CAT Bucyrus MK4HE Single Boom Hydraulic Jumbo Operator Manual SN S07-4525

BI615748

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI615748

MK4HE Single Boom Hydraulic Jumbo Operator Manual Ser. # S07-4525

BI615748

PARTS ORDERING & PRODUCT SUPPORT Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.

1.

IDENTIFICATION OF THE MACHINE Always furnish the Terex / Reedrill Model Number and Serial Number when ordering parts.

This information is found on the machine nameplate. Rock Drills have the serial number stamped on the cylinder.

2.

PART NUMBER AND DESCRIPTION In addition to the Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensioned sketch or return the part to be replaced, transportation charges prepaid.

3.

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

MAILING ADDRESS Terex Reedril 2555 Maley Drive Sudbury, Ontario Phone 705-524-5000 Fax 705-524-5111 FOR PARTS ORDER ENTRY Within U.S.A. Telephone 1-800-854-9030 Within U.S.A. Telefax 1-800-582-6570 Telephone (903) 786-2981 Telefax (903) 786-6407

FOR PRODUCT SERVICE & WARRANTY Within U.S.A. Telephone 1-800-258-0009 Telephone (903) 786-2981 Telefax (903) 786-6408

BI615748

Introduction

WARNING: BEFORE operating this machine or performing any service / maintenance on it, you are advised to throughly read this manual.

BE SURE you understand all the warnings and cautions listed in the Safety Section.

WARNING: If the Jumbo is shipped to a new destination by people not familiar with the Jumbo, always include either a complete instruction book or a copy of the following topics from Section 2: Pre-Operation Checklist Startup Procedure Tramming Procedure Engine Shutdown Procedure Towing

NOTE:

Introduction

Concerning Schematics: The hydraulic, Pneumatic and Electrical Schematics depicted in this manual are general in nature. They are intended for use in understanding how the basic systems operate. Refer to the Parts List for the specific machine for a detailed listing of the schematics.

i

BI615748

MK4HE/D Articulated Hydraulic Jumbo

Fig. i-1 MK4HE/D - Right Front View

Fig. i-2 Left Side View

Fig. i-3 Rear Right Side View ii

Introduction

BI615748

MK4HE Articulated Hydraulic Jumbo The Terex Reedrill MK4HE is an extremely rugged, underground drill jumbo that is able to operate in headings as small as 6 feet (1.83m) wide and drill headings as large as 13 feet (3.96m) high.

The single boom, fully hydraulic MK4HE Jumbo includes a diesel propelled carrier with articulated steering and an electrically powered hydraulic drilling system.

A simple hydraulic system makes the MK4HE suitable for extremely tough working conditions and provides low power consumption. Equipped with Terex Reedrill hydraulic rock drill model HPR3818. This unit can be used for various mining and construction applications. This Jumbo has a carrier driven by a water cooled Deutz diesel engine model 1013C, with hydraulic driven and 4wheel drive system.

The electrically driven main hydraulic drilling systems are equipped with variable volume piston pumps. The MK4HE also features an ani-jam system, automatic drill return system, parallel drilling system, and constant sting system.

This manual provides operating instructions, a technical description of the MK4HE Jumbo, servicing and routine maintenance procedures, an explanation of the different MK4HE Jumbo systems and component replacement procedures.

Introduction

iii

BI615748

BI615748

Table of Contents SECTION 1

SAFETY AND OPERATION WARNINGS

SECTION 2

OPERATING INSTRUCTIONS

SECTION 3

ADJUSTMENTS AND MAINTENANCE

Overview of Potential Hazards ................................................................................................ 1-2 Safety Instructions .................................................................................................................. 1-3 Before Operation.................................................................................................................. 1-3 Operation ............................................................................................................................. 1-3 After Operation ..................................................................................................................... 1-3 Maintenance ........................................................................................................................ 1-4 Equipment Transfer .............................................................................................................. 1-4

Pre-Operation Checklist ......................................................................................................... 2-2 After a Long Transport or Period of Standstill ........................................................................ 2-2 MK4HE - Startup and Operation ............................................................................................. 2-5 Starting the Engine ............................................................................................................... 2-5 Normal Shutdown ................................................................................................................. 2-6 Emergency Shutdown ........................................................................................................... 2-6 Automatic Machine Shutdown Functions ............................................................................... 2-7 Setting Up for Drilling ........................................................................................................... 2-8 Stabalizing the Jumbo for Drilling .......................................................................................... 2-9 Applying AC Power for Drilling ............................................................................................ 2-10 Water System Check .......................................................................................................... 2-10 Start Main Pumps ............................................................................................................... 2-10 Drilling Procedures ............................................................................................................. 2-11 Manual Hole Collaring ........................................................................................................ 2-12 Anti-Jam System ................................................................................................................ 2-12 Changing Bits .................................................................................................................... 2-12 Checks During Drilling ........................................................................................................ 2-13 Roof Bolting (Positioner Lift Lever) ..................................................................................... 2-13 Console Controls ................................................................................................................. 2-14 Anti-Jam Circuit ................................................................................................................... 2-17 Anti-Jam System ................................................................................................................ 2-17 Setting and Testing Anti-Jam .............................................................................................. 2-17 Drill Control Valve ................................................................................................................. 2-18 Rotation ............................................................................................................................. 2-18 Feed .................................................................................................................................. 2-18 Drill (Hammer) .................................................................................................................... 2-18 Automatic Drill Return ........................................................................................................... 2-19 Automatic Drill Return Circuit (ADC) ................................................................................... 2-19 Low Water Pressure Cutoff ................................................................................................. 2-19 Feed Paralleling System ...................................................................................................... 2-20

Initial Machine Setup and Adjustments .................................................................................... 3-2 Diesel Engine ...................................................................................................................... 3-2 Air Compressor.................................................................................................................... 3-2

Introduction

i

BI615748

Table of Contents Boom Auto-Parallelism ......................................................................................................... 3-3 Water Injection Pump ............................................................................................................ 3-5 Drill Air / Oil Mist Lubricator .................................................................................................. 3-5 Drill Rotation Speed and Pressure ........................................................................................ 3-6 Drill System Pressure ........................................................................................................... 3-6 Boom Control Valve and Feed Extend Pressure ................................................................... 3-7 Drill Feed and Feed Collaring Pressure................................................................................ 3-7 Hammer Collaring Pressure ................................................................................................. 3-8 ADC (Automatic Drill Console) ............................................................................................. 3-8 Anti-Jam Adjustments ........................................................................................................... 3-8 Machine Set-Up & Pressure Setting Chart ........................................................................... 3-10 Bolt Torque Specifications .................................................................................................... 3-11 Hydraulic General Specifications .......................................................................................... 3-12 Operation ........................................................................................................................... 3-12 Rotation ............................................................................................................................. 3-12 Feed Pressure Adjutment ................................................................................................... 3-12 Hammer Pressure .............................................................................................................. 3-12 Collaring Hammer Pressure ............................................................................................... 3-12 Constant Feed Setting ....................................................................................................... 3-12 Auto Return ........................................................................................................................ 3-12 Anti-Jam System ................................................................................................................ 3-13 Setting and Testing Anti-Jam .............................................................................................. 3-13

SECTION 4

PREVENTATIVE MAINTENANCE

SECTION 5

GLOSSARY

General .................................................................................................................................. 4-2 Lubrication and Inspection ...................................................................................................... 4-2 Preventative Maintenance Chart ............................................................................................. 4-3 Pre-Operation Checklist ......................................................................................................... 4-4 System Checks ...................................................................................................................... 4-6 Prior to Engine Start for New or Reconditioned Machines ..................................................... 4-6 Hydraulic System Checks....................................................................................................... 4-7 Power Steering Pump .......................................................................................................... 4-7 Main Hydraulic Pumps .......................................................................................................... 4-7 Drill Operator's Maintenance Checklist ................................................................................... 4-8 Periodic Maintenance Chart ................................................................................................... 4-9 Troubleshooting.................................................................................................................... 4-10

ii

Introduction

BI615748

Section 1

Safety

Safety

1-1

BI615748

Overview of Potential Hazards The Jumbo is a heavy moving machine with booms capable of extending their reach vertically and horizontally. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly inspected and maintained. The operators should read this manual and have been trained to use the machine in an appropriate and safe manner.

In this section and those that follow, the word: DANGER means that severe injury or death will result from failure to follow instruction.

WARNING means that severe injury or death can result from failure to follow instruction.

CAUTION means that minor injury or property damage can result from failure to follow instruction.

NOTE means that special attention should be given to the instruction.

POTENTIAL HAZARD

EFFECT

PREVENTION

Electrical Contact

DANGER: Will cause Serious Injury or Death.

Keep all equipment parts, tools and personnel at least 10 FT. (3 m) away from all electrical power lines.

Contaminated Air

DANGER: WILL cause Serious Injury or Death.

Do Not run machine in an area without good ventilation.

Unit Overturn

WARNING: Can Cause Serious Injury or Death.

Do Not operate jumbo on grades in o excess of 35% (20 ). o Do Not swing booms more than 25 from centerline of machine without extending jacks.

Moving Boom or Parts

WARNING: Can Cause Serious Injury or Death.

Do Not operate machine or boom until all people are clear of the area.

Do Not lubricate or service while machine is running.

High Pressure Air or Fluid

WARNING: Can Cause Serious Injury or Death.

Relieve pressure on hydraulic and pneumatic systems before loosening hoses or connections.

1-2

Safety

BI615748

Safety Instructions Before Operation 1.

Study this manual and fully understand the controls.

2.

Be sure all safety guards are securely in place.

3.

Wear safety helmet, glasses and hearing protection when operating or working on machine.

4.

Do Not operate machine with: • Hydraulic or air leaks • Broken or damaged electrical wiring or components • Damaged hydraulic hoses or fittings • Worn or damaged parts

5.

Never refuel machine while engine is running.

6.

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

7.

Be sure drill area is clear of all obstructions before operating machine.

8.

Use safety chain when using towbar.

Operation 1.

Do Not use the machine for any other purpose than what it was designed for. This machine is designed for blasthole drilling operations only.

2.

Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing and hands clear of moving parts.

3.

Do Not travel on grades in excess of 35% (20 ), or on soft or unstable ground or close to unsupported excavations.

4.

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

5.

Do Not stand directly under a boom or feed.

6.

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

7.

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

8.

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

9.

Do keep work areas clean and clear of cuttings, hand tools and other objects.

o

After Operation 1.

Safety

Follow Shut Down Procedures given in Section 2 of this manual.

1-3

BI615748

Safety Instructions Maintenance 1.

Do Not service or perform maintenance while machine is running.

2.

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

3.

Be Sure each person is adequately trained to perform service and maintenance procedures.

4.

A Warning Tag must be placed on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.

5.

Be Sure you have adequate lighting when performing service.

4.

Relieve Pressure on hydraulic or pneumatic systems before loosening connections or parts.

5.

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

6.

Do Not weld or grind near oil lines.

7.

Do Not attempt to remove radiator cap when engine is hot or has overheated.

8.

Be Sure machine and components are well supported before servicing or replacing parts.

9.

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

10. Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can give off hydrogen which is a highly explosive gas.

11. Be Sure no tools or other loose objects are left on the engine or drive mechanisms. They could be thrown by this equipment with a powerful force.

Equipment Transfer 1.

If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics: • Safety Section • Operation Instructions including: • Pre-Start Checks • Start-up • After Start Checks • Shutdown Procedure • Tramming Machine

1-4

Safety

BI615748

Section 2

Operating Instructions

WARNING: If the Jumbo is shipped to a new destination by people not familiar with the Jumbo, always include either a complete instruction book or a copy of the following topics from Section 2: Pre-Operation Checklist Startup Procedure Tramming Procedure Engine Shutdown Procedure Towing

Operating Instructions

2-1

BI615748

Pre-Operation Checklist After a long transport or a period of standstill: 1.

Inspect the Jumbo for damage incurred during shipping and handling.

2.

Clean the Jumbo if necessary.

3.

Tighten all loose bolts.

4.

Check the engine according to the Deutz Engine Instruction Book.

5.

Be sure the fuel tank is at least partially full (fig. 2-1). If the engine runs out of fuel, the complete fuel system must be bled of air and primed.

6.

Check the battery. Make sure that the battery disconnect switch is in the "ON" position. (fig. 2-2)

7.

Prior to tramming, check that the Jumbo Articulation is not locked. (fig. 2-5)

8.

Grease all grease cups. (See "Drill Operator's Checklist").

9.

Check the oil level in the hydraulic tank with the "Oil Level Indicator" mounted on the oil tank (fig.

2-4).

10. If the hydraulic oil is low, fill it with recommended hydraulic oil. Use the 24 volt filling pump via the 10 micron filter mounted near the tank.

11. If the tank has been empty, check that the inlet lines leading from the tank to the pumps are all filled with hydraulic oil.

12. Check oil level (outriggers, booms and feeds retracted).

If the Jumbo has not been used for an extended period of time, or has been transported over a long distance, extend outriggers to a firm footing and move all cylinders (Boom, Positioner, Feed Extension) with the Engine Auxiliary Pump and control levers. Then check the oil level in the hydraulic tank again. Before tramming; boom, drill, and feed should be retracted as far back as possible. Position boom at centerline of machine.

• Be sure the outriggers are completely raised and retracted.

• Move Tram/Drill selector switch to "Tram"position (fig. 2-3).

• Release the brake.

• Be sure no hoses are dragging on the ground while the Jumbo is moving.

1

2 Fig. 2-1 Fuel Tank 1. Fuel Gauge 2. Fuel Tank Cap 2-2

2

1

Fig. 2-2 Battery Compartment 1. Battery 2. Battery Disconnect Switch Operating Instructions

BI615748

Pre-Operation Checklist

1

9

8

1

7

5

6 2

3 Fig. 2-3 1. Deutz Display 2. Park Break 3. Start Switch 4. Drill / Tram 5. Engine Fault Light

4 Fig. 2-4 Hydraulic Tank 1. Oil Level Indicator

6. Engine Fault Test 7. Front Lights 8. Rear Lights 9. Coolant Temp.

1

Fig. 2-5 Articulation Lock Bar 1. Articulation Lock Bar Operating Instructions

2-3

BI615748

Pre-Operation Checklist

1

20

2 3

19

18

4

5 6

17

7

16

8

15 14

13 12

Fig. 2-6 1. HPR3818 Drill 2. Timberock Feed 3. Canopy 4. Hydraulic Oil Filters 5. Hydraulic Tank

2-4

6. Heat Exchanger 7. Air Compressor 8. Main Electrical Panel 9. Cable Reel 10. Diesel Engine

11

10

9

11. Diesel Fuel Tank 12. Power Pack 13. Rear Carrier Frame 14. Engine Control Panel 15. Front Carrier Frame

16. Outriggers 17. Drill Control Console 18. Boom 19. Feed Dump Actuator 20. Feed Table

Operating Instructions

BI615748

MK4HE - Startup and Operation Starting the Engine: 1. Complete the Pre-Operation Checklist.

2. Place the Drill / Tram selector switch (1) in the TRAM position.

3. Push the Parking / Emergency Brake button (2) down to insure the brakes are set.

4. Turn the ignition switch (3) to the "ON" position and leave it there for at least 30 seconds. The Deutz display (4) should come on, indicating the engine is ready to start. (if there are any engine faults please use the Deutz user instructions located in the back of the Service manual to identify and rectify the problem before proceeding) 5. Turn the ignition switch (3) past the START position to engage the starter.

6. Allow the engine to warm up briefly at low RPM before proceeding.

It is good practice to operate the engine in the high idle range. Operating the diesel at low RPM for extended lengths of time will result in glazing of the rings and excessive smoke. Tram the unit to the area where drilling will take place.

CAUTION:

BE SURE the leveling jacks are completely retracted, and the booms are in a "Closed-In" position, fully retracted for tramming.

4

1 2

Operating Instructions

3

Fig. 2-7 1. Drill/Tram Selector Switch 2. Parking/Emergency Brake 3. Ignition Switch 4. Deutz Display

2-5

BI615748

MK4HE - Startup and Operation Normal Shutdown: 1. Return all hydraulic controls to NEUTRAL position. Boom and feed should be centered along the centerline of machine and lowered as low as possible.

2. Move the Drill / Tram selector valve handle to the TRAM position.

3. Engage parking brake, by pushing the brake release switch DOWN. 4. Turn Drilling and Tramming lights OFF. 5. Turn ignition switch OFF. 6. Turn Battery disconnect switch OFF.

Emergency Shutdown: 1. Turn ignition switch OFF. This will activate the emergency shutdown system and shutdown the entire machine.

2. In case of fire, activate the fire suppression system (if equipped), turn ignition switch OFF and move a safe distance away from machine.

3. Before starting the machine again, be sure all controls are in the OFF or NEUTRAL position.

If a machine malfunction was the cause for the emergency shutdown, be sure all necessary repairs have been made.

CAUTION:

ONLY use the EMERGENCY SHUTDOWN is case of emergency.

Machine damage could result by not following NORMAL SHUTDOWN procedures.

2-6

Operating Instructions

BI615748

MK4HE - Startup and Operation Automatic Machine Shutdown Functions: If, during operation of the jumbo, the machine shuts down unexpectedly, indicator lights on the control panel normally indicate the cause of the shutdown. An empty fuel tank will not activate an indicator light.

The following conditions will actvate an indicator light and cause the machine to shutdown: • Low hydraulic fluid level.

• High hydraulic fluid temperature in the hydraulic reservoir.

• Hight engine coolant temperature.

• Low engine oil pressure.

The operator should frequently monitor all gauges and instruments, noting any unusual reading which might lead to the machine shutting itself down unexpectedly. An instrument or gauge reading out of normal range indicates a potential problem which should be reported to the maintenance department.

Operating Instructions

2-7

BI615748

MK4HE - Startup and Operation Setting up for Drilling WARNING:

Use extreme caution when moving this machine.

DO NOT descend any grade that the machine cannot climb.

DO NOT descend grades faster than the machine can travel ground - maximm 6 m.p.h (9.7 km / h) DO NOT use the parking / emergency brakes as a regular service brakes.

DO NOT tram this vehicle if there is any indication of malfunction or damage to the transmission, brakes, axles or wheels.

DO NOT swing either boom more then 25º from centerline of machine. If boom is positioned 25º or more from center, the crrier may become unstable and could tip over.

Before the Jumbo is trammed to the drilling area, a properly sized electrical trailing cable should be connected and wound onto the cable reel. The capacity of electric cable is generally limited by the temperature rating of the insulation. Cable wound onto a cable reel cannot adequately dissipate heat and must be severely derated as a function of the number of wraps of cable on the drum. Other factors such as the desired cable length and the voltage drop should also be considered when sizing the cable, as well as the ambient temperature of the operating environment. Consult the cable supplier for recommendations.

Connect the electric cable to the power source, but do not switch on the power until the Jumbo is completely set up for drilling. Tram the Jumbo to the tunnel face, unreeling the cable from the Cable Reel. Depending upon the capacity rating of the trailing cable, additional cable may be required to be unspooled from the reel after set-up to comply with manufacturers' recommendations and applicable electrical codes.

Extend the Leveling Jacks to ensure that the Jumbo remains stable. Set the brake and stop the diesel engine.

Before applying power, and with the main circuit breaker off, check that all power and control circuit breakers in the main switch box are closed. Close the switch box, turn on the electric power and close the main circuit breaker.

Turn on the drilling lights. Connect the flushing water and start the water booster pump.

NOTE If the pump will not start, the trail cable may be improperly connected and the phase sequence relay on the machine not energized, preventing starting.

2-8

Operating Instructions

BI615748

MK4HE - Startup and Operation Stabalizing the Jumbo for Drilling: 1. Tram the Jumbo to the drilling area and position the machine so the feeds and booms can reach the maximum number of drill hole locations.

2. With the engine running, fully extend the right and left hand horizontal jacks and lower the jacks to securely stabalize the Jumbo. The front of the Jumbo need not be raised to the maximum height for good stability, but the weight of the front of the machine should rest on the jacks rather than the tires.

3. Adjust canopy height as desired.

2

1

Fig. 2-8 Outriggers 1. Left Outrigger 2. Right Outrigger

2 1 Fig. 2-9 Outrigger Controls 1. Left Outrigger 2. Right Outrigger

Operating Instructions

2-9

BI615748

MK4HE - Startup and Operation Applying AC Power for Drilling: 1. Set the parking / emergency brake on the Jumbo, stop engine and turn ignition switch to OFF. 2.Turn on the electric power and close the main circuit breaker on the main switch box.

3. Turn on the drilling lights from the pushbutton box in the center of the drill console.

4. Connect the flushing water and start the water booster pump from the pushbutton box in the center of the drill console.

WARNING: BEFORE initial start-up of Jumbo, the main switchbox must be checked by a qualified electrician. All circuit breakers should be closed and the main switchbox door should be closed and secured with fasteners. The main switchbox door IS NOT to be opened by the Jumbo drill operator.

ALL checks are to made by a qualified electrician.

NOTE

If the pump will not start, the trail cable may be improperly connected and the phase sequence relay on the machine not energized, preventing starting.

Water System Check: Check the water pressure. If the hydraulic drilling system is water cooled (not air cooled), at least 25 PSI water pressure should be available before starting the main pump units. (For drilling use - minimum 80 PSI (5.5 bar)).

NOTE

If water pressure is too low, the low water pressure switch installed at the water booster pump outlet will not allow pump to run.

Start Main Pumps: Be sure that all control levers are in neutral position. Then start the main pump for the hydraulic drilling system.

2-10

Operating Instructions

BI615748

MK4HE - Startup and Operation Drilling Procedures: 1. Position the Jumbo near the drill face so all holes can be drilled without moving the Jumbo.

2. After setting jacks, move the boom and feed into position for drilling the first hole. The angle of the drill feed to the drill face is controlled by the feed swing lever and the feed dump lever.

2a. The feed is automatically kept parallel. (See previous description of feed paralleling system.) Once selected, the angle of the feed will automatically be kept the same from hole to hole - as long as the feed swing lever, the feed dump lever and powered dump feed lever for bolting are not moved.

2b. Select the angle of the feed (hole) with the feed dump lever and the feed swing lever and then place the drill holes where they are wanted on the drill face with the boom lift, boom swing, boom extension and feed roll levers. Drill all holes slightly upward (if possible), (except the lifters). This will help to get all cuttings out of the holes and keep holes free from water. If lifters must be very flat, drill lifters with drill feed rotated on its side.

3. Use the feed extend lever and sting the end of the feed in the rock. The feed extend lever may be left in the full forward position to maintain constant stinging pressure on the feed extension cylinder. This will assist the operator in maintaining hole alignment.

CAUTION: Never use drill feed extension cylinder at the same time.

Never press the bit against the rock face with the feed extensions.

NOTE

In some instances, it is not possible to use feed sting due to a very uneven tunnel face, in this case collaring must be done carefully.

4. Turn water valve ON and be sure water is flowing out of the drill bit.

5. The anti-jam lever should be up (ON).

6. The hammer collaring lever should be up (ON).

7. Push the drill rotation lever into the forward rotation (counter clockwise) position.

8. Push the drill (hammer) lever and the feed lever forward all the way to collar the hole.

9. After the hole is collared (drill bit about 2-3" [5-7.6 cm] deep into the rock), push the hammer collaring lever down (OFF). Full hammer pressure is now available to the drill and feed for normal drilling.

10. Drilling is now automatic. If "bad ground" is encountered, the anti-jam system will back the drill out and resume forward travel when the "bad ground" is cleared and solid rock is again encountered. At the end of the hole, the drill hammer will automatically shut off and the feed direction will reverse, bringing the drill steel out of the hole.

11. Move the rotation lever back to the center position to stop drill rotation when the bit clears the hole.

12. Turn air / water valve OFF. The drilling sequence is now complete.

Operating Instructions

2-11

BI615748

MK4HE - Startup and Operation Manual Hole Collaring: Push the hammer lever forward. Ease the feed lever forward and move the rock drill forward on the feed until the bit contacts the rock. Do not push the feed lever all the way forward untill collaring of the hole has been accomplished. After you have drilled a collar of 2 - 3" [5-7.6 cm], ease the feed lever into its forward position. The rock drill will automatically drill the hole.

Anti-Jam System: If, during the drilling cycle, some incompetent ground is encountered, the anti-jam system will activate. The operator will note the drill out of the hole and then returning to the forward direction of travel. The anti-jam system will continue to operate until the bit is clear in the hole. When the antijam system is functioning, the operator should normally not attempt to operate the feed lever. If, for some reason, the operator feels it is necessary to operate the feed lever, the anti-jam valve should be switched OFF and the feed lever returned to neutral for a few seconds to completely render the anti-jam system inoperative. It is desirable for the operator to develop a drilling sequence, which minimizes hole-to-hole movement and boom interference.

Changing Bits: Push the hammer valve forward or ON. Leave the rotation lever in its neutral position. Use the feed lever, and gently push the bit against the rock. Let it hammer for a few seconds.

NOTE

2-12

Operating the hammer for extended periods with loose drill string parts can cause damage to shanks, couplings, bits and drill steel.

Operating Instructions

BI615748

MK4HE - Startup and Operation Checks During Drilling: Check for oil leakage from hoses and connections. If encountered, make necessary corrections. Never tighten hydraulic hose connections while system is pressurized. Check for water leakage from the front head of the rock drill. If extensive leakage is observed, stop drilling and call the service person to replace water seals.

Watch for excessive vibration of the hose. Excessive vibration indicated the drill accumulators are not properly charged. In such a case, stop drilling immediately and call for the service person.

Watch for hoses becoming tangles when the boom is moved, particularly, when boom rollover function is used.

Check the condition of the filter bypass indicator while the drill is operating. Operating a unit with dirty filter will lead to premature failure of hydraulic components.

Roof Bolting (Positioner Lift Lever): As standard the booms are delivered with a feed table dump feature. For roof bolting, use the positioner lift lever for vertical feed positioning.

NOTE

The feed tables are bolted in the face drilling or bolting position. Remove the locking bolt before actuating the valve to reposition the feed table, then reinstall locking bolt.

Operating Instructions

2-13

BI615748

Console Controls Boom/Feed Control Valve Bank - Provides the operator with all positioning controls for placing the feed in position to drill. Pushing the lever forward will move that particular function forward, down, to the right, or clockwise. Pulling the lever backward will move the particular function back, up, to the left, or counterclockwise.

4

5

6

7

8

9

10 11

12

13

14

2 3

15

1 Fig. 2-10 Boom/Feed Controls 1 - Hammer 6 - Feed Swing 2 - Rotation 7 - Feed Dump 3 - Feed 8 - Positioner Lift 4 - Feed Roll 9 - Boom Extend 5 - Feed Extend 10 - Boom Swing

11 - Boom Lift 12 - Feed Pressure Adjustment 13 - Feed Pressure Adj Up/On Down/Off 14 - Anti Jam On/Off 15 - Air/Water

1. Hammer Control Valve - Controls the flow of oil to the hammer oscillator. The valve is normally placed in the full ON position, which starts the flow of oil to the oscillator at a reduced pressure for collaring the hole. After the hole is properly collared and full feed pressure is obtained, the oscillator pressure automatically increases to full system pressure.

2. Drill Rotation Control Valve - Pushing the drifter rotation control valve forward starts drifter rotation in the counterclockwise direction, which is the normal direction for drilling. Moving the lever backward reverses rotation for uncoupling steel or any function requiring reverse rotation.

3. Feed Control - Moving the feed control lever toward the boom, or forward, causes the drifter to move forward toward the end of the feed. Moving the control lever backward toward the operator reverses the oil flow to the feed, and the drifter returns to the back of the feed. In the forward feeding position, you will not a spring override in the control lever; moving the lever into the spring override position allows for high speed or fast forward of the drifter on the feed.

4. Feed Roll - When the lever is moved into the forward position, the feed will roll in a clock wise direction.Moving the feed roll lever backward, results in the feed to roll in a counter clockwise direction.

2-14

Operating Instructions

BI615748

Console Controls 5. Feed Extend - When the feed lever is placed in a forward position, the feed itself will move further from the boom console. If the feed lever is placed in the opposite direction, backwards the feed will then retract itself closer to the boom console.

6. Feed Swing - When the feed swing lever is moved in a forward position, the feed will move to the right. When the lever is moved to the backward position, the feed will move to the left.

7. Feed Dump - Moving the feed dump lever forward, will the cause the feed to rotate downwards. If the lever is placed in a backward position, it will have the opposite effect and rotate itself upwards.

8. Power Dump - Moving the power dump lever forward, will rotate downwards. If the lever is placed in a backward position, it will have the opposite effet and rotate itself upwards.

9. Boom Extend - By placing the boom extend lever in a forward position, will extend the inner tube of the boom outwards. When the lever is place in a backward position, it will cause the tube to retract itself back inwards.

10. Boom Swing - When the boom swing lever is moved in a forward position, the boom will move to the right. When the lever is moved to the backward position, the boom will move to the left.

11. Boom Lift - When the lever is placed in a forward position, the boom will move on a negative angle in a horizontal plane. Moving the boom lift lever backwards, will lift the boom on a positive angle in a horizontal plane.

12. Feed Pressure Adjustment - Turning the feed pressure adjustment knob will adjust the pressure up or down of the feed.

13. Up/On Down/Off - Emergency Stop. When the button is in the up position, the emergency brakes have been applied. When the button is in the down position, the emergency brakes are off.

14. Anti-Jam On/Off - When the lever is in the upward position, the anti-jam is turned ON. When the lever is in the downward position, the anti-jam is OFF. 15. Air/Water - Under normal drilling conditions, this valve must be in the WATER ON position.

Air only, may be selected for recleaning holes, if that becomes necessary. When the cam valve on the feed is triggered at the end of the hole, the drill will shut off and the feed will reverse. It also has an OFF position to manually shut both air and water off. The air/water valve may be switched to AIR or to OFF until the next hole is started.

Operating Instructions

2-15

BI615748

Console Controls Auxilary Drill Control Valve Bank - Controls feed, rotation and hammer functions.

16 17 18 19 Fig. 2-11 Drill Control Valve Bank 16 - Right Jack Control 17 - Left Jack Control 18 - Canopy Control 19 - Cable Reel Control

16. Right Jack Control - When the control valve lever is operated, fluid is directed to the end of the cylinder to extend the outrigger assembly. When that assembly is fully retracted, the sequence valve receives a pressure signal and shifts causing the foot to extend to the ground. When the outrigger is retracted, fluid moves to the end of the cylinder to retract the outrigger from the ground.

When the foot of the outrigger is fully retracted, the sequence valve shifts and fluid is directed to the outrigger cylinder which retracts the assembly toward the frame.

17. Left Jack Control - When the control valve lever is operated, fluid is directed to the end of the cylinder to extend the outrigger assembly. When that assembly is fully retracted, the sequence valve receives a pressure signal and shifts causing the foot to extend to the ground. When the outrigger is retracted, fluid moves to the end of the cylinder to retract the outrigger from the ground.

When the foot of the outrigger is fully retracted, the sequence valve shifts and fluid is directed to the outrigger cylinder which retracts the assembly toward the frame.

18. Canopy Control - When the lever is moved to the right, the canopy will go upwards in height. When the lever is moved to the left, the canopy will go downwards.

19. Cable Reel Control - When the cable reel lever is moved to the right, the reel will retract.

When the cable reel lever is moved to the left, the reel will extract.

2-16

Operating Instructions

BI615748

Anti-Jam Circuit Anti-Jam System

The anti jam system is used when drilling in broken or faulted ground. In order to enable this function the anti-jam on/off valve must be placed in the on position. During normal drilling rotation pressure is usually maintained between 600-psi and 900-psi. If the rotation pressure rises above 1200-psi at the rotation pressure switch because of the bit jamming in the hole the anti jam relief will open and send a hydraulic signal to the anti jam feed valve. This valve will switch the pressure from the feed forward line of the feed cylinder to the reverse line, which will reverse the direction of the feed cylinder and bring the drill out of the hole. When the rotation pressure drops below 1200-psi the anti jam feed valve will return to its normal state and the drill will start traveling forward again.

Setting and Testing Anti-jam

To adjust the anti-jam system; cap the forward rotation pressure line at the rotation motor and place the anti-jam on/off lever in the on position. With the hammer at the back of the feed place the feed valve lever in the forward position. Slowly move the rotation valve lever to the forward rotation position and watch the rotation pressure rise. The rotation pressure at which the feed reverses is the anti jam pressure. By moving the rotation lever to the reverse position the rotation pressure will drop and the feed will resume forward travel. If the feed fails to return to the forward direction check the anti-jam drain orifice as it may be plugged. This orifice size determines the distance the feed reverses during an anti-jam situation. To adjust the anti jam pressure the anti jam pressure relief under the drilling console must be turned in or out. This pressure can be adjusted to suit bit size and ground conditions.

Fig. 2-12 Anti-Jam Circuit Operating Instructions

2-17

BI615748

Drill Control Valves The drill control valve banks provide easy control of rotation, feed and hammer functions.

Rotation

The rotation section is comprised of a directional valve and an inlet section. The pressure setting of the rotation pump is normally 2500 PSI (172.4 bar) and the flow set at approximately 1015 GPM (37.9-56.9 liter/m).

Feed

The Feed forward circuit is adjusted at the feed valve A port to 1050 PSI. Feed reverse circuit is adjusted at the B port to 2500PSI. The forward feed for collaring can be redced by a reducing vaqlve that will dump Feed LSA port to the tank.

Drill (Hammer)

The hammer ON circuit is adjusted at the hammer valve A port to 2450 PSI maximum. The hammer pressure for collaring can be reduced by a alve that dumps the hammer LSA port to tank.

Fig. 2-13 Drill Control Valves 2-18

Operating Instructions

BI615748

Automatic Drill Return Automatic Drill Return Circuit (ADC) The jumbo is equipped with an automatic retract, drill shutoff and adjustable hole depth. The system is comprised of an auto return plunger that travels with the drill. There is an auto return bracket that is situated on the feed cylinder and is adjustable to obtain a maximum hole depth or a reduced hole depth depending on ground conditions and pressure switch to activat the solenoid valve for the auto return.for the auto return.

When the plunger (drill saddle) reaches the auto return bracket on the end of the cylinder, the plunger is pushed in and the hydraulic pressure reaises, the pressure switch activated and power is sent to the solenoid valve for the auto return which then reverses the feed and shuts off the hammer.

Low Water Pressure Cutoff

When the low water pressure solenoid valves receive a signal from the low water pressure switch (located at the water pump) they activate the ADC system. This causes the drills to shut off and return to the back of the feed. The low water pressure solenoid valves are mounted under the right and left drill control consoles.

Fig. 2-14 Automatic Drill Return Circuit Operating Instructions

2-19

BI615748

Feed Paralleling System Because the functions of both the lift and the swing paralleling system are identical, only the principles will be discussed here. The parallel system is comprised of a master cylinder, mounted at the boom base, and a slave cylinder, mounted at the positioner. In the vertical plane, the positioner dump cylinder is the slave. In the horizontal plane, the positioner swing cylinder is also the slave.

When the boom lift lever is operated at the console, fluid is directed to the main boom lift cylinder causing the boom to raise or lower. The master cylinder is forced to move because of a direct mechanical connection to the boom. As the master cylinder moves, fluid is displaced from the end of the cylinder in which the piston is moving. That fluid moves to the same end of the slave cylinder causing the slave cylinder to move in the opposite direction. This reverse direction cylinder movement causes the feed to lift/dump inversely to the boom movement, thereby maintaining the same angle to the face at all times.

The boom swing works on the same principle, but in the horizontal plane. When fluid is directed to the boom swing cylinder, the master cylinder also moves because of a direct mechanical connection. When the master cylinder is forced to move, the slave creates parallel movement of the positioner.

Each parallel system is equipped with an externally mounted dual counterbalance valve. This valve performs the following functions: 1.

Prevent fluid from returning to the reservoir through the control spool when parallel system is functioning.

2.

Provides a relief path for excessive pressure in parallel system.

When the operator moves the positioner dump or positioner swing control lever, fluid is directed through the external counterbalance valve to the cylinder being operated. Because the master cylinder is mechanically locked in its position, the fluid is directed to the positioner cylinder. This allows independent operation of the positioner dump and swing.

.

Fig. 2-15 Feed Parallelism System - Lift or Swing 2-20

Operating Instructions

BI615748

Section 3

Adjustments and Maintenance

Adjustments and Maintenance

3-1

BI615748

Initial Machine Setup and Adjustments During the initial commissioning of the jumbo, a number of adjustments must be made for local conditions and application requirments. This will be done by or under the supervision of Terex / Reedrill service technician commissioning the unit. Any time major repairs are made to the machine or conditions change, mine maintenance personnel will also need to make appropriate adjustment.

NOTE

Virtually all pressure and flow control devices on this jumbo utilize adjustment screws fitted with jam nuts to secure the screws in place after adjustments have been made. It is important to hold the adjustment screw firmly in place while tightening the jam nut as the adjustment may tend to change as the nut is tightened. Settings should be rechecked after tightening the jam nut to insure the adjustment has been secured at the proper setting.

Diesel Engine:

The fuel settings on the DEUTZ BF4M1013C turbocharged diesel engine has been set at the factory for operation at 12,000 to 14,000 ft. above sea level (3650 to 4270 meters). If the unit is to operate at a significantly different elevation, the fuel settings should be re-calibrated by a certified Deutz technician. For User Instructions please refer to the Deutz Installation and User Instructions located at the back of the Service Manual.

Air Compressor:

The following conditions should exist for maximum performance of the compressor. The Drill Rig should be as close to level as possible when operating. The compressor will operate on a 15 degree sideward and lengthwise tilt without any adverse problems. Operation in ambient temperatures above 100 F (38 C) may experience high temperature shutdown. Please consult Infinity Operator & Service Manaul for complete instructions regarding the Air Compressor (located in Service Manual).

3-2

Adjustments and Maintenance

BI615748

Initial Machine Setup and Adjustments Boom Auto-Parallelism:

The boom auto-parallelism feature normally requires no adjustment. This feature utilizes a master / slave hydraulic cylinder fluid displacement design in both horizontal and vertical planes to automaically maintain a given angle of the drill feed to a vertical drill face as the boom is repositioned for each new drill hole. As the boom is moved in either horizontal or vertical planes, fluid is displaced from a master cylinder in a corresponding slave cyliner ( the feed swing or feed dump cylinder) causing the drill feed to move in the opposite direction from the boom to maintain the same drilling angle into the drill face. Dual pilot operated counterbalance valves are used to act as both check and relief valves for this circuit in such a way that as long as the pressure required to actuate the slave cylinder is less than the relief setting of these valves, all fluid remains in the circuit and the slave cylinder is actuated to perform its paralleling movement. If the relief setting of the counterbalance valves is less than the pressure required to move the slave cylinder, the fluid is diverted from the circuit and slave cylinder does not move.

When using the MK4 Jumbo in applications other than drilling in parallel horizontal blast holes in a vertical face (drift development), it is normally advantageous to nullify the auto-parallel feature by adjusting the counter balance valves to thier minimum setting, cancelling the auto-parallelism feature. This is done by turning the adjustment screws of all four counter balance valve cartridges counter-clockwise to thier minimum setting.

Adjustments and Maintenance

3-3

BI615748

Initial Machine Setup and Adjustments

4

5

6

7

8

9

10 11

12

13

14

2 3 15

1 Fig. 3-1 Boom/Feed Controls 1 - Hammer 2 - Rotation 3 - Feed 4 - Feed Roll 5 - Feed Extend

6 - Feed Swing 7 - Feed Dump 8 - Positioner Lift 9 - Boom Extend 10 - Boom Swing

11 - Boom Lift 12 - Feed Pressure Adjustment 13 - Feed Pressure Adj. - Up/On Down/Off 14 - Anti Jam On/Off 15 - Air/Water

16 17 18 19 Fig. 3-2 Drill Control Valve Bank 16 - Right Jack Control 17 - Left Jack Control

3-4

18 - Canopy Control 19 - Cable Reel Control

Adjustments and Maintenance

BI615748

Initial Machine Setup and Adjustments Water Injection Pump:

The water injection pump is an air powered pressure intensifier which pressurizes water from the on board water tank for injection into the blow air stream to suppress dust while drilling. The pump is designed to stall out whenever the blow air solenoid valve is shut off. Because the pump can pressurize the water to several times the air pressure at which is operating, an air pressure regulator is provided to limit the air pressure to the pump to keep the potential water pressure down to a safe level. Normally 25 to 30 PSI air pressure is adequate to create enough water pressure to inject it into the blowing air stream. The amount of water used should only be enough to suppress the dust in the cuttings created during drilling. This is controlled by the needle valve located on the drill control console. Sufficient water must be used to maintain a safe environment for the operator and the equiptment, but excess water usage will limit the amount of drilling that can be done without refilling the water tank. Once the volume of water has been set, frequent readjustment should not be necessary. A water filter separator is furnished with the assembly to protect the pump from moisture in the compressed air which accelerates wear in the pump. Water collected in the bottom of this filter assembly should initially be checked at least once each shift and emptied as it accumulates. Depending upon moisture content of the air in the mine, the frequency of servicing can then be established. The water pump should not be run dry and may be damage if run for a prolonged period without water. If the water supply has been exhausted, normally indicated by the sudden discharge of a large amount of dust from the drill hole, the machine should be shut down and the water tank refilled.

Drill Air / Oil Mist Lubricator:

The lubricator assembly is located on the front frame of the jumbo under the boom and behind the outrigger housing. The air / oil mist lubrication system oprates continuously while the air compressor is running (anytime the jumbo is in "Drill" mode). The oil reservoir holds approximately 4 liters of rock drill oil. A slight tube is provied to determine the oil level in reservoir. It should be filled approximatly every four operating hours (operation in "Drill" mode) with a high quality moderatly low viscosity rock drill oil (ISO 100 grade is perferred). The oil consumption rate is controlled by the adjustment knob on the top of the lubricant head. After the air compressor pressure adjustments have been made, the flow rate of lube oil can be set while drilling. The lubricator should provide between 600 and 900 milliliters (.6 to .9 liters) per hour to the drill front end. The lubricator head has a small sight bubble on the top which shows the oil being dropped into the air stream. The adjustment is capable of providing from only a few drops of oil per minute to a continuous stream.

Start by adjusting the rate to where a continuous stream of oil can be seen in the sight bubble and then adjust the rate downward until the oil can be seen forming individual dropsbefore entering the air stream. Monitor and adjust the oil flow rate as necessary to actieve the recomended rate. It may take several shifts to get the oil flow rate adjusted properly. It is important to never operate the drill if lube oil is not being supplied to the drill. Not only must the lube oil reservoir never be allowed to run dry while drilling, but close attention must be given to the hosees and fittings feeding the air / oil mist into the drill. If they become broken or damaged, they bust be replaced or repaired before continuing to drill.

The lubricator ony requires a few cfm of air flow to draw lube oil from the reservoir and atomize it into the air stream. If an excessive amount of compressed air is being used for this function, less air will be available to clean the hole while drilling or the power consumption of the air compressor may be higr than necessary, reducing the power available to the rock drill. If it is felt that the air consumption is excessive, a restriction may be installed in the air line to reduce the air flow.

However, sufficient air flow must be maintained to exclude cuttings from the front of the drill, especially when drilling up holes.

Adjustments and Maintenance

3-5

BI615748

Initial Machine Setup and Adjustments Drill Rotation Speed and Pressure:

The hydraulic flow for the drill rotation function is supplied by the rear section of the tandem gear pumps mounted to the back of the main hydraulic pistion pumps (one diesel driven, the other electric motor driven). These pumps are designed o provide sufficient oil flow to operate the rotation function at a slightly higher speed than the maximum rotational speeds used in normal drilling applications. As these pumps are of the fixed displacement type, they are sized to provide this flow based on the particular model drill being used and speed of the prime movers running them (diesel engine or electric motor). The inlet section of the drill control valve allows the flow from these pumps to be diverted to the hydraulic tank at low pressure when the directional control section for rotation is in the neutral (center) position. As the directional control section is actuated to start the drill rotation function, the hydraulic fluid flow increases as movement of the valve spool increases. The excess hydraulic fluid flow provided at the top of the valve near the handle attachment. Adjustment of these screws will allow the valve to be set to provide the proper amount of hydraulic fluid to set the maxumim desired rotation speed in both directions. The rotation is normally operated between 170 and 210 RPM for drilling reletively small holes. The speed is usually determined by measuring the speed of a freely rotating drill rod with a hand held strobe type tachometer. An adjustable unloading relief valve in the inlet section limits the maximum operating pressure of the rotation circuit. This is at the factory at 2250 PSI. Depending upon conditions, operating pressure for this circuit is usually between 800 and 1400 PSI. All flow from the rotation pump, including and excess flow, is pressurized to the operating pressure of the rotation circuit plus the bias spring valve of the loader in the drill valve inlet section - approximatly 100 PSI. (Also see Anti-Jam Adjustments)

Drill System Pressure:

The hydraulic flow to the hammer, feed all positioning functions (as well as the tramming functions), and the hydraulically driven fan of the oil cooler is provided by the main piston pumps.

These are load sensing, variable volume, axial piston type pumps which can operate at various pressures and flow depending upon the system demand. One pump is driven by the diesel engine, and an identical unit is driven by the AC electric motor. Adjustment screws on the pump control block are provided to adjust the maximum pressure the pump can generate, (pressure override or POR control), and to adjust the stand-by and differential pressure.

The stand-by / differential pressure normally needs no adjustment as it is factory preset. This is pressure produced by the pump when in the unloaded condition. If adjustment is ever required, this pressure may be set as high as 400 PSI, but a much lower setting is normal.

The pressure override on the diesel driven pump is set at 4000 PSI, as pressures up to this value may be required for the tramming function. The pump operates completely in a load sence mode while tramming, which means it operates only at the pressure required to move the load plus differential pressure. A load sence pressure signal from the Tram / Steering valve is sent back to the pump load sence port through a series of pilot lines and shuttle valves. This would normally force the pump to go to its maximum pressure setting - as limited by the pressure override control - in this case 4000 PSI. This is much higher pressure than is required to operate the drilling functions, so a small pilot pressure relief valve is provided to reduce the load sence pilot signal to the pump to the desired pressure setting for drilling. This allows the pump to operate as a pressure compensated pump, maintaining the desired pressure setting reguardless of the load pressure or flow requirements of the system. The desired operating pressure for the HPRH-3813 hammer is normally 2200 and 2500 PSI. As the hammer operates at drill system pressure, the relief valve should be adjusted accordingly. The drill pump pressure (when in "Drill" mode) may be read on the hydraulic pressure guage on the drill console.

3-6

Adjustments and Maintenance

BI615748

Initial Machine Setup and Adjustments Drill System Pressure - continued:

The pressure override (pump compensator) of the electric motor driven pump needs only to be set at the highest pressure required of any function during drilling - typically 2600 to 2700 PSI. This pressure can be set by temporarily raising the setting of the relief valve controlling drill system pressure in the "Drill" mode of operation to 3000 PSI while operating the electric motor driven pump.

The Drill / Tram selector must be in the "Drill" mode and the Pump Load / Unload toggle valve must be in the "Load" position. The POR may be adjusted to the desired pressure setting. After setting the pump POR, the relief valve must be returned to its original setting.

Boom Control Valve and Feed Extend Pressure:

The Feed extend function allows the feed guideshell (feed bem) to extend from the feed mounting table so the rubber stinger pad at the forward end of the feed can be secured to the rock for stabilizing the feed during drilling. The feed extend hydraulic cylinder must operate at much lower pressure than most other functions of the drilling system, typically at 900 to 1100 PSI. The hydraulic control for this function is located on the eight section boom control valve on the drill operator's console. The boom control valve sends load sense signals to the main drill pump through shuttle valves. This allows the functions controlled by the boom control valve to operate at a higher pressure than the drill system. Setting pressure of any functions on this valve is controlled by a pilot relief valve which limits the load sence pilot signal pressure. Normally, 2500 PSI or less is adequate to operate any of these functions. The relief valve is located under the drill control console near the boom control valve. It is identical to the relief valve controlling drill system pressure. The feed extend directional control section of the boom control valve is slightly different from all the other sections, in that a pressure limiter adjuster is provided in the body of the valv (opposite the handle end) which controls the maximum feed extend operating pressure. The feed extend pressure is set at the factory to 1000 to 1100 PSI, but depending upon the application, this may require adjustment to assure a secure achoring of the feed at the rock face, but not with such force that hole alignment cannot be maintained or undue stresses are placed on the boom system.

Drill Feed and Feed Collaring Pressure:

The drill feed pressure and the drill feed (hole) collaring pressures are set at the factory at 1050 PSI and 750 PSI respectively. These are simply starting points and most likely will have to be readjusted for the particular conditions and applications encountered. If the feed pressure is set too high, excessive drill front end wear, bent drill steel and premature bit wear may result. If feed pressure is too low, breaking or excessive heating of the drill shank, drill steel and couplings (if used), and damage to the rock drill may result. During the first few holes being drilled, the feed pressure should be reduced until a loose clattering sound from the drill is being noted, and then increased until this loose clattering abates. This should be used as the inital feed pressure setting for the particular conditions. During the first few weeks of drilling with a new machine, some additional feed pressure adjustments will likely be required to optimize drill performance and drill string and bit life. The feed pressure is adjusted to 1050 PSI via LSA. The adjustment knob protrudes outward slightly from the console top plate. A kurlded locking nut is provided to lock the adjustment in place after adjustments have been made. As with all other pressure controls on the jumbo, turning the knob clockwise will increase the pressure, and turning the knob counter-clockwise will reduce the pressure. Once the initial feed pressure adjustments are made, the feed collaring pressure should be set to 250 to 300 PSI below the feed pressure setting. The feed collaring is the feed pressure used while starting a new drill hole (collaring a hole). The drill feed directional control, the middle working section of the drill control valve, should be fully shifted to the reverse position to allow the rock drill to fully retract on the feed with the hydraulic pressure continuing to act on the feed Adjustments and Maintenance

3-7

BI615748

Initial Machine Setup and Adjustments Drill Feed and Feed Collaring Pressure - continued:

drive motor. The feed circuit pressure may be read on the Feed Pressure guage on the drill console. When the Collaring On/Off selector valve is shifted to the ON position, the feed pressure is controlled by the feed collaring maifold block. The valve adjust identically to the feed pressure control. When the collaring On/Off valve is shifted back to the OFF position, the feed operating pressure will immediatly rise to the normal feed pressure setting.

Hammer Collaring Pressure:

Hammer Pressure can be lowered by turning the hammer pressure adjustment knob to the desierd pressure of 1600 PSI to 2000 PSI.

ADC (Automatic Drill Console):

The ADC system automatically shuts off the hammer and reverses the feed direction when the rock drill reaches the forward end of the feed at the completion of a full depth drill hole. Pressure is maintained at a plunger situated beside the drill on the drill saddle which is depressed. When the drill saddle reaches the auto return bracket on the feed cylinder (move the auto return bracket down the feed cylinder, will reduce hole depths), this will create pressure. A pressure switch is activated, this sends an electric current to a solenoid operated valve to activate the pilot port of the feed and hammer valves (feed reverses and hammer shuts off).

Anti-Jam Adjustments:

The Anti-Jam system automatically momentarily reverses the feed direction; a predetermined level which is an indication of the bit and steel becoming stuck in the drill hole. As the bit again makes contact with the bottom of the hole and feed pressure rises to normal levels, the hammer will return to full power. When drilling in broken ground where jamming of the drill steel may be problematic, the anti-jam may continue to re-actuate and repeat the cycle until the bit passes through the poor ground.

The forward rotation pressure is senced by a sequence valve in the anti-jam activation pressure, or trip point, is normally set at 300 to 400 PSI above the normal rotation operating pressure. It may be easier to simply disconnect both forward and reverse rotation hoses at a convenient point and join them together through the valve or flow meter. With the Anti-jam On/Off valve in OFF position and rotation direction circuit to rise to its maximum pressure setting (2250 PSI). This may be read on the rotation pressure guage on the drill control console. The maximum rotation pressure may be reset, if necessary. (See Drill Rotation Speed and Pressure.)

Open the metering valve until the rotation pressure falls to a value approximatly 300 PSI higher than normal rotation operating pressure. With the anti-jam sequence valve adjustment screw turned clockwise to its maximum setting, the Anti-jam On/Off selector valve shifted to the ON position, and with the rock drill advancing slowly forward on the feed. By opening the in-line metering valve slightly to reduce the hydraulic pressure in the forward rotation circuit, the drill should revert to advancing in the forward direction. By slowly closing the metering valve to increase the rotation pressure to the sequence valve trip pressure value, the drill should again reverse direction on the feed. This trip point pressure value can be determined by monitoring the rotation pressure guage. After adjustments are completed, tighten the jam nut on the sequence valve adjustment screw.

3-8

Adjustments and Maintenance

BI615748

Initial Machine Setup and Adjustments Anti-Jam Adjustments - continued:

By using the in-line metering valve to cycle the direction of the drill back and forth as it travels on the feed, the needle valve controlling the Anti-jam sensitivity may be set. The sensitivity adjustment controls the time (and distance) the drill will continue to retract on the feed once the jam is cleared and the forward rotation pressure has returned to normal. Turn the adjustment screw clockwise until the valve is fully closed off, and then turn the adjustment screw back counterclockwise approximately one-quarter turn. Allow the drill to feed forward and then activate the antijam by closing off the in-line metering valve until the drill reverses direction on the feed. Immediatly open the metering valve back up noting how far the drill continues to travel in reverse until it then reverts back to advancing in the forward direction. By making slight adjustments in the response sensitivity needle valve, the distance the drill retracts on the feed can be controlled. This didtance should be set to 2 to 3 ft (60 to 90 cm). This procedure may be repeated several times to finalize adjustments.

NOTE

The needle valve (sensitivity adjustment) must never be shut off completely, as this will cause the feed system to work in reverse indefinately and cause operational malfunctions in the feed circuit. If opened too far, the anti-jam may not function at all and excessive pump flow will be diverted to the hydraulic reservior, resulting in excessive heat generation and power consumption.

After all adjustments are made, remove the in-line metering valve and reconnect the fluid lines.

Adjustments and Maintenance

3-9

BI615748

Machine Set-Up & Pressure Setting Chart Machine Set-up and Pressure Settings NOTE

3-10

The following settings are starting points only. Each application normally requires different settings of some functions.

COMPONENTS 1. Pump Compensator

SPECIFICATIONS 2800 PSI (179.3 bar)

2. Rotation Pump Compensator

2400 PSI (158.6 bar)

3. Power Steering

2600 PSI (172.4 bar)

4. Drill Pump Suction

1" HG-5: Maximum

5. Rotation Pump Suction

1-3" HG-5" Maximum

6. Power Steering Suction

1-3" HG-5" Maximum

7. Feed Extend

1500 PSI

8. Feed Pressure

1000 PSI, 2500 PSI Override 650 PSI Collaring

9. Boom Valve Compensator

2700 PSI

10. Rotation Pump Flow

17 GPM Depending on drill requirements.

11. ADC Pilot Pressure Reducing Valve

320 PSI

12. Outrigger Sequence Valves

1800-1850 PSI

13. Hammer Compensator

2400 PSI Drilling pressure at backhead is normally approximately 200 PSI less than pump press.

14. Drill Pressure Return

Should be 120 PSI

15. Hydraulic System Temperature

Should be 1200F - 1600F (49-710C) (Non Adjustable)

16. Hydraulic System Shutdown

1800 F

17. Drill H.P. Accumulator

30% of Inlet Pressure (maximum)

18. Drill L.P. Accumulator

30% of Outlet Pressure (maximum)

19. Pump Motor Speed

Should be 1450/1500 - 50 HZ (1750-1800 - 60 HZ)

20. Engine Speed

2300 No Load RPM

21. Main Pump FlowMax. High Pressure Output

50 HZ = 33-35 GPM (125-132 liters) 60 HZ = 40-42 GPM (151-159 liters)

22. Power Steering Flow

10 GPM (38 liters) @ 2300 Eng. RPM

23. Engine Cooling Fan Intake

10oF (-12oC) Above Ambient Max.

24. Vickers Pump Stand-by Pressure

500 PSI

25. Temp Switch

1800 F

Adjustments and Maintenance

BI615748

Bolt Torque Specifications Procedure No. 1-87 REVISION A

Torque Values: Bolts, Screws and Studs (Lubricated or Plated) Tolerance Values in all cases to +5 % - 0 % of the Value listed below.

Note: K = .15 for plated or lubricated fasteners.

Nominal Diameter

UNC

UNF

UN

SAE Grade 5 ASTM A-449 Tightening Torque Ft. Lbs. (Nm) Newton meter

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2

6 (8.2) 13 (17.7) 23 (31.3) 35 (47.6) 57 (77.5) 82 (111.5) 113 (153.7) 200 (272) 322 (437.9) 483 (656.9) 596 (810.6) 840 (1142.4) 1102 (1498.7) 1462 (1988.3) 1714 (2331) 2576 (3503.4) 3768 (5124.5) 5155 (7010.8) 6996 (9514.6) 9231 (12554.2) 7 (9.5) 14 (19) 26 (35.4) 40 (54.4) 64 (87) 91 (123.8) 127 (172.7) 223 (303.3) 355 (482.8) 528 (718.1) 668 (908.5) 930 (1264.8) 1254 (1705.4) 1645 (2237.2)

1-3/4 2 2-1/4 2-1/2 2-3/4 3

1879 (2555.4) 2857 (3885.5) 4127 (5612.7) 5726 (7787.4) 7693 (10462.5) 10064 (13687)

Adjustments and Maintenance

SAE Grade 8 Tightening Torque Ft. Lbs. (Nm) Newton meter 9 (12.2) 18 (24.5) 33 (44.9) 55 (74.8) 80 (108.8) 115 (156.4) 159 (216.2) 282 (383.5) 455 (618.8) 681 (926.2) 966 (1313.8) 1363 (1853.7) 1786 (2429) 2371 (3224.6)

10 (13.6) 20 (27.2) 37 (50.3) 60 (81.6) 90 (122.4) 128 (174.1) 180 (244.8) 315 (428.4) 502 (682.7) 746 (1014.6) 1083 (1472.9) 1509 (2052.2) 2034 (2766.2) 2668 (3628.5)

3-11

BI615748

Hydraulic General Information Operation With the diesel engine running and Drill selected on the Drill/Tram Switch the engine rpm will raise to high idle speed. The tram/steer joystick and park brake button will be de-energized, the tram lock out valve will be energized.

When the hammer, feed or rotation valves are moved the hydraulic system will load the selected function will operate.

Rotation The rotation is controlled by the rotation valve section, rotation speed is controlled by adjusting the stoke limiter adjustments on the rotation valve section. Maximum rotation pressure is adjusted by setting the forward load sense relief to 2500-psi.

Feed Pressure Adjustment The feed pressure is controlled by the feed valve load sense relief and is adjustable between 0psi and 1200-psi. This is done by screwing in or out the feed pressure regulator. The feed pressure is limited to a maximum of 1200-psi by the feed pressure load sense relief.

Hammer Pressure Maximum hammer pressure is by setting the hammer pressure load sense relief, this is normally adjusted to 2600-psi.

Collaring Hammer Pressure The collaring hammer pressure can be adjusted placing the collaring on/off valve in the on position and screwing in or out the hammer pressure regulator. The hammer pressure can be reduced for hole collaring; this is normally adjusted to 1200-psi and is limited to a maximum of 2600psi by the hammer pressure load sense relief.

Constant Feed Sting The constant feed sting feature is used to keep the feed in contact with the rock face while drilling. The constant sting lever is detented and has a reduced forward pressure 1500-psi, which is adjusted, on the load sense port of the valve.

Auto Return As the drill reaches the end its travel the auto return plunger will be depressed an adjustable stop. The plunger sends a hydraulic pressure signal to the hammer reset pressure switch. When this switch closes an electrical signal is to the hammer lockout valve and the feed reverse valve. The hammer lockout valve closes and shuts off the hammer, the feed reverse valve switches the feed A and B lines and the feed operates in reverse bring the drill all the way to the back of the feed. To start drilling again the hammer reset button must be pushed. If the hammer and feed levers have been left in the on position the drill will start hammering again and the feed will start traveling forward. To shut the feed and hammer off the levers must be returned to the neutral position.

3-12

Adjustments and Maintenance

BI615748

Hydraulic General Information Anti-Jam System The anti jam system is used when drilling in broken or faulted ground. In order to enable this function the anti-jam on/off valve must be placed in the on position. During normal drilling rotation pressure is usually maintained between 600-psi and 900-psi. If the rotation pressure rises above 1200-psi at the rotation pressure switch because of the bit jamming in the hole the anti jam relief will open and send a hydraulic signal to the anti jam feed valve. This valve will switch the pressure from the feed forward line of the feed cylinder to the reverse line, which will reverse the direction of the feed cylinder and bring the drill out of the hole. When the rotation pressure drops below 1200-psi the anti jam feed valve will return to its normal state and the drill will start traveling forward again.

Setting and Testing Anti-jam To adjust the anti jam system; cap the forward rotation pressure line at the rotation motor and place the anti jam on/off lever in the on position. With the hammer at the back of the feed place the feed valve lever in the forward position. Slowly move the rotation valve lever to the forward rotation position and watch the rotation pressure rise. The rotation pressure at which the feed reverses is the anti jam pressure. By moving the rotation lever to the reverse position the rotation pressure will drop and the feed will resume forward travel. If the feed fails to return to the forward direction check the anti jam drain orifice as it may be plugged. This orifice size determines the distance the feed reverses during an anti-jam situation. To adjust the anti jam pressure the anti jam pressure relief under the drilling console must be turned in or out. This pressure can be adjusted to suit bit size and ground conditions.

Adjustments and Maintenance

3-13

BI615748

Hydraulic General Information

Fig. 3-3 Feed / Rotation Schematic

3-14

Adjustments and Maintenance

BI615748

Section 4

Preventative Maintenance

Preventative Maintenance

4-1

BI615748

Preventive Maintenance General Preventive maintenance is vital to personnel protection and lower operating costs. The Jumbo requires regularly scheduled maintenance to keep it operating efficiently.

The maintenance intervals presented in this section are recommended by Terex Reedrill. The actual operating environment of the machine may dictate a re-analysis of the maintenance interval for a specific operation.

For efficient maintenance of the machines, it is suggested that a log book be established to record the date, engine hours, and drill hours when each maintenance was done.

Lubrication and Inspection WARNING:

DO NOT attempt lubrication or service while the machine is running. Be sure the hydraulic system is not pressurized before loosening any and connections or parts.

CAUTION:

To avoid unnecessary machine repairs, keep the following in mind when handling fuels and lubricants: Clean grease fittings with a clean cloth before greasing.

Keep all fuels and lubricants stored in clean and tightly sealed containers.

Keep filler caps clean of dust and oil.

Replace filters inside a shop or when there is no visible dust in the air.

Never re-use paper filters.

Wash metal parts of filters with clean oil, but do not wipe the parts with a cloth.

Wipe up any over spill with a clean cloth.

Keep dirt and dust from entering any fluid system.

Keep the fuel storage containers and system filled.

Watch for metal filings on any magnetic drain plugs. Filings are a sign of internal component wear or maladjustment. If a source can be determined and repaired as part of scheduled maintenance, costly down time can be avoided later.

4-2

Preventative Maintenance

BI615748

Preventive Maintenance Chart COMPON ENT GROUP

INTERVAL HOURS

SERVICE LOCATION

REQUIRED MAINTENANCE

RECOMMENDED LUBRICANT

RESERVOIR

CHECK FLUID LEVEL

MOBIL DTE18 OR EQUIVALENT

RESERVIOR FILL PUMP FILTER

CHECK INDICATOR

1754667

HYDRAULIC RETURN FILTERS

CHECK INDICATOR

99739

HYDRULIC INLET FILTER

CHECK INDICATOR

22459

ENGINE

CHECK OIL LEVEL

DIESEL ENGINE OIL SEE ENGINE MANUAL

CABLE REEL BEARINGS AND ROLLERS

GREASE

NLGI #2 GREASE

WATER STRAINER

CHECK & CLEAN

CARRIER ALL LUBE POINTS

GREASE

NLGI #2 GREASE

ELECTRIC MOTOR BEARINGS

LUBRICATE

NON-FLUID OIL CORP G-60 OR CHEVRON SRI #2

HYDRAULIC OIL

CHECK LEVEL

MOBIL DTE 18 OR EQUIVALENT

PUMP DRIVE GEARBOX

CHECK OIL LEVEL

HD80W-90 GEAR OIL

HYDRAULIC OIL

CHANGE OIL

MOBIL DTE 18 OR EQUIVALENT

RESERVOIR FILL PUMP FILTER

REPLACE FILTER

1754667

HYDRAULIC RETURN FILTERS

REPLACE FILTER ELEMENT

99739

HYDRAULIC INLET FILTER

REPALACE OR CLEAN FILTER ELEMENT

22459

WATER STRAINER

REPLACE SCREEN

FEED CABLE TENSION

CHECK TENSION ADJUST IF NEED BE

HOSE TENSION

CHECK & ADJUST

100 HOURS OR WEEKLY

HYDRAULIC CYLINDER PINS & PIVOT POINTS

GREASE

NLGI #2 GREASE

2 HOURS

CHUCK END

GREASE

PG55 GREASE

8 HOURS

WATER SWIVEL SEALS

CHECK FOR LEAKAGE REPLACE IF NEED BE

100 HOURS

ACCUMULATOR CHECK CHARGE PRESSURE CHARGE IF NEED BE

CARRIER (SEE CARRIER MANUFACTURER'S MANUAL FOR 100 HOURS ADDITIONAL INSTRUCTIONS) 200 HOURS

400 HOURS

FEEDS BOOMS POSITIONER

DRILL

8 HOURS OR EACH SHIFT

Preventative Maintenance

REPLACEMENT PART NUMBER

312810

4-3

BI615748

Pre-Operation Checklist After a long transport or a period of standstill: 1.

Inspect the Jumbo for damage incurred during shipping and handling.

2.

Clean the Jumbo if necessary.

3.

Tighten all loose bolts.

4.

Check the engine according to the Deutz Engine Instruction Book.

5.

Be sure the fuel tank is at least partially full (fig. 4-1). If the engine runs out of fuel, the complete fuel system must be bled of air and primed.

6.

Check the battery. (fig. 4-2)

7.

Prior to tramming, check that the Jumbo Articulation is not locked. (fig. 4-5)

8.

Grease all grease cups. (See "Drill Operator's Checklist").

9.

Check the oil level in the hydraulic tank with the "Oil Level Indicator" mounted on the oil tank (fig.

4-4).

10. If the hydraulic oil is low, fill it with recommended hydraulic oil. Use the 24 volt filling pump via the 10 micron filter mounted near the tank.

11. If the tank has been empty, check that the inlet lines leading from the tank to the pumps are all filled with hydraulic oil.

12. Check oil level (outriggers, booms and feeds retracted).

If the Jumbo has not been used for an extended period of time, or has been transported over a long distance, extend outriggers to a firm footing and move all cylinders (Boom, Positioner, Feed Extension) with the Engine Auxiliary Pump and control levers. Then check the oil level in the hydraulic tank again. Before tramming; boom, drill, and feed should be retracted as far back as possible. Position boom at centerline of machine.

• Be sure the outriggers are completely raised and retracted.

• Move Tram/Drill selector switch to "Tram"position (fig. 4-3).

• Release the brake.

• Be sure no hoses are dragging on the ground while the Jumbo is moving.

1

2 Fig. 4-1 Fuel Tank 1. Fuel Gauge 2. Fuel Tank Cap 4-4

2

1

Fig. 4-2 Battery Compartment 1. Battery 2. Battery Disconnect Switch Preventative Maintenance

BI615748

Pre-Operation Checklist

1

9

8

1

7

5

6 2

3 Fig. 4-3 1. Deutz Display 2. Park Break 3. Start Switch 4. Drill / Tram 5. Engine Fault Light

4

6. Engine Fault Test 7. Front Lights 8. Rear Lights 9. Coolant Temp.

Fig. 4-4 Hydraulic Tank 1. Oil Level Indicator

1

Fig. 4-5 Articulation Lock Bar 1. Articulation Lock Bar Preventative Maintenance

4-5

BI615748

System Checks Prior to Engine Start for New or Reconditioned Machines A. Start up - Grease and Oil 1. Grease all fittings - multi-purpose grease (NLGI#2) 2. Engine Fuel - Diesel 3. Engine Oil 4. Main motor grease 5. Engine air cleaner oil 6. Axle oil - ring and pinion / reducer box / planetaries 7. Hydraulic oil (Mobile DTE 18 or Equivalent) 8. Prime power steering pump 9. Prime right and left hand main pumps B. Back Out - Power Steering Pump Compensator C. Back Out - Pressure Reducing Valve for Feed Extend D. All Levers in Neutral E. Joystick in Neutral F. Install all Gauges 1. Pump suctions 2. System presure (tram pump) 3. Charge pressure (tram pump) 4. Feed extend G. Use Auxiliary Hdraulic Power Source to Retract all Boom and Feed Functions 1. Feed retracted 2. Drill retracted 3. Booms inboard and horizontal 4. Outriggers up H. Charge Drill High Pressure Accumulators I. Charge Drill Low Pressure Accumulators

4-6

Preventative Maintenance

BI615748

Hydraulic System Checks Power Steering Pump

New of Reconditioned Machines 1. Connect water line 2. Install guages in outrigger cylinders. Set sequenc valves at 1800 PSI (124.1 bar) 3. Extend outriggers 4. Install guage 0-3000 PSI (0-206.8 bar) in feed cylinder. Set feed extend pressure reducing valve at 1000 PSI (69 bar). This adjustment required for right and left hand booms.

5. With Outriggers down, cycle all boom / positioner / feed function relationships.

6. Check hydraulic reservoir level.

7. Check for leaks.

8. Run cable reel.

9. Set cross port relief valve at 300 PSI (20.7 bar)

Main Hydraulic Pumps

New or Reconditioned Machines 1. Connect electric power.

2. Connect air and water lines.

3. Check for leaks 4. Jog pump motors and check for proper rotation.

Jog water pump motor and check for proper rotation.

Jog compressor motor and check for leaks 5. Install suction and by-pass guages.

6. Set control valves in neutral position.

7. Start right hand pump motor Check for leaks.

8. Check suction pressure - 1-2" (2.5 - 5 cm) Hg. 9. Observe hydraulic oil level.

10. Set ADC pilot pressure at 400 PSI (2.5-5 cm) Hg. 11. Observe hydraulic tank flow and aeration.

12. Start left hand pump in same manner.

13. Run main pumps and cycle all functions slowly to remove any remaining air.

14. Cycle all functions and observe system for leaks or any other malfunctions.

15. Check system pressure temperature - 120 - 160 °F (49-71°C).

Preventative Maintenance

4-7

BI615748

Drill Operator's Maintenance Checklist Drill Operator's Maintenance Checklist Hydraulic tank

Check oil level, fill as required

Compressor

Check oil level, fill as required Check air inlet filter

Booms

Grease all lubrication points Check bolts for loose bolts tighten as required Check for damage to cylinders Check hydraulic hosing condition

Feeds

Grease lubrication points Check feed cable tension adjust as required Check drill saddle wear pads adjust as required Check drill hose tension adjust as required

Drills

Grease drill daily before every round - 5 shots st the top of the rotation housingand on the bottom - 12 shots or untill it comes out of relief Check shank bushing lubrication and hosing Check drill mounting bolt torque

Carrier

Check engine oil level Check engine coolant level Check fuel level Check drill lubrication tank oil level Grease carrier lubrication points

4-8

Preventative Maintenance

BI615748

Periodic Maintenance Chart Component Service Interval

8 hours

50 hours

250 hours 1000 hours

Carrier

Hydraulic tank level

Check

Check

Check

Return filter

Check indicator

Check indicator Change

Change

Pressure filter

Check indicator

Check indicator Change

Change

Hydraulic tank vent

Check

Check

Change

Change

Hyraulic tank fill filter

Check indicator

Check indicator Change

Change

Fuel/Water seperator

Drain

Drain

Change

Change

Change

Change

Check

Change

Change

Change

Change

Engine air filter

Check

Change

Change

Engine air cooler

Check

Check

Check

Wheel motor oil

Check

Change

Change

Compressor air filter

Check

Change

Change

Fuel Filters Engine oil

Check

Engine oil filter

Boom

Feed

Rock drill

Drain and replace

Compressor oil

Check

Check

Change

Change

Receiver tank

Drain

Drain

Drain

Drain

Rock drill oil tank

Check

Check

Check

Change

Water Y strainer

Check/Clean

Check/Clean Change/Clean

Hydraulic oil Cooler

Check

Check

Check

Hydraulic cylinders

Check

Check

Check

Check

Hydraulic hosing

Check

Check

Check

Check

Pins and bushings

Check

Check

Check

Check

Boom extend wear pads

Check

Check/Clean

Check/Clean Check/Clean

Feed cable tension

Check

Adjust

Adjust

Adjust

Hose tension

Check

Adjust

Adjust

Adjust

Hose reel drum

Check

Check

Check

Check

Drill saddle wear pads Centralizer Traveling Centralizer Stinger pad

Check Check Check Check

Adjust Check Check Check

Adjust Check Check Check

Adjust Check Check Check

Follow maintance manual

Preventative Maintenance

4-9

BI615748

Troubleshooting Problem

Probable Cause

Remedy

1. Pump makes unusual noise "TURN OFF MOTOR IMMEDIATELY"

Low oil levels High viscosity (heavy) oil Air entering suction line

Add oil, Check for leaks Use only recommended oil Repair air leaks

2. Pump cavitation “TURN OFF MOTOR IMMEDIATELY”

Collapsed suction line Hydraulic filters clogged

Check and replace Clean and replace

3. Pump starving “TURN OFF MOTOR IMMEDIATELY”

Low oil level Wrong type of oil Pump return line inlet blocked Hose ruptured

Add oil, Check for leaks Replace with recommended oil Isolate blockage and clean Replace

4. Hydraulic system inoperative

Pump worn out Low oil level Dirty pump, oil lines; filter

Replace Add oil, Check for leaks Clean system

5. Hydraulic system operates too slowly

Pump oil output insufficient Hydraulic lines or fittings wrong Restriction in lines High viscosity (heavy) oil

Check recommended flow and pressure Check and repair damaged parts Clean orreplace Use only recommended oil

6. Low hydraulic system pressure

Low oil level Collapsed suction hose Pump compensator set too low

Add oil, Check for leaks Check and replace hose Set to recommended pressure

7. Hydraulic cylinder won’t move

Hydraulic cylinder leaking Worn or damaged seals Collapsed hydraulic hose Bent hydraulic cylinder High viscosity (heavy) oil Low hydraulic system pressure

Repair or replace Reseal Replace Replace Use only recommended oil Check hydraulic system

8. Hydraulic cylinder won’t hold

Worn piston cups Hydraulic line leaking Dirty or worn control valve Air in hydraulic cylinder Damaged holding valve

Replace Repair leaks Clean or replace control valve Bleed hydraulic cylinder Replace

9. Hydraulic system overheating

Inadequate cooling

Be sure of adequate water pressure Drain and replace with recommended oil Replace

Dirty oil Defective thermal mixing or dump valve Fouled heat exchanger 10. Oil Foaming

Low oil level Water in oil Air in oil Incorrect oil

4-10

Replace Add oil, Check for leaks Drain; replace with recommended oil Locate source of air and correct Use only recommended oil Preventative Maintenance

BI615748

Section 5

Glossary

Glossary

5-1

BI615748

Glossary The following is a list of terms commonly used in the mining and construction industry. This list is not exhaustive, but pertains primarily to underground jumbos discussed in this manual.

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

Belleville Washer..............Another name for "Spring Washer".

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

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

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

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

Drifter ..............................Another term for a rock drill. In this manual the term "rock drill" is used for consistancy.

Drill Rod ..........................Another name for "drill steel".

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

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

Drill String .......................Refers to multiple pieces of drill steel joined together.

Dump ..............................Term used to describe the position of the feed reletive to the centerline of the boom. Dump UP tilts back of feed towards boom, dump DOWN tilts the back of the feed away from boom.

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

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

Feed Mounting ................Another name for "Feed Table".

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

Hammer .........................A term sometimes used for "rock drill".

5-2

Glossary

BI615748

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

Oscillator ........................A term sometimes used for the rock drill "hammer".

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

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

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

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

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

Spring Washer ...............A cup shaped washer that, when compressed provides a "spring-like" action. Aso called "Belleville washer".

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

Stinger..............................A device attached to the end of the feed which retracts the rock face to stabilize the feed while drilling.

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

Tram................................To move and steer the machine from the tram station.

Glossary

5-3

BI615748

Notes

5-4

Glossary