ends. Check the O-rings on the fittings and replace them if they are worn or damaged.

5.Using a strap wrench on the displacement cylinder, screw it out of the pump adapter (43) and slide it down as far as it will go.

6.Pull the connecting rod (35) down as far as it will go. Remove the cotter pin (204).

NOTE: For the 35 in. length pump, the priming cylinder and the priming piston must be completely removed before you can pull down the displacement cylinder far enough to remove the cotter pin (204).

7.Unscrew the piston coupling (103) to remove the pump.

RECIPROCATOR REPAIR

NOTE: Clean and inspect all parts for wear or damage. Replace parts as needed. For the best results, always replace all the O-rings and seals when you disassemble the pump. A repair kit is available.

NOTE: Assembly tool 181–619 is required for reassembling the reciprocator.

NOTE: For the following step 12, Loctite® 242 thread sealant and Loctite Primer T or PermaLoc® 115 thread sealant and Perma-Bond® Surface Conditioner I are required. Be sure their shelf-life is within the manufacturer’s recommendations.

1.Loosen both nuts on the fluid tube. Use a wrench to rotate the tube fittings to the side, and then remove the tube. Check the O-rings on the fittings and replace them if they are worn or damaged. Install plugs in the fittings to prevent contamination.

2.Remove the capscrews (3), nuts (36) and lockwashers (37) on the top of the reciprocator. See Fig. 3

3.Remove the four capscrews (46) and the base (33). Tap the adapter (43) with a plastic mallet to loosen it and pull it off the bottom cap (32). See Fig. 3. If needed, replace the seals.

NOTE: See Fig. 5 for steps 4 to 14 except where noted.

4.Tap the bottom of the displacement rod (34) with a plastic mallet to loosen the cylinder (25).

5.Grasp the valve spool (31) and pull it off the cylinder and tie rods (38). Pull the cylinder and piston off the bottom cap (32). It is not necessary to remove the tie rods from the cap.

6.Lay the assembly on its side. Place a clean rag over the valve mechanism to prevent losing the detent balls. Slide the guide clamp (28) down off the valve sleeve (29) while holding the balls (7) and spring (6) in place.

7.Slide the cylinder (25) off the displacement rod (34). Hold the hex end of the displacement rod in a vise and use a spanner wrench in the pin holes of the piston (22) to screw it off the rod.

WARNING:Be careful not to scratch the outside of the displacement rod.

8.Visually inspect the spring (21). If there is wear or damage, proceed with this step. Remove the nut (18), spring (21) and retainers (20) from the stop rod (12). Reassemble with a retainer (20) on each end of the new spring (21). Adjust the nut to obtain the dimension shown in Fig. 4

9.Inspect the guide clamp (28) for wear or damage. If replacement is necessary, remove the screw (11) from the rod (12). Replace damaged parts and the trip rod guides (27). Thoroughly clean any adhesive residue from the screw (11) and the internal threads of the rod (12).

NOTE: Use a surface cleaner such as chlorinated solvent on the threads and blow with compressed air. A #10–24 UNC–2B tap can be used to remove adhesive from the internal threads of the rod.

NOTE: Thread sealant and primer are required for steps 10 and 11. Also see the Note at the beginning of this procedure.

10.Apply three drops of fresh thread sealant to the first two or three internal threads of the rod (12). Apply primer to the external thread of the screw (11). Let dry for three or four minutes. Assemble then tighten the screw to 30 - 34 in.lbs. (3.4 - 3.8 NM). Remove excess sealant. Allow 24 hours to cure before operating the reciprocator.

11.Normally the valve sleeve (29) and valve stop (26) do not have to be replaced. However, if either part must be replaced, first soak the parts in hot water to loosen the sealant. Clean all sealant from the threads of any part you are reusing and apply three drops of thread sealant to the first two or three internal threads of the valve stop (26). Apply primer to the external thread of the valve sleeve (29). Let dry for three or four minutes. Assemble. Remove excess sealant. Allow 24 hours to cure before operating the reciprocator.

12.Remove the O-ring (13) from the bottom of the spool valve (31) and replace it with a new O-ring.

13.Use a spanner wrench to screw the piston (22) onto the displacement rod (34). Tighten to 30 - 40 ft.lbs. (41 - 54 NM).

14.Install O-ring (49) in the deep lower groove of the piston (22) and install the seal (23) over the O-ring. Install the piston bearing (24) around the upper groove of the piston. Holding the piston bearing in place to avoid damage, slide the cylinder over the piston and press it down.

WARNING: When inserting the piston into the cylinder, carefully guide the piston seal (23) and bearing (24) to prevent damaging these parts.

15.Lay Assembly A and Assembly B on the workbench.

16.Slide Assembly B into the center of the tool. Align the upper detent holes of the guide clamp (28) with the center line of the tool. See Fig. 6

17.Insert the spring (6) and one ball (7) into the valve stop (26) of Assembly A. Tilt the valve stop and start guiding it into the tool, making sure the ball is sliding into the rounded slot in the tool. Place the other ball at the other end of the spring and push it in with your thumb while rotating the valve stop (26) until the spring is horizontal and the balls are in place. Continue holding this assembly together. See Fig. 6

18.Place your thumbs on the valve stop (26), grasp the bottom of the tool with your other fingers and press the assemblies together. Make sure the balls (7) snap into the upper set of holes in the guide clamp (28), and the curved ends of the guide clamp have engaged the valve sleeve (29) groove. See Fig. 6. Slide the tool back over the rod (12) to remove it.

NOTE: Refer to Fig. 7 for steps 19-26.

19.Install the pump adapter (43) and seals.

20. If the tie rods (38) were removed, reinstall them with the short threaded end up. The other end should be screwed about 9/16" into the bottom cylinder cap (32).

NOTE: When reinstalling the cylinder (25) in step 20, be sure the “P” port in the valve spool (31) and the port in the bottom cylinder cap (32) are in line with each other. Be sure the O-rings (13) are in place in the valve spool and cylinder cap.

21.Slide the cylinder (25) with the piston/displacement rod already installed in it, into the groove in the bottom cylinder cap (32). Position the spool valve (31) over the cylinder and press down firmly.

22.Install the capscrew (3), O-ring (39) and washer (2). Install the lockwashers (37) and nuts (36). Tighten the nuts to 28 - 32 ft.lbs. (36 - 43 NM).

WARNING: Never install the fluid tube before tightening the tie rods. Doing so could cause misalignment and damage the reciprocator when it is operated.

23.Reinstall the fluid tube and fittings. Tighten to 25 - 35 ft.lbs. (34 - 48 NM).

24.Pull the displacement rod (34) in and out to be sure it moves easily with only a little resistance from the rod seal.

25.To reconnect the reciprocator and pump, install the O-ring (17). Screw the connecting rod (35) into the displacement rod (34.) Install the cotter pin (204). Install a new copper gasket (202). Make sure the seal (203) in the bottom of the adapter (43) is in good condition. Push the cylinder up into the adapter and engage the threads. Screw in the pump using a strap wrench for the final tightening. See Fig. 8

26.Connect the hydraulic supply and return hoses to the fittings.

CAUTION:To reduce the risk of static sparking, be sure to reconnect the ground wire before operating the pump.

PUMP REPAIR

1.If possible, flush the pump. Follow the Pressure Relief Procedure.

2.Follow the Disconnecting the Reciprocator and Displacement Pump procedure.

3.Place the pump in a vise. Unscrew the priming cylinder (111). See Fig. 9

4.Unscrew the priming piston (112) and the piston rod (119).

5.Loosen the packing housing (110). Unscrew the cylinder (118).

6.Unscrew the packing housing (110) and remove all parts.

7.Unscrew the priming tube (108) and remove all parts.

8.Unscrew the piston stud (107) and remove all parts.

9.Clean all parts thoroughly with a compatible solvent. Inspect the parts for wear, and replace as needed. Scoring or irregular surfaces on the priming tube (108), or inside the cylinder (118) causes premature packing wear and leaking.

NOTE: The balls (116) cannot be reseated on the hardened seats (102). However, the seats can be reversed and used a second time.

NOTE: Lubricate all parts with a light, waterproof grease.

10.Assemble the piston (107), spacer (106), seal (105), packing (104), gasket (115), seat (102), and ball (116). Install the pin (101) in the coupling (103). Screw the coupling onto the piston (107) and tighten to 60 ft.lbs. (80 NM).

11.Install the pin (117) in the piston. Assemble the ball (116), seat (102), gasket (115), piston (107) and priming tube (108). Tighten the piston and priming tube to 60 ft.lbs. (80 NM).

12.Slide the assembly into the cylinder from the top.

13.Assemble the seal (113), packing (114) and bearing (109) on the packing housing (110). Firmly screw the packing housing into the cylinder (118).

14.Models 223 thru 513 and 223 thru 514 only: Screw the piston rod (119) onto the priming tube (108). Tighten to 35 ft.lbs. (47 NM).

15.Place the gasket (202) in the base of the reciprocator. Place the O-ring (203) into the groove of the pump adapter (43). Screw the cylinder into the pump adapter.

16.Firmly screw the priming piston (112) onto the piston rod (119). Tighten to 35 ft.lbs. (47 NM).

17.Firmly screw the priming cylinder (111) onto the cylinder (118).

18.Reconnect the ground wire to the reciprocator if it is disconnected.

For a typical schematic, refer to Fig. 10 on the following page.

LUBRICATION POINTS

The lubrication charts in this section show the principal points on the machine to be lubricated. Automatic lube systems should be checked daily to see that they are operating properly and that each lube point is receiving the correct amount of lubricant. The types of lubricants are described in LUBRICANT BENCHMARKS in this section of the manual.

GEARCASE AND RESERVOIR CAPACITIES

The frequency of lubrication given in each chart is intended as a guide. Under unusual operating conditions, some points may require more frequent lubrication or other special attention. Use good judgement in lubricating the machine. If a bearing is showing signs of trouble, such as overheating or unusual noise, it shoud be given immediate attention. Make sure the lubricant is not dirty or of the wrong grade. Then the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is so that no lubrication point will be missed, and none will be over-lubricated. It is usually best to do this at the beginning of each shift.

LOWER WORKS LUBRICATION

* Pack cavities at crawler frame and bearing block; Check annually.

NOTES: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station. On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

NOTES: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station.

On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

MAST LUBRICATION ~PART 1

NOTES: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station. On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

MAST LUBRICATION ~PART 2

NOTES: •Lube Point 10 must be accessed by removing the plug (or cover) on the side of the gearcase cover then carefully aligning the lube fitting in the pulldown gear accordingly.

•The above frequencies are for manual lubrication. For automatic lube systems the frequencies are set at the lube control station.

•On automatic lube systems, the injectors should be set at full opening at initial start-up, then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

MAST LUBRICATION ~PART 3

NOTES: The above frequencies are for manual lubrication. When equipped with an automatic lube system the frequencies are set at the lube control station. On automatic lube systems the injectors should be set at full opening at start-up of a new machine and then readjusted as required. Refer to LUBRICANT INJECTORS in this section of the manual.

LUBRICANT CLEANLINESS

Even the best lubricant is of little or no value if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean.

Follow these points of good lubrication practice:

•Keep all oil and other lubricants in tightly covered containers.

•Wipe off covers before opening containers.

•Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off before using them.

•Wipe off each fitting before attaching the lubricant gun.

•Wipe off oil filler caps or covers and the surrounding area before removing them.

LUBRICANT SELECTION

The selection of the proper lubricants for use on this machine is critical to its reliability. Improperly lubricated bearings, gears, couplings, and other precision parts quickly fail. For this reason, lubricants selected in accordance with the “American Standards Testing Material” (ASTM) standards are recommended. These standards were compiled in cooperation with major petroleum suppliers to ensure the consumer of an exact supply to specific requirements, regardless of source.

We recommend you advise your petroleum supplier of the following information to assist him in selecting the proper product for each application of this machine.

Final acceptance of all lubricants supplied to this standard will be based upon their satisfactory performance in the intended application, and does not relieve the supplier of performance responsibility for brand name products.

Operation of this machine in extreme temperatures (below -20°F/-29°C or above 110°F/44°C) requires special lubrication. Note the temperature ranges on the following lubricant specification sheets. Contact your local supplier, your Bucyrus representative, or the Service Department of you local Bucyrus International office for recommendations if you require additional information or advice.

•STORE LUBRICATION DRUMS ON THEIR SIDE, WITH THE OPENING TOWARD THE TOP.

•STORE ALL LUBRICANTS IN TIGHTLY COVERED CONTAINERS!

•WIPE OFF COVERS AND SURROUNDING AREA BEFORE OPENING!

•FILTER ALL OIL BEFORE ADDING IT TO THE SYSTEM!

•USE ONLY CLEAN and PROPER LUBRICANTS!

•DO NOT MIX TYPES or BRANDS of LUBRICANTS!

Even the best lubricants are less useful in preventing wear if they become contaminated by dirt or water due to careless handling or storage.

ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT

SCOPE: Lubrication performance requirements and recommendations for Air Compressor (Screw-type) Lubricants.

IMPORTANT NOTE

These lubricant performance requirements for screw-type air compressors are only good for A-C Compressor Corporation screw compressors. If the machine is equipped with air compressors manufactured by other than A-C you must refer to the vendor’s maintenance information provided with the machine and Section 7 of this manual.

LUBRICANT RECOMMENDATIONS:

The following lubricants are recommended:

1.If the ambient temperature is expected to always be above -26°C (-15°F), use either:

Automatic Transmission Fluid (ATF) - General Motors Dexron III or Ford Type F. or

Synthesized Hydrocarbon Fluid - Mobil Rarus SHC 924.

2.If the ambient temperature is expected to drop to -40°C (-40°F), use Mobil Rarus SHC 1024 or Phillips Philesco ISO32 or equivalent.

NOTE: If the ambient temperature drops below -26°C (-15°F), it may cause the lubricant to thicken in the oil cooler and could result in unit shutdown after a short run. If this happens often and the compressor is being lubricated with ATF, it is recommended that a synthesized hydrocarbon lubricant be used, instead.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

MPO - MULTIPURPOSE OIL

SCOPE: Lubricant performance requirements for Multi-Purpose Oil.

APPLICATION: The addition of a lubricant to the compressed air system (not for screw-type air compressor systems - see ACSL), hand oil cans, etc.

GENERAL REQUIREMENTS:

1.Must be fluid at temperature applied.

2.Should contain rust inhibitor.

3.Motor oil - API service classification “MS”.

VISCOSITY RECOMMENDATIONS:

1. Air Line Lubricant

AMBIENT TEMPERATURESAE NUMBER

Below 10°F5W

Above 10°F10W

2. Hand Oil Can - Viscosity suitable for application and temperature.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

Bucyrus recommends hydraulic oil suitable for year-round use, rather than summer or winter only, which can create a mixing of viscosities if a complete draining of oil is not accomplished. This can compromise the intended oil viscosity.

The oil viscosity benchmark for this machine is 3,000 centistokes (CST) maximum on the coldest day for start-up, and 10 centistokes absolute minimum on the hottest day during machine operation. Optimum oil viscosity at normal operating temperatures is 30 to 60 centistokes.

For climates that rarely see ambient temperatures drop much below freezing (25°F to 32°F), a paraffinic-based petroleum hydraulic oil with little or no viscosity improver (VI) can be acceptable.

For climates where ambient temperatures drop as low as -40°F on their coldest day and are as high as 104°F on their hottest day, a higher VI fluid is required. Paraffinic-based fluids should NOT be used where ambient temperatures reach freezing or slightly below freezing. At freezing or slightly below freezing temperatures, the paraffin wax starts to solidify causing the fluid to have a thicker viscosity than the temperature-viscosity curve actually implies. In addition, the VI additive in petroleumbased oils has the ability to be mechanically sheared, causing the viscosity to drop. This can result in a fluid that can be totally incorrect for use after it has been in service for some time.

For all the above reasons, plus concerns of the oxidation-rate and water-ingestion that leads to sludging, Bucyrus recommends draining intervals of 2,000 hours when using petroleum-based paraffinic or naphthenic-type hydraulic oils.

The preferred hydraulic oil for this machine is a PAO (poly-alpha-olefin) synthetic fluid with a naturally high VI. Examples being: 198 for Shell® Oil Tellus T 722, a range of 135 to 145 for Mobil® Oil SHC 500 series, 134 for Esso/Exxon® Terrestic SHP 22 Hydraulic Fluid, or 135 for Conoco® SYNCON AW Oil.

The 3 to 4 times multiplier in the cost of synthetic fluids, as compared with paraffinic-based petroleum oils, is offset by the fact that the synthetic oil can be left in the system 4 times longer (i.e. 8,000 hours) before a drain interval requirement. The savings with synthetic fluid use results because the frequency of draining intervals is decreased by a factor of 4. This reduces the maintenance time dedicated to changing the system oil and the cost of system oil disposal to 1/4 of what they would otherwise be.

With all of the above in mind, using a SHC-type oil from Shell®, Mobil®, Esso/Exxon® or Conoco® can result in considerable cost savings, whether the mine is located in a cold or warm climate.

PAO SYNTHETIC HYDRAULIC FLUID

The following bar graph shows recommended viscosity grades for SHC hydraulic oil for various ambient temperatures. For temperatures outside of these ranges, contact the Bucyrus Service Department for recommended oil.

Recommended Viscosity vs. OAT Chart

PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID

Approved oils will typically have Denison HF-O specification certification. In general, the oils will meet the following minimum requirements:

1.Maximum Viscosity = 14,000 SUS (3,000 CST) at the minimum expected ambient temperature (for start-up).

CAUTION:Starting with viscosities greater than 3,000 CST could void warranty.

2.Minimum Viscosity = 65 SUS at the maximum operating temperature of the hydraulic system.

3.Ideal Viscosity = 100 SUS at normal operating temperature of the hydraulic system.

4.Minimum Viscosity Index = 90

5.Neutralization Number = 10 or less for new oil.

6.Oxidation Hours to 2.0 Neutralization Number per D-943 = 1,500 hours minimum.

7.Demulsibility (easy separation from water) per D-1401 = 30 ±15 minutes to 3 ml. max. of emulsion.

Recommended Viscosity vs. OAT Chart

CAUTION:In general, water will not separate from motor oils or automatic transmission fluids, therefore these fluids are NEVER recommended as hydraulic system fluids.

8.Hydrolytic Stability per D-2619 = Copper wt. loss not to be more than .50 mg/cm 2

The oil should contain rust and oxidation (R+O) inhibitors and foam depressants.

CAUTION:The use of water or glycol base or any other fire resistant fluid is prohibited since serious damage to the hydraulic system will occur which will void the warranty on the machine hydraulic system.

Obtain oil from a reputable supplier. Contact the Bucyrus Service Department for specific oil recommendations or approval.

The lower figure on the previous page illustrates the acceptable temperature range for various viscosity grades (VG) of oil assuming a viscosity index of 125.

1.The left side of the bars show the absolute minimum ambient temperature for cold startup.

2.The right side of bars show the absolute maximum oil temperature.

3.Ideal maximum operating oil temperature is a viscosity of 100 SUS.

NOTE: When determining an oil for the hydraulic system, Bucyrus designed the system for an all-year oil and for use without heaters. The hydraulic system is tailored to the ambient temperature at the customer’s mine and the correct type of hydraulic fluid is selected. For extremely cold temperatures, a very light fluid is used with oversize oil coolers to accommodate higher summer temperatures. With this procedure, viscosity limits as little as 30° above ambient can be met.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANT

SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

SCOPE:

This specification covers the requirements for “Enclosed Gearcase Lubricant” used on models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

The materials furnished under this specification are intended to lubricate spur and helical gears as well as anti-friction bearings at the interior of enclosed planetary and non-planetary type gearcases (Propel, Rotary, Pull Down and Pump Drive).

This specification covers “Enclosed Gearcase Lubricants” that may be applied in service at temperatures ranging from –50ºC (-58ºF) to the highest ambient temperature conditions.

GUIDELINES FOR SELECTING AN APPROVED LUBRICANT:

Step #1

Using Table 1, determine the recommended oil type (Mineral or Synthetic) based upon the anticipated ambient temperature range.

AMBIENT TEMPERATURE RANGE:

Ambient Temperature: The ambient temperature is defined as the air temperature in the immediate vicinity of the gearcase.

a Use atmospheric temperature for gearcases located outside of the machinery house (Rotary, Pull Down and Propel Gearcases).

b Use machinery house temperature for gearcases located inside of the machinery house (Pump Drive Gearcase) for some machines are equipped with machinery house heaters.

c For cold weather applications, the pour point of the lubricant must be at least 5°C (9°F) below the minimum ambient starting temperature. If the ambient starting temperature approaches the lubricant pour point, oil sump heaters may be required to facilitate starting and ensure proper lubrication. Use oil temperature for gearcases having oil sump heaters.

Bucyrus International, Inc.

SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANT

SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 1

Ambient Temperature Range

14 F to 100 F (-10 C to 37 C)

Less than 14 F to 120 F

(Less than -10 C to 50 C)

Step #2

ISO Viscosity Grade / Oil Type

ISO VG 220 / Mineral or Synthetic (poly- -olefin) Oil

ISO VG 220 / Synthetic (poly- -olefin) Oil

Select an approved lubricant for the Propel, Rotary, Pull Down and Pump Drive Gearcases from the Approved Lubricant Tables 2 & 3.

The pour point and flash point of individual brand name gear oils must be observed. Refer to the oil manufacturers technical data sheets for these properties.

APPROVED LUBRICANTS:

Lubricants that have been approved for use by the Gearcase manufacturers are listed in the Approved Lubricant Tables 2 & 3. The use of non-approved lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/regulatory requirements.

Bucyrus International, Inc.

SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANT

SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 2

Approved Mineral Oil Lubricants (ISO VG 220)

Manufacturer

BEL-RAY

BP CASTROL

CHEVRON

Product Description

Bel-Ray 100 Gear Oil 90

Energol PM 220

Energol GR-XP 220

Energol GR-XF 220

Alpha SP 220

Alpha MAX 220

Optigear BM 220

Tribol 1100/220

Chevron Ultra Gear Lube 220

Gear Compound EP 220

ESSO Spartan EP 220 (Only Product Originating from Europe)

FUCHS Renolin CLP 220 Plus

LE (Lubrication Engineers)

MOBIL

Almasol 607

Mobilgear XMP 220

PETRO CANADAUltima EP 220

SHELL

TEXACO

Omala F 220

Auriga EP 220

Meropa 220

Meropa WM 220

WHITMORE Paragon 220

Bucyrus International, Inc.

SPECIFICATION FOR ENCLOSED GEARCASE LUBRICANT

SD4722 (June 26, 2006)

Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 3

Approved Synthetic (Poly- -olefin) Oil Lubricants (ISO VG 220)

Manufacturer Product Description

BEL-RAY

BP

Synth Gear Oil 6690

Enersyn EP-XF 220

Enersyn HTX 220

Optigear Synth. A 220

Optigear Synth X 220

Alphasyn EP 220

CASTROL

Alphasyn T 220

Tribol 1510/220

Tribol 1710/220

CHEVRON Tegra Synth Gear Lube 220

FUCHS

MOBIL

PETRO CANADA

SHELL

TEXACO

WHITMORE

SPECIFICATION REVISIONS:

Renolin Unisyn CLP 220

Mobil SHC 630

Mobilgear SHC 220

Mobilgear SHC XMP 220

Ultima Synth EP 220

Omala HD 220

Pinnacle EP 220

Decathlon F 220

This specification is subject to change without notice. Please refer to the Bucyrus International, Inc web site www bucyrus com for the latest specification.

SPECIFICATION FOR MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005)

SCOPE:

1 This specification covers “Multi-Purpose Grease”.

2 Materials furnished under this specification are primarily intended to lubricate heavy duty ball, roller, and plain bearings.

3 The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors or metering blocks.

4. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS:

1 Heat Resistance - Shall be thermally stable, should not flow or harden in service.

2 Retention - Shall not exhibit high leakage.

3 Stability - Shall work continuously with a minimum change in consistency.

4. Water Resistance - Shall withstand water washout or leaching.

5. Reversibility - Shall be stable with repeated heating and cooling.

6. Pressure Separation - Shall resist oil-soap separation.

7 Extreme Pressure - Shall withstand heavy shock loading.

8 Compatibility –

a Low temperature greases shall be compatible with mineral oil base greases.

b. Grease must be compatible with oil seal lip materials (Nitriles, Viton), and all centralized lubrication system components (i.e. gaskets, o-rings, vent valves, etc.). Reference ASTM D 4289-03.

9 Compounding –

a Suitable for producing the extreme pressure characteristics (without inert fillers) required for heavy duty ball, roller, and plain bearing lubrication.

SPECIFICATION FOR MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005)

b Base fluid is to be mineral or synthetics which are compatible with mineral base.

c Thickener types are to be of the following varieties: Aluminum, Lithium, or Calcium.

Bucyrus International, Inc.

SPECIFICATION FOR MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005)

MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY REFERENCE REQUIREMENT

SPECIFICATION FOR MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005)

PROPERTY REFERENCE REQUIREMENT

Pressure Oil Separation

Grease Mobility

The Lubrication Engineers Manual (United States Steel).

The Lubrication Engineers Manual (United States Steel).

U S Steel test method - Cake penetration not less than 25% of grease penetration.

U S Steel method - not less than 0 10 grams flow per second at the lowest anticipated ambient temperature. (Testing temperature not less than -34°C/-30°F).

Pumpability, Lincoln Ventmeter

The Lubrication Engineers Manual (United States Steel).

To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Lubricating Solids (Molybdenum Disulfide, Less than or equal to 5% Graphite, Etc.)

% by Weight

Lubricating Solids (Molybdenum Disulfide, 10 Microns Graphite, Etc.)

Particle Size, (Microns, max.)

NOTES:

1 Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

2 Low Temperature Grease - For extended use in low temperature

(-12°C to -46°C / +10°F to -50°F) areas, this product should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. This product should meet the Mobility and Pump-ability criteria for the lowest anticipated ambient temperature. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

Bucyrus International, Inc.

SPECIFICATION FOR MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005)

CERTIFIED LUBRICANTS:

Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Multi-Purpose Grease” (see the Bucyrus International, Inc web site www bucyrus com for the latest listing) The use of non-certified lubricants may invalidate the Bucyrus International, Inc product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction:

Bucyrus International, Inc.

Engineering Services & Technical Support

1100 Milwaukee Avenue

South Milwaukee, Wisconsin 53172

Phone (414) 768-4000

SPECIFICATION REVISIONS:

This specification is subject to change without notice. Please contact the following for the latest specification:

Bucyrus International, Inc.

Engineering Services & Technical Support

1100 Milwaukee Avenue

South Milwaukee, Wisconsin 53172

Phone (414) 768-4000

SPECIFICATION FOR OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005)

SCOPE:

1. This specification covers “Open Gear Lubricant”.

2. Materials furnished under this specification are primarily intended to lubricate open gears, but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel mechanism components.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles.

4 This specification covers open gear lubricants that may be applied in service at temperatures ranging from -50°C (-58°F) to the highest ambient temperature conditions. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS:

1 Materials furnished under this specification may be asphaltic (bitumen) compounds, or blends of a thickener and mineral oils and/or synthetic fluids They may be in the form of viscous fluids, semi-fluid greases or pastes.

2. Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed film and boundary conditions.

3. Open gear lubricants supplied under this specification must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between applications under all operating conditions.

4. Various grades or consistencies of open gear lubricants may be required to provide proper lubrication and application properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or exceed the minimum performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

SPECIFICATION FOR OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005)

5 Viscosity, a fluid's resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to produce a lubricating film between two interfacing surfaces. All lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives such as resins or polymers. Some "viscosity enhancers" are shear sensitive, which could result in insufficient protection of the lubricated components under high load, elevated temperatures and/or high shear conditions The viscosity of the fluids utilized in the open gear lubricants shall be sufficient under operating conditions for the product to meet or exceed the performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

6 Open gear lubricants supplied under this specification must be specifically formulated to protect surfaces, reduce wear, and provide satisfactory service life under all anticipated operating conditions.

7 Open gear lubricants supplied under this specification must have excellent water tolerance and rust preventive qualities, as well as minimal dripping qualities for operation over wide temperature ranges.

8. Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to ensure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip materials (Nitriles, Viton) Reference ASTM D 4289-03.

9 For extended use in low temperature areas, open gear lubricants supplied under this specification should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

Bucyrus International, Inc.

SPECIFICATION FOR OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005)

MINIMUM PERFORMANCE REQUIREMENTS:

PROPERTY REFERENCEREQUIREMENT

Flash point of product as applied, minimum (base product with diluent) ASTM D92 / ISO 2592

Ambient Temperature (See Note #1)

-50°C(-58°F) to +10°C(50°F) 61°C (142°F)

Above +10°C(50°F) 80°C (176°F)

Flash point of base fluid(s), minimum

D92 / ISO 2592140°C (284°F) Rust protection

24hr. @ 100°C (212°F)

Maximum scar, mm (base product without diluent)

Adhesive properties

Pumpability, Lincoln Ventmeter

Must adhere to surfaces at the lowest anticipated ambient temperature.

To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Minimum Base Fluid Viscosity

Note #1)

NOTE:

1 Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

Bucyrus International, Inc.

SPECIFICATION FOR OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005)

CERTIFIED LUBRICANTS:

Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Open Gear Lubricant” (see the Bucyrus International, Inc web site www bucyrus com for the latest listing) The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction:

Bucyrus International, Inc.

Engineering Services & Technical Support

1100 Milwaukee Avenue

South Milwaukee, Wisconsin 53172

Phone (414) 768-4000

SPECIFICATION REVISIONS:

This specification is subject to change without notice. Please contact the following for the latest specification:

Bucyrus International, Inc.

Engineering Services & Technical Support

1100 Milwaukee Avenue

South Milwaukee, Wisconsin 53172

Phone (414) 768-4000

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

SCOPE:

Materials furnished under the specifications for “OGL–Open Gear Lubricant (SD4713)”, “MPG-Multi Purpose Grease (SD4711)” and “Dragline Enclosed Gearcase Lubricant” (SD4721 Part A) are intended for use on Bucyrus International, Inc. mining machinery (Electric Mining Shovels, Draglines and Rotary Blasthole Drills).

Lubricants certified by their manufacturers as complying with these Bucyrus International, Inc. specifications are listed in the tables below.

LUBRICANT SELECTION:

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Each lubricant listed in the tables below has a unique operating temperature range. It is the responsibility of the lubricant manufacturer to recommend the appropriate products based upon the applicable Bucyrus lubricant specification (SD4711, SD4713 and SD4721 Part A) and the anticipated ambient temperature range for each application.

CERTIFIED LUBRICANT LISTING FOR “OGL–OPEN GEAR LUBRICANT (SD4713)”

Molylube SF 100 Medium 77010

Bel Ray Molylube SF 100 Heavy 77000

Bel Ray Molylube Unee NS 70550

Bel Ray Molylube Unee 70600

Bel Ray Molylube Unee 70540

Bel Ray Molylube SD-1 70620

Bel Ray Molylube Gear TAC Light 68990

Bel Ray Molylube Gear TAC Regular 68940

Bel Ray Molylube Gear TAC Medium 68950

Castrol Molub-Alloy 936 SF Light

Castrol Molub-Alloy 936 SF Medium

Castrol Molub-Alloy 936 SF Heavy

Castrol Molub-Alloy 936 SF Heavy A

Chemtool Inc.Alpha OGL-680

Chemtool Inc.Alpha OGL-1860

Chemtool Inc.Alpha OGL-3600

Haycock Petroleum Shovel Lube OGL 1 5 Ultra

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

Imperial Oil / Esso Dynagear Heavy

Imperial Oil / Esso Dynagear Extra

Lubritene Lubrene Multi Serv OGL

Lubritene Lubrene Multi Serv OGL-H

Lubritene Lubrene OGL-e

Lubritene Lubrene Bio Serv OGL

Petro-Canada Vulcan Synthetic All Season

Petro-Canada Vulcan Synthetic 2200

Petro-Canada Vulcan Heavy

Petron Petrotac EP Premium 30-B

Petron Petrotac EP Premium 10-B

Schaeffer Mfg. Silver Streak Quickvent All Season (#196ALL)

Schaeffer Mfg. Silver Streak Quickvent Arctic (#196ARC)

Schaeffer Mfg. Silver Streak BGL 100

Schaeffer Mfg. Silver Streak BGL 200

Schaeffer Mfg. Silver Streak BGL 300

Shell Malleus Grease GL 3500

Shell Malleus OGM Heavy

Shell Malleus OGM Extra Heavy

Stewart Lubricants & Service Co (SLS) SLS BI OGL Heavy

Talcor OGP V Whitmore

CERTIFIED LUBRICANT

LISTING FOR “MPG-MULTI-PURPOSE GREASE (SD4711)”

Page 2 of 6

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

Bel Ray Molylube 126 EP 23200

Bel Ray Molylube 126 EP 23220

Bel Ray Molylube 126 EP 23242

Bel Ray Termalene EP 72400

Bel Ray Termalene EP 72420

Castrol Molub-Alloy 4086-0

Castrol Molub-Alloy 4086/460-1

Castrol Molub-Alloy 777-1 ES

Castrol Molub-Alloy 777-2 ES

Chemtool Inc. CSC 174 MGD

Chemtool Inc. CSC MP1-220

Chemtool Inc. CSC MP1

Chemtool Inc. CSC MP0

Chemtool Inc. CSC MP00

Exxon Ronex Extra Duty 2

Exxon Ronex Extra Duty Moly 2 / Mobilgrease XHP 462 Moly

Haycock Petroleum Calcuplex M5 NLGI #1

Haycock Petroleum Calcuplex M5 NLGI #2

Imperial Oil Epic EP Moly

Imperial Oil Unirex EP 1 Moly

Lubrication EngineersAlmagard Vari-Purpose 3750

Lubrication EngineersAlmagard Vari-Purpose 3751

Lubrication EngineersAlmagard Vari-Purpose 3752

Lubrication EngineersAlmaplex Ultra-Synthetic 1299

Lubritene Lubrene Li 500 EP 2

Lubritene Lubrene LiM 500 EP 2

Lubritene Lubrene AXM 1000 EP 1

Lubritene Lubrene AXM 1000 EP 2

Lubritene Lubrene AXM 500 EP 1

Lubritene Lubrene AXM 500 EP 2

Lubritene Lubrene LXCa 700 EP 2

Lubritene Lubrene Li 900 WP EP 2

Lubritene Lubrene EMV-2

Petro-Canada Supreme Arctic

Petro-Canada Supreme EP1

Petro-Canada Supreme EP2

Petro-Canada Precision XL 3 Moly EP1

Petro-Canada Precision XL 3 Moly EP2

Petro-Canada Precision XL 5 Moly EP0

Petron Petro-Plate M5/800 NLGI #1

Schaeffer Mfg. Moly Ultra 800 EP #1 (#221)

Schaeffer Mfg. Moly Ultra Red EP #1 (#229)

Schaeffer Mfg. Moly Supreme #1 (#238)

Schaeffer Mfg. Moly EP Synthetic Blend #1 (#274)

Shell Albida Grease HDX2

Shell Albida Grease MDX 1

Shell Albida Grease MDX 2

Shell Alvania Grease SDX2

(January 22, 2007) Page

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

CERTIFIED LUBRICANT LISTING FOR “DRAGLINE ENCLOSED GEARCASE

LUBRICANT (SD4721 Part A)”

Mineral Oils

SBF (ISO VG

Exxon / Esso Spartan EP 460 (ISO VG 460)

Exxon / Esso Spartan EP 1000 (ISO VG 1000)

Lubritene Lubrene Syn 1500 (ISO VG 1500)

Lubritene Lubrene Super Series Gear Oil 1500 (ISO VG 1500)

Lubritene Lubrene Super Series Gear Oil 1000 (ISO VG 1000)

Mobil Mobilgear 600XP 460 (ISO VG 460)

Mobil Mobilgear 634 (ISO VG 460)

Mobil Mobilgear XMP 460 (ISO VG 460)

Mobil Mobilgear 639 (ISO VG 1000)

Petro-Canada Ultima 460 (ISO VG 460)

Petro-Canada Ultima 1000 (ISO VG 1000)

Schaeffer Mfg.#209A Universal Gear Lube (ISO VG 460)

Schaeffer Mfg.#209A Universal Gear Lube (ISO VG 1000)

Schaeffer Mfg.#294 Supreme Gear Lube (ISO VG 460)

Schaeffer Mfg.#294A Supreme Gear Lube No Tack (ISO VG 460)

Shell Omala 460 (ISO VG 460)

Shell Omala 1000 (ISO VG 1000)

Shell Omala 1500 (ISO VG 1500)

Shell SP Plus Gear Oil (ISO VG 1500)

Talcor Gear Oil EP (ISO VG 1000)

Whitmore Mfg. Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 460)

Whitmore Mfg Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1000)

Whitmore Mfg Co. Paragon Heavy Duty Enclosed Gear Oil (ISO VG 1500)

Whitmore Mfg Co. Paragon Gold High Performance Gear Oil (ISO VG 1000)

Synthetic (PAO) Oils

Manufacturer

Product Description

Bel Ray Synthetic Gear Oil 460 (ISO VG 460)

Bel Ray Synthetic Gear Oil 1000 (ISO VG 1000)

Lubrication Engineers 9846 Synolec Gear Lubricant (ISO VG 460)

Lubrication Engineers 9899 Synolec Gear Lubricant (ISO VG 1000)

Mobil Mobil SHC 634 (ISO VG 460)

Bucyrus International, Inc.

CERTIFIED LUBRICANTS LISTING

(January 22, 2007)

Mobil Mobilgear SHC XMP 460 (ISO VG 460)

Mobil Mobilgear SHC 460 (ISO VG 460)

Mobil Mobil SHC 639 (ISO VG 1000)

Mobil Mobilgear SHC 1000 (ISO VG 1000)

Mobil Mobilgear SHC 1500 (ISO VG 1500)

Schaeffer Mfg.#167 Pure Synthetic Gear Lube (ISO VG 460)

Schaeffer Mfg.#167 Pure Synthetic Gear Lube (ISO VG 1000)

Shell Omala HD 460 (ISO VG 460)

Shell Omala HD 1000 (ISO VG 1000)

Whitmore Mfg. Co. GF 365 Synthetic Gear Fluid (ISO VG 460)

Whitmore Mfg Co. GF 365 Synthetic Gear Fluid (ISO VG 1000)

Whitmore Mfg Co.Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 460)

Whitmore Mfg Co.Decathlon HD Series Synthetic Enclosed Gear Oil (ISO VG 1000)

LUBRICANT CERTIFICATION PROCESS:

Lubricant manufacturers seeking to certify their products should contact the following for direction:

Bucyrus International, Inc.

Engineering Services & Technical Support

1100 Milwaukee Avenue

South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

REVISIONS:

This listing is subject to change without notice. Please refer to the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing.

Section 4 Preventive Maintenance

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Section 4 Preventive Maintenance

This section of the manual describes those aspects of preventive maintenance such as inspection, adjustment and routine repetitive tasks of this machine. Information related to lubrication techniques, frequency, and service points is also partially included. Further detailed information can be found in Section 3 ~ LUBRICATION and Section 5 ~ SERVICE PROCEDURES

Reproducible maintenance schedules that may assist in record keeping and maintenance scheduling can be found at the end of this section.

INTRODUCTION

A Preventive Maintenance Program is a systematic series of operations performed periodically on equipment to prevent breakdowns.

Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only new at one point in time. From that moment the machinery begins to deteriorate through use and aging. A well organized maintenance program will avoid unexpected high-cost breakdowns and will increase component life.

A systematic approach to the program should be followed, and detailed records of all findings kept, to detect potential problem areas. Valuable time and effort can be saved if defects are corrected before they lead to a major breakdown. The records should be reviewed often and kept on file for future reference.

Personnel involved in the program should complete an established training program, to know WHAT to check and HOW to rectify any potential problem area. When personnel are able to perform routine maintenance and normal repairs efficiently, downtime is reduced and machine productivity increased. To keep the machine in good running condition the necessary parts, tools and current information should be kept on hand.

Equipment maintenance is a science and its practice an art. This art can be divided into 6 types of operations - they are:

Inspection is probably the most important operation. Careful observation of all parts of the equipment is required. Slight abnormalities might not interfere with the equipment performance but all abnormalities should be discovered early. When inspecting, notice placement, state of cleanliness, color, etc. of part(s). Example: discoloration indicates overheating;.

Cleaning, and keeping clean, is essential for good operation. Periodic cleaning should be more frequent on exposed parts than those which are contained within cabinets. Parts, connections and joints should be free of dust, corrosion and other foreign matter.

A Feeling operation is used more often to check guarded rotating machinery for vibration due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical items should be performed as soon as possible AFTER power has been removed and the circuit grounded. Feeling of excessive heat may indicate an overloaded condition and should be corrected.

A Tightening operation should be done on all connections that have worked loose due to vibration, etc. Loose parts are a definite hazard because they may fall out of place and damage nearby components. The importance of firm mounting and tight connections cannot be overemphasized. Always replace missing or broken bolts with proper size and use the correct tools.

Adjusting should be done when inspection indicates that it is required to maintain normal operating conditions. Specific adjustment is contained in the “Mechanical Adjustment Section” of this manual, the electrical manual or the component manufacturer’s manual.

Lubrication refers primarily to the application of CORRECT LUBRICANT in the CORRECT AMOUNT to bearings and other rotating parts. It also means the application of a light oil to door hinges or other sliding surfaces. Use only clean and proper lubricant.

Planned maintenance, common sense and good judgment are less costly and more effective than panic maintenance. Action taken on recommendations made on the following inspection checklists by the maintenance department, should reduce repair and maintenance costs and increase production.

Replacing worn components with genuine Bucyrus parts on a scheduled basis will avoid costly down-times and emergency repairs. The cost of parts is small when compared to unscheduled breakdowns that result in excessive overtime man-hours and lost machine production.

Whenever a problem is indicated, the inspector should briefly explain it on the maintenance report along with his signature. Then, an authorized person should briefly explain a solution to the problem. Finally, CORRECT THE PROBLEM.

ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM

•Preventive Maintenance Program.

•Well Trained and Motivated Work Force.

•Effective Communications.

•Proper Equipment Selection and Procurement.

•Meaningful Documentation.

•Cooperation with the Operations / Maintenance Department.

•Warehouse Support.

•Good Shop Facilities.

SCHEDULED PREVENTIVE MAINTENANCE PROGRAM

Economically maintaining the productivity and performance of a Bucyrus Blast Hole Drill requires maintenance and inspection activities in a scheduled manner. Manpower requirements and performance of needed maintenance during scheduled downtime dictates a system which recognizes the recommended inspection interval. For example, crawler assemblies are exposed to severe service and should be inspected every maintenance period, while other components can be reasonably expected to operate twice this interval before inspection. By staggering the inspection or servicing of these items, labor time and work-force size is balanced.

Maintenance and component inspection should be performed simultaneously during scheduled downtime. A history of maintenance practices has shown that parts replacement and component rebuild in advance of destructive failure yields the lowest operating costs. Keeping good records is vital to support any preventive maintenance program. Early “change-out” reduces unscheduled downtime and prevents secondary damage. Record keeping should be an “easy to use” format and contain enough detail to isolate the function. For example, drill bit wear will often directly relate to the number of holes drilled rather than machine operating hours. However, power transmission shafting and bearings wear rates correspond closer to operating hours. Since basic machine life extends over thousands of operating hours, maintenance records can be utilized to forecast budgets for maintenance expenditures. This makes records a very valuable planning tool for mine management.

Use the Bucyrus maintenance program that is outlined here to formulate a schedule suited to the work-force and mining environment. Over a period of time, additional inspection or planned work may supplement the activities described in this manual.

GENERAL SAFETY CONSIDERATIONS

The importance of overall safety in maintenance should always be emphasized; drilling operations may involve a variety of hazardous conditions. Many critical machine components are subject to wear and other deterioration which limits their useful life; thus making them expendable. When new, all such parts have a built in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a potential problem. Similarly, failure to replace various mechanisms to ensure proper performance of the machine could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators, and maintenance personnel should continuously follow safe practices.

MAINTENANCE DURING MACHINE OPERATION

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

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

Automatic lubrication systems function throughout the operational cycles of the machine. These systems release pre-measured lubricant which extends the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

CAUTION: A repair or maintenance job is not complete until all guards, plates and other safety devices have been replaced before the equipment is restored to operation.

MAINTENANCE PRECAUTIONS

The operator must be sure that the equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a possibly yielding support surface. Before beginning repair or adjustment, the operator shall:

1.Lower the Pulldown/Rotary gearcase to its lower stops.

2.Set all brakes.

3.De-energize control functions.

4.Do whatever else is necessary to prevent accidental movement of the machine.

DANGER: HIGH VOLTAGE! If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when repair work is being done.

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the OFF position and tagged. The lock and tag should be removed only by the maintenance people who installed them, or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.

Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled.

DANGER:Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches.

While performing maintenance, the awkward positions assumed, and the handling of heavy parts often increases the possibility of injuries. As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

DANGER:Many of the components comprising this machine are heavy, bulky items. EXTREME CAUTION SHOULD BE USED WHEN LIFTING THESE ITEMS. PERSONNEL SHOULD BE CERTAIN OF THE WEIGHTS OF COMPONENTS BEFORE ATTEMPTING TO LIFT THEM, EITHER MANUALLY OR WITH A LIFTING DEVICE. ALL APPLICABLE SAFETY RULES SHOULD BE FOLLOWED WHEN USING A CRANE OR OTHER LIFTING DEVICE. Be aware of the load rating, lifting height and swing radius of the lifting device before lifting a load. Failure to follow all applicable safety rules when performing maintenance could result in serious injury, or death.

FREQUENCY OF INSPECTION AND MAINTENANCE

The suggested maintenance schedule is developed on a planned usage of 5,000 operating hours per year. This is a planned reference only. The actual conditions within the mine site, the operator’s abilities and habits, along with the quality of components and consumables will ultimately drive the inspection schedule used on the machine.

Care should be taken to properly evaluate the maintenance approach during the initial period after machine commissioning.

MAINTENANCE SCHEDULES

The following maintenance schedule is based on a typical machine. Certain features or configurations may be different on a specific machine. This maintenance schedule is intended to outline the intervals for the various repetitive maintenance requirements. For any assistance, refer to the appropriate section in this Maintenance and Operation Manual, or contact the Bucyrus International service representative.

NOTE: This maintenance schedule is not to be substituted for Section 5 ~ SERVICE PROCEDURES in this manual.

MAINTENANCE INSPECTION CHECK POINTS

DAILY 49HR

EXTERNAL INSPECTION

1.Check areas around and under the machine for signs of water or lubricant leaks. If single droplets of water or lubricant are noticed, leakage is minimal. Determine the source of the leak and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine the source and take remedial action immediately.

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

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

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

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

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.

ITEM #

49HR

Blast Hole Drill

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

DAILY Check Points (cont.)

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

7.Inspect the underside of the machine for cracks, loose hoses or wires, dirt or ice accumulation, or other deterioration or damage. If loose wires are noted, do not touch them but notify an electrician immediately.

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

9.Inspect the mast braces and locking pins. Replace missing or defective components immediately. Verify that all adjusting bolts are properly adjusted. Check all hoses and cylinders for leaking.

CAUTION:Use a safety belt and lanyard to protect against falls when climbing on the mast braces or working on the machinery house roof.

10.Inspect the 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.

Date:

Shift:

Inspected By:

Supervisor:

Check Points

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

12.Inspect the mast structure for bent or broken chords or plates, loose or broken parts, proper rack lubrication or excessive rack wear. Inspect ladders, handrails and platforms for broken or missing parts. Repair or replace broken or missing parts immediately.

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

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

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

Date:

Shift: Inspected By:

Supervisor:

DAILY Check Points (cont.)

ONBOARD INSPECTION

1.Inspect the air compressor lubrication lines for leaks. Correct any leaks found immediately.

2.Check the condition of the 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 pre-cleaner element. Inspect the housing and ducting for damage or leaks. Repair or replace leaking components.

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

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

5.If the machine is equipped with a bit lubricator for the main air system, check that the lubricator is full.

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

7.Close and lock all electrical cabinet doors.

CAUTION: Assume all parts inside of the electrical cabinets are energized. All electrical components should be serviced by qualified electrical personnel only.

Date:

Shift:

Inspected By:

Supervisor:

DAILY Check Points (cont.)

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

9.Check the operator’s display terminal for any faults.

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

NOTE: 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 of the components located there.

11.Inspect the auxiliary winch and auxiliary winch line.

12.Check the oil level in the pump drive gearcase. Fill with recommended oil to the proper level.

13.Check all controls for free operation. Return all controls to the OFF or SET position.

14.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.

Date:

Shift: Inspected By:

Supervisor:

DAILY Check Points (cont.)

NOTE: 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 DIRT FROM THE OPERATOR’S CAB

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

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

16.Inspect the automatic breakout wrench for free operation, broken or missing parts, proper lubrication, lubricant leaks or excessive dirt accumulation. Repair or replace parts as necessary. Be certain that the breakout wrench is retracted.

17.Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or lubricant leaks. Be certain that the upper gate is closed and that the rack is in the stored position.

Date:

Shift:

Inspected By:

Supervisor:

18.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.

19.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.

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

21.Inspect the rotary drive unit for excessive wear or dirt accumulation. Inspect the guide rollers for proper adjustment and excessive wear. Check for loose or missing bolts and bent or cracked structural members.

22.Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper adjustment and excessive wear.

Date:

Shift:

Inspected By:

Supervisor:

DAILY Check Points (cont.)

23.Inspect the pulldown gearcase for lubricant leaks, dirt accumulation and other damaged or missing parts. Check the lubricant level in the gearcase. Fill to recommended level with an approved gear lubricant. Check the pulldown motor ventilation inlets for leaves, papers, rags, etc. blocking the flow of air.

24.Check the hoist brake for proper operation.

25.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.

26.If the machine is equipped with a fire suppression system, perform any applicable checks or inspection as described in the fire suppression system owner’s manual.

AFTER START-UP INSPECTION

27.Check all brakes for proper setting and releasing.

28.Listen for unusual noises in the gearcase.

29.Check all bearings for unusual noises and excessive heat.

Date: Shift: Inspected By:

Supervisor:

MAINTENANCE INSPECTION CHECK POINTS

EVERY 100 HOURS, OR WEEKLY (WHICHEVER OCCURS FIRST)

1.Check for missing or worn crawler link pins and retaining pins.

2.Check for cracked or worn crawler links.

3.Check the tumblers and rollers for cracking, wear and lubrication.

4.Check for cracking of the crawler frames.

5.Check for excessive dirt accumulation.

6.Check for proper belt adjustment (1-3 inch sag between end of upper slide and drive or take-up tumbler).

7.Check drive tumbler for cracking and wear.

8.Check the oil level in the propel planetary gearcases.

CAUTION:BE CAREFUL WHEN REMOVING THE PLUGS, ESPECIALLY IF THE UNIT IS HOT. PRESSURE BUILDS IN THE GEARCASE AND AS THE LAST THREAD OF THE PLUG IS REMOVED, THE PLUG MAY FLY-OFF WITH SOME FORCE.

9.Check the propel gearcase. Hydraulic motor and hydraulic lines for leaks.

10.Check that rear axle bearing block bolts are tight.

11.Check front equalizer axle for wear and cracking.

49HR ITEM #

R

49HR Blast Hole Drill

NOTED DISCREPANCY

Date:

Shift: Inspected By:

Supervisor:

100 HOURS, OR WEEKLY (cont.)

12.Check equalizer axle pins for wear and lubrication.

13.Check dust curtains for wear or damage. Check that the curtains are not frozen to the ground.

14.Check the curtain raising levers for wear, damage, lubrication.

15.Check the curtain raising cylinders for wear, damage or leaking.

16.Check the dust deflector for wear or damage.

17.Visually check the condition of the trail cable.

18.Check the cable reel for damage, wear and lubrication. Manually lubricate the drum shaft bearings - 2 points.

19.Check the cable reel controls for ease of operation and hydraulic leaks.

20.Check the cable reel drive chains for wear, damage, lubrication and adjustment.

21.Check the leveling jack frames for cracking.

22.Check the leveling jack shoes for cracking. Clean off any dirt or rocks.

23.Check for missing or worn shoe pins and retaining pins.

24.Check the leveling jack spuds for proper lubrication.

Date:

Shift:

Inspected By:

Supervisor:

100 HOURS, OR WEEKLY (cont.)

25.Check the leveling jacks for oil leaks.

26.Check the mainframe for cracking.

27.Check the retractable stairway for proper operation.

28.Check the outside of the machinery house and cab for damage or cracking.

29.Check that all blowers for ventilating and radiators are not obstructed.

30.Check dry-type dust collection unit duct and hoses for leaks.

31.Lube drive shaft bearings on dry-type dust collection unit.

32.Check that water tank is full.

33.Check the condition of the mast braces and brace pins.

34.Check the mast brace lock cylinders and hydraulic lines for leaks.

35.Check that the mast hoist cylinder pins and retaining pins are in place.

36.Check the mast structure for wear, damage or cracking.

37.Check the mast’s racking for wear, damage and lubrication.

38.Check the mast ladder, safety guards and platforms for cracking and missing bolts.

R

49HR

49HR Blast Hole Drill

ITEM # NOTED DISCREPANCY

Date:

Shift:

Inspected By:

Supervisor:

100

OR WEEKLY

39.Check the condition of the auxiliary winch line.

40.Check the condition of the mast head sheaves.

41.Check the condition of the upper portion of the tool racks.

42.Check the condition of the mast air pipe, bull hose and lube lines. Visually check the condition of the electrical lines.

ON-BOARD INSPECTION

43.Check oil level in the pump drive gearcase. Add oil if required.

44.Check the mast hoist cylinder anchor pin and retaining pins.

45.On the drilling deck, check the guide bushing for wear.

46.Check the tool wrenches for wear, lubrication and oil leaks.

47.Check the lower portion of the tool racks for wear or damage.

48.Check the pawls in the rack pockets that they work freely.

49.Check that the rack levers work freely.

50.Lubricate the rack lower arms. Check the cylinders.

Date:

Shift:

Inspected By:

Supervisor:

100 HOURS, OR WEEKLY (cont.)

51.Check the rotary coupling for cushion wear and tightness of bolts.

52.Check the oil level in the rotary gearcase. Add oil if required.

53.Check the gearcase and frame for cracking and oil leaks.

54.Check the guide rollers for proper adjustment.

55.Check the pulldown gearcase for cracking and oil leaks.

56.Check the oil level in the pulldown gearcase. Add oil if required.

57.Check the hoist brake on the pulldown gearcase for proper operation.

58.In the machinery house, check the oil level in the hydraulic reservoir. Add oil if required.

59.Check all oil filters. Change if required.

60.Check all belt drives for proper belt tension.

61.Check the oil level in the screw compressor separator. Add oil if required.

62.Check all hydraulic, air, lube piping for leaks.

ITEM #

R

49HR

49HR Blast Hole Drill

NOTED DISCREPANCY

Date:

Shift:

Inspected By:

Supervisor:

MAINTENANCE INSPECTION CHECK POINTS

EVERY 500 HOURS, OR MONTHLY (WHICHEVER OCCURS FIRST)

1.Check the crawler belt adjustment and adjust belts if required.

2.Position the machine so that crawler rollers and take-up tumblers can be checked for excessive movement which indicates bushing wear.

3.Take sample of propel gearcase oil for testing.

CAUTION:Be careful when removing the plugs, especially if the unit is hot. Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with some force.

4.Remove rotary gearcase inspection cover and inspect gearing.

5.Take sample of rotary gearcase oil for testing.

6.Check the rotary gearcase drive shaft bearing adjustment and adjust if required.

7.Remove pulldown gearcase inspection cover and inspect gearing.

8.Take sample from the pulldown gearcase oil for testing.

Date: Shift: Inspected By: Supervisor:

500 HOURS, OR MONTHLY (cont.)

9.Check the rotary air seal and replace it if required.

10.Take sample of hydraulic oil from reservoir for testing.

11.Check and clean or replace all air filters.

12.Check and clean or replace all oil filters.

13.Take a close look at all structural units, including crawler frame, axles, mainframe and mast. Check for cracking, stress marks or buckling.

14.Take care of any deficiencies found during prior inspections which did not require immediate action.

ITEM #

R

49HR

49HR Blast Hole Drill

NOTED DISCREPANCY

Date:

Shift: Inspected By: Supervisor:

MAINTENANCE INSPECTION CHECK POINTS

EVERY 2500 HOURS, OR SEMIANNUALLY (WHICHEVER OCCURS FIRST)

1.Position the machine so that one takeup tumbler and lower roller can be removed for inspection of the bushings.

2.Drain the propel gearcase and fill with new oil.

CAUTION:BE CAREFUL WHEN REMOVING THE PLUGS, ESPECIALLY IF THE UNIT IS HOT. PRESSURE BUILDS IN THE GEARCASE AND AS THE LAST THREAD OF THE PLUG IS REMOVED, THE PLUG MAY FLYOFF WITH SOME FORCE.

3.While the gearcase is drained, inspect the gears, pinions, bearings and seals.

4.Drain the pump drive gearcase and fill with new oil.

5.Drain the rotary gearcase and fill with new oil.

6.While the gearcase is drained, remove the motor and inspect the gears, pinions, bearings and seals.

7.Drain the pulldown gearcase and fill with new oil.

Date: Shift: Inspected By: Supervisor:

2500 HOURS, OR SEMI-ANNUALLY (cont.) 49HR

8.While the gearcase is drained, inspect the gears, pinions, bearings and seals.

9.Re-pack the bearings in the masthead winch sheaves.

10.Drain the auxiliary winch and fill with new oil.

11.Drain the hydraulic reservoir and fill with new oil.

12.Change all hydraulic oil filters.

13.Correct any deficiencies found during prior inspections which did not require immediate action.

14.Clean up around the machine and touchup paint any parts of the machine where paint is missing and rusting could occur.

ITEM #

R

49HR Blast Hole Drill

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

Section 5

Service Procedures

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Section 5

Service Procedures

LOWER WORKS

The Lower Works consists of two crawler side frames, each with a planetary propel gearcase, drive tumbler, load rollers and a crawler belt. The crawlers are attached to the machine with two axles. The propel drive is at the front of this machine.

CRAWLER FRAMES

Inspect the crawler frames for cracks or damage. Pay particular attention to the axle attachment points and the bottom flange plate. Any cracks, wear or damage should be repaired immediately. Repair of the crawler frames may be accomplished while the crawler frames are attached to the machine or the crawler frames may be removed to facilitate repair.

To remove the crawler frames from the machine proceed as follows:

1.Disconnect all hydraulic and lubrication lines connected to the crawler frame. Be sure all joints are clean and all lines and ports are plugged.

2.Using the machine’s leveling jacks, raise the machine sufficiently to allow blocking to be placed under the bottom of the crawlers. Allow the blocking to extend 6 to 8 feet from the crawler frame. Blocking material should be selected to facilitate the sliding of the crawler frame away from the machine.

Crawler Frame Blocking for Removal

3.Slowly lower the jacks just until the weight on the axles has been removed. Securely block the machine mainframe in this position.

4.From this point either one or both crawler frames may be removed from the machine.

NOTE: Steps 5 through 17 describe the procedure for removing and reinstalling one crawler frame. If both frames are to be removed, repeat steps 5 through 14 for the other crawler frame.

CAUTION:If both crawler frames are to be removed, block the equalizer axle to prevent unexpected pivoting.

5.Remove rear axle retainer shims and fabreeka thrust washer.

6.Remove the end pin retainer. Then remove the end equalizer axle pin.

7.Using suitable rigging and a suitable vehicle(s), pull the crawler frame outward, away from the machine. Place the crawler frame in a position to be repaired or handled with lifting equipment.

8.Repair the crawler frame and components as necessary.

9.To replace the crawler frame, position the crawler in line with the rear axle.

10.Lubricate the rear axle, equalizer axle pin and bores. Ensure that the rear axle is packed with lubricant.

11.Using suitable rigging and vehicle(s), slowly pull the crawler frame toward the machine. Make sure the crawler is straight as it is being pulled onto the axle.

12.When the crawler is in position, insert the equalizer axle end pin and its retainer.

13.Ensure that the crawler frame is seated against the pipe spacer. Adjust the gap (.10-.17”) between the thrust washer and retainer by adding and removing shims.

14.Apply Loctite and tighten the retaining plate bolts to 1000 Ft.Lbs.

15.Connect the hydraulic and lubrication lines.

16.Raise the machine with the leveling jacks just enough to remove all blocking, then lower the machine.

17.Propel the machine to check the operation of the crawler components.

AXLES

The crawler frames are attached to the machine by two axles. The front axle (equalizer axle) allows the front of the crawlers to pivot, equalizing the load of the machine between the two crawlers. Each end of the axle is pinned to the crawler frames while the middle of the axle is pinned to the bottom of the machine mainframe.

The rear axle is the pivot axle in that as the front of the crawlers move up and down to equalize the loads when propelling over rough terrain, the rear of the crawler pivots about the rear axle. This axle is solidly attached to both sides of the mainframe and does not move during operation.

Inspect the axles and the attachment points frequently for loose bolts or hardware. Inspect the axles for cracks or damage. Repair or replace the axles if worn or damaged. Inspect the pivot pins and retainers for wear or damage and replace as necessary.

Normally the axles will not need repair during the life of the machine. Accidents or abnormal wear situations do occur, however, that may make repair of the axles necessary. Due to the inaccessibility of the axles, removal from the machine is necessary for repairs.

CAUTION: Do not weld on the rear axle for any reason. Axle failure would result.

To remove the equalizer axle from the machine:

1.Following the procedure listed under CRAWLER FRAMES, remove one crawler from the machine. Position the crawler away from the machine to allow removal of the axles from beneath the machine. Be sure the machine and the opposite crawler are securely blocked.

2.To remove the equalizer axle, first remove the remaining equalizer axle end pin, then securely block the axle to allow removal of the PIVOT pin.

3.Remove the axle pivot pin. The pivot bearing block may be removed to facilitate removal of the pin.

Front Equalizer Axle

4.Remove the axle from beneath the machine and repair or replace as necessary.

5.Reinstall the axle by first positioning the axle to allow installation of the pivot bearing block and/or pivot pin. Install the bearing block and/or pivot pin.

6.Install the equalizer axle pin and retaining pins onto the crawler attached to the machine.

To remove the rear axle:

a.Remove the remaining rear axle retainer, shims and Fabreeka thrust washer. Securely block the axle to allow it to slide out of the crawler frame.

b.Remove the bearing block bolts attaching the axle to the mainframe.

c.Slide the axle from the crawler frame and remove from beneath the machine. Replace the axle as necessary.

d.Position the axle to allow it to slide into the crawler frame.

e.Pack the axle bearing bores with lubricant in the crawler frame and slide the axle into the crawler frame.

f.Align the axle with the mainframe. Install the bearing block and bolts to attach the axle to the mainframe.

7.Install the crawler frame as described in CRAWLER FRAMES

8.Using leveling jacks, or by any other means available, raise mainframe to remove the majority of the upper works weight from the rear axle. Hold mainframe in this position for tightening of axle block bolts.

9.Assemble the axle block bolts, Fabreeka washers and hard steel washers.

10.Tighten the nuts on all bolts hand tight (approx. 20 Ft.Lbs.) so there are no gaps between washers. Then turn each nut one additional turn and lock with cotter pin.

Rear Axle

11.Raise the machine slightly with the leveling jacks and remove the remaining blocking. Lower the machine to the ground.

LOWER ROLLERS

Inspect the lower rollers for cracks and damage that can impair normal tracking of the crawler belts.

Once a month raise the machine with the leveling jacks to allow inspection of the rollers. Block the machine in a raised position. Using a suitable lever, check the clearance of the roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive. Some side-toside clearance is normal.

The most common problem encountered with lower rollers is bushing wear. However, over a period of time, the rollers will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Refer to the welding instructions in Section 9 ~ ENGINEERING DATA

If bushing replacement is necessary, the roller must be removed from the machine. To accomplish this:

1.Relieve the crawler belt tension as described in CRAWLER BELT ADJUSTMENT

2.Using the machine leveling jacks, raise the machine sufficiently to allow removal of the roller. Block the machine in the raised position. It may be necessary to jack the crawler belt away from the crawler frame and block in position to remove the extreme front or rear rollers.

3.Remove lubrication guards and lube lines, if so equipped, to gain access to the roller shaft.

4.Remove the capscrew and retainer securing the lower roller shaft to the crawler frame.

5.Support the lower roller with suitable blocking. Remove the roller shaft.

6.Remove the blocking and lower the roller out of the crawler frame.

7.Inspect the roller bushing. Remove and replace the bushing if necessary. Inspect the lower roller shaft. Replace if worn. Inspect the crawler frame in the area of the lower roller. Repair shaft bore or thrust surfaces if necessary.

8.Lubricate the roller bushing and shaft. Install roller in crawler frame and block in line with the shaft bore.

9.Insert the roller shaft.

10.Install the retainer and capscrew to secure roller shaft to crawler frame. Remove the roller blocking.

11.Install and adjust lubrication guards and lube lines if so equipped.

12.Adjust belt tension as described in CRAWLER BELT ADJUSTMENT

13.Remove blocking and lower machine. Propel the machine to distribute the lubricant evenly in the roller and check roller operation.

UPPER ROLLERS

Inspect the upper roller for cracks and damage that can impair normal tracking of the crawler belt.

Once a month use a jack to lift the crawler belt off the upper roller. With a suitable lever, check the clearance of the roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.

The most common problem encountered with upper rollers is bushing wear. However, over a period of time, the roller will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Refer to the welding instructions in Section 9 ~ ENGINEERING DATA

If bushing replacement is necessary, the roller must be removed from the machine. To accomplish this:

1.Relieve the crawler belt tension as described in CRAWLER BELT ADJUSTMENT

2.Using a jack, raise the crawler belt high enough so that the upper roller can be removed. Block the belt in this position.

3.Remove the capscrew and retainer securing the roller shaft to the crawler frame.

4.Support the roller with suitable blocking and remove the roller shaft. Remove the roller and blocking from the crawler frame.

5.Inspect the roller bushing. Remove and replace the bushing if necessary. Inspect the roller shaft. Replace if worn. Inspect the crawler frame in the area of the upper roller. Repair shaft bore or thrust surfaces if necessary.

6.Lubricate the roller bushings and shaft.

7.Install roller into the crawler frame and block in line with the shaft bore.

8.Install the roller shaft and secure the shaft with the retainer and capscrew. Remove the roller blocking. Remove the crawler belt blocking.

9.Adjust belt tension as described in CRAWLER BELT ADJUSTMENT .

10.Lubricate the roller. Propel the machine to distribute the lubricant evenly and check roller operation.

TAKE-UP TUMBLERS

Inspect the take-up tumbler for cracks and damage that can impair normal tracking of the crawler belts.

Every six months raise the machine with the leveling jacks to allow inspection of the tumblers. Block the machine in a raised position. Using a suitable lever, check the clearance of the tumbler bushing by lifting and then lowering the tumbler. Replace the bushing if the clearance is excessive.

The take-up tumblers do not frequently require replacement or repair. The most common problem encountered is bushing wear. However, it is possible for the tumbler to develop cracks. When cracks do occur, they can be repaired by gouging out metal on both sides of the crack, and welding the crack. Follow welding instructions in Section 9 ~ ENGINEERING DATA

If bushing replacement is needed, the tumbler must be removed from the machine. To accomplish this:

1.Position the machine so that the take-up tumbler to be removed is over a slight depression in the ground (about 6 inch deep). This depth will be enough to relieve the weight of the machine from the tumbler.

2.Relieve crawler belt tension and separate the crawler belt as described in CRAWLER BELT ADJUSTMENT. Separation of the belt should take place at a point near the take-up tumbler and the links laid back out of the way.

3.Remove the shim guards and lube lines if so equipped.

4.Using a suitable lifting device to support the take-up tumbler, remove the shaft from the tumbler. Lift the tumbler from the crawler frame.

5.Remove the supports and shims from the crawler frame.

6.Inspect the tumbler bushings. Remove and replace the bushings if necessary. Inspect the tumbler shaft and replace if necessary. Inspect and clean the shaft supports. Replace if worn. Inspect the crawler frame in the areas where the supports slide. Rebuild and grind if worn.

7.Lubricate the tumbler bore and shaft. Install the supports in the crawler frame. Using a suitable lifting device, position the tumbler in the crawler frame.

8.Install the bearing tumbler shaft and secure with the shaft retainer pin.

9.Reassemble the crawler belt. Adjust the crawler belt tension as per CRAWLER BELT ADJUSTMENT.

10.Replace the shim guards and lube lines if so equipped.

11.Propel the machine to distribute the lubricant evenly in the tumbler bushing and check operation of tumbler.

Inspect the drive tumbler for cracked and broken lugs and other defects that can impair normal tumbler function and belt tracking. Check the tumbler retainer bolts for tightness.

Drive Tumbler and Planetary Gearcase Installation

Repair of the drive tumbler is limited to repair welding of the lugs or roller area or replacement of the entire unit. Contact your local Bucyrus International representative for a specific weld repair solution to the tumbler. To replace the drive tumbler:

1.Relieve the crawler belt tension and separate the crawler belt as detailed in CRAWLER BELT ADJUSTMENT. Separation of the crawler belt should take place near the drive tumbler and the links laid back out of the way.

2.Using the machine leveling jacks, raise the machine sufficiently to allow the drive tumbler to clear the lugs on the crawler belt. Block the machine in the raised position.

3.Remove the tumbler retainer bolts and remove the tumbler from the planetary gearcase.

NOTE: The tumbler retainer bolts are metric.

4.Inspect the drive tumbler. Repair or replace if the lugs or rolling surface are worn or damaged.

5.Install the drive tumbler on the planetary gearcase. Tighten the gearcase-to-frame mounting bolts to 2,600 Ft.Lbs. (lubed) and the tumbler-to-gearcase bolts to 1,100 Ft.Lbs. (lubed).

Follow the tightening sequence as shown in the Gearcase Housing Bolt Tightening Sequence on page 20.

6.Remove all blocking and lower machine. Verify that all of the rollers and the drive tumbler are resting on the roller path of the belt.

7.Assemble and adjust the tension of the crawler belts as described in CRAWLER BELT ADJUSTMENT.

8.Propel the machine to check the operation of the drive tumbler.

PROPEL PLANETARY GEARCASE

The planetary gearcase should be checked daily for oil leaks. The oil level should be checked weekly by removing the oil level plug.

CAUTION:BE CAREFUL WHEN REMOVING THE PLUGS, ESPECIALLY IF THE UNIT IS HOT. Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with some force.

Monthly, the external bolts of the gearcase should be randomly inspected for tightness. Bolt torques are shown in DRIVE TUMBLER

GEARCASE REMOVAL AND INSTALLATION

To remove the gearcase from the crawler frame proceed as follows:

1.Remove the drive tumbler as described in DRIVE TUMBLER .

2.Remove the hydraulic motor from the gearcase. If necessary, disconnect the hydraulic lines from the motor. Tag and plug the lines and the motor ports. The motor coupling sleeve will be removed with the motor.

CAUTION: Failure to thoroughly clean dirt from joints before opening hydraulic lines could lead to component failure if dirt gets into the system.

3.Remove the hydraulic line from the gearcase brake port. Tag and plug the line and the brake port.

4.The gearcase is mounted in the crawler frame so that the hydraulic motor mounting is 15° from horizontal. Before removing gearcase match-mark the gearcase and crawler frame so that at reassembly the gearcase will be at the desired angle. Refer to the figure on the following page.

5.Secure a crane to the gearcase and remove the mounting bolts. Remove the gearcase from the crawler frame.

6.Installation of the gearcase is the reverse of removal. Tighten the mounting bolts to specifications. Use the following tightening sequence.

NOTE: The gearcase mounting bolts are metric.

CHECKING/CHANGING OIL

1.Check the level of the oil in the gearcase every day by removing the level plug. The oil should be up to the bottom of the hole. Fill as necessary.

2.Examine the (magnetic) level plug. The oil should be its normal color with some possible fine metal particles. Clean the plug and install it in the gearcase cover.

If the oil is not its normal color, it should be replaced. If the oil is black the gearcase has been running above 300° F for extended amounts of time. If the oil is a milky yellow color, it has been contaminated with water.

When in doubt, submit an oil sample to any laboratory that performs contamination analysis services. The oil should be changed when the contaminants exceed 10,000 particles per million.

Change the oil every 2000 hours, (1) year or if found to be contaminated.

LUBRICANT SPECIFICATIONS

Propel Gearcase Lubrication Specifications

1.The oils shown in the chart above contain phosphorous type extreme pressure additives. Other oils of equivalent quality and properties may be used, provided they contain phosphorous type extreme pressure additives.

Propel Gearcase Oil Change Intervals

2.Contamination depends on operating conditions and operating temperatures. Operating at temperatures of 180° F or above for continuous service will require more frequent oil changes.

GEARCASE DISASSEMBLY AND INSPECTION

Obtain a seal and bearing kit for the gearcase, then refer to Planetary Gearcase figure on previous page and disassemble and inspect the gearcase as follows:

1.Clean the outside of the gearcase so that it is free from dirt and oil. Match mark the ring gears and covers.

2.Before removing the planet gears from their carriers, write double numbers with paint to record the position of all planetary gears and bearing shafts.

3.Remove the hydraulic motor from the drive.

4.Remove the brake coupler (107), retaining plate (106) and bolt (129).

5.Loosen and remove the brake bolts (122), and slide out the complete brake assembly.

6.Remove the snap ring (36), then pull out the input shaft (12) with outer bearing (24).

7.Loosen and remove the internal bolt (52) and the external bolts (51).

8.Lift off housing (1), and lift out the first planet stage (7).

9.Disassemble the input shaft by removing the bearings (24) from the shaft (12).

DISASSEMBLY OF THE HOUSING

1.Pull out the bearing (24). Loosen and remove the bolts (48).

2.Pull out the sun gear shaft (11) and remove the snap ring (39).

3.Cut the ball bearing cage, notch the inner and outer race, and remove the bearing balls (27).

4.Tilt and remove the spur gear (10) and press out the bearing outer race (27) from the spur gear (10).

5.Remove screw plugs (61) and reverse the housing and press out the bearing inner race (27) from the housing (1).

DISASSEMBLY OF THE FIRST PLANET

STAGE

1.Remove the snap rings (95). Pull off the planet gears (90) with outside bearings (91) and remove bearings (96).

2.Remove the stay rings (93, 94). Pull off the inside bearings (91).

3.Disassemble the sprocket hub (13). Remove the O-Ring (34). Press out the pilot ring (17) and remove the O-Ring (33).

4.Disassemble the support ring (3). Press out the face seal (32).

DISASSEMBLY OF THE OUTPUT PLANET STAGE

1.Remove the spherical roller bearing (22). Remove the cylindrical roller bearing (23). Next, remove the snap rings (45).

2.Drill out the planet pins (18) - to avoid damage to the planet carrier bores drill a diameter (5 mm) smaller than the pin diameter and push out the remaining shell.

3.Lift out the planet gears (8).

CAUTION: Full complement roller bearings can fall apart.

4.Carefully slide bearings (25) out, keeping them in their assembled state.

CAUTION: Rollers and inner races must not be switched between bearings.

5.Remove locating rings (20). Then, remove snap rings (38).

ASSEMBLY PROCEDURE

ASSEMBLY OF OUTPUT PLANET STAGE

1.Install snap rings in the planet gears (5). Install one locating ring (38) in each planet gear (8).

2.Install one bearing (25) into each planet gear (8). Install spacers (15) and 2nd locating rings (20) into each planet gear (8). Press opposite bearings (25) into each planet gear (8).

CAUTION: Observe direction of bearing assembly per drawing.

3.Insert assembled planet gears (8) into planet carrier (5) and center them with the help of an undersized pin.

4.Freeze planet pins (18) using liquid nitrogen.

CAUTION: Observe safety regulations regarding the use of liquid nitrogen.

5.Hold planet pins with a gripping device and slide into the bores. Install the snap rings (45).

6.Mount spherical roller bearing (22) and cylindrical roller bearing (23), heated to approximately 80° C. or 176° F.

CAUTION: Observe direction of bearing assembly per drawing.

ASSEMBLY OF FIRST PLANET STAGE

1.Install snap rings (96) into planet gears (90). Press one bearing (91) each over their outer rings into the planet gears (90).

2.Install locating rings (93, 94). Press opposite bearings (91) over their outer rings into the planet gears (90).

CAUTION: Observe direction of bearing assembly per drawing.

3.Mount assembled planet gears (90), heated to approximately 80° C. or 176° F., onto the pins of the planet carrier (7). Press only over the inner rings of the bearings. Install the snap rings (95).

ASSEMBLY OF HOUSING

1.Install outer race and roller assembly of inboard cylindrical roller bearing (24) into housing (1). Install spur gear (10) without ball bearing, into the housing (1).

2.Press the ball bearing (27) over inner and outer rings into the spur gear (10) and onto housing (1).

CAUTION: Ball bearing has to be seated against shoulder in housing.

3.Install snap ring (39). Press sun gear shaft (11) in spur gear (10) against ball bearing (27). Tighten bolts (48) with torque wrench and secure with Loctite.

ASSEMBLY OF INPUT SHAFT

1.Press the cylindrical roller bearing inner rings (24) onto input shaft (12). Insert assembled output planet stage (5) into twin ring gear (2).

2.Apply surface sealer to the mating surface of the support ring (3) and fit into the ring gear (2). Tighten bolts (49) with torque wrench, 410Nm.

3.Install face seal (32) into support ring (3).

ASSEMBLY OF SPROCKET HUB

1.Lubricate the internal spline of the sprocket with gear oil and press sprocket hub (13) onto planet carrier (5) against spherical roller bearing shoulder (22). Insert O-Ring (34).

2.Insert O-Ring (33) into the pilot ring (17). Press the pilot ring (17) into the sprocket hub (13). Tighten the bolts (47) with torque wrench, 1000Nm.

3.Insert assembled first planet stage (7) into the twin ring gear (2) and output planet stage (5).

4.Apply surface sealer to the mating surface of the housing (1). Insert sun gear (11) and fit the housing (1) onto the twin ring gear (2).

5.Tighten internal bolt with torque wrench, 86Nm (52) and secure with Loctite. Tighten external bolts (51) with torque wrench, 86Nm.

6.Install input shaft into housing (12, 10, 1). Install outer race and roller assembly of outboard cylinder roller bearing (24) onto input shaft (12).

7.Install the snap ring (36), and the O-Ring (35). Next, install the brake and tighten bolts (122).

8.Mount the coupler (107), retaining plate (106) and bolt (129) to the hydraulic motor.

NOTES :Perform a test run prior to putting the drive into service. Fill the drive with proper gear oil to the oil level as indicated on the installation drawing. Check all screw plugs for tightness. Listen for abnormal noises and monitor the temperature during the testing. Check the drive for oil leakage. Tighten the bolts to the torque listed in Gearcase Bolt Torques below, using the tightening pattern in Gearcase Housing Bolt Tightening Sequence on page 20.

Gearcase Bolt Torques

Gearcase Brake

1.Mount, Motor

GEARCASE BRAKE REPAIR

Refer to the following instructions and the graphic on the previous page for brake repair:

1.Park the machine on a level area away from mine traffic.

2.Raise the machine using the leveling jack until sufficient work clearance is achieved and the machine is in the level position.

3.Using a small boom truck or chain hoist and a sling support the propel motor.

4.Remove the hydraulic lines and cap and plug the lines as required.

NOTE :There should be enough slack in the hydraulic lines to remove motor without requiring the disconnection of hydraulic lines, but it will be more difficult to realign the motor with the splines during the reassemble process.

5.Remove the motor bolts and slide the motor back until the motor has disengaged the splines.

Caution:Do not have excessive lifting force on the motor during disassembly or the motor output shaft may break or become damaged.

6.Lower the motor to the ground or a secure platform.

7.Remove the #6 hose connect from the brake housing; cap and plug the hose.

8.Support the brake housing with a small boom truck or a chain hoist.

9.Remove the 4-mounting bolts (22).

10.Slide the brake housing back until the housing is clear of the shaft.

11.Lower the motor to the ground or suitable platform.

12.Transport the brake housing to a workshop environment.

13.Specialty tools are required to disassemble the brake assembly.

14.Cut a plate .5” thick 5” in diameter with a .75” hole in the center.

15.Cut a second bar 2” wide, 1” thick, and 12” long; drill a .75” hole in the center.

16.Cut a .75” threaded rod 12” long. You will require two .75” nuts with matching thread pitch.

17.Install the rod into the brake housing with the 5” plate on the planetary side and flat bar on the motor end.

18.Turn the nuts on each end and tighten unit the plate are tight against the housing and brake plate.

19.Center the 5” circular plate in the brake housing, allowing enough room to remove the snap ring.

20.Tighten the nut on the rod until the snap ring (19) is no longer loaded.

Caution:This assembly is under a high spring load and items 19 or 20 should not be removed unless the spring pressure has been removed or contained.

21.Remove the snap ring (19).

22.Loosen the nuts on the rod until the springs are fully released.

23.Remove the rod and 5” circular plate.

24.Apply air pressure to the brake port to remove the piston.

25.Remove the brake disc and keep the plates in order.

26.Inspect the plates for wear or warping.

27.Check the internal and external spines for wear ( Typically wear limit is .012”).

28.Replace worn components as required.

29.Always replace the brake piston seals.

30.Reinstall the brake seals on the piston.

31.Place the brake housing planetary side up using two 4” X 4” block to support the housing with a minimal distance of 3” between the blocks.

32.Lubricate each of the brake discs in clean gear oil. Install the brake pack into the housing using the same order as the discs were originally removed.

33.Lubricate the brake piston and seal and install into the housing being careful not to damage the seals.

34.Slide the motor coupler into the brake discs for alignment purposes. Center the shaft in the brake to ensure proper align for reinstallation of the brake housing

35.Install the brake plate (8). Maintain slight pressure on the brake pack while slowly removing the motor coupler.

36.Using the circular plate and rods (or press) recompress the springs until the snap ring (19) can be reinstalled. Care should be taken not to shift the brake disc until the snap ring (19) is in place.

37.Remove the circular plate and rod.

38.Transport the brake housing back to machine.

39.Reinstall the housing using a new sealing O-Ring. If the brake pack does not align to the splines, pressure can be applied to the brake port to release the brake discs. Use the motor coupler to aid in the alignment of the assembly.

40.Apply Loctite to the mounting bolts and torque to 250ft-lbs.

41.Align the clutch shifting collar (4) and ensure the clutch-shifting fork is working properly.

42.Reinstall the motor using a new O-Ring seal: Apply Loctite to bolts and torque to 200 ft-lbs

43.Reinstall hydraulic hoses if removed.

44.Refill any losses in lubrication.

45.Start machine, ensure the clutch fork is engaged, and test the crawlers.

46.Lower the machine and retest crawler.

47.Put machine back to work.

FIELD BRAKE PACK REPLACEMENT

1.Park the machine on a level area away from mine traffic.

2.Raise the machine using the leveling jack until sufficient work clearance is achieved and the machine is in the level position.

3.Using a small boom truck or chain hoist and a sling, support the propel motor.

4.Remove the hydraulic lines and cap and plug the lines as required.

NOTE: There should be enough slack in the hydraulic lines to remove motor without requiring the disconnection of hydraulic lines, but it will be more difficult to realign the motor with the splines during the reassemble process.

5.Remove the motor bolts and slide the motor back until the motor has disengaged the splines.

Caution:Do not have excessive lifting force on the motor during disassembly or the motor output shaft may break or become damaged.

6.Lower motor to the ground or secure platform.

7.Remove the shifter fork to provide clearance for the removal of the brake discs.

8.The #6 hose should still be connected to the brake housing. Use the hand pump located by the boarding stairs to build up pressure to release the brakes.

9.Once the brake is released, check to ensure no spring pressure is against the disc (10).

10.Remove the snap ring (20).

11.Remove the brake pack keeping the brake discs in order.

12.Inspect the plates for wear or warping.

13.Check the internal and external spines for wear (Typically wear limit is .012”)

14.Lubricate each of the brake discs in clean gear oil. Install the brake pack into the housing using the same order in which the discs were originally removed.

15.Install disc (10).

16.Install the snap ring (20). Check to ensure that the snap ring is seated in the groove.

17.Release the brake pressure at the hand pump.

18.Check that the brake is set.

19.Reinstall the shifter fork (2).

20.Align the clutch shifting collar (4) and ensure the clutch-shifting fork is working properly.

21.Reinstall the motor using a new O-Ring seal. Apply Loctite to bolts and torque to 200 ft-lbs.

22.Reinstall hydraulic hoses if removed.

23.Refill any losses in lubrication.

24.Start machine, ensure the clutch fork is engaged, and test the crawlers.

25.Lower the machine and retest crawler.

26.Put machine back to work.

OIL SEAL INSTALLATION

Refer to the figure below and install oil seals as follows:

1.Clean mating surfaces of dirt, oil and grease.

2.Spread a thin layer of silicon sealer over the entire outside seal diameter.

3.Spread the silicone sealer evenly at the space between the exterior seal diameter and the seal bore after pressing the seal.

4.The sealer that accumulates along the interior fills the space like a fillet. It is important that this is only a small amount.

5.The oil seal must be installed square with the shaft. When the oil seal is at an angle with the shaft, it will sweep oil out of the gearcase.

FACE SEAL INSTALLATION

Refer to the figure below and install the output shaft to gearcase housing cover face seals as follows:

1.Examine the seals. The rubber toric (1) should be seated uniformly on seal ring (2).

2.Use seal installer tool (5) to install the seal by applying even pressure. The installer tool is available from the seal manufacturer. If the seal tool is not used, place fingers on rubber toric ring only and press.

NOTE: Always install face seals in matched pairs of two toric rings and two face seals.

3.Check dimension "X". It must be uniform around the circumference of the seal.

4.Before assembling, wipe the seal faces to remove any foreign material.

5.Place a few drops of oil on a cleaning tissue and completely coat the sealing faces to assure corrosion protection and provide initial lubrication.

1.Rubber Sealing Ring or Toric

2.Metal Seal Ring

3.Seal Retaining Lip

4.Seal Seat

5.Installer Tool

CRAWLER BELTS

The crawler belts should be inspected frequently to prevent an unexpected breakdown. Check the links for cracks, worn lugs, elongated link pin bores and other damage. Minor cracks in the link do not constitute a major problem. However, cracked links should be repaired by welding or replaced. Links with broken or worn drive lugs should be replaced as soon as possible as they can cause the belt to ride off the rollers or take-up tumblers. Links with elongated pin bores should be checked carefully for cracks at the pin lugs and replaced if badly worn or cracked. Bent, broken, or badly worn link pins should be replaced.

CRAWLER BELT ADJUSTMENT

To determine if the crawler belts should be adjusted, raise the machine up on the leveling jacks so that the crawler belts are hanging free and not contacting the ground. At the center of the crawler frame measure the clearance between the bottom of the crawler frame and the roller surface of the crawler links. The minimum clearance is 11 inches and the maximum clearance is 15 inches. When the maximum clearance is reached, the crawler belts must be adjusted to 11-12 inches. Do not operate machine with belt slack in excess of maximum clearance.

Crawler Belt Clearance

Adjust the crawler belts at the take-up tumbler of the belts. The take-up tumblers are mounted on shafts which are mounted in supports, which in turn ride in slots in the crawler frames. Shims placed ahead or behind the supports position the tumbler to provide the desired belt tension.

Crawler belt tension is adjusted on one crawler at a time.

To adjust the belt tension:

1.Using the leveling jacks, raise the machine until the crawlers and belts are suspended above the ground. Block the machine in this position.

2.Remove the tumbler shim guards from the inside and outside of the crawler frame to be adjusted.

3.Position suitable 25-ton hydraulic jacks behind each of the supports.

4.Remove several shims from behind the supports.

5.Actuate the hydraulic jacks to push the supports rearward to provide the desired belt tension. Make sure the supports slide straight in the crawler frame and do not become twisted.

6.Insert sufficient shims in front of the supports to maintain the adjustment. Several different thicknesses of shims are provided. Be sure that the shims are the same thickness behind each support.

7.Remove the hydraulic jacks. Reinstall the shim guards on the crawler frame.

8.Repeat the above procedure for the other crawler belt if necessary.

9.Remove all blocking and lower machine.

LINK REPLACEMENT

To replace a link in the crawler belts:

1.Propel the machine to position the defective link in an accessible position near one end of the crawler.

2.Remove the tension from the belt by removing all of the tensioning shims from behind the take-up tumbler supports. Refer to CRAWLER BELT ADJUSTMENT for details of this procedure.

3.Secure the belt against unwanted movement.

4.Attach a suitable lifting device to the defective link. Separate the belt at the defective link by removing the two link pins securing the link to one end of the belt.

5.With the lifting device, lower the end of the crawler belt with the defective link to the ground.

6.Remove the defective link from the belt.

7.Install the replacement link on the end of the belt resting on the ground.

Supporting the Crawler Belt with a Lifting Device

8.Using the lifting device, lift the end of the belt into position to insert the remaining link pins.

9.Insert the link pins and secure with cotter pins.

10.Remove any equipment securing the belt against movement.

11.Readjust belt tension as described in CRAWLER BELT ADJUSTMENT

BELT REPLACEMENT

Belt replacement is not frequently required. To replace a belt, first propel the machine to firm, flat, level ground.

1.Remove tension from the belt by removing the shims from behind the take-up tumbler supports as described in CRAWLER BELT ADJUSTMENT

2.Separate the belt at the midway point of the upper slide by removing the link pins.

3.Attach a suitable lifting device to the ends of the belt and drag and lift each end of the belt off the crawler frame and lay it on the ground.

4.Using the machine leveling jacks, raise the machine sufficiently to allow the old belt to be dragged from underneath of the crawler frame. Securely block the machine in this position.

5.Using a suitable vehicle and rigging, drag the old belt from underneath of the crawler frame.

6.Assemble the new belt and lay it flat on the ground near the crawler frame.

7.Using a suitable vehicle and rigging, drag the new belt underneath of the crawler frame so that the roller path in the center of the belt is aligned with the lower rollers, drive tumbler and take-up tumbler.

8.Remove the blocking and slowly lower the machine until the crawler rollers and tumblers are resting on the belt.

9.Using a suitable lifting device, lift the ends of the belt into a position to insert the link pins.

10.Insert the link pins and cotter pins to connect the belt.

11.Readjust the belt tension as described in CRAWLER BELT ADJUSTMENT

MAINFRAME

The mainframe on this machine consists basically of two I-beams joined with bracing and covered on the top surface with plates. Inspect the mainframe for wear, damage or cracks. Pay particular attention to the following critical areas:

•Cross bracing and deck plates which tie the top and bottom flanges of the I-beams together.

•Mast lock pin attachment areas.

•Leveling jack attachment areas.

•Areas where the mast A-Frame is pinned to the mainframe.

•Mast hoist cylinder attachment lugs and the immediate area surrounding these lugs on the mainframe.

Cracking, wear or damage to the critical areas listed above require immediate repair. The urgency of repair to other areas of the mainframe is dictated by the area in which the repair must be done and the severity of the damage. Minor damage may not require immediate attention but all damage to the mainframe should be repaired at the first available opportunity.

Repair to the mainframe is limited to repair welding. Follow the recommended procedures outlined in Section 9 ~ ENGINEERING DATA. If damage is severe or unusual circumstances arise, contact the Bucyrus Service Department for specific recommendations.

BIT VIEWING HATCH

The bit viewing hatch is mounted in the mainframe in line with the drill pipe and the operator’s station. When the hatch cover is lowered, the operator can view the bit as a new hole is started.

The structure should be checked monthly for weld cracks. The cylinder and hydraulic lines should be checked daily for leaks.

MAST A-FRAME

The mast A-Frame is a welded structure that is pinned to the mast and the mainframe and helps support the mast at its lower end. The rear leg anchor pins are hydraulically operated.

This structure should be checked monthly for weld cracks, structural bending and wear. The cylinders and hydraulic lines should be checked daily. Any cracking, wear, or damage to the A-Frame must be repaired immediately. Repair to the A-Frame is limited to repair welding. Contact your local Bucyrus International representative for a specific weld repair solution.

LEVELING JACKS

Inspect the leveling jacks for structural damage, proper lubricant coating and proper operation. Verify that all bolts are tight and all pins are in place. Check the jack pads for cracks or damage. Clean excess material from the jack pads. Check the jack spuds for wear or damage. Verify that the spuds are coated with lubricant.

The jacks operate properly when they do not settle or creep either while the machine weight is resting on the jacks or when the jacks are in the stored position. To check the jacks, raise the machine on the leveling jacks until the machine is completely off of the ground. Scribe a line on the jack spuds 1 foot below the jack housing. Allow the machine to remain idle for 1 hour. Measure the distance between the scribe lines and the jack housings. If the jacks have drifted more than 1/4 inch, the jack(s) and/or other hydraulic components are leaking and should be repaired.

Repair of the leveling jacks is limited to repair welding of selected components and clean-out of others. Repair welding of structural damage is allowable on the jack casing and jack pad. Follow the recommended repair welding practices outlined in Section 9 ~ ENGINEERING DATA to repair these items. If damage to the jack spud had caused it to become bent or out-of-round, WELDING IS NOT RECOMMENDED. Instead replace the damaged spud.

Repair of the hydraulic cylinder is limited to clean-out of the cylinder. Repair of the cylinder itself follows the basic procedures for repair of any hydraulic cylinder.

Repair of the jack casing is limited to repair of minor cracks or damages. Should any serious damage occur, consult the Bucyrus International Service Department for repair details. Note that bolts securing the rear jack casing to the mainframe should be tightened to 390 Ft. Lbs. (snugtight) then turned an additional 1/2 turn. Refer to turn-of-the-nut tightening method in Section 9 ~ ENGINEERING DATA. There should be hardened washers under bolt heads and nuts.

To remove and replace a hydraulic cylinder and jack spud proceed as follows:

1.If repairing the rear jack, lower that jack until the pad is 1 or 2 inches from the ground. Raise the other three jacks to the full retracted position.

If repairing a front jack, both front jacks should be lowered to 1 or 2 inches from the ground. Raise the rear jacks to the full retracted position.

2.Stop the hydraulic pump and relieve any pressure in the system by loosening the reservoir breather. When trapped air in the reservoir is relieved, immediately replace the breather.

3.Carefully disconnect the main hydraulic lines attached to the counterbalance valve at the jack cylinder.

NOTE: Do not disturb the lines going from the counterbalance valve to the electric junction box.

4.Cap the ends of the hoses removed in step 3.

CAUTION:If working on a rear jack, refer to steps 5 through 8 and 15 through 31. If working on the front jacks, refer to steps 9 through 31.

5.For rear jack repair, with an open-end wrench remove the female half of the quick disconnect from the male half that is attached to port PR of the counterbalance valve. Leave the 1/4 inch hose attached to the female half of the quick disconnect.

6.When step 5 has been completed, disconnect the 1/4 inch hose at the electric junction box.

CAUTION:ALWAYS MAINTAIN A FIRM GRIP ON THE HOSE WHILE THE OIL IS FLOWING. Do not allow the stream of oil to contact skin as injury may occur.

7.Place the open end of the above hose into an empty 5 gallon pail and reattach the female half of the quick-disconnect to the male half that is still attached to port PR. When the quick disconnect opens, a stream of oil from the rod side of the cylinder will exhaust from the 1/4 inch hose into the pail. This will allow the jack pad to lower by gravity to the ground. The oil will stop flowing.

8.Again remove the female quick-disconnect half with the hose as in step 5 and reconnect the hose onto the port of the electric junction box.

9.For front jack repair, uncouple the quick-disconnect at both front jacks, using a 1-1/4 inch open-end wrench. The male half of the quick-disconnect will remain attached to the valve.

10.At just one front jack remove the other end of the quick-disconnect hose from the electrical junction box on the jack.

11.Place the hose end, removed from the electrical junction box, into a clean five gallon container. (Two additional 5 gallons will be required to handle the oil from both front jacks.)

CAUTION:ALWAYS MAINTAIN A FIRM GRIP ON THE HOSE WHILE THE OIL IS FLOWING FROM IT. Do not allow the stream of oil to contact skin as injury can occur.

12.Re-couple the quick-disconnect. As the connection nears completion, oil will run out of the hose-end in the container and the jack pad will drop to the ground. This will relieve all pressure on the piston rod and create a vacuum on the housing-end of the cylinder.

13.A helper will be required to remove the oil from the other front jack. While one person continues to hold the disconnected hose into an empty 5 gallon container, the other re-couples the quick-disconnect on the other front jack. The oil from this jack will now flow from the hose being held.

14.When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

15.Remove the male half of the quick-disconnect from port PR and thread it loosely into the female half. Cover the open end with a protective cap.

16.Remove the 3/8 inch hose at the counterbalance valve and plug the open end of the hose.

17.Insert a SAE-6 steel O-Ring boss plug into ports PR and PH.

18.Remove the casing cover bolts.

NOTE: If one of the front jacks is to be repaired, the mast brace support must be removed and an eyebolt installed in the cover for removal purposes.

19.Remove the capscrew securing the shoe retainer to the spud. Separate the shoe from the spud and remove the retainer and split retainer from the shoe.

20.Attach a suitable lifting device to the lifting lug or eyebolt on the casing cover and carefully lift the spud and cylinder from the casing.

21.To remove the cylinder from the spud, remove the pipe plugs securing the spud foot pin and remove the pin.

22.Slide the cylinder from the spud. Remove the casing cover from the cylinder.

23.Repair or replace components as necessary.

24.Install the casing cover on the cylinder.

NOTE: The cylinder rod should be retracted fully into the cylinder body. If not, using hydraulic pressure retract the hydraulic cylinder to the fully-retracted position. Note that hydraulic pressure must be used and pressure be exerted at port VR before the counterbalance valves will allow the cylinder to move. Use oil similar to what is used in the hydraulic system.

25.Using a suitable lifting device, slide the cylinder, cylinder body end first, into the spud.

26.Align the foot pin holes and insert the foot pin. Secure with the square head pipe plugs.

27.Using a suitable lifting device, lower the spud and cylinder assembly into the jack casing.

28.Attach the casing cover to the casing. Note that the rear jack casing cover bolts must be tightened to 480 Ft.Lbs. There should be no plating or lubrication on the bolts.

29.Install the fittings into the hydraulic cylinder and attach the hydraulic hoses.

30.Position the pad under the jack and slowly lower the spud end into the pad. Attach the jack pad to the spud using the split retainer and solid retainer. Tighten the retainer capscrews to 280 Ft.Lbs. (dry threads).

31.Cycle the jack 2-3 times to check the operation of the unit and to remove any air pockets created during the repair procedures. The jack should be extended and retracted to the maximum without lifting the machine.

MACHINERY HOUSE

Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures and bracing. Always restore defective structural members to their original state by repair welding.

Periodically inspect the hinges and latches on all doors and windows to insure they will remain closed during machine operation. Verify the sealing of all doors and windows to prevent the entrance of dust. Search thoroughly for all loose or missing bolts. The absence of these fasteners can result in excessive vibration and wear of house components. Inspect the condition of the paint on both the interior and exterior surfaces of the house. Prepare and paint any areas where the paint has been damaged or any areas where repairs have been made.

Machinery House - Exploded View

Repair of the machinery house is usually limited to repair of individual structures within the house. Repair welding should follow the guidelines detailed in Section 9 ~ ENGINEERING DATA. Any repair procedure should be undertaken with the object being to prevent the entrance of dust, dirt, or moisture into the house. All joints in the house structure should be adequately sealed and openings in the machinery house should be kept to a minimum.

The machinery house roof is removable, as well as the cross members over the main air compressor. Verify that the cross members are securely fastened. Verify that the roof is sealed properly and that the clamps are secured.

WALKWAYS AND LADDERS

Inspect all handrails, walkways, platforms, stairs and ladders on the machine daily. Verify that all structural members are in good repair and that all fasteners and welds are intact. Repair or replace components immediately to insure the integrity of the structures and ensure compliance with safety regulations.

Retractable Boarding Stairway

Keep all walkways, stairways and ladders clear of materials which could present slipping or tripping hazards. Keep walkways clear of tools, supplies or other obstructions. Clean up all grease or oil spills immediately.

OPERATOR’S CAB

Inspect the operator’s cab daily for cracks or structural damage to all side, roof and floor panels. Check the doors and windows for proper operation and correct sealing. Keep the cab clear of all oil, grease or water spills to help prevent slipping.

OPERATOR’S SEAT

The individual operator may adjust the operator’s seat as desired with respect to height, tilt and travel. Periodically lubricate all bearings and pivot points to maintain smooth movement.

OPERATOR’S CONTROLS

Inspect all of the operator’s controls daily for wear or damage. Verify the correct operation of all controls daily. Repair or replace malfunctioning controls immediately. Clean all nameplates and markers and maintain all markers and signs in a legible condition including warning signs.

Operator’s Controls

MAST ASSEMBLY

The mast is a fabricated structure made of steel tubes and formed plates. The structure is formed by four vertical tubes tied together on three sides with tubular lacing. The fourth side is open to allow the rotary drive unit to be raised and lowered the length of the mast.

Inspect the structure daily for wear or damage. Inspect all mast ladders and platforms for loose hardware and structural integrity. Inspect the racking on the outside of the rear mast tubes for proper lubrication and any wear or damage. Inspect the mast hinge pins and the structure surrounding the pins for wear or damage. Verify that the hinge pin keepers are in place and tight. Inspect the mast hoist cylinder attachments for wear or damage. Lubricate the pins weekly with the appropriate lubricant. Inspect the mast lock pins for wear and damage. Verify that the lock pin hydraulic cylinders and hydraulic line are not leaking.

Every 80 operating shifts lower the mast and inspect all welds thoroughly for cracks or damage. Clean the racking on the outside of the two rear mast tubes and check the welds securing the racking to the tubes.

Repair of the mast structure is limited to repair welding of cracked or broken welds or components or replacement of severely damaged structures. Contact your local Bucyrus International representative for a specific weld repair solution. When repairing mast structures by welding it is important to keep in mind that the repair should return the structure to its original condition. All welds should be smooth and any notches or undercuts should be welded and ground. Do not add reinforcing material or change the geometry of the structure. Replace any damaged components with material of the same strength and cross section.

MAST SAFETY SLINGS

The mast safety slings are used to help prevent drill pipe from coming loose from the rotary unit and falling off the machine or onto the operator’s cab. The slings should be checked weekly to verify that all braces are properly adjusted and all yoke pins are secured in place. Repair of the safety slings consists mainly of replacing worn or damaged components. Repair welding may be used to repair cracks. Refer to Section 9 ~ ENGINEERING DATA.

ROTARY GEARCASE

CAUTION: UNEXPECTED OPERATION OR MOVEMENT OF THE PULLDOWN UNIT AND/OR ROTARY GEARCASE DURING SERVICE OR INSPECTION PROCEDURE CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Inspect the rotary gearcase every shift for loose or missing hardware. Check the gearcase for lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper lubricant to the required level. If water has accumulated in the gearcase remove the drain plug and completely drain the case. Refill the gearcase to the required level with an approved lubricant. Check the air swivel for leaks and repair as necessary.

Every 80 operating shifts partially drain the gearcase and remove the inspection cover. Inspect the gear teeth for wear or damage. Check the rotary drive shaft bearing pre-load. If any clearance exists in the drive shaft bearings it will be necessary to adjust the pre-load by removing shims from the lower retainer.

DRIVE SHAFT ADJUSTMENT

The drive shaft must be adjusted to give 0.003 - 0.005 inch pre-load on the bearings. To adjust the bearing preload proceed as follows:

1.Remove the capscrews which secure the lower bearing retainer to the gearcase. Remove the retainer shims.

NOTE: Cut shims in half for ease of removal and installation.

2.With the shims removed, reinstall the capscrews and tighten to 60 Ft.Lbs. to insure proper bearing seating.

3.Remove all the capscrews except two 180° apart. Retighten the remaining two capscrews to 50 Ft.Lbs. in 10 Ft.Lbs. increments so that the retainer remains square to the case. Turn the shaft and recheck the capscrew torque.

4.Measure the gap between the retainer and gearcase at both capscrews. Obtain the average gap by dividing the sum of the measurement by 2.

5.The average gap minus .003 to .005 inch is the total shim pack thickness required to provide .003 inch to .005 inch pre-load on the bearings.

6.Remove the two remaining capscrews and install the required shim pack and capscrews. Tighten the capscrews to 200 Ft.Lbs.

Repair of the rotary motor and the rotary coupling are covered under separate topics. Repair of the rotary gearcase is limited to replacement of worn or damaged components. The unit may be repaired in place on the machine or may be removed from the machine and repaired elsewhere. Refer to ROTARY/PULLDOWN GUIDE FRAME for the procedure necessary to remove the assembly from the machine. To repair the gearcase either on or off of the machine use the following procedure:

1.Securely block the gearcase in the upright position. Remove the rotary motor from the gearcase. Refer to ROTARY MOTOR. Drain the oil from the gearcase. Remove the motor adapter ring. Remove the motor O-Ring from the gearcase.

NOTE: If the drive unit is left on the machine, lower it to the bottom of the mast and rest it on the lower stops. Shut off and tag the controls.

2.Remove the air pipe and gasket from the swivel housing.

3.Remove the gearcase front cover and gasket.

4.Remove the intermediate shaft upper bearing cover and cover O-Ring. Remove the upper bearing retainer.

5.Install an eyebolt into one of the tapped holes in the top of the intermediate shaft. Support the shaft with rigging and a crane.

6.Support the intermediate gear with blocking so that when the shaft is removed the gear will not fall.

7.Remove the capscrews securing the lower bearing retainer to the gearcase. Remove the bearing retainer. Remove the O-Ring from the retainer.

8.Slowly lower the intermediate shaft out of the gearcase. Remove the lower bearing, retainer, and spacer from the shaft. The lower bearing has an interference fit of .0005.0025 inch to the shaft.

NOTE: The inner race of the upper bearing has an interference fit of .0006 - .0017 inch to the shaft and may require a slight force to separate it from the shaft.

9.Position the intermediate gear to be removed through the front opening of the gearcase. Remove the gear and upper bearing inner race and seal sleeve.

10.Remove the upper bearing cage and oil seal from the upper bore in the gearcase.

11.Support the drive shaft with blocking under the rotary coupling.

12.Remove the lockwire and capscrews securing the swivel housing to the gearcase. Remove the housing.

13.Remove the seals, and spacers from the housing.

14.Remove the locknut, lockwasher and spacer at the top of the drive shaft.

NOTE: The locknut has left hand threads.

15.Remove the capscrews attaching the lower bearing retainer to the gearcase.

16.Slowly lift the gearcase until the vertical shaft gear is resting on the bottom of the gearcase. If the weight of the vertical shaft will not free itself from the upper bearing inner race, additional force will have to be placed on the top of the shaft to force the race off the shaft as the gearcase is raised. The race has an interference fit of .0001 -.0021 inch to the shaft.

17.When the upper race is removed from the shaft, continue raising the gearcase until it clears the shaft. Remove the shaft and lower the gearcase back onto its blocking.

Rotary Machinery Drive Shaft Assembly

18.Remove the upper bearing inner race, seal sleeve, gear spacer and gear from the gearcase through the front opening.

19.Remove the upper bearing cage, oil seal and O-Ring from the upper bearing carrier. Remove the upper lower bearing cup from the lower bearing carrier. The cup has an interference fit of .0004 -.0050 inch to the carrier.

NOTE: The upper and lower bearing carriers are press fit to the gearcase and should be removed only if damaged or worn.

20.Remove the drive shaft clamp collars. Refer to SHOCK COUPLING or ROTARY COUPLING later in this section of the manual.

21.Remove the rotary coupling lower half from the upper half of the coupling.

CAUTION:In the following step a torch is used to heat the upper coupling half. When using the torch be sure to take all safety precautions. Also use suitable protective equipment when handling the heated item.

22.Use a torch to heat the upper coupling half and separate the two sections of the drive shaft. Remove the O-Ring from the drive shaft.

23.Slide the lower bearing retainer assembly from the shaft upper section and disassemble as follows:

a.Remove the O-Ring and shims.

b.Remove the seal retainer capscrews and retainer.

c.Remove the seals and spacer.

d.Remove the lower bearing cup from the retainer. The cup has an interference fit of .0010 -.0050 inch to the retainer.

24.With a bearing puller, remove the lower bearing cage and the upper lower bearing cage from the shaft.

NOTE: The lower bearing cage has an interference fit of .0005 - .0025 inch to the shaft. The upper lower bearing cage has an interference fit of .0028 - .0048 inch to the shaft.

25.Inspect all components. Repair or replace all components as necessary.

CAUTION: There are a number of steps in the following procedure which require heating of certain items prior to assembly. Use suitable protective equipment when handling the heated items.

26.To reassemble the gearcase first clean all components thoroughly. Inspect all bores and shaft surfaces and remove any nicks or burrs. Lightly oil all parts. Apply Loctite® #271 to all clean threads at assembly. Be sure to follow manufacturer’s instructions when using Loctite.

27.Install the lower bearing cup in the upper bearing carrier. This cup is interference fit to the carrier and will have to be pressed in. Be sure the cup is tight against the shoulder in the carrier.

28.Install the lower bearing cages on the drive shaft upper section. These cages are interference fit and will require heating in an oil bath to 250° - 300° F prior to assembly. Be sure the cages are tight against the shoulders of the shaft.

29.Assemble the lower bearing retainer assembly as follows:

a.Install the lower bearing cup in the retainer. This cup is interference fit and will have to be pressed in. Be sure the cup is tight against the should of the retainer.

b.Install the oil seals and spacer in the retainer. Be sure the lips of the seals face toward the bearing cup.

c.Install the seal retainer and capscrews. Tighten and lockwire the capscrews.

d.Install the O-Ring on the retainer.

30.Install the retainer assembly on the drive shaft upper section. Do not install the shims on the retainer.

31.Install the O-Ring in the bottom of the shaft upper section.

32.Heat the upper shock coupling half in an oven or oil bath to 250° - 300° F maximum. Install the rotary drive collar on the coupling. Insert coupling half on the half drive shaft and install clamp collars and bolts. Allow shaft to cool to ambient temperature.

33.Remove the clamp collars and install the rotary coupling upper cushion seal strip. Reinstall the shaft clamp collars, tighten bolts and lockwire. The splits in the collars should be offset 90 degrees from each other.

34.Reinstall remaining parts of shock coupling per ROTARY SHOCK COUPLING.

35.Install the drive gear in the gearcase. Make sure the gear is aligned to the shaft bore. Slowly raise the gearcase so that the shaft can be positioned for installation.

36.Securely block the drive shaft in an upright position. Slowly lower the gearcase down onto the shaft being careful not to damage the shaft threads. It may be necessary to rotate the gear slightly to align the splines of the gear and shaft.

37.Insert and snug tighten the lower bearing retainer capscrews.

38.Install the gear spacer, seal sleeve and upper bearing oil seal. Be sure the lip of the seal faces upward. Heat the upper bearing inner race in an oil bath to 250° - 300° F maximum and install on the shaft tight against the sleeve. Install the bearing spacer, lockwasher and locknut, then tighten the locknut firmly. Allow the race to cool to ambient temperature.

39.When the race has cooled remove the locknut and lockwasher, and install the upper bearing cage. Reinstall and tighten the lockwasher and locknut.

40.Preload the lower bearings as follows:

a.Tighten the lower bearing retainer capscrews to 60 Ft.Lbs. to insure proper bearing seating.

b.Remove the capscrews except two 180° apart. Retighten the remaining capscrews to 50 Ft.Lbs., in 10 Ft.Lbs. increments, so that the retainer remains square to the gearcase. Turn the shaft and recheck the capscrew torque.

c.Measure the gap between the retainer and gearcase at both capscrews. Obtain the average gap by dividing the sum of the measurements by 2.

d.The average gap plus .003-.005 inch is the total shim pack thickness required to provide .003-.005 inch preload on the lower bearings.

e.Remove the two remaining capscrews and install the required shim pack and capscrews. Tighten the capscrews to 200 Ft.Lbs. and lockwire.

NOTE: If the shims are complete circles, cut in half for ease of installation.

41.Install the seals and spacer in the swivel housing. Be sure the seal lips are facing upward. Install the O-Ring in the bearing carrier.

42.Install the swivel house and secure with the capscrews. Tighten and lockwire the capscrews.

43.Install the intermediate gear and block in place. Set the seal sleeve on top of the gear. Align the bore of the gear with the bore of the shaft.

44.Heat the lower bearing in an oil bath to 250° - 300° F maximum and install the bearing on the shaft. Secure the bearing with the retainer and lockwire the capscrews.

45.Install the O-Ring in the lower cover. Insert the shaft assembly into the gearcase. Install the lower cover and secure it with the cover capscrews. Tighten and lockwire the capscrews.

46.Install the upper oil seal. Heat the inner race of the upper bearing in an oil bath to 250°300°F maximum and install on the shaft. Be sure the race is tight against the spacer, then secure the race with the bearing retainer. Tighten and lockwire the retainer capscrews. Allow the race to cool to ambient temperature.

47.Install the upper bearing cage in the gearcase. Install the O-Ring on the upper cover and install the cover on the gearcase. Tighten and lockwire the cover capscrews.

48.Install the motor per ROTARY MOTOR and fill the gearcase with an approved lubricant. Lubricate all lube points with an approved lubricant.

ROTARY MOTOR

Inspection, lubrication and maintenance instructions for the rotary motor are described in the manufacturer’s Motor Manual. To remove the rotary motor proceed as follows:

1.Lower the rotary drive unit to the bottom of the mast and rest it on the lower stops.

DANGER: HIGH VOLTAGE! OPEN AND TAG THE AUXILIARY POWER AND CONTROL BREAKERS IN THE MACHINERY HOUSE BEFORE ATTEMPTING TO DISCONNECT THE MOTOR LEADS. Failure to comply may result in serious injury or death.

2.Have an electrician identify and disconnect the electrical leads to the rotary motor. Remove the cable from the junction box on the motor.

3.Remove the motor attachment stud nuts and washers.

4.Using a suitable crane and rigging, lift the motor from the rotary gearcase.

5.Repair or replace the motor as necessary.

6.The motor pinion is press fit to the motor shaft. Refer to Section 9 ~ ENGINEERING DATA for instructions regarding replacement or installation of the motor pinion.

7.Prior to installation of the motor, clean the mounting surfaces on both the gearcase and the motor.

8.Install the rotary motor in reverse order of removal. Tighten the attachment stud nuts using turn-of-the-nut method. Tighten nuts snug, and then an additional 1/3 turn. Refer to Section 9 ~ ENGINEERING DATA

ROTARY COUPLING

The rotary coupling is an optional assembly that connects the rotary drive shaft to the tool string. The coupling incorporates rubber cushions to reduce shock loading and an O-Ring to seal the main air passage. Inspect the rotary coupling every shift for loose or missing bolts or other wear or damage. Check the coupling frequently for air leaks and worn cushions. Check the coupling teeth for wear and damage.

CAUTION: UNEXPECTED OPERATION OR MOVEMENT OF THE PULLDOWN UNIT AND/OR ROTARY GEARCASE DURING SERVICE OR INSPECTION PROCEDURES CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Repair of the rotary coupling is limited to replacement of the lower coupling half, rubber cushions, and O-Ring. Replacement of the upper coupling clamp collar or drive shaft is detailed in ROTARY GEARCASE .

To replace the cushions, lower coupling half or O-Ring in the rotary coupling, proceed as follows:

1.Lower the rotary drive unit until it is approximately 6 inches from the stops.

2.Securely block under the lower half of the rotary coupling. Lower the rotary drive unit to rest the coupling on the blocking. Set the hoist brake and tag all controls to prevent unauthorized operation.

3.Remove the coupling bolts from the assembly.

4.Raise the rotary drive unit to allow access to the lower coupling half. Set the hoist brake and tag all controls.

5.Remove the lower cushion, seal strip and O-Ring from the coupling half.

6.Lift the upper coupling clamp collar to allow access to the upper cushion and seal strip. If the cushion is original equipment on the machine, it will be necessary to cut the cushion to allow removal.

7.Replace the upper cushion with a split type cushion and a new seal strip.

8.Lightly lubricate the O-Ring and groove. Install the ORing on the lower coupling half.

9.Install the lower cushion and a new seal strip on the lower coupling half.

10.Slowly lower the rotary drive unit to bring the coupling halves together. Be careful to align the two halves before lowering the drive unit completely.

11.Install the coupling bolts and lockwire as required.

NOTE: When installing coupling bolts use a dial indicator to check levelness of the lower half of coupling. If not level, tighten the bolts until equally tight and lower half is level.

12.Remove all blocking and test the coupling for proper operation.

ROTARY SHOCK COUPLING

The rotary shock coupling is an optional assembly that replaces the standard rotary coupling lower half. The shock coupling is used to reduce the shock loading transmitted to the rotary drive unit.

NOTE: The procedures detailed here are for a Bucyrus shock coupling. Since shock couplings manufactured by companies other than Bucyrus may be furnished with the machine, be sure to verify that the shock coupling being repaired is one manufactured by Bucyrus before using the procedure listed below.

Inspect the shock coupling monthly for loose or missing nuts, other wear, damage or air leaks. When the cushions have worn to a point that the 0.375 inch pre-load can no longer be obtained, the cushions must be replaced. If the bailing air is escaping from the shock coupling, the seals should be replaced. At this time, also check the seal tube for wear and replace if required.

CAUTION:UNEXPECTED OPERATION OR MOVEMENT OF THE PULLDOWN UNIT AND/OR ROTARY GEARCASE DURING SERVICE OR INSPECTION PROCEDURES CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Repair of the shock coupling is limited to replacement of worn or damaged components. Replacement of any of the components will require disassembly of the unit

To disassemble the shock coupling proceed as follows:

1.Place secure blocking under the shock coupling and lower it onto blocking. Shut off and tag the controls.

2.Remove the lock wire and slotted nuts from the shock coupling bolts. Remove the bolts and washers.

3.Be sure the coupling lower half is securely blocked, then slowly raise the rotary machinery until the drive shaft lower section clears the shock coupling lower half. Shut off and tag the controls.

4.Separate the upper cushion, lower cushion, cushion retainer, seal tube and seals from the lower half of the shock coupling.

5.If the drive shaft lower section is to be removed, use the procedure as outlined in steps 20 and 22 of ROTARY GEARCASE

6.Clean and inspect all components of the assembly. Replace worn or damaged components as necessary.

7.If removed, reinstall the drive shaft lower section per steps 31 and 32 under ROTARY GEARCASE

8.Assemble the upper cushion, lower cushion, cushion retainer, seal tube and seals to the coupling section.

9.Securely block the assembly in line with the drive shaft lower section. Lower the rotary unit slowly until the shaft is seated in the coupling. Do not compress the cushions. Be careful not to damage the seals.

10.Install the shock assembly bolts. Apply Loctite to the threads and hand tighten the slotted nuts to establish a free height. Refer to preload chart in Section 9 ~ ENGINEERING DATA for nut tightening.

11.Progressively tighten the nuts no more than 1/2 turn at a time until tightening is completed. Install lockwire.

CAUTION:UNEXPECTED OPERATION OR MOVEMENT OF THE PULLDOWN UNIT AND/OR ROTARY GEARCASE DURING SERVICE OR INSPECTION PROCEDURES CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

The rotary guide frame assembly consists of two frames that support the rotary machinery and the pulldown machinery. The guide frames also include the guide rollers which are used to align and secure the guide frame assembly to the mast.

Inspect the entire guide frame daily for loose or missing hardware. Inspect the bumper blocks for wear or damage and replace if necessary. Inspect the rack pinions for wear or damage. Check the adjustment of the guide rollers and adjust if necessary. Inspect the alignment of the guide frame in the mast. Check the main air pipe connections for leaks. Verify that the chock bars securing the rotary gearcase are in place and that the welds on the chocks are intact. Check the lubrication of the rack pinion.

GUIDE ROLLER ADJUSTMENT

The guide rollers on the rotary/pulldown guide frame keep the assembly aligned to the mast and the rack pinions in contact with the mast rack. As the guide rollers wear, it is necessary to periodically adjust the clearance between the rollers and the mast rack mounting tee. To adjust the guide rollers proceed as follows:

1.Position the rotary/pulldown unit so that the upper guide rollers and rack pinions are accessible. Shutdown and tag the controls.

2.Using a suitable jack or pulling device, pull or push the rack pinion retainer snug against the mast on both sides of the mast. This assures that the backlash of the pinions is correct.

NOTE: Also measure the distance from the face of the mast tubular column to the center of the bearing housing mounting bolt. This measurement will be used later to determine if the unit is parallel to the mast. This distance, dimension “X” in Section H-H, should be approximately 16.785 inches.

3.Remove the capscrew, nut and washer from the upper front guide roller eccentric pin handle. Move the handle until a gap of .060 inch exists between the roller and the mast column. Secure the handle with the capscrew, nut and washer.

Upper Guide Rollers

4.Remove the nut, washer and capscrew that secure the lower REAR guide roller eccentric pin handle. Move the handle to position roller against the mast, then measure the distance from face of the mast to the center of the rotary gearcase mounting bolts. This distance, dimension “Y” in Section J-J, should be approximately 16.035 inches. If it is not, continue moving the pin handle until the specified distance is reached. Secure the handle with the capscrew, nut and washer.

NOTE: Any variance in the “X” dimension from theoretical must be accompanied by a similar variance in the “Y” dimension to keep the head paralled to the mast.

(Right Hand Shown, Left Hand Opposite)

5.With a suitable jack or pull device, pull or push the roller snug against the mast.

6.Remove the lower FRONT handle from the camshaft. Rotate the cam shaft to bring the guide rollers in to contact with the mast collumn.

7.Align the handle on the cam shaft so that it is located between the maximum travel positions indicated in the above figure.

8.Fasten the handle to the cam shaft.

9.Hold the eye bolt to prevent it from rotating. Loosen then tighten the nuts on the eye bolt to extend the spring 0.25 inch.

Lower Guide Rollers (Left Hand Shown, Right Hand Opposite)

GUIDE FRAME REPAIR

Repair of the rotary/pulldown guide frame is limited to replacement of worn or damaged components. Repair welding of any of the components is not recommended. Since only limited repairs to the guide frame are possible with the unit installed on the machine the entire rotary/pulldown unit should be removed from the machine prior to repairs. Replacement of the rack pinions and guide rollers is possible without removal of the entire guide frame from the machine. The repair procedures for these components are included in the following procedures. To remove the guide frame assembly complete with the rotary gearcase and pulldown machinery from the machine, proceed as follows:

1.Lower the rotary drive unit to its lowest position and rest it on the lower mast stops. Open the auxiliary power and control breakers and tag all controls to prevent unauthorized operation.

2.Remove the upper air pipe from the swivel housing and from the guide angle. Discard the gasket. Use new gaskets at re-assembly.

3.Disconnect the electrical leads to the rotary and pulldown motor and remove the cable from the drive unit.

4.Disconnect and remove the lubrication hoses leading to rotary drive unit, if so equipped.

5.Using a suitable crane and rigging, support the entire rotary/pulldown unit.

6.Remove the upper and lower front guide roller eccentric pin handle anchor bolts and turn the handles to back off on the tension on the rollers to the mast.

7.Remove the capscrews that secure the bearing to the eccentric pins.

NOTE: It may be necessary to rotate the eccentric pin to gain access to the retainer capscrews.

8.Support the upper roller assembly and the lower roller assembly. Then using the pin handles, pull the upper and lower front eccentric pins from the rollers, bearing housings and guide frames.

9.With the crane and rigging installed in Step 5, lift the rotary/pulldown unit from the mast and place it on secure blocking.

10.Completely disassemble the front upper and lower guide rollers and eccentric pins which were removed in Steps 6 and 7. The bearings have an interference fit of .0010-.0030 inch to the roller and will require a puller for removal.

11.Remove the shipper shaft pinion retainers and remove the pinions.

12.Remove the rear guide roller retainer capscrews and remove the retainers, shims, rollers and spacers from the pin. Remove the bearings from the rollers. The bearings have an interference fit to the roller and will require a puller for removal.

13.Using the eccentric pin handles, pull the rear guide roller eccentric pins from the frame. Separate the handle from the eccentric pins.

14.Separate the pulldown motor coupling. Remove the motor hold-down bolts, chocks and shims. With a crane and suitable rigging remove the motor.

15.Remove the two spreaders at the top of the guide frame. Remove the pulldown unit guard.

16.Remove the bolts that secure the shipper shaft end bearing housings to the guide frames. Slide the housings toward the pulldown gearcase.

NOTE: The shipper shaft end bearing outer labyrinth seal is press fit to the bearing housing and will require a certain amount of force to separate it from the bearing housing. Remove the outer labyrinth seals.

17.Remove the pulldown gearcase hold-down bolts, chocks and shims. With a crane and suitable rigging maneuver the gearcase out of the guide frame and place it on secure blocking.

18.Remove the pulldown unit base.

19.Verify that the rotary gearcase is securely blocked and supported.

20.Using a suitable crane and rigging, support one side of the guide frame.

21.Remove the bolts securing the guide frame to the rotary gearcase and remove the guide frame from the rotary gearcase.

NOTE: It may be necessary to remove the upper chock bar from the guide frame in order to remove the guide frame from the rotary gearcase.

22.Repeat Steps 21 and 22 for the opposite guide frame.

23.Clean and inspect all components and replace as necessary.

24.Reassemble the guide frames and install on the machine in reverse order of disassembly. Note the following:

a.Locate and assemble the shipper shaft bearing housings to the guide frames.

b.Assemble the upper and lower guide rollers and handles to the guide frames. Shim the rollers to achieve .003 inch roller bearing end-play. Tighten the retainer capscrews to 55 Ft.Lbs.

NOTE: The upper and lower front rollers will have to be removed when the rotary/pulldown unit is installed in the mast.

c.Install the right and left guide frames loosely to the rotary gearcase so that the guide frames tip outward to allow the pulldown base to be installed.

d.Install the pulldown base with dowels and clearance bolts. Install dowels and clearance bolts in the rotary gearcase and tighten all bolts.

NOTE: All dowels are to be removed after chock bars are in place and replaced with bolts.

e.Install the pulldown gearcase and align to the center of the shipper shaft bearing housings. Shim the case as required to center the shaft to housings. Insure that the inboard retainers are loose on the shipper shaft when installing the case.

f.Install the bearings to the shipper shaft bearing housings and install all retainers and rack pinions. Chock the gearcase in place.

g.Install pulldown motor and align motor and coupling as follows:

1.Verify that the motor armature is centered and then position the motor so that there is a gap of .19 inch between shafts (approx. 1.44 inch between coupling hub faces).

2.The coupling should be aligned within .002 inch offset and .002 inch angular misalignment. To find the angular misalignment, measure the gap (“L”) between the coupling hubs along the circumference. The point 180° from the minimum measurement should be within .002 inch (.0508 mm).

3.Use shims under the motor mounting feet to achieve proper alignment.

4.When properly aligned, tighten motor hold-down bolts and weld chocks to the motor base.

CAUTION:In the following steps when welding chocks, be sure to follow all safety precautions. Also use suitable protection equipment when handling heated items.

5.Pack the coupling with lubricant.

h.Lay the rotary/pulldown unit down and install all lower chocks.

i.Remove the front upper and lower guide rollers and install the rotary/pulldown unit in the mast. Install the front upper and lower guide rollers and adjust per GUIDE ROLLER ADJUSTMENT.

j.Install the air pipe and lube line. The motors should be reconnected by an electrician.

25.Lubricate all points and verify correct operation of the rotary/pulldown unit.

PULLDOWN GEARCASE

CAUTION:UNEXPECTED OPERATION OR MOVEMENT OF THE PULLDOWN UNIT AND/OR ROTARY GEARCASE DURING SERVICE OR INSPECTION PROCEDURES CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. Lower the pulldown unit to its lowest possible position or secure it in place. Lockout and tag controls to prevent unexpected operation.

Inspect the pulldown gearcase every shift for loose or missing hardware. Check the gearcase for lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper lubricant to the required level. If water has accumulated in the gearcase, remove the drain plug and completely drain the case. Refill the gearcase to the required level with an approved lubricant.

Repair of the pulldown gearcase is limited to replacement of worn or damaged components. Refer to ROTARY/PULLDOWN GUIDE FRAME for the procedure necessary to remove the assembly from the machine. To repair the pulldown gearcase proceed as follows:

NOTE: BEFORE PROCEEDING, THE PULLDOWN GEARCASE MUST BE REMOVED FROM THE MACHINE PER STEPS 17 THROUGH 20 OF ROTARY/PULLDOWN GUIDE FRAME

CAUTION:Be sure the rotary/pulldown guide frame is secured to the mast by cable or other means. The rack pinions and upper guide rollers may be removed for this procedure.

1.Remove the bearing spacer from the ends of the shipper shaft. Use a puller to remove the end bearing from the shaft. The bearings have an interference fit to the shaft.

2.Slide the bearing housing from the shaft and separate the inner labyrinth seal from the housing.

3.If not previously done, drain the gearcase.

4.Remove bearing cover from the pinion end of the second intermediate shaft. Remove the ORing from the cover.

5.Remove the encoder housing cover, gasket and housing from the opposite end of the second intermediate shaft.

6.Remove the encoder coupling spring pins, then remove the encoder and coupling. Remove the retainer/encoder support from the gearcase. Remove the O-Ring and oil seal from the retainer.

7.Remove the bearing retainer from each end of shipper shaft. Separate O-Ring, oil seal and labyrinth seal from each retainer.

8.Remove the rod bolts, tapered pins and capscrews securing the gearcase cover to the gearcase. With a crane lift the cover from the gearcase.

9.Lift the shipper shaft from the gearcase. Remove the bearing spacer from the long end of the shipper shaft.

10.Remove the bearing retaining nut, lockwasher, bearing and bearing spacers from each end of the shaft.

11.Slide the shipper shaft gear from the shaft.

12.Remove the first intermediate pinion bearing retainer and shims.

13.Press the pinion assembly from the shaft. The bearings have an interference fit to the shaft. Remove pinion spacer from the shaft.

14.Separate the bearings and spacer from the pinion. The cup of the brake end bearing has an interference fit to the pinion and will require a puller for removal.

15.The first intermediate gear is interference fit to the pinion and should only be removed if required. If the pinion and gear are to be separated the lube fittings must first be removed.

16.Lift the second intermediate shaft from the gearcase. Remove the pinion end bearing retainer and bearing. The bearing has an interference fit to the shaft and will require a puller for removal.

17.Remove the encoder end bearing retainer and bearing. The bearing has an interference to the shaft and will require a slight force for removal.

18.Remove the gear spacer. The gear is interference fit to the shaft and will require a puller for removal. Remove the gear end key.

Pulldown Machinery Input Shaft

19.Remove the brake housing and cage mounting capscrews. Slide the brake assembly from the brake drive hub. Disassemble the brake as covered under HOIST BRAKE

20.Remove the brake drive hub retainer capscrew and retainer. Remove hub, hub spacer and oil slinger.

21.At the coupling end of the shaft remove the bearing carrier capscrews. Slide the shaft assembly from the gearcase. Remove the carrier gasket.

22.Remove spacer and bearing from the brake end of the shaft. The spacer and bearing are interference fit to the shaft and will require a slight force for removal.

23.Use a puller to remove half coupling from the end of the shaft.

24.Remove seal retainer from bearing carrier. Remove O-Ring, oil seals and seal spacer from the retainer.

25.Remove the bearing spacer and coupling spacer. The coupling and bearing have an interference fit to the shaft and will require a slight force for removal. Remove the carrier and bearing as an assembly, then separate them.

26.Remove the seal retainer from the brake side of the gearcase. Remove the gasket and oil seal from the retainer.

27.Clean and inspect all parts and repair or replace all damaged or worn parts. Reassemble in the reverse order of disassembly noting the following:

CAUTION:During reassembly of the pulldown gearcase certain items must be heated or cooled for assembly purpose. When heating or cooling the items take all necessary precautions and use suitable protective equipment when handling the heated or cooled items.

a.The input shaft bearings, bearing spacer and coupling half are interference fit to the shaft and will require heating to install.

b.Use thread locking compound on the brake hub retainer capscrews, the coupling end bearing oil seal retainer capscrews and the brake drive ring mounting capscrews. Tighten drive ring mounting capscrews to 140-150 Ft.Lbs.

c.Fill the cavity between seals with lubricant at assembly.

d.The second intermediate shaft bearing and gear are interference fit to the shaft and will require heating to install.

e.Use thread locking compound on the encoder end bearing retainer socket head capscrews.

f.The first intermediate shaft should be assembled as follows:

1.Install the pinion inner spacer on the shaft.

2.If removed during disassembly, reinstall the gear on the pinion. The gear is interference fit to the pinion and will require heat to install. Be sure key is installed in gear.

3.Install the inner bearing outer race in the pinion. Race is interference fit to the pinion and will require cooling to install. Slide the pinion assembly over the shipper shaft as far as it will go.

4.Heat the inner races of the pinion bearing and install with the spacer between them. Use the special spacer supplied with tools to clamp the bearing races. Secure the assembly with the bearing lock nut.

5.Assemble the remaining outer race and retainer. Install three capscrews equally spaced and tighten to 50 Ft.Lbs. Measure the gap at all three unused holes and calculate the average. Install the shim pack equal to average gap and install and tighten all retainer capscrews.

6.Remove the special spacer and install the remaining material.

HOIST BRAKE

CAUTION:UNEXPECTED OPERATION OR MOVEMENT OF THE PULLDOWN UNIT AND/OR ROTARY GEARCASE DURING SERVICE OR INSPECTION PROCEDURES CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. Lower the pulldown unit to its lowest possible position (0.04) or secure it in place. Lockout and tag controls to prevent unexpected operation.

The hoist brake is a spring-set, electric-release brake. Periodically inspect the brake (every 2000 hours min.) for wear by measuring the air gap through slots in the cage. One indication of brake wear is a brake release fault signal. When the air gap becomes excessive, the brake will not release. When the air gap reaches 0.065 inch, the gap should be adjusted. Normal operating gap is 0.040 inch. When the friction disc pack is worn to 1/2 its original thickness, the disc pack should be replaced.

BRAKE WEAR ADJUSTMENT

1.Make sure the mast machinery is blocked or manually locked in the lowered position. The brake needs to be released to perform the adjustment.

2.Remove the housing screws and brake housing using care to keep from damaging the switches located on the circumference of the coil housing.

3.Insert brass feeler gages (0.040 inch supplied with brake) into air gap at the three slots and release the brake electrically or with the manual release bolts.

4.Remove the locking screws from the wear adjusting ring in the slots of the cage.

5.Insert the adjusting rod into one of the holes in the wear adjusting ring and rotate counterclockwise to the end of the slot. Repeat until resistance is felt.

6.Remove the gages and turn the adjusting ring to the nearest end of the slot. Remove the rod and reinstall the locking screws.

7.Make sure the brake release switches are clean and actuate freely.

8.Set the brake and reinstall the housing. Apply a bead of silicon sealant to all exterior joints.

REPLACEMENT OF FRICTION DISCS

1.Energize the magnet and clamp the armature to the magnet body with four manual release bolts. De-energize the magnet and remove the leads.

2.Remove the cage mounting bolts and magnet body and armature assembly. Back-off the wear adjusting ring slightly to allow space for a new friction disc pack.

3.The friction disc pack may now be slid from the hub and cage. Note the order of the pack so that the new parts can be installed correctly.

4.Reinstall new friction discs in the correct order, with the intermediate discs between each friction disc.

5.Replace the magnet body and armature assembly. (Arrows stamped on each part must be in line.)

6.Reconnect the lead wires, energize the brake and remove the four manual release bolts.

7.Set the air gap to .040 inch per BRAKE WARE ADJUSTMENT.

DISASSEMBLY OF MAGNET BODY AND ARMATURE

1.Place the assembly in a press.

2.Press the armature against the magnet body and remove the manual release bolts from the armature. (6500 Lbs. press force required.)

3.Slowly release the pressure until the spring pressure is relieved. Remove the armature. The pressure spring assemblies may now be removed.

REASSEMBLY OF THE MAGNET BODY AND ARMATURE

1.Place the magnet body with its flange side up on a spacer on the press base.

2.Insert the pressure spring assemblies and set the armature in place being sure to align the arrows on the armature and magnet body. Insert temporary pins into the release bolt holes for aligning.

3.Press the armature against the magnet body (6500 Lbs. press force), remove the temporary pins and install four manual release bolts. Tighten the bolt to hold the armature against the magnet body. Remove the assembly from the press.

Hoist Brake Assembly

PIPE RACKS

The pipe racks are used to store drill pipe in a position from where they can be easily inserted into the drill string. The pipe racks are operated by a hydraulic cylinder which swings the rack into position to accept or deliver drill pipe.

Inspect the pipe racks daily for loose or missing hardware or any wear or damage. Inspect the racks each shift for proper operation. Verify that the pipe is held securely by the upper gate. Check the operating cylinder for proper operation and any oil leaks. Check the bushings on both the pipe racks for wear and replace as necessary. Check the pawls in the pocket on the lower end of the pipe rack for proper operation. Remove any dirt, ice or other debris from the pipe pocket and verify the operation of the gate operating system if no pipe is stored in the rack. Lubricate all points with the required lubricant.

Pipe Rack - Right

Pipe Rack - Left

With the exception of the bushings there are no other wear items on the pipe racks. All major components of the pipe racks should last through the lifetime of the machine. Repair of the pipe racks is limited to replacement of bushings and thrust washers. To replace the bushings and thrust washer, proceed as follows:

1.Raise the rotary drive unit to its highest position and set the hoist brake.

2.Disconnect, plug and tag all hydraulic lines to the pipe racks.

3.Secure the pipe rack to prevent movement.

4.Remove the bolts attaching the upper pivot bracket to the bracket support. Remove the bracket and then remove the bushing from the bracket.

5.Remove the bushing retainer. Remove the split bushing half from the bushing retainer.

6.Secure a suitable crane and rigging to the pipe rack. Separate and remove the rack positioning cylinder. With the crane, lift the pipe rack from the mast bottom plate.

7.Remove the bushing and thrust washer from the mast bottom plate and the split bushing half from the bushing retaining block.

8.Clean and inspect all components. Replace worn or damaged components as necessary.

9.Reinstall in reverse order of disassembly. Lubricate all lubrication points and check for proper operation.

Pipe Rack Bushings and Support Brackets

TOOL WRENCH

The tool wrenches consist of the Tool Wrench and the Breakout Wrench. They are used to clamp the drill pipe in order to break a pipe joint. The tool wrenches are two specially-built hydraulic cylinders operating inside a square casing. A spring loaded pawl engages a pocket in the drill pipe to prevent rotation of the pipe.

Inspect the tool wrenches daily for loose or missing hardware, or any wear or damage. Inspect the wrenches each shift for proper operation. Check each wrench and associated hydraulic lines for oil leaks and repair any leaks found immediately. Verify that the pawls are fully extended and secured with a dowel rod. Verify that the wrenches can pivot about the rear pin. Clean any accumulation of cuttings from beneath the wrenches. Verify that the top blocks are in place and intact. Verify that the rear pin bearing blocks are secured firmly to the drill deck and that the piston rod anchor bolts are secure. Lubricate the assembly with an approved lubricant at the recommended intervals.

Replace the entire tool wrench, remove the two hydraulic lines from the piston rod and then remove the four bolts securing the bearing blocks. Repair of the tool wrench itself follows standard procedures for repair of hydraulic cylinders.

Repair of the tool wrenches is essentially limited to replacement of the pawl insert. To replace the pawl insert, proceed as follows:

1.Remove the defective tool wrench from the drill deck by removing the hydraulic lines leading to the piston rod and removing the 4 bolts securing the bearing blocks to the drill deck.

2.Using suitable equipment compress the pawl springs slightly to remove pressure from the pawl retaining pin.

3.Remove the pawl retaining pin.

CAUTION:The pawl is spring loaded. BE SURE TO ADEQUATELY RESTRAIN THE PAWL BEFORE REMOVING THE RETAINING PIN. Failure to restrain the pawl will result in it being forcibly ejected from the cylinder body, possibly causing death or serious injury to personnel in the area.

4.Completely relax the tension on the pawl springs. Remove the pawl and pawl springs from the cylinder body.

5.Inspect the springs and pawl and replace as required.

6.Lubricate the springs and pawl with an approved lubricant and reassemble the components in reverse order of disassembly.

BREAKOUT WRENCH

The breakout wrench is used to break pipe joints that will not break using the rotary drive.

With the pipe secured by the tool wrenches, the breakout wrench switch is turned to and held in the EXTEND position. The breakout wrench extends, grips the pipe, then turns, breaking the pipe joint.

REPAIR

The breakout wrench should be inspected daily for wear or damage, loose or missing hardware, and proper operation. Repair of the breakout wrench is limited to the replacement of worn or damaged components.

GENERAL GUIDELINES FOR DISASSEMBLY

1.Remove attachment pins to remove hydraulic cylinders.

2.Remove pin to dismount lever.

3.Remove pins to dismount jaws.

4.Remove pins to sidemount arm. Check for excessive wear on brass washers.

5.If jaw replacement is necessary, teeth or jaw inserts must be removed. Softly strike the tooth to take it out.

6.Reinstall in reverse order, except for cotter pin.

7.Check the operation of the wrench. If the inserts contact the pipe, wrench is ready for use. If inserts do not contact the pipe, repeat steps.

AUXILIARY WINCH

The auxiliary winch is used to lift tools on and off the drilling deck. The winch consists of a hydraulically driven reel mounted at the bottom of the mast, a cable with hook, and cable guide sheaves at the top of the mast.

The oil level in the winch should be checked monthly. The sheaves at the top of the mast should be checked monthly for wear or damage. Once a year the sheave bearings should be repacked with lubricant.

For repair of the hydraulic winch refer to HYDRAULIC SYSTEM .

MAST BRACES

The mast braces on the machine are used to support the mast while propelling.

Inspect the mast braces daily for loose or missing hardware or any wear or damage. Replace any missing hardware and repair any damage immediately. Inspect the upper anchor pins, washers and retainer pins daily. Make sure that the retainer pins are in place. Inspect the mast brace structure for cracks and any other damage. Repair the mast brace structure using the repair welding techniques listed in Section 9 ~ ENGINEERING DATA. Inspect the telescoping lock pins for wear. The telescoping lock pin cylinders and hydraulic lines should be checked daily for leaks. Verify that the adjustment bolt lock nuts are tight and that the mast braces are adjusted properly.

Inspect the mast braces sleeves and supports for wear, damage or loose or missing hardware. Lubricate all pins with an approved lubricant at the recommended intervals. Lubricate the adjustment bolt with a rust inhibiting oil as required. The mast braces are not normally considered wear items; therefore, any repairs required will have to be handled on an individual basis.

CAUTION:THE MAST BRACES ARE CRITICAL COMPONENTS. CONSULT THE BUCYRUS SERVICE DEPARTMENT BEFORE ATTEMPTING MAJOR REPAIR OR MODIFICATIONS.

MAST BRACE ADJUSTMENT

Normally the mast braces are adjusted during the machine erection and further adjustment is not necessary. Special circumstances may require the readjustment of the mast braces to original settings. To readjust the mast braces proceed as follows:

1.Remove the telescoping lock pins from the mast braces.

2.Accurately level the machine. Be certain that all four corners of the machine are at the same elevation and that the mast is positioned vertically.

3.Loosen the adjustment bolt lock nut.

4.Turn the adjustment bolts until the telescoping lock pins can be freely inserted (approx. 14.25 inches ±2.50 inches from the centerline of the adjustment bolt pin to the end of brace).

5.Lock the adjustment bolt in place with the lock nut.

CAUTION:Once the mast braces are adjusted, it is not necessary to alter the adjustment unless the mast brace is replaced. Difficulty in pinning the mast braces usually results from the machine not being level or the mast not being vertical. ARBITRARY ADJUSTMENT OF THE MAST BRACES WITHOUT ACCURATELY LEVELING THE MACHINE MAY CAUSE SERIOUS DAMAGE TO THE MAST AND SHOULD BE AVOIDED.

NOTE: Proper adjustment of the mast braces is made with the machine leveled and supported on jacks. Difficulty will later be encountered in removal or reassembly of the telescoping lock pin if the machine is resting on the crawlers.

HYDRAULIC SYSTEM SYSTEM OPERATION

The following description consists of an overview of the systems and the relationship of the schematics to the actual components on the machine.

This machine has two separate, though not independent, major hydraulic systems: Propel circuit and Cylinder circuit. Both systems use a common 108 gal. capacity reservoir. The pumps for the circuits are driven through a gearcase by the main compressor motor. The gearcase will increase, decrease or maintain the same speed ratio between the motor speed and the pump speed. The main compressor motor determines the gear ratio of the gearcase.

The circuit consists of two hydraulic pump/motor drives, one for each crawler. Piggybacked to the left propel pump is a single gear pump which supplies oil under pressure to leveling jacks and mast raising cylinders and actuators. Piggybacked to the right propel pump is a two-section gear pump. The cover end pump supplies control pressure for the propel pumps as well as pilot pressure for the mast hoist, auxiliary winch and pipe rack valves. This pump also supplies oil to actuate the bit viewing hatch cylinder, boarding stair cylinder and the lube system.

The propel circuit includes brake controls for each crawler. For towing purposes, the system is equipped with a hand pump for manual release of the crawler brakes.

The shaft end pump of the two-section gear pump supplies oil under pressure to the remaining hydraulic cylinders and actuators of the machine.

The systems are totally sealed and filtered to keep the oil as clean as possible.

The gearcase with pumps is mounted to the rear drive shaft of the main air compressor motor. The reservoir, oil cooler and mainframe manifold valves are located at the rear of the machinery house and the various cylinders are mounted at various points around the machine.

If the machine is equipped with a cable reel, the complete cable reel hydraulic system, including reservoir, pump and motor are part of the cable reel unit.

CYLINDER CIRCUIT HYDRAULIC SYSTEM

Fluid for this system is supplied from the common 108 gallon reservoir. The single gear pump and two-section gear pump supply oil to the actuators at the following rates:

2704 RPM @......................................60 HZ

Single Pump....................................65 GPM

Shaft End Pump..............................17 GPM

Cover End Pump.............................18 GPM

2253 RPM @......................................50 HZ

Single Pump....................................54 GPM

Shaft End Pump..............................14 GPM

Cover End Pump.............................15 GPM

The multiple station manifold valve assemblies contain control valves for the various actuators. The control valves will be assembled in stacks – one stack for each actuator. A typical valve stack could include a relief valve, a flow control valve, a check valve, a quick disconnect valve for pressure testing and a solenoid valve.

Most hydraulic lines run from the manifold valve to bulkheads, then from the bulkheads to the actuators. All oil returning to the reservoir passes through 10 micron filters before entering the reservoir.

PROPEL CIRCUIT HYDRAULIC SYSTEM

Fluid for the propel system is also supplied from the 108 gallon reservoir. Most hydraulic control valves of the propel circuit are modules bolted directly to the pumps. The pilot pressure valve and brake valves are separate from the pumps. The oil for each pump control circuit is directed through a 10 micron filter equipped with a 25 PSID bypass valve.

The pilot pressure is controlled to 600 PSI by the sum of the 450 PSI relief valve and the 150 PSI supercharge relief.

The pumps are equipped with two main relief/pressure override assemblies referred to as a combination valve; one for the forward propel side, and the other for the reverse propel side.

The pressure override portion of the assembly is set at 4500 PSI. The main relief portion is set 500 PSI above the pressure override as a fixed nonadjustable level.

The pressure override valve prevents continuous dumping of excessive flow, at load pressure, through the main relief valves. This eliminates unnecessary heating of the oil and protects the pump and motor from damage.

HYDRAULIC SYSTEM CLEANLINESS

It is extremely important to use the correct oil in the system. It is equally important to keep the oil clean. Whenever a repair procedure requires a connection to be broken or a part to be replaced, first clean the immediate area around the joint and/or part to be replaced. This step is required to assure no contaminates enter the system through the hydraulic lines or replacement parts.

While performing the repair keep everything clean and also keep openings covered or plugged until they are reconnected. Contamination is the most common cause of trouble in a hydraulic system. It causes excessive wear of parts, interferes with the close clearances, and hinders normal operation.

NOTE: Never add oil to the system by removing the reservoir breather and pouring it in through the funnel. Even new drum oil is dirty and can cause sticking valves.

IMPORTANT: When hydraulic oil is added to the system, it should always be pumped into the system through the quick-disconnect coupling at the top of the tank. This connection insures that the new oil will pass through the tank return filters before entering the system.

If the pump used to add the oil is equipped with a filter buggy and the pump has been used for other fluids, the pump system and filter buggy must be purged of the other fluid prior to connecting the pump unit to the quick-disconnect coupling. This purging can be accomplished by flushing the pump unit and filter buggy with at least one gallon of the specified hydraulic oil.

For hydraulic oil benchmarks refer to HYDRO - HYDRAULIC OIL in Section 3 ~ LUBRICATION.

OIL AND FILTER CHANGES

During normal operation change the filter element when indicated by the condition indicator. This should be done with the oil at normal operating temperature and also whenever the oil is changed.

NOTE: Before changing the element, open the circuit breaker for the hydraulic pump motor. Be sure there is no pressure on the system to prevent possible oil leakage.

The change frequency for hydraulic oil depends on the type of oil used in the machine. This cycle can range from 2,000 hrs. for standard grade petroleum base type oil as determined by the lube bench marks, to 8,000 hrs. for certain synthesized hydrocarbon hydraulic oils as noted in the lube bench marks. These change frequencies can be shortened or lengthened depending on the condition of the oils. To determine the condition of the oils, samples should be taken periodically (i.e. 200 hrs.) and analyzed by a reputable manufacturer. When taking oil samples, never take the sample from the tank drain system. If possible, the sample should be taken from a point near the return manifold just before the return filters.

CAUTION:To minimize fire hazard, allow no open flames or other ignition sources when changing oil.

Water should be drained from the bottom of the hydraulic oil reservoir once a day, after a period of shutdown and when the oil is cold.

WEEKLY MAINTENANCE CHECKS

Check for correct operation of all components of the system. Valves, cylinders, motors and pumps should operate smoothly, with no jerking or binding. Check the oil level in the reservoir. The reservoir should be almost full (108 gal.) when the mast is horizontal and all other cylinders are retracted. With the mast vertical and all other cylinders retracted, the reservoir should be slightly below 7/8 full.

CAUTION: Before topping off the fluid in the hydraulic tank, VERIFY THAT THE MAST CYLINDERS ARE EXTENDED AND ALL OTHER CYLINDERS ARE RETRACTED. Failure to comply with the above (i.e. jack cylinders extended) will overfill the tank when the jack cylinders are retracted and will cause the tank to rupture.

CAUTION:DO NOT OPERATE WITH LOW OIL LEVEL. Operating with low oil level can cause cavitation and air pockets. This will cause faulty operation and can also cause damage to the system components.

Inspect all components and lines to be sure they are in good operating condition. Check for obstructed or distorted cylinders. Inspect the system for leaks. If a leak is found, tighten the screws or fittings around the leaking area before beginning major repairs. If that does not stop the leak, it may then be necessary to repair or replace the leaking part. If an O-Ring is damaged or missing from the hydraulic plumbing, check O-Ring kit 68120749 for replacement O-Rings.

The hydraulic oil reservoir is epoxy coated on the inside to prevent scale and oxidation.

CAUTION:DO NOT WELD ON THE RESERVOIR; IT WILL DAMAGE THE COATING.

HYDRAULIC PUMP DRIVE

The hydraulic system pumps are driven by the main air compressor motor through a gearcase. The gearcase is mounted to the compressor base. The oil level in the gearcase should be checked weekly and oil added if required. Daily check the gearcase for oil leaks and repair as required.

To remove and disassemble the gearcase, proceed as follows:

1.Place the machine in a secure area to perform the repair. Shut off and tag the controls.

2.Drain the oil from the gearcase. There is approximately 7.75 qts. of oil in the gearcase.

3.Remove the pump mounting capscrews and remove the pumps and gaskets.

4.Separate the gearcase drive coupling. Remove the gearcase mounting bolts. Remove the gearcase from the mounting pads. Note the thickness of shims.

5.On a clean surface, position the gearcase so that the hydraulic pump adapter plates are facing up. Remove the plate mounting bolts and lift the adapter plates from the gearcase.

Hydraulic Pump Drive Gearcase

6.Lift the driven gears and their bearings from the gearcase. This can be done by hand since the bearings are slip-fit to the gearcase and adapter pad bores. The bearings are press-fit to the gear hubs. It may be necessary to tip the gear slightly to clear the drive gear bearing pocket.

7.After the driven gears have been removed, turn the gearcase over so that the drive shaft and gear can be removed.

8.Remove the shaft adapter mounting bolts and remove the adapter assembly and gasket from the gearcase.

9.Separate the drive shaft adapter assembly as follows:

a.Remove the large snap ring from the bore of the adapter.

b.Remove the small snap ring from the drive shaft and pull the shaft from the adapter. Take care not to damage the oil seal.

c.Remove the bearing from the adapter. Remove the oil seal from the adapter.

10.Clean and inspect all parts. Repair or replace all damaged or worn parts and reassemble in reverse of disassembly, noting the following:

a.When reassembling the gearcase, use new seals, gaskets and bolts.

b.Use Locktite® 262 on all bolts and tighten all bolts to 200 Ft.Lbs.

c.When installing gearcase coupling, proceed as follows:

1.Verify that the motor shaft is centered.

2.Mount the coupling hubs on the motor and gearcase.

3.Mount the gearcase so that a .51 inch gap exists between the ends of the shafts.

4.Check the coupling for angular and offset misalignment. Maximum misalignment should not exceed .002 inch. Use shims under the gearcase feet to correct misalignment.

5.Tighten the coupling capscrews (dry threads) to 30 Ft.Lbs.

LEVELING JACK COUNTERBALANCE VALVE

If it becomes necessary to perform maintenance on the leveling jack counterbalance valve for any reason, relieve pressure in the cylinder using the following procedure:

1.Position the machine with crawlers on the ground and jacks retracted so that the jack pads are approximately one inch off the ground.

2.Turn off the hydraulic pump and relieve any pressure in the system by loosening the reservoir breather. When trapped air in the reservoir is relieved, immediately replace the breather.

REAR JACKS

1.Uncouple the quick disconnect using a 1-1/4 inch open end wrench. The male half of the quick disconnect will remain attached to the valve.

2.Remove the other end of the quick disconnect hose from the electrical junction box on the jack.

3.Place the hose end, removed from the electrical junction box, into a clean five gallon container.

4.Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

CAUTION:ALWAYS MAINTAIN A FIRM GRIP ON THE HOSE WHILE THE OIL IS FLOWING FROM IT. Do not allow the stream of oil to contact skin as injury can occur.

5.When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

6.With the pressure relieved, the counterbalance valve or jack cylinder can now be safely repaired.

FRONT JACK

1.Uncouple the quick disconnect at both front jacks, using a 1-1/4 inch open end wrench. The male half of the quick disconnect will remain attached to the valve.

2.At one front jack only, remove the other end of the quick disconnect hose from the electrical junction box on the jack.

3.Place the hose end, removed from the electrical junction box, into a clean five gallon container. (Two additional 5 gallons will be required to handle the oil from both front jacks.)

4.Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

CAUTION:ALWAYS MAINTAIN A FIRM GRIP ON THE HOSE WHILE THE OIL IS FLOWING FROM IT. Do not allow the stream of oil to contact skin as injury can occur.

5.A helper will be required to remove the oil from the other front jack. While one person continues to hold the disconnected hose into an empty 5 gallon container, the other re-couples the quick disconnect on the other front jack. The oil from this jack will now flow from the hose being held.

6.When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

7.With the pressure relieved, the counterbalance valve or jack cylinder can now be safely repaired.

PRE-START INSPECTION

If the machine hydraulic systems have had a major overhaul, the following prestart inspection should be completed before start-up of the machine.

CAUTION: Before starting pumps, establish a safe walking perimeter around machine to reduce possible injury to ground personnel due to automatic operation of boarding stair, dust curtain, or cable reel.

NOTE: Read all instructions before starting any individual test. Initial each step after its completion or record the requested information.

1.Check all lines and fittings for tightness and plumbing accuracy.

2.Visually check that no open port exists on any valve.

3.If the crawlers or mast have been removed from the machine, be sure that all ports have been plugged or capped and all loose lines terminated in a quick disconnect or plugged with a steel fitting.

NOTE: Make note of the oil manufacturer and type of oil being used in this hydraulic system (e.g. Conoco Syncom AW22).

4.Verify that the hydraulic reservoir is filled to the correct level with the required hydraulic oil.

5.Check the suction plumbing and the reservoir for external leaks.

6.From the test kit install 0-1500 PSI gauges to test ports 14 and 15 at the left and right propel pump charge filter outlet, respectively.

NOTE: All pressure gauges must be calibrated before using.

7.Verify that pump drive gear box is filled with 7.75 quarts of SAE. 80 - 90W oil.

8.Check the pump drive motor for correct rotation by jogging the main compressor start/stop pushbuttons, or PTO clutch, if diesel driven. Pump drive gearcase input shaft rotation is opposite pump shaft rotation.

9.After completing step #6, continue to jog the electric motor until pressure on the gauges at the test ports 14 and 15 is 100 PSI.

10.When pressure rise is verified, turn on the hydraulic pumps and visually check all plumbing for leaks.

HYDRAULIC SYSTEMS TESTS

The hydraulic systems are equipped with quick disconnect test ports for checking the operation of the systems.

These tests are designed to assure that the specified units are operating correctly and, if they are adjustable, that they are adjusted to the correct pressure setting. The results of each of the following tests should be noted in a log book. On future checks and in case of system failure, pressure readings can be compared to help locate the failure.

NOTE: For location of test points on the machine refer to the schematics at end of this section of this manual.

CAUTION:Before attaching or disconnecting pressure gauges to test ports be sure that the hydraulic pumps are turned OFF.

Propel Pump Charge Pressure:

NOTE: Charge pump relief adjustment is on right side of pump.

1.With pump controls set to NEUTRAL and the pumps running, check the pressure at test port 14 on a 1500 PSI gauge. Set the charge pump relief pressure of the left propel pump as required to obtain 350 PSI ±10 PSI (use 1-1/16 inch hex wrench and screwdriver).

2.With the pump controls in neutral and the pumps running, check the pressure at test port 15 on a 1500 PSI gauge. Set the charge pump relief pressure of the right propel pump as required to obtain 350 PSI ±10 PSI (use 1-1/16 inch hex wrench and screwdriver).

3.Turn off the pumps.

Control Pressure:

1.Electrically disconnect the Pilot Pressure Valve (PPV) at station 6 of the 6-station manifold. This is located immediately above and to the rear of the jack valve stand. With a 1500 PSI gauge at test ports 7 and 17, turn the pumps on. Record the pressure at test ports 7 and 17 (approx. 150 PSI). The pressure at test port 17 should be greater than at port 7.

NOTE: Before performing step 2, warm-up the hydraulic system so that the oil cooler motor has cycled ON at least once.

Sundstrand Pump Relief Ports

2.With the solenoid wires reconnected to Pilot Pressure Valve (PPV), start the pumps. After 10 seconds, with PPV energized, observe the pressure at test port 17. Adjust the relief valve at station 6 as required to see: 1000 ±10 PSI if GRACO central lube pump is used or 600 PSI ±10 PSI if LINCOLN central lube pump is used. Adjustment is facing the wall, opposite the electrical solenoid.

3.Record the pressure at test port 7 (approx. 150 PSI).

4.Note whether GRACO or LINCOLN central lube pump is on the machine.

Propel Enable Valve and Low Speed Select:

1.With the drill/propel select switch in PROPEL NORMAL, in on-board propel, with a 1500 PSI gauge at test ports 8 and 18, start the pumps and press the drill/propel ON pushbutton. Record the pressure at test ports 8 and 18. Test port 18 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK. Test port 8 reading should be zero (0).

2.With the pump still running, lift one propel joystick out of the DETENT position and then release it. Do the same with the other joystick.

NOTE: There is no need to move the joysticks out of NEUTRAL. Lift the joystick clutch straight up to engage solenoid Propel Active Valve (PAV).

Performing step 2 will cause PAV to energize. This should cause the pressure at test port 18 to go from 600 PSI to 0 and test port 8 should go from 0 to 600 PSI.

3.With a 1500 PSI gauge at test port 9 and the pumps running, rotate the Propel Selector Switch to SLOW speed and record the pressure. This should be within 50 PSI of control pressure check step 2.

4.With the Propel Selector in NORMAL, record the pressure at test port 9. (Should read zero.)

Jack Cylinder Check in Manual Mode:

NOTE: UNDER NO CIRCUMSTANCES MUST EITHER 3-SPOOL VALVE OR RELIEF VALVE ADJUSTMENTS BE ALLOWED TO BOTTOM-OUT. The spool valve is located on the back wall of the machinery house to the left of the hydraulic oil tank and slightly below the top of the tank. The main relief is near the inlet port.

1.With a 7,500 PSI gauge at test port 16 and the pumps running, energize auto level in RETRACT mode. With all cylinders fully retracted, adjust the 3-spool valve relief to exactly 3,300 PSI.

2.Check all jack controls for proper operation (i.e. moving the right front jack control to EXTEND, extends the right front jack. Check both directions with all 4 jacks).

NOTE: Recheck the hydraulic oil level and add oil as required.

NOTE: Set flow controls per FLOW CONTROL. Check before continuing with step 3.

3.Back-out the relief valve adjustment 1/8 turn and then tighten the jam nut.

4.Install a 0-1,500 PSI gauge at test port 70, located at the inlet to the back pressure valve underneath and slightly to the left (rear) of the 3-spool valve.

5.With the right front jack manually extending from full RETRACT position, adjust back pressure relief as necessary to 400 PSI.

6.With step 5 complete, install a 7,500 PSI gauge at test port 16. With the right front jack extending from full RETRACT towards the ground, adjust the relief valve located at the inlet of the jack spool valve on the jack stand to 3,200 PSI.

NOTE: Do not bottom any relief valve adjustments.

7.Recheck all jack controls for proper operation of the jacks.

8.Install all four jack pads.

Flow Control:

1.Remove the hose nearest the wall from the 3rd flow control (counting from left to right) on the jack valve stand. Install a -10 ORS steel plug into the open hose.

2.Install a 20 GPM Hedland flow meter #700-020 (inlet side) into the open port of the flow control.

3.Disconnect the hose coming from the spool valve to the 7th flow control. Install a steel -10 ORS cap onto the flow control’s open port.

4.Connect the outlet side of the flow meter to the hose just removed from the 7th flow control.

5.With the pumps running and with the aid of a helper, energize the left rear jack, in either UP or DOWN mode, to show flow in the meter. Adjust the flow regulator to the EXACT flow required.

NOTE: If all 4 jack cylinders are the same size (i.e. all are 8 inch bore diameter or all are 9 inch bore diameter), then do not use the flow setting chart. Instead, set all 8 flow controls to 15 GPM for 60 Hz machines as well as for 50 Hz machines running at 3,000 RPM input speed. All other 50 Hz machines are to be set at 12.5 GPM. If all 4 jack cylinders are not the same size, use the chart that follows.

6.After first flow regulator is tested, substitute the remaining untested regulators into the 3rd position until all eight flow regulators have been checked. All flow regulators MUST end up in their proper position when test is complete.

NOTE: During calibration of the flow controls, as well as anytime the jacks are being operated in MANUAL or AUTO-LEVEL mode, the flow controls should not exhibit any chattering or screaming noise.

7.With step 6 complete, reassemble hoses to proper ports.

8.Complete JACK CYLINDER CHECK IN MANUAL MODE starting with step 3.

NOTE: Read items 1 through 5 of this test before continuing.

1.Lower all jacks to the ground. The jack pads must be firmly on the ground but not lifting the machine.

NOTE: If in steps 2 and 3 the crawlers are not mounted and the machine is resting on blocks, only lift the machine a few inches.

2.Manually extend the left and right front jacks simultaneously to lift the front of the machine.

3.Manually extend the left and right rear jacks simultaneously to lift the rear of the machine.

4.Continue to lift the machine by alternating front to rear until the crawler tracks have cleared the ground by 3 or more inches. If the crawlers are not mounted, lift the machine approx. 6 inches off the blocks.

5.With the machine approximately level, position all manual jack controls to NEUTRAL and check for jack cylinder drift. Drift should not exceed 1/8 inch in 30 minutes.

Brake Release Pressure:

NOTE: The crawlers must be mounted to the mainframe for this test.

1.With 0-1500 PSI gauges at test ports 5 and 6 and the pump running, the pressure should be at or near zero with the propel joysticks in neutral and the drill/propel select switch in PROPEL NORMAL mode.

2.With the pump still running, lift one propel joystick and release it, then lift and release the other propel joystick. Anytime either or both joysticks are lifted full up out of the DETENT position, the Propel Active Valve (PAV) will energize and the pressure at test ports 5 and 6 should be the same as pressures noted in step 2 of CONTROL PRESSURE.

3.With drill/propel select rotated to DRILL mode, pressure at test ports 5 and 6 should be zero regardless of whether the joysticks are in or out of the DETENT position.

Propel Brake Emergency Release:

NOTE: This test must be performed with the pumps OFF.

1.Insert 0-1500 PSI gauges at test ports 5 and 6, rotate the bypass valve handle (located on the left side surface of left front jack housing) fully clockwise, and close the hand pump bypass valve, manually operate the pump handle to raise the pressure on the gauge until the operator’s display terminal screen displays: PROPEL BRAKE TOW RELEASE. Record the pressure that causes the operator’s display terminal screen display to appear. (Pressure should be 500 PSI.)

2.With step 1 complete, continue to operate the pump until the gauge shows 1,000 PSI. Record the amount of pressure drop in 5 minutes (should not be more than 500 PSI).

NOTE: Pressures in step 1 and step 2 should also appear at test ports 5 and 6 on 0-1500 PSI gauges.

Propel Pump Main Relief Pressure:

NOTE: During this test the crawlers must be mounted and there should be no crawler movement .

The main relief valves are on the top of the pump, as mounted on machine.

1.With the machine raised on jacks, a 7,500 PSI gauge at test ports 1 and 2 and a 0-1,500 PSI gauge at test port 59, disconnect the propel brake release line at the brakes and plug the hoses with a -6 O-Ring seal plug. Leave the port on the brakes open; do not cap or plug the fittings.

NOTE: Use a 5 mm Allen wrench and a 3/4 inch open end wrench to adjust main relief valves.

2.With the pumps running, energize the Propel Active Valve (PAV). Note the presence of 600 PSI at test port 59. Operate the left crawler control in the FORWARD direction by manually pressing coil PLV-FWD. Adjust the relief as required to 5,400 PSI on gauge at test port 1.

3.Maintain step 1. Place the left crawler control in the REVERSE direction by manually pressing coil PLV-REV. Adjust pressure as required to see 5,400 PSI at test port 2.

4.With the machine raised on jacks and a 7,500 PSI gauge at test ports 3 and 4, check the main relief pressures on the right crawler pump.

5.With the pumps running, operate the right crawler control in the FORWARD direction by manually pressing coil PRV-FWD. Adjust the main relief valve as required to 5,400 PSI on the gauge at test port 4.

6.Repeat step 5 except place the right crawler control in the REVERSE direction by manually pressing coil PRV-REV. Adjust the pressure as required to 5,400 PSI at test port 3.

7.Reconnect the propel brake release hoses that were disconnected in step 1.

8.De-energize Propel Active Valve (PAV).

Crawler Function:

NOTE: Check that the crawler gearcases have each been filled with 7.5 gallons of 80W-90W oil.

1.With the propel selector in SLOW SPEED, check the left crawler function in FORWARD and REVERSE. Record the time for 3 revolutions of the crawler sprocket:

60 Hz should be 3 revolutions in 63 seconds.

50 Hz should be 3 revolutions in 75 seconds.

2.Repeat step 1 with the propel selector in NORMAL SPEED. Record the time for 10 revolutions of the crawler sprocket:

60 Hz should be 10 revolutions in 67 seconds.

50 Hz should be 10 revolutions in 80 seconds.

3.Repeat step 1 for the right crawler.

4.Repeat step 2 for the right crawler.

Bit Viewing Hatch:

Check the function of bit viewing hatch with the switch in the operator’s cab. The hatch should open and close smoothly with no chattering action.

Boarding Stair:

Check the function of the boarding stair with the switch in the operator’s cab. The stairway should raise and lower smoothly with no chattering action.

Main Flow Valve:

1.With a 0-1,500 PSI gauge at test port 26 and with the pumps running, set the backpressure relief to 300 PSI.

2.With a 0-1,500 PSI gauge at test port 23 and with the pumps running and all valves deenergized, record the pressure observed.

3.With a 0-7,500 PSI gauge at test port 23 and with a 0-1,500 PSI gauge at test port 26, start the pump and energize the main flow valve (MFV) via the hydraulic test function. Adjust the relief valve of the center sandwich valve at station 1 to 3,000 PSI at test port 23. Record the pressure at ports 23 and 26.

NOTE: The top most sandwich valve of station 1 will be adjusted with the water injection pump function check.

Breakout Wrench and Tool Wrench:

Check the function of the breakout wrench and tool wrench with switches in the operator’s cab.

Dust Curtain Cylinders:

1.Check the direction of cylinder thread versus switch position.

NOTE: After 3 - 5 cycles, operation should be smooth with no jerkiness or chattering.

2.Adjust the door stops.

Dust Seal Slider:

Operate the dust seal slider forward and reverse to check function. Record the pressure observed at test port 24 on a 0-7,500 PSI gauge.

Mast Lock:

1.With a 0-7,500 PSI gauge at test port 21, energize Mast Lock Latch solenoid and check its function.

2.Adjust the relief as required to 1,000 PSI.

NOTE: Adjustment is facing away from left wall.

3.With the gauge still at test port 21, energize the Mast Lock Unlatch solenoid. The pressure should be 3000 PSI.

4.Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 21.

Mast Brace Lock Cylinders:

1.With a 0-7,500 PSI gauge at test port 23, energize the Mast Brace Lock (MBLV) solenoid and check its function.

2.Adjust the relief as required to 1,000 PSI while the Mast Brace Lock (MBLV) is energized.

3.Energize the Mast Brace Unlock (MBLV) solenoid. The pressure should be 3,000 PSI.

4.Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 23.

A-Frame Lock Cylinders:

NOTE: This test should not be run unless the mast is fully up or unless the mast is off the machine. Also, the mast lock cylinder pins MUST be extended before conducting this test.

1.With a 0-7,500 PSI gauge at test port 22, energize the A-Frame Lock (AFLV) solenoid and check its function.

2.Adjust the relief as required to 1,000 PSI. Adjustment is facing away from left wall.

3.Energize the A-Frame Unlock (AFLV) solenoid. The pressure at port 22 should be 3,000 PSI.

4.Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 22.

Mast Lock Constant Pressure:

1.With a 0-1,500 PSI gauge at test port 61, start the pump.

2.Rotate the Mast Lock switch to UNLOCK and then return the switch to NEUTRAL.

3.With the switch at NEUTRAL, the pressure at test port 61 should be 0.

4.Rotate the Mast Lock switch to LOCK and then return the switch to NEUTRAL.

5.With the switch at NEUTRAL, the pressure at test port 61 should be the same as pressures noted in step 2 of CONTROL PRESSURE

Mast Brace Constant Pressure:

1.With a 0-1,500 PSI gauge at test port 60, start the pump.

2.Rotate the Mast Brace switch to UNLOCK and then return switch to NEUTRAL.

3.With the switch at NEUTRAL, the pressure at test port 60 should be 0.

4.Rotate the Mast Brace switch to LOCK and then return the switch to NEUTRAL.

5.With the switch at NEUTRAL, pressure at test port 60 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

A-Frame Lock Constant Pressure:

1.With a 1,500 PSI gauge at test port 65, start the pumps.

2.Rotate the A-Frame Lock switch to UNLOCK and then return the switch to NEUTRAL.

3.With the switch in NEUTRAL, the pressure at test port 65 should be 600 PSI.

4.Rotate the A-Frame Lock switch to LOCK and then return the switch to NEUTRAL.

5.With the switch at NEUTRAL, the pressure at test port 65 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

MAST RAISE/LOWER

NOTE: This adjustment limits the maximum lowering speed of the mast.

1.With the pumps shut down, adjust the Hoist Flow Control located under the deck just forward of the rear torque tube. Loosen the setscrew and turn the adjustment in all the way.

2.Back out the adjustment 6 full turns and tighten the setscrew.

3.Install a 0-7,500 PSI gauge at test port 16 and proceed as follows:

a.If the mast is not mounted to machine, position the mast/winch selector to MAST HOIST and operate the master switch in MAST RAISE mode. If the cylinders are connected, the cylinder rods should both be extending.

b.When the rods have fully extended, the pressure gauge reading will be 2,500 PSI.

c.With the master switch in LOWER mode, the cylinder rods will retract. The pressure gauge reading should then be 2,500 PSI.

d.If the mast hoist cylinders are not mounted, then pressures at step 3b and step 3c will be seen almost as soon as the master switch is moved from NEUTRAL.

NOTE: The following step 3e is to be done with the jacks FIRMLY on the ground.

e.If the mast is mounted, check its function carefully by raising it 6 - 12 inches out of the rack. Observe the pressure on the 0-7,500 PSI gauge at test port 16. If more than 2,500 PSI is needed to lift the mast from the rack, adjust the port relief on the hoist side as necessary. Record the pressure needed to raise the mast.

f.Carefully position the master switch to LOWER mode and observe the “inching” capability of the control.

g.Raise the mast to full vertical (with the machine level and on all 4 jacks).

h.With a 0-7,500 PSI gauge at test port 16, observe the pressure needed to pull the mast out of vertical. Adjust the lower mode port relief as necessary to generate enough pressure. Record the observed pressure.

i.With a 0-7,500 PSI gauge at test port 16, the mast in a vertical position and with the mast brace and mast lock pins engaged, operate the mast hoist in RAISE and LOWER mode to set the port relief valves to 200 PSI greater than pressures observed at steps 3e and 3h respectively. Record set pressures.

NOTE: An alternate way to accomplish step 3i is to disconnect hoses at both mast hoist cylinders and plug the hoses with steel ORS plugs. With the hoses plugged, start the pumps and operate the mast hoist in RAISE and LOWER mode to set the port reliefs to 200 PSI greater than observed at 3e and 3h respectively. When the reliefs are set, reconnect the hoses and check the function of the mast hoist.

Bucyrus International, Inc.

Auxiliary Winch:

With a 7,500 PSI gauge at test port 16, proceed as follows:

NOTE: If the mast is not mounted, skip to step 4.

1.With the mast lowered and in the rack, operate the winch with no rope on the drum to check the winch direction verses master switch position.

2.Check the ability to smoothly start in the HOIST and LOWER mode.

3.Check the drum RPM in the HOIST and LOWER mode and record. Drum speed should be: 10 revolutions in 17 seconds (36 RPM).

4.If the mast is not mounted, set the port relief to 3,000 PSI in the HOIST position when moving the master switch out of NEUTRAL. Moving the hoist lever to full LOWER position should display 3,300 PSI on the gauge.

NOTE: If the mast is mounted, the port relief setting may be observed by first disabling WACV electrically and then proceeding per step 4.

Hydraulic Central Lube Drive Pressure:

NOTE: Steps 1 through 3 apply to a LINCOLN lube system with a LINCOLN lube pump only.

1.With the Lube Cycle Control Valve (LCCV) electrically disconnected and the pumps running, energize the Lube Enable Valve (LEV) solenoid.

2.Adjust the pressure reducing valve attached to the lube pump manifold to 450 PSI on a gauge attached to the manifold.

3.With the Lube Cycle Control Valve (LCCV) electrically connected and with the pumps running, observe that the lube pump is functioning.

NOTE: If grease is not pumped during the test, don’t run test step 3 any longer than necessary to see that the pump is cycling.

NOTE: There should be NO external hydraulic oil leakage during test.

NOTE: Steps 4 through 10 apply to a LINCOLN lube system with a GRACO lube pump.

4.Attach a 0-1,500 PSI gauge at test port 64.

5.Disconnect the hose from the upper run connection of the tee at test port 64. Plug and cap both open connections.

6.With the pumps running and the Lubrication Timing Screen displayed on the operator’s display terminal, press F9 to energize Lube Enable Valve (LEV) solenoid.

7.With step 6 complete, adjust the reducing valve to 900 PSI and then lock the jam-nut on the adjusting screw.

8.Press F9 on the operator’s display terminal to de-energize the Lube Enable Valve (LEV) solenoid.

9.Turn off the pumps and reconnect the line that had been disconnected in step 5.

10.Start the pumps and engage the Manual Lube Cycle (F9) to ensure that the pump functions properly.

NOTE: If grease is not pumped during the test, don’t run step 10 any longer than necessary to see that the pump cycles.

Window Guard Function:

CAUTION: Before starting test, make sure there is nothing laying on the window guard that could fall off. This could cause injury to personnel or damage to machinery. Keep personnel away from window guard area during test.

1.With a 0-1500 PSI gauge at test port 75 and with the Window Guard Valve (WGV) de-energized, energize the Main Flow Increase Valve (MFV) via the hydraulic test function on the operator’s display terminal screen.

2.Adjust the pressure reducing valve (same valve that test port 75 is attached to) to 500 PSI.

3.De-energize the Main Flow Increase Valve (MFV) and energize the Window Guard Valve (WGV) to check its function. After 3 or 4 cycles, the window guard should operate smoothly and without chatter.

Check Jacks in Auto Level Mode:

1.Manually position all jacks midway between the ground and fully up.

2.Position the auto level switch to RETRACT mode and observe that all 4 jacks simultaneously retract.

3.Insure that all 4 jacks are fully up, at which time the operator’s display terminal screen will show the jacks to be fully up and the retract solenoids at the jack valve control manifold have each turned off. The Jack Loader Valve (JLV) will stay energized as long as the switch position is maintained in RETRACT. When the auto level switch is returned to NEUTRAL, solenoid JLV should turn off.

4.With all jacks fully retracted, position the auto level switch to EXTEND and observe that all 4 jacks extend simultaneously. Do not extend the jacks all the way to the ground.

5.Run each jack down individually and manually check that each ground pressure switch activates and is shown on the operator’s display terminal screen.

6.Repeat steps 2 and 3.

7.With step 6 complete, position the auto level switch to EXTEND and observe the following actions of auto level while maintaining switch position:

a.Starting from full retract into extend, all cylinders will extend at once.

b.As each cylinder pad is lowered enough to generate ground pressure, it will stop moving until all four cylinder ground pressure indications are shown on the operator’s display terminal.

c.If the machine is out of level, it will level itself (first side to side and then front to back).

d.The machine will raise up straight and level on all four jacks.

NOTE: Step 5, step 6, and step 7 must be done with EXTREME care if the crawlers are not mounted to machine.

8.Position auto level switch to RETRACT to check its function.

NOTE: If the crawlers are not mounted on the machine, step 8 should not be run unless AT LEAST one observer is present outside the machine.

Pipe Rack Position:

With a 0-7,500 PSI gauge at test port 16, the selector switches in the operator’s cab set to DRILL mode and at PIPE RACK/JOINTS, proceed as follows:

1.Raise the left joystick out of detent, without leaving NEUTRAL, for one second.

NOTE: Step 1 is intended to allow sufficient time for the pipe rack lock pin to unlock the rack before the rack is allowed to be moved.

2.Move the joystick to full stroke, first in one direction and then the other. Pressure should increase smoothly with increasing stick travel. Pressure should be 2,500 PSI at maximum stroke in STORE position. Adjust the port relief as required. The pressure should be 3,200 to 3,300 PSI at maximum stroke in OVER-THE-HOLE position.

3.Recheck with the selector rotated to all four positions.

Pipe Rack Lock and Gate Cylinder Port Relief:

With the mast in the vertical position, attach a 1,500 PSI gauge to test port 52. With the pumps running, set the relief valve at station 3 of the 8-station valve located directly above auxiliary winch to 600 PSI.

Pipe Thread Lubricator:

NOTE: Station 2 of the 4-station manifold is located on right side wall of the machinery house.

1.Disconnect the hose at port A of the manifold station 2 and use a 6-ORS plug and cap to seal both openings.

2.Install a 0-1,500 PSI gauge at test port 71.

3.With the pumps running and the Lubrication Timing Screen showing on the operator’s display terminal, press F7 to energize the Pipe Thread Lubricator Valve (PTLV) solenoid.

4.Adjust the reducing valve at station 2 to 900 PSI on the gauge.

5.Press F7 again to de-energize (PTLV) solenoid.

6.Turn off the pumps and reconnect the line that had been disconnected in step 1. Remove the pressure gauge.

CAUTION:If the following step 7 will be run with grease (not dry), advise personnel to stay away from grease discharge.

7.With the hydraulic pumps running, press F8 on the operator’s display terminal to energize the Pipe Thread Lube Pump and observe that the pump runs.

NOTE: The pump will time-out between 1 and 10 seconds with initial time-out being set at 2 seconds. Time-out is set on the Lubrication Timing Screen on the operator’s display terminal.

Pipe Positioner Function:

Check positioner function as follows:

1.With the positioning switch set to OVER-THE-HOLE, the clamp stays open until the position cylinders are fully retracted, after which time the clamp should close.

NOTE: The clamp must NOT close until after the position cylinders are fully retracted.

2.When positioning the switch to STORE (i.e. moving away from Over-The-Hole), the clamp must open first, then the position cylinders will extend the clamp away from the drill steel to the STORED position.

NOTE: The position cylinders must not move until the clamp is fully open.

Center Guide Function / Constant Pressure:

1.Attach a 0-1,500 PSI gauge to test port 77 at station 7 of the 8-station manifold assembly in the mast.

2.Attach a 0-7,500 PSI gauge to test port 80 at port 3 of the line-mounted dual-relief valve in the mast.

3.Attach a 0-1,500 PSI gauge to test port 79 at port 5 of the line-mounted dual-relief valve in the mast.

4.With steps 1 through 3 complete, proceed as follows:

a.Activate the center-guide switch to OVER-THE-HOLE position and maintain the switch position while setting the relief valves.

b.Observe that the pressure at test port 77 is at or near zero.

c.Set the relief valve controlling pressure at test port 80 to 2,600 PSI.

d.Set the relief valve controlling pressure at test port 79 to 500 PSI.

e.Return the switch to its spring-centered position and observe that the pressure at test port 77 is 600 PSI.

NOTE: When returning the switch to NEUTRAL the center guide over-the-hole constant pressure valve will turn ON at station 7 of the 8-station manifold assembly.

5.Remove the gauges at test ports 79 and 80 and install a 0-1500 PSI gauge at test port 78 at station 5 of the 8-station manifold assembly.

6.With the center guide still over-the-hole from steps 4 and 5, position the switch to STORE and observe that the pressure at test port 77 drops from 600 to nearly 0 PSI.

7.The pressure at test port 78 should be at or near zero while the switch is held in STORE position.

8.When the center guide is at STORE position, return the switch to NEUTRAL and observe that center guide store constant pressure valve turns ON to raise 600 PSI at test port 78.

9.When 600 PSI shows at test port 78, test port 77 should be at or near zero.

10.When 600 PSI shows at test port 77, the pressure at 78 should be at or near zero.

11.Anytime the center guide over-the-hole or store solenoid is energized, the store and over-thehole constant pressure valves should be turned OFF.

Automatic Breakout Wrench:

1.Attach a 0- 1500 PSI gauge to test port 82 on the reducing/relieving valve to the right of the 8station valve on the mast.

2.Set the reducing valve to 550 PSI.

3.With the drill steel in the head, lower the head until the steel enters the deck bushing. Engage the tool wrenches to securely grasp the pipe.

Activate the automatic breakout wrench switch to EXTEND and then RETRACT to check proper function.

DUST CONTROL

The maintenance of the water injection system consists mainly of keeping the water tank full of clean water, checking weekly that the pump and valves are operating correctly, and that all hoses and fittings are not leaking.

DUST CONTROL OPERATION

With the operating mode switch in the DRILL position, the main compressor operating, and the butterfly valve open, turn switch WIS on the operator’s console to the ON position. Solenoid valve WPSCV will open allowing hydraulic fluid to the water pump drive motor. At the same time the solenoid valve WICV will open the ball valve allowing water to flow from the tank to the pump. In addition the ball valves will close.

The amount of water supplied is governed by the speed of the pump motor. Moving switch WIR on the operator’s console clockwise will increase the amount of water. A full clockwise position will supply the maximum amount of water.

Because water is always available at the pump inlet, water will begin pumping immediately. Water will flow from the pump through a flow control valve back to the tank. Once the water pressure increases over 30 PSI (check-valve cracking pressure) and overcomes air pressure from the mast air line, the water will begin to flow to the mast air line. Water will continue to flow until the water injection system is turned OFF or the main butterfly valve starts to close.

When the water injection system shuts down for any reason, the main butterfly valve will close and the drain valves will open to drain the system by gravity.

FILLING THE WATER TANK

The fill line of the water tank includes a ball valve-type shutoff and a basket-type strainer.

When filling the water tank, connect the water supply hose to the ball valve. Open the ball valve and fill the tank. When the tank is full, shutoff the ball valve and disconnect the water supply hose. Reopen the ball valve and allow the water in the fill line and tank standpipe to drain out. While the water is draining out it will backflush the strainer.

NOTE: Care must be taken in extreme cold weather to prevent the strainer from freezing. This may happen as the water is draining out of the fill line and backflushing the strainer.

If the strainer must be removed for cleaning, proceed as follows:

1.Loosen the two handscrews on the strainer cover.

2.Move the cover to the side. The strainer basket will drop out of the housing.

3.Clean the strainer basket and reassemble into the housing.

4.Close the cover and tighten the cover handscrews.

WATER INJECTION DRAINING PROCEDURE

NORMAL MACHINE OPERATION

The machine uses an automatic line drainage system. Once the water injection is shut off, a drain valve opens inside the tank. This allows the residual air pressure in the main air pipe to push the water out of the feed line that connects the main air pipe to the water injection supply line. The drain valve will remain open until the water injection is turn on.

MACHINE WITHOUT POWER FOR LESS THAN 8 HOURS

The water should be left in the tank if power is to be removed for less than 8 hours. The tank should be kept as full as possible when machine power is off. The tank is insulated and the water will slow the freezing process.

MACHINE WITHOUT POWER FOR 8 HOURS OR MORE

1.Turn off the power to the water injection tank heaters (WTH1, WTH2, & WTH3) and water injection compartment heaters (WICH1, WICH2, & WICH3). The breakers for these heaters are located in the load center near the front of the machinery house.

2.Drain the water using the large ball valve located at the bottom of the water injection tank.

3.Remove the access cover from the top of the water injection tank.

4.Pull the pump upward slowly allowing the water to drain from the pump output line. The hose should be brought to a level above the water injection drain valves. Hold the pump as the highest point in the system until all of the water has been drained from the pump and output hose.

5.Lower the pump into the water injection tank until it rests in the cradle at the bottom of the tank.

6.Replace the access cover.

Once power has been reestablished and the machine is ready for operation, refill the tank and turn the heater breakers back on.

SOFT START MAINTENANCE DURING COMMISSIONING

1.Torque all power connections during commissioning. This includes pre-wired equipment.

2.Check all of the control wiring in the package for loose connections. FOR THE FIRST MONTH AFTER THE STARTER HAS BEEN PUT IN OPERATION

1.Re-torque all power connections every two weeks. This includes pre-wired equipment.

2.Inspect the cooling fans after two weeks to ensure proper operation. AFTER THE FIRST MONTH OF OPERATION

1.Re-torque all power connections every year.

2.Clean any accumulated dust from the starter using a clean source of compressed air.

3.Inspect the cooling fans every three months to ensure proper operation.

4.Clean or replace any air vent filters on the starter every three months.

NOTE: If mechanical vibrations are present at the installation site, inspect the connections more frequently.

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Section 6 Brakes and Couplings

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Section 6

Brakes and Couplings

BRAKE HUB INSTALLATION

Brake hubs must be shrunk onto tapered motor shafts in order to achieve the tension and lockup required for the torque values involved. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

1.Clean the bore and shaft to remove any deformity and foreign matter.

2.Install the cold hub onto the shaft

3.Measure the position of the hub on the shaft carefully. Measure from the end of the shaft to the end of the hub.

4.Remove the hub.

5.Pre-heat the hub until the “estimated temperature difference” has been reached. Refer to table below.

Hub Adapter Pre-Heat Advance Requirements

NOTE: This table makes reference to brake hubs only, motor coupling advance data appears in a separate table later within this section.

Example:

If the shaft temperature = 25°C (77°F) and the estimated temperature difference from the table is 100°C (180°F), the hub must be heated to 125°C (257°F) for mounting.

CAUTION:Brake Hub temperature should never exceed 190°C (374°F) for installation.

CAUTION: PRE-HEATED COMPONENTS TEMPERATURES WILL OFTEN BE HEATED TO TEMPERATURES THAT CAN BE EXTREMELY HAZARDOUS. Use extreme care and always wear appropriate safety equipment when working with or around pre-heated components.

6.Wipe all oil from both the shaft and the bore of the hub prior to installation.

7.Replace the heated hub on the shaft.

8.Take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the hub and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact.

MOTOR COUPLING INSTALLATION

Motor couplings must be shrunk onto tapered motor shafts in order to transmit the torque values involved without slippage. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

1.Clean the bore and shaft to remove any deformity and foreign matter.

2.Install the cold coupling onto the shaft

3.Measure the position of the coupling on the shaft carefully. Measure the distance from the end of the coupling to the end of the shaft. The dimension derived during this step will be used later.

4.Remove the coupling.

5.Pre-heat the item until the “estimated temperature difference” has been reached. Refer to the following table.

Motor Coupling Pre-Heat Advance Requirements

Example:

If the shaft temperature = 25°C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the coupling must be heated to 125°C (257°F) for mounting.

CAUTION:Pinion or Brake Coupling temperature should never exceed 190°C (374°F) for installation.

CAUTION: PRE-HEATED COMPONENTS TEMPERATURES WILL OFTEN BE HEATED TO TEMPERATURES THAT CAN BE EXTREMELY HAZARDOUS. Use extreme care and always wear appropriate safety equipment when working with or around pre-heated components.

6.Wipe all oil from both the shaft and the bore of the coupling prior to installation.

7.Replace the heated coupling hubs on the shaft.

8.Take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the coupling and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact by marking during initial fit-up and comparing to actual fit after assembly.

MOTOR COUPLING ALIGNMENT

Final alignment of direct-driven units is made by moving or shimming the unit so that misalignment of the unit and drive shafts is within required tolerance from the general arrangement drawing received with the machine. Misalignment can be either offset, angular, or a combination of both. Misalignment can occur in both the vertical and the horizontal plane. Refer to the following illustrations to bring couplings within the maximum acceptable misalignment.

The following method of coupling alignment uses a dial indicator. Readings taken 180 degrees apart will measure the runout in one plane. It is important to rotate both shafts to avoid errors due to surface imperfections of the shafts or couplings.

PARALLEL MISALIGNMENT

Checking for Parallel Misalignment

1.Mount the indicator on this coupling hub.

2.Take readings in the horizontal plane at 90 and 270 degree positions on the hub while turning the shafts.

3.Correct offset misalignment in the horizontal plane by shifting inboard and outboard feet an equal distance.

4.Take indicator readings in the vertical plane at 0 and 180 degree positions.

5.Correct offset misalignment in the vertical plane by adding or removing an equal thickness of shims at each foot.

Checking for Angular Misalignment

1.Mount the indicator between the coupling hubs.

2.Measure the gap between the hubs at 90 and 270 degree positions.

3.Shift the outboard feet until coupling faces are parallel in the horizontal plane.

4.Take coupling readings at 0 and 180 degree positions.

5.Raise or lower the outboard feet with shims to parallel coupling faces in the vertical plane.

This condition is encountered often after major repairs have been made to a machine. To remedy this condition approach the problem from one aspect (either angular, or parallel) at a time. Once close perform the procedure for the other. Duplication of either, or both processes may be required.

Example of Parallel Misalignment

Example of Angular Misalignment

Example of Combination Misalignment

Section 7 Compressed Air System

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Section 7 Compressed Air System

COMPRESSED AIR SYSTEMS

The main air system supplies compressed air for bailing the hole during drilling. The air also cleans and cools the bearings in the bit. The air is compressed by a rotary oil flooded screw air compressor. Inlet air passes through a filter before entering the compressor.

Inside the air end the air stream will pass through a poppet valve used to control the amount of air in the compressor. Oil is then injected into the air stream to lubricate, cool and seal the screws of the air end. The compressed air/oil mixture leaves the air end and enters the separator tank. The separator tank removes the oil from the air stream. The separator uses swirling action in combination with 3 filter elements to remove the oil from the air. The air is then passed through a butterfly valve into the mast air pipe.

When the main air valve is activated, a butterfly valve in the mast air pipe is opened and the air flows through the main air piping to the rotary head. A passage in the rotary shaft allows air to flow into the drill pipe, through the bit and out of the hole, carrying out the cuttings.

When the compressor is unloaded by the operator switching into vent mode, the poppet valve at the inlet of the compressor closes, the main air valve closes in the discharge pipe, the blowdown valve opens allowing the air in the tank to go to atmospheric and the horsepower drawn from the motor will be greatly reduced.

The general maintenance required for the main air system consists mainly of inspection of the components of the system to see that they are working properly and that all liquids are at their proper levels.

AIR COMPRESSOR

The air compressor assembly is composed of the air end, separator tank and associated piping, valves, gauges and filters. The compressor is located on the left side of the machine at the rear of the power module.

Separator Control Components

AIR INTAKE FILTER

CAUTION:Take care to not allow dust, dirt or any foreign objects to fall into the compressor inlet during filter servicing.

This machine uses canister type air intake filter assemblies. One is located on the air compressor and one on the engine. To replace a filter element, remove the top cover, replace the element and reinstall the cover. New sealing washers should be used when servicing the air cleaner.

Should the air intake assembly require removal, remove the 12 hex head capscrews that fasten the intake to the machine, then lift the intake assembly off the machine. Remove and replace the mounting gasket if required. Reinstallation is the opposite of removal.

An air flow indicator is located at the base of the intake filter. Flow through the system will draw the indicator in toward the component during operation. If air flow is indicated while the system is off, push the reset pushbutton to restore the indicator.

Each of the three air cleaners located on top of the manifold consist of 1) a filter precleaner, and 2) the air cleaner. The precleaner filter should be inspected frequently and cleaned whenever necessary. The air cleaner medium should also be inspected at regular intervals (at least every two months), or more often as conditions warrant. If dirty, the medium can be cleaned in a soapy water solution. Allow the medium to dry completely before reinstalling it. The Primary Air Cleaner Medium should be replaced annually, or whenever a tear, hole or rupture is found during inspection.

A drain valve is located beneath the main frame immediately below the separator tank. Use this valve to drain oil from the tank. Also located here is a quick fill port with a check valve. The quick fill point is locate on the outer walkway. The check valve is used in line to prevent oil back flow.

VARIABLE VOLUME CONTROL

The variable volume feature is used to decrease the bailing velocity to reduce or eliminate sandblasting of the drill pipe and bit. This will result in increased life of these components. To reduce the bailing velocities, reduce the air flow rate or “CFM” of the compressor. Turning the variable volume control switch on the operator’s display will open the poppet valves integral to the compressor, reducing in three steps (1 - Poppet Open 92%, 2 - Poppet Open 75%, 3 - Poppet Open 68%) the amount of air produced by the compressor.

With the compressor CFM reduced, the operator can inspect the size of the chips produced from drilling and keep track of the life of the bit and drill tool. From this information, the optimum air volume can be determined.

Many bit manufacturers have instructional literature available with bit pressure tables. These tables will show what the bit pressure should be based on the size of orifices in the bit and the CFM produced by the compressor. Once the desired bailing velocity has been determined, adjust the variable volume switch to obtain the desired bit pressure.

NOTE: After adjusting the variable volume control, especially when reducing the compressor CFM by a large amount, make sure the tank pressure while drilling is greater than 30 PSIG. This will avoid excessive oil carryover.

Refer to the figure below for variable volume component locations.

The air compressor separator tank contains 3 air filter cartridges. These must be changed at 4000 hours or anytime more than 10 PSI pressure differential exists across the filters, or if the compressor starts to bypass oil. To replace the separator filter cartridges:

1.Shut down the machine. Ensure that the engine and compressor are powered down. Relieve any residual pressure in the main air line and the separator tank.

2.Loosen the 24 hex nuts that attach the separator cover to the tank. Loosen each nut enough to allow the attaching bolt to be pulled away from the tank and lowered.

3.With all 24 bolts pulled away, use the installed hydraulic jack at the lower, front of the separator tank to raise the separator cover enough to clear the filter cartridges.

NOTE:Be sure that the cover seal is not damaged during cover seal removal.

4.Once lifted, rotate the cover out of the way.

5.Remove the 3 hex nuts and the filter retainer which covers one of the filter cartridges.

6.Pull the filter cartridge out of the separator tank. Repeat for the remaining 2 cartridges.

Inspect all parts. Repair or replace as required. Reassembly is the opposite of disassembly. Note the following:

SEPARATOR COVER HARDWARE TIGHTENING PROCEDURE

Refer to the label on the left side of the separator tank. If the label is not readable, use the following tightening sequence.

Tighten all 24 bolts hand-tight to begin. Then tighten all bolts in order. Start at any bolt and continue around in consecutive order. Tighten the bolts incrementally 3 times as follows:

1.Tighten ALL bolts to 25 Ft. Lbs.

2.Tighten ALL bolts to 60 Ft.Lbs.

3.Tighten ALL bolts to 90 Ft.Lbs.

Compressor Air End Assembly

The air end of the compressor is an oil flooded, single-stage, twin screw, rotary type. The suction (inlet) port is located on the top, drive shaft (inboard) end of the compressor. The discharge port is located on the bottom (outboard) end. The air end is directly driven through a flexible coupling from the power drive transmission. The male rotor of the air end is driven by a gear mounted on an independent input shaft and a mating gear on the male rotor. The female rotor is driven by the male rotor because the rotors are meshed.

Air circulates through the system beginning at the air intake filter, passes through the intake valve and into the air end where it is compressed. As the male rotor is turned counterclockwise (by the clockwise rotation of the gear shaft and gears - not shown), it drives the female rotor counterclockwise. This action causes air to be drawn through the suction port completely filling the uncovered channels or grooves between the spiral (helical) lobes in the male and female rotors.

As the rotors continue to turn, the lobes begin to inter-mesh at the bottom. This inter-meshing causes the spiral grooves to become shorter, thus resulting in the compression of the air entrapped in the grooves. Compression continues until the grooves are uncovered by the discharge port. From the air end, compressed air is discharged at rated pressure into the air/oil receiver.

During the compression process, cool oil is injected into the entrapped air by a gear-type oil pump, direct driven by the outboard end of the female rotor. The oil is injected for the following reasons:

Cooling: The oil removes the heat of compression to maintain discharge air temperatures below 225°F.

Sealing: The oil seals the internal clearances between the rotor, cylinder, and discharge end casing to prevent loss of air volume back to the inlet.

Lubrication: The oil lubricates the rotors, bearings, gears, and mechanical shaft seal.

Separation of the oil from the air which was injected into the air end during compression begins in the separator. From 90% to 95% of the oil separation from the air is accomplished by a decrease in air velocity, changes in flow direction, adequate baffling and proper location of the inlet port. Final air/oil separation is obtained by forcing the flow through the separator elements to provide practically oil-free air at the outlet. Oil collected by the separator elements is returned to the system by the compressor scavenging line. To prevent tank over-pressurization, an air pressure relief valve is installed downstream or on the dry-side of the separator elements.

COMPRESSOR START-UP

NOTE: For accurate readings, the machine must be level when checking the oil level.

1.COMPRESSOR OIL - The compressor air end, separator and cooler must be filled with the recommended compressor oil.

NOTE: After initial start-up, the oil level in the separator will drop due to the oil filling the piping system. Shut down the compressor after approximately 15 minutes of operation. Allow the machine to sit for 10 to 15 minutes to allow air bubbles to settle out of the oil. Check the oil level gauge. If the oil level is below the sight glass, refill to the top of the sight glass.

CAUTION:The system contains hot oil under pressure. Always check the pressure gauge to make certain the pressure is at zero before opening the fill plug.

2.DRAIN THE CONDENSATE - Open the drain valve slightly to drain off any condensate into a container. Close the valve securely when oil appears. Dispose of the oil and condensate properly.

3.START THE UNIT - Start-up the compressor.

4.OBSERVE THE DISCHARGE AIR PRESSURE - During drilling operations, the main air valve will maintain a minimum pressure of approximately 30 PSIG in the receiver. Pressure higher than this minimum will be regulated by the drill bit orifice size or air pressure control valve setting. The discharge air pressure must not operate above the maximum rating plate pressure during the loaded cycle. However, momentary high pressures up to the 75 PSIG are permitted (e.g. to blow out clogged drill bit orifices).

NOTE: The tank safety valve is set at 140 PSI and should be replaced or serviced anytime it is opened.

5.OBSERVE THE DISCHARGE AIR TEMPERATURE - The maximum discharge air temperature must not exceed 225°F.

NOTE: The air temperature limit is factory set to shut down the unit at 225°F.

6.OBSERVE THE OIL INJECTION TEMPERATURE - The oil injection temperature must not exceed 180°F.

7.PERFORM MAINTENANCE CHECKS - Refer to the proper area of this manual for recommended maintenance checks.

8.UNLOAD THE COMPRESSOR – To unload the compressor, the compressor vent valve (CVV) is energized, closing the inlet valve, and the drill air solenoid valve (DAV) is energized to close the main air valve. The air pressure in the tank is bled down using the blow down solenoid valve. Air pressure in the tank will range from 0 to 45 PSI, depending on the quality of the seal on the inlet valve.

NOTE: The discharge air temperature must not exceed 225oC. Oil injection temperature must not exceed 180oF.

9.In cold weather, immediately after start-up, the CVV valve is forced closed loading the compressor and building 65 psi in the reserviour tank. This feature is used to heat the air compressor oil more rapidly. The resulting higher pressure will push the oil through the oil cooler when the thermostatic valve opens.

COMPRESSOR SHUTDOWN MODES

COMPRESSOR FAILURE FAULT

The compressor will shut down if the air temperature is above 100oC and the oil temperature is less than 40oC below the air temperature.

Example:Air Temp. (105oC) > Oil Temp. (64oC) > Fault

COMPRESSOR COOLING FAILURE FAULT

The compressor will shut down if the air temperature is above 100oC and the oil temperature is within 10oC of the air temperature.

Example:Air Temp. (105oC) > Oil Temp. (99oC) > Fault

COMPRESSOR OVERHEAT FAULT

The compressor will start to go into safety mode. Remove the load on the compressor. This fault occurs when the air temperature is above 100oC and the oil temperature is within 40oC of the air temperature, but is not within 10oC of the air temperature.

COMPRESSOR AIR TEMPERATURE FAULT

If the air temperature reaches 107oC the compressor will shut down.

THERMOSTATIC CONTROL VALVE

The thermostatic (3-way) control valve controls the oil flow to maintain a 130°F (54°C) minimum oil injection temperature.

On start-up, with the unit cold, the thermal element is open to the bypass line. Oil flows from port B through port A to the compressor, bypassing port C to the cooler. The element is factory set to open at 130°F (54°C). As the receiver oil warms up to this temperature, the thermal element gradually closes port B and opens port C. This allows the cool oil from the radiator cooler to mix with the bypass oil. After the unit is warmed-up, the thermostatic control valve will normally be open to port C. This produces an oil injection temperature above 130°F (54°C), but not higher than the 150°F (65°C) maximum allowed.

If the compressor shuts down under high air temperature conditions, the thermal element may be stuck in the bypassed position from port B to port A. Let the unit cool down and then restart the compressor. If the oil injection temperature continues to rise past the 150°F (65°C) maximum allowable, shutdown the unit immediately. Remove, clean, test, and replace the thermostatic element, if required.

Remove, clean and test the thermostatic control valve as follows:

1.Shut down the compressor. Lockout and tag the compressor controls. Allow the system to cool if at all possible. Drain the oil. Relieve the oil pressure in the lines to and from the thermostatic valve.

2.It may be necessary to remove the thermostatic valve from the machine in order to separate the components. However this is not required. At least disconnect the compressor supply hose at valve port A.

DANGER:STORED ENERGY! At operating temperature, the hydraulic fluid is are hot and pressurized. Hot hydraulic fluid may cause burns. Hydraulic fluid under pressure may cause injury or death if not released in a controlled manner before the lines are disconnected.

3.Remove the four bolts and lockwashers attaching the adapter housing at port A.

4.Remove the adapter housing and O-Ring.

5.Remove the thermostatic element assembly and seal.

6.Clean the element and test as follows:

CAUTION:The valve housing and thermostat may be hot. Use suitable protective equipment when handling any hot items.

7.Place the element in 150°F (65°C) water and stir the water vigorously with the element for 5 minutes. Immediately place the element in the housing. If the element is fully stroked, the seating of the element against the upper housing can be felt. If the element is not fully stroked and seated, replace with a new element, [130°F (54°C) setting] .

CAUTION:Replacement element must be the same as the original. Do not replace with other brands.

8.Clean the internal surfaces of the adaptor housing and the main valve housing.

9.Lubricate a new O-Ring and slide it over the top of the element assembly and into position on the element.

10.Place a new housing gasket in the recess of the main valve housing.

11.Insert the element into the adapter housing. Install the adapter housing over the element.

12.Install the housing capscrews and lockwashers and tighten. Refill the oil in the system. Remove the compressor lockout and restart the compressor. Test for leaks and for proper operation.

INTAKE VALVE, AIR END

The intake valve plate and operating piston are located in the upper section of the air end cylinder. To service the intake valve proceed as follows:

CAUTION:Take great care not to allow cleaning material, debris, tools or small components to fall into the air intake opening.

1.Remove the air intake filter adapter flange bolts.

2.Carefully lift the air intake filter assembly from the air end.

NOTE: DO NOT slide the air cleaner off the air end as damage to the intake operating piston rod could occur. The intake assembly must be lifted straight up several inches to clear the valve assembly.

3.Remove and discard the air cleaner to air end mounting flange gasket.

NOTE: Take care not to damage the valve plate retaining flange by dropping, etc.

4.Remove the valve plate retaining flange bolts, if used, and remove the flange.

NOTE: A high temperature chemical sealer is used as a gasket between the flange and air end.

5.Lift the intake valve plate up and off the piston rod.

6.Remove the valve plate spring from the retainer.

7.Remove the piston retainer plate bolts and remove retainer plate.

NOTE: A high temperature chemical sealer is used as a gasket between the plate and the piston cylinder.

8.Remove the piston springs. Remove the piston and rod assembly by pulling up on the piston rod. Remove the piston seals from the piston. Discard the seals.

9.Remove the piston cylinder socket head bolts and remove the piston cylinder.

NOTE: A high temperature chemical sealer is used as a gasket between the piston cylinder and air end.

10.Clean all parts thoroughly. Inspect for wear or damage and replace as required. Make certain all old sealing material is removed from the sealing surfaces.

CAUTION:Take great care not to allow cleaning material, debris, tools or small components to fall into the air intake opening.

Normally, further disassembly is not required. However, if the operating piston or piston rod is to be replaced, refer to step 11. If the operating piston rod bushing is to be replaced refer to step 12.

11.To replace a piston or piston rod, proceed as follows:

a.Place the piston rod in a soft (wood, copper or brass) jaw vise and clamp securely.

b.With the correct size wrench, loosen and remove the piston rod bolt.

c.Replace the damaged parts and reassemble the piston on the piston rod.

d.Coat the threads of the piston bolt with thread locking compound (Loctite(r) 242 or equivalent).

e.Reinstall the bolt and tighten securely.

12.To replace the piston rod bushing in the piston retainer, proceed as follows:

a.Place the piston retainer bottom-side-down on a solid, flat surface (bench or press base). Using the correct size shoulder drift (bushing drive), drive or press the bushing downward and out of the retainer.

NOTE: To loosen the locking compound on the bushing, it may be necessary to heat the retainer with a soft flame to 200°F (93°C). This will soften the locking compound.

CAUTION:Take all necessary precautions when heating the retainer. Also, use proper equipment when handling the heated item.

b.Clean the bore of the bushing thoroughly.

c.Coat the new bushing with locking compound (Loctite 609 or equivalent) and reinstall (press or drive) the bushing into the retainer.

d.Allow the retainer to set for 15 minutes to cure the compound. Remove all excess compound.

e.Check the fit of the bushing on the piston rod for free movement. Remove burrs and burnish the bushing as necessary to obtain free movement of the piston rod in the bushing. Apply a small (1/16" diameter) continuous bead of sealer (Loctite 515 or equivalent) to the piston cylinder mounting face of the air end cylinder.

13.Reinstall the piston cylinder (with the bolt holes correctly aligned) on the mounting face on the air end cylinder.

14.Coat the threads of the piston cylinder bolts with locking compound (Locktite (r) 242 or equivalent) and install the piston cylinder. Tighten securely.

15.Install new seals on the piston. Position the seals so that the upper seal-lip is turned up and the lower seal-lip is turned down.

16.Lubricate the piston seals and piston cylinder bore with silicon lubricant (Dow Corning 55M or equivalent).

17.Insert the piston into the piston cylinder. Take care not to deform or damage the seals during installation.

18.Reinstall the piston springs.

19.Apply a small (1/16" diameter) continuous bead of sealer (Locket 515 or equivalent) to the top end of the operating piston cylinder.

20.Coat the threads of the piston retainer bolts with locking compound (Locket 242 or equivalent).

21.Install piston retainer with bolts. Tighten bolts securely.

22.Reinstall the intake valve plate spring.

23.Reinstall the intake valve plate. Make certain the valve plate slides freely on the operating piston rod.

24.Apply a small (1/16" diameter) continuous bead of sealer (Loctite 515 or equivalent) to the valve plate retaining flange mounting surface of the air end cylinder (inlet opening).

25.Carefully reinstall the valve plate retaining flange with bolt holes correctly aligned. Reinstall the flange retaining bolts, if used.

26.Install a new air intake filter mounting flange gasket.

27.Reinstall the air intake filter. Reinstall the bolts and tighten securely.

AIR END INPUT SHAFT OIL SEAL REPLACEMENT

The air end input shaft rotary oil seal may be replaced as follows:

1.Remove the drive shaft guard cover.

2.Remove the coupling halves. (Remove main motor to gain access to the coupling halves.)

3.Retain the coupling halves.

4.Disconnect and remove the oil line from the seal retainer.

5.Match-mark the seal retainer and gear housing cover to assist with correct reassembly.

6.Remove the oil seal retainer bolts and remove the retainer.

7.Remove the oil seal assembly, including the spring and spring guide, from the input shaft.

8.Remove the oil seal face insert, with O-Ring seal, from the retainer. Remove the retainer ORing seal from the retainer. Discard the face insert, with O-Ring seal, and retainer O-Ring seal.

9.Thoroughly clean all remaining parts.

10.Lubricate the new seal face insert and O-Ring seal with clean compressor oil. Install the insert in the seal retainer. Install the new retainer O-Ring seal and lubricate with clean compressor oil.

11.Lubricate the rotary seal assembly with clean compressor oil, including the carbon ring. Install the seal spring guide, spring and seal assembly on the input shaft.

NOTE: Remove all burrs that may be on the input shaft prior to installing the seal.

CAUTION:Be careful not to scratch the seal face insert, or scratch or break the carbon ring of the seal assembly. Wipe the tapped (mating) surfaces of the seal insert and carbon ring with a clean lint-free cloth before installing the seal retainer.

12.Carefully reinstall the seal retainer and retainer bolts. Tighten the bolts securely.

13.Reinstall the oil line on the seal retainer.

14.Install the coupling halves and reinstall the main motor, making sure to accurately align the main motor and air end shafts. When installing the coupling halves, use loctite and torque bolts to 75 ft/lbs on both the compressor and pump drive ends and then reinstall the drive shaft cover guard.

INLET REGULATING VALVE

At start-up, the rotation of the compressor rotors produces a vacuum downstream from the inlet regulating valve. This drop in pressure causes the atmospheric pressure upstream of the valve to “push” the inlet valve completely open and thus provides full flow of air into the compressor. As explained above, the inlet valve is closed to restrict the amount of air allowed into the compressor. A piston located under the inlet valve is used to close the valve. The air control valve and CVV valve are used to control oil or air flow into the piston chamber. The orifice in the system is required to bleed air from the inlet valve piston or diaphragm when full air is required again.

In addition to regulating the inlet air volume, the inlet valve also acts as a check valve when the compressor shuts down. When the compressor shuts down, the regulating valve spring will rapidly close the inlet valve. This prevents the pressurized air and oil in the compressor and downstream system from flowing back through the inlet air filters.

AIR PRESSURE CONTROL VALVE

The purpose of the air pressure control valve is to control the receiver pressure by opening or closing the inlet regulating valve. If the receiver air pressure is not equal to 75 PSI, when the inlet poppet valve is closed, the air pressure control valve setting must be re-adjusted as follows:

1.Start the compressor and bring system up to normal conditions.

2.In the operator’s cab, place the Drill – Vent Mode selector switch in the Vent Mode.

3.Loosen the DIN connector at the top of the CVV valve and disconnect it from the valve.

4.Locate the Air Pressure Control Valve, on the bottom of the manifold, directly below the CVV.

5.Loosen the locknut on the air pressure control valve stem. Rotate the adjustment screw until 75 PSI is observed at gauge P3. Clockwise to increase pressure, counterclockwise to decrease pressure. Re-tighten the lock nut.

6.Return the plug on the CVV valve for at least one minute.

7.Remove DIN connector at the top of the CVV valve again to verify that the pressure at P3 is set to 75 PSI.

8.If the pressure is at 75 PSI, reinstall the DIN connector on CVV and return the machine to operation.

This temperature gauge is a direct reading temperature gauge which indicates the air temperature at the compressor discharge flange.

CAUTION:This reading must not exceed 225°F (106°C) at any time.

SAFETY RELIEF VALVE

The pressure safety relief valve is located on the side of the receiver and is set to relieve the pressure at 125 PSIG. Periodic checks should be made to insure its proper operation.

CAUTION:Never operate the unit without a proper safety valve setting.

SOLENOID BLOWDOWN VALVE

The solenoid blowdown valve is installed on the receiver outlet and will automatically open and blowdown the receiver, piping and compressor air end when the compressor is stopped. The blowdown time is approximately one minute to reduce the pressure down to 0 PSIG.

NOTE: Too rapid a blowdown would cause oil foaming and excessive oil carry-over past the oil separator.

COMPRESSOR OIL STRAINER & FILTERS

The compressor oil system contains one oil filter. This 10 micron filter is installed to filter the oil supply to the compressor (rotors), bearings, mechanical seal, and gears where clean oil is especially desired for optimum life expectancy.

The fluid flow is always from the inside to the outside of the filter element. A diverter/bypass valve, located in the filter head, reduces turbulence and minimizes pressure drop. The diverter/bypass valve insures full-flow filtration until bypass is reached. The large size of the valve insures a low pressure drop when bypass setting is reached.

It is important that the filter element be changed when the compressor oil filter symbol appears on the PLC and a closed filter, or when a visible indicator appears on the COFS. As a preventative maintenance procedure, the user should consider changing the filter elements at least every oil change, even though the the indicator may not have tripped. Clean oil is essential for maximum compressor life.

When replacing the filter element, use the following procedure:

1.Shut down the compressor and relieve all pressure in the filter line.

2.Remove drain plug and drain oil from filter.

NOTE: Place a large oil pan under drain before removing plug. Replace and tighten plug.

3.Loosen the bolts on top of the filter. Rotate cover and lift-off from housing. Remove bypass valve by lifting on handle provided.

4.Reach into filter bowl and remove element. Dispose of used element.

5.Slide the new filter element into bowl, making sure it slides over the bottom sleeve. Check tightness of mounting sleeve each time the filter element is changed.

6.Inspect the O-ring gasket in the filter head and replace only if it is cut or cracked.

7.Replace the top of the filter housing, making sure the sleeve goes into the filter element.

8.Tighten the filter cover and torque hand tight.

9.Restart and check for leaks.

NOTE :For Compressor oil requirements and procedures, refer to Section 3 - LUBRICATION in this manual.

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Section 8

Heating, Ventilation, and Air Conditioning

HOUSE VENTILATION FAN AND FILTER

The machinery house is equipped with a ventilation fan and inertial filter which provides clean ventilation air to the main air compressor and machinery house. The machinery house is pressurized slightly above the atmospheric pressure by the fan. This serves to keep dust and moisture from entering the machinery house. The ventilation fan should be operating any time the machine is being operated. Keep all machinery house doors closed at all times to prevent the entrance of dust. Inspection of the ventilation fan itself is not required except as necessary to repair some malfunction.

Machinery House Ventilation Fan

The inertial filter cleans the air entering the machinery house. This filter is self-cleaning and does not require routing service typical of other filters. Proper operation of the filter, however, is dependent upon proper air flow. Restriction of the intake by leaves, rags and paper will lessen the effectiveness of the filter and ventilation fan. A light coating of dust on the blades of the filter is normal and will not impair the efficiency of the filter. To remove material which has accumulated on the blade surfaces, it is necessary to remove the filter cell and steam clean the blades.

INSPECTION

Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate freely without binding.

If vibration is detected, check the following.

1.Bearing and drive alignment

2.Shaft straightness

3.Wheel or sheaves loose on shaft

4.Loose or worn bearings

5.Loose mounting bolts

6.Motor out-of-balance

7.Sheaves out-of-balance

8.Nose cap loose on wheel

9.Worn or corroded wheel

10.Accumulation of material on the wheel

11.Cracks on blades and/or at the hub

12.Worn fan blades and hubs

LUBRICATION

All bearings are pre-lubricated and sealed at the factory. Under normal temperature condition (20° to +150°F), when the fans are circulating clean air, the bearings are considered lubricated for life and additional lubrication is unnecessary. If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication is required.

For normal temperatures, a high quality, light neutral mineral grease is used. It is free of abrasive fillers and highly resistant to oxidation. When fans are operating at elevated temperatures (166°F or higher), silicone or lithium soap base grease should be used. This high temperature grease should have a breakdown point above 350°F.

Use a low pressure grease gun for fan bearings. It is preferable that either the gun or the fitting be vented. To prevent overfilling apply only a small amount of grease. This is especially important when extended lubrication piping is used and the bearing cannot be observed.

AIR CONDITIONER

This section applies to the SIGMA MPV9 air conditioner only. If using any other air conditioner, disregard this section.

SIGMA MPV9 climate control units are heavy duty systems designed to be roof mounted on the cabs of industrial and mining equipment. This unit will provide superior performance in a variety of climate conditions and under the most harsh environment.

Operator’s Cab Heating/Air Conditioning Unit

Inspect the air conditioning unit on the operator’s cab roof for proper operation, structural integrity and sealing. All permanent side panels should be in place and adequately sealed and secured.

EVAPORATOR

Air is drawn from beneath the unit, passes over the heat exchanger coil and the heating elements into a double-wheel fan where it is discharged through the base of the unit into the conditioned space below. The refrigerant flow is metered by an externally mounted TX valve, and is cut off by a liquid line solenoid valve. The heat exchanger is large, constructed of heavy gauge tubing with a coarse fin pitch to reduce clogging. The fan motor is a large shaft, totally enclosed unit that is air cooled.

All pressure controls within the evaporator unit are fully sealed, preset and O-Ring connected.

CONDENSER

The compressor is a heavy duty, fully sealed scroll type device. The unit is mounted in flexible mounts to reduce noise and vibration. All connections are either soldered, O-Ring type or rotalok. A large liquid drier is placed within the liquid line to filter moisture from the refrigerant. The condenser operates at a single speed only.

SPECIFICATIONS

17.5 Amps19.0 Amps21.0 Amps

RefrigerantHFC 134a – 24 lbs.

OilPOE Variety Mobil Arctic EAL22CC or ICI Emcarate RL32CF

Compressor Fully sealed, scroll type

Condenser Coil5 row, 3/8 inch copper tube with 8 aluminum fins/inch

Evaporator Coil4 row, 3/8 inch copper tube with 10 aluminum fins/inch

Detailed information on the MPV9 can be found in the vendor’s documentation that accompanied the machine and the General Arrangement drawings provided by Bucyrus International.

Section 9 Engineering Data

Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Section 9

Engineering Data

CAPSCREW (BOLT) GRADE

The grade classification of a capscrew (bolt) is identified by the marks on the head as shown below:

Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.

BOLT TIGHTENING

TORQUE WRENCH METHOD

The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1 lists torque values for lubricated or plated threads and for using hardened washers. Table 2 lists those for dry threads.

The bolts should be tightened to the specified total value in increments, alternating from bolt to bolt to assure gradual, even pull-up of mating parts. Tightening should progress systematically from the most rigid part of a joint to its free edges.

Circular bolt patterns should be tightened in a diametric crosshatch pattern while applying torque in increasing values to ensure proper pullup of parts.

Table 1 - Lubricated or Plated Threads or with Hardened Washers

Table 2 - Dry Threads

TURN-OF-NUT METHOD

CAUTION:THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC threads, contact the Bucyrus International Service Department.

NOTE: When using this procedure the bolt threads and the surfaces under the bolt head and nut must be lubricated. This procedure is applicable only if the joint and under head surfaces for bolt and nut are machined for parallelism.

1.The bolts should be brought to a “snug tight” condition to insure that the parts of the joint have good contact with each other. “Snug Tight” is defined as the tightness attained by tightening a bolt to the value specified in the table on the following page. Snug tightening should progress systematically from the most rigid part of the joint to its free edges while alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts have been snugged, the first bolts tightened at the most rigid part of the joint should be rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the snug tightening sequence should be repeated for all bolts in the connection. This rechecking and re-torquing procedure should be repeated as many times as is required until the joint is completely pulled up and all bolts are at the specified “snug tight” torque. Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.

Table of Snug Tight Torque Values

2.The nuts and bolts should then be matched marked by center punching the bolt end and nut. On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened additionally by the applicable amount of nut rotation as specified. It is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

NOTE: Nut rotation is read between punch mark on the bolt and punch mark on the nut. For rod bolts, nut rotation is the cumulative total rotational movement between punch marks on both ends of the rod bolt.

WIRE LOCKING CAPSCREWS

Wire locking of capscrews is used when maximum lock assurance is required when periodic visual inspection is not possible.

The illustrations below show the recommended wire locking methods for various right hand thread capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd numbered patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock together.

Patterns for Wirelocking Capscrews

Use 14 gauge soft annealed lockwire. Thread the wire through the capscrew head so that tightening stress on the wire will exert a tightening torque on the direction of capscrew thread. (The illustrations show lock wire threading for right hand threaded capscrews. Reverse the lock wire patterns shown for left hand capscrews.)

MAINTENANCE WELDING

These recommendations for repair welding apply to the major structural members of the machine. The high cyclic loading characteristics of the machine are considered in the design and material selected for the construction of the machine. However, due to unusual operational conditions that may be encountered and to the great number of cyclic loadings that may be applied to the machine, fatigue cracks or other abnormalities may occur. Early detection of these conditions through regular machine inspection helps to avoid problems or emergency breakdowns.

Maintenance welding is applied to the repair of cracked or broken structural components. Reconditioning of broken parts by the application of heating, cutting and welding processes requires attention to a number of details, careful adherence to the repair procedure and observance of federal, state and local safety regulations.

CAUTION:WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE GENERATION OF TEMPERATURES UP TO THOUSANDS OF DEGREES AT WHICH METALS MELT AND VAPORIZE. When proper precautions are taken to protect personnel and property against the heat, evolved gases and fumes, electric shock and radiation, no harm will result either to personnel or property. In gas heating and cutting, the handling and storage of compressed gases present other hazards that also must be protected against to provide a safe working environment.

Safety precautions should conform to the latest edition of ANSI standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society.

Reconditioning of failed members requires attention to a number of details and careful application of the repair procedure. Only in certain cases is it necessary to strengthen members by added reinforcement.

WARNING: REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY UPON RECOMMENDATION BY BUCYRUS INTERNATIONAL, INC. IMPROPERLY APPLIED REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON THE PERFORMANCE AND LIFE OF THE STRUCTURE.

A broken member is best repaired by making a complete penetration weld, preferably by welding from both sides, using the correct welding electrode and observing all precautions such as preheat, back-gouging, etc. The complete penetration groove weld should be ground flush with the base metal on both sides to remove all surface irregularities. An alternate procedure incorporates backup bars to ensure sound, complete penetration welds in the repair area. Be sure to follow all applicable safety measures and federal, state and local regulations.

A complete penetration weld repair conditioned by grinding instead of adding reinforcement is favored to maintain the original pattern of stress flow designed into the structural members. Addition of reinforcement which is not part of the design can reduce fatigue strength because of the change in geometry from the original structure.

Effective repair welding of cracked, broken or bent structural members of the machine involves knowledge of the types of steel used, proper welding electrodes and recognized good welding practice. The chemical composition, mechanical properties and thickness of the steel determine the welding electrode to be used and the preheat temperature required. Refer to the STEEL TYPES Table later in this section for the types of steel used and the recommended electrode and preheat.

WELDING ELECTRODES

With the exception of the boom, weld repairs on the various structures of the machine can be made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both are low hydrogen electrodes which deposit weld metal having excellent properties at strength levels with 70,000 to 80,000 PSI, and impact properties from -20o to -75oF. These are all-position electrodes which produce high quality welds for repairing the structural components of heavy machinery.

NOTE: Although these electrodes are of superior quality, care must be exercised in their application. Low hydrogen electrodes are highly susceptible to moisture pick-up after removal from sealed containers. To maintain low hydrogen, crack-resistant properties, they must be stored in electrode ovens at 250oF up to the time of use. Small portable rod ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes cannot be over-emphasized.

Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.

These cracks can propagate in service and lead to ultimate failure of the part. It is necessary to adhere strictly to recognized good welding practice regarding the handling, storage and use of low hydrogen electrodes. To avoid underbead cracks, remove all oil or grease or other contaminates from the surface and be sure the steel is dry.

Preheat to the required temperature. Use only dry electrodes taken from the electrode oven. After exposure to the air, the electrodes must be returned to the oven. Time limit outside the oven is four hours for E7018 and two hours for E8018C1 electrodes.

Joint Preparation for Repair of Cracks

Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 4560o included angle for rewelding. If cracked through the full thickness and if it is possible to make the repair from both sides, a double V preparation is preferred. When welding from both sides, back-gouging for complete penetration is always recommended.

When it is not physically possible to back-gouge and weld the second side, an alternate approach must be taken. Sometimes it is possible to gouge through to completely remove the crack, then fit a back-up bar on the underside to facilitate making a complete penetration weld.

NOTE: The back-up bar must fit tightly to the underside otherwise poor welding conditions conducive to cracking may occur.

When it is not possible to fit a back-up due to limited accessibility to the underside, it is advisable to remove a portion of the defective plate and weld in a new piece, using back up bars on all sides to ensure complete penetration welds.

A further alternative is to gouge through, removing the crack, and then weld small stringer beads to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be essentially full penetration, but will be less than perfect on the under side. The other methods are preferred in the order described, that is, welding both sides, welding against a back-up bar, or completely replacing a section of plate.

PREHEAT

When preheating, apply heat to a broad, general area surrounding the repair location. A soaking heat which thoroughly penetrates the material through the full thickness is preferred to high surface temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat source can be left operating during welding to maintain the minimum preheat temperature. Preheat temperatures up to 400oF, depending upon the steel analysis, are adequate under most conditions for major repairs. As previously stated, preheat temperatures are determined by the type of steel in the structure. Temperatures should be measured with temperature indicating crayons.

WELDING TECHNIQUE

Maximum electrode sizes are 1/4 inch for flat position, 3/16 inch for horizontal position and 5/32 inch for vertical and overhead positions. Use a split weave as soon as bead width is large enough to accommodate beads side by side. Throughout all welding be certain thorough fusion with the base metal and adjacent weld beads is obtained on all weld passes. Clean off all slag between passes and all craters before starting the next electrode.

Inspect closely for cracks, undercut or overlap of beads, and gouge out or grind flaws where they occur before continuing. It is very important on highly loaded parts, particularly members subject to cyclic or dynamic stresses, to obtain sound repair welds.

The presence of any stress risers on the surface of a part is detrimental to fatigue life and can result in future cracking. Therefore, it is essential that the finished repair be smooth and well blended into the base metal. Repair weld any undercuts, grind off overlapped weld beads and blend out any notches or gouges. The best condition in a repair weld location is provided by grinding the repair smooth and flush with the surface of the base metal. Final grinding direction is to be identical with the direction of applied load on the structure. Refer to the figure on the following page.

REPAIR WELDING OF BROKEN PARTS

All recommendations given for repair of cracks apply to repair of broken parts, with additional corrections. Depending on the size and cross-section of the part, a specific sequence of welding procedures may be required in making the repair. These techniques include back-step welding sequence, block welding sequence, alternating from side to side, welding simultaneously on opposite sides, etc. All of these precautionary measures are intended to minimize shrinkage stresses and subsequent distortion or cracking during welding. The method to follow should be determined after a careful analysis of the situation and by approaching the problem with common sense. Generally a procedure which has proven successful in previous experience could logically be applied in most cases.

Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has cracked in service, must be carefully considered before that repair measure is decided upon. Additional material added for strengthening alters the configuration and geometry of the member, possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts at strengthening by added plates only serves to “chase the crack someplace else.” The stress flow in the part has been altered, creating a location for stress concentration. Attachments requiring fillet welds across a tension member for example, are poor repair methods. A sound repair weld, carefully made and smoothly blended into the base metal on all sides, is preferable to additional reinforcements. Any application of reinforcements requires careful consideration regarding total overall effect on the structure during service, and should be done only after consulting Bucyrus International, Inc.

WELDING AND CUTTING EQUIPMENT

The welding and cutting equipment needed for general repair welding is listed below.

WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing)

OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses

HEATING TORCHES, Butane (for Boom Welding)

ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines)

WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4"

C02 - Welding Grade - 45oF Max. Dew Point

OXYGEN - Cutting, and Heating

ACETYLENE

WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts

BLOWERS, Ventilating (for Compartment Welding,)

GRINDERS, Wheel - Air Powered w/Wheels

TARPAULINS - Fireproof (for Boom Welding Shelters)

ASBESTOS GLOVES

CUTTING GOGGLES, Dark

SOAPSTONE MARKERS

ANTI-SPATTER COMPOUND

TEMPILSTIKS - 200o and 400o

STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT

The equipment recommended for stress relieving, after repair welding, is listed below.

TEMPERATURE MEASURING EQUIPMENT

SPEEDOMAX, “W” Multipoint, Potentiometer Recorder

POWER REQUIREMENT - 120 Volts, 60 or 50 Hz.

RANGE - 0 to 1500oF

CALIBRATION - Chromel-Alumel Thermocouple Wire

ACCURACY RATING - 0.3% of Electrical Span

CHART SPEED - 2" per Hour

THERMOCOUPLE SELECTION - Six (6) Points

FLUORESCENT LIGHTING

MANUFACTURER - Leeds & Northrup Company

THERMOCOUPLE EXTENSION WIRE

DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded

LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500 Ohms or 410 Feet.

WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20oC (66oF) - Chromel - OhmsAlumel - .0683 Ohms.

WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid

WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow)

OVERALL COLOR - Yellow

CATALOG No. 16-59-17

POLARITY DISCONNECT

CHROMEL-ALUMEL COMPENSATED CONNECTION

JACK Color Code (Yellow) - Catalog No. 040419

PLUG Color Code (Yellow) - Catalog No. 040434

CABLE CLAMP - Catalog No. 072513

ADAPTER - Catalog No. 076794

THERMOCOUPLE ELEMENT

CHROMEL-ALUMEL - Type K - Swagged One (1) Inch Stripped

CHROMEL POSITIVE WIRE Color Code (None)

ALUMEL NEGATIVE WIRE Color Code (Red)

CATALOG No. 8784-K-1-3-12"-D

1.588003 Kaopak Flex Heaters

2.588004 Kaopak Collector Streamer Type

3.Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved

Thermocouple Assembly, Complete

Catalog No. 8784-K-1-3-12"-Q

Temperature Heating Pellets

Range: 1050oF 1100oF - 1200oF 1250oF

Mean Accuracy: +/-1%

These Tempil Pellets will begin to melt at the temperature specified.

GEAR INSPECTION

An important part of machine maintenance is regular inspection of gears. This should include the gears and pinions of the pulldown, rotary and propel machinery.

Listen for any unusual noises or vibrations which would indicate excessive wear patterns of gears and pinions. Usually this would necessitate prompt attention before complete failure occurs.

Of primary importance in proper gear operation is correct lubrication. Always check to see that all the gears are adequately lubricated. See the Lubrication Section in this manual for further information on correct lubricants and their application.

A condition of normal wear should result when gears do not operate at excessive loads or temperatures and correct lubricants are used.

Gears are designed to function satisfactorily during the entire life of the machine. Their failure to do this indicates some unusual conditions. Regardless of gear design, size or construction, correct lubrication is essential to assure minimum wear, quiet operation and long service life. Gear tooth shapes are very accurately manufactured, nevertheless there will always be microscopic surface irregularities which cause frictional resistance. With the gears in proper mechanical condition and with correct lubrication, friction is reduced, wear is practically eliminated and gears should operate efficiently. However, even with correct lubricants properly applied, certain mechanical or operating conditions can cause wear and destruction of teeth. Destruction seldom takes the form of tooth breakage, but usually shows up as damage to the contact surfaces.

Such surface failure may rapidly destroy the original tooth contour, preventing smooth, quiet operation. This failure may be directly attributable to overloading, overheating, shock, abrasives, chips, improper alignment, loose bearings or deflection of shafts or housing.

Many terms are employed to graphically describe the appearance of damaged tooth surfaces. The terms pitting, abrasion, scratching, spalling and galling are the major types of failures under which all of the other failures can be grouped. These five types of failure have different basic causes. From the lubrication point of view, the cause of the failure is of major interest rather than the appearance of the surfaces. These gear-tooth failure classifications are shown in the figure.

Gears and pinions may show some minor pitting which is usually normal. However, any heavy pitting or spalling or any abnormalities as shown will necessitate replacement.

AEROQUIP ORS CONNECTIONS

The Aeroquip ORS type connection is used throughout the hydraulic system of this machine.

The ORS connection has an O-Ring groove machined into the flat male face. This flat face and ORing mate with the connection’s other machined face to form a virtually leak-free seal.

The face-seal concept allows the components to be installed or replaced without moving mating components or applying strain on tube and hose lines. The swivel nut can be retracted to inspect seal placement and joint fit prior to assembly.

When using this connection, remove the O-Ring from the male face and fill the groove with a high quality multi-purpose grease, then install the O-Ring in the groove. The grease will additionally seal around the O-Ring while helping to retain the O-Ring in the groove. The grease will also lubricate the connection while it is being assembled.

There is no need for special torque of the connection as the installer can “feel” when the fitting is tight.

ORS Connection Assembly