CAT Bucyrus Shaft Jumbo Two Boom Air Jumbo Operator Manual SN S09-6230, S09-6240

BI615827

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI615827

Shaft Jumbo Two Boom Air Jumbo

Operator Manual Serial #: S09-6230, S09-6240

BI615827

Parts Ordering & Product Support

Use only genuine Terex parts in the maintenance, rebuild, or repair, of Terex machines. Terex shall have no liability as to any unauthorized modification of machines or parts and shall have no obligation or liability as to any machines or parts which have been improperly handled, or which have not been operated, maintained, or repaired according to Terex's furnished manuals, or other written instructions, or which are operated with other than genuine Terex parts.

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 Model Number and Serial Number when ordering parts. This information is found on the machine nameplate.

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 P. O. Box 998 Sherman, TX. 75091-0998

SHIPPING ADDRESS Terex 3501 S. FM Hwy 1417 Denison, TX. 75020

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

BI615827

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 Air System Operation Shutdown Procedure

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

BI615827

Shaft Jumbo

Fig. 1-1 Two Boom Air Shaft Jumbo Frame - Jumbo #1 - RS

ii

Introduction

BI615827

Shaft Jumbo The Terex Air Shaft Jumbo is an extremely rugged shaft sinking unit.

The two boom, Air/Hydraulic Jumbo includes two complete systems or units; each consisting of an air powered hydraulic drilling system, water system and air drill system. For our purposes here we will be referring to one complete system, or unit as Jumbo #1 and the other as Jumbo #2.

A simple hydraulic system makes each unit suitable for extremely tough shaft sinking conditions without the aid of electricity. Each unit is equipped with a Boart S36 air rock drill, specially designed SJ105 Hydraulic Boom and Hydraulic Timberock Feed.

The air driven hydraulic drilling systems are equipped with tandem gear pumps. Each unit also features a parallel drilling system, and constant sting system.

This manual provides operating instructions, a technical description of the Air Shaft Jumbo, servicing and routine maintenance procedures, and an explanation of the various Air Shaft Jumbo systems.

Fig. 1-2 Air Shaft Jumbo Boom and Feed

Introduction

iii

BI615827

Shaft Jumbo

Fig. 1-3 Two Boom Air Shaft Jumbo Frame - Jumbo #1 - LS

iv

Introduction

BI615827

Shaft Jumbo

Fig. 1-4 Two Boom Air Shaft Jumbo Frame - Jumbo #2 - RS

Introduction

v

BI615827

Shaft Jumbo

Fig. 1-5 Two Boom Air Shaft Jumbo Frame - Jumbo #2 - LS

vi

Introduction

BI615827

Table of Contents SECTION 1

SAFETY AND OPERATION WARNINGS

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

SECTION 2

OPERATING INSTRUCTIONS

Pre-Operation Checklist ......................................................................................................... 2-2 Setting Up for Drilling ............................................................................................................. 2-3 Air System Operation ........................................................................................................... 2-3 Air System Check ................................................................................................................ 2-3 Water System Check ............................................................................................................ 2-3 24V Electrical Check (optional) ............................................................................................ 2-3 Activate Air Supply ............................................................................................................... 2-3 Connection Locations, Shutdown Locations ........................................................................... 2-4 Shutdown Procedures ............................................................................................................ 2-5 Emergency Shutdown ........................................................................................................... 2-5 Fire Supression .................................................................................................................... 2-5 Normal Shutdown ................................................................................................................. 2-5 Automatic Machine Shutdown Functions ............................................................................... 2-5 Drilling Procedures ................................................................................................................ 2-6 Set-up For Drilling ................................................................................................................ 2-6 Changing Bits ...................................................................................................................... 2-7 Checks During Drilling .......................................................................................................... 2-7 Drill Control Functions ............................................................................................................ 2-8 Instrument Panel ................................................................................................................... 2-9 Drill Console ........................................................................................................................ 2-9 Air Drilling Valve ................................................................................................................... 2-10 Rotation ............................................................................................................................. 2-10 Air/Water ............................................................................................................................ 2-10 Hammer ............................................................................................................................. 2-10 Drill Control Valve Schematic ............................................................................................. 2-11 Feed Paralleling System ...................................................................................................... 2-12 Constant Sting Circuit (Feed Extend) .................................................................................... 2-13

SECTION 3

ADJUSTMENTS AND PREVENTATIVE MAINTENANCE

Initial Machine Setup and Adjustments .................................................................................... 3-2 Air Regulator ........................................................................................................................ 3-2 Lubricator ............................................................................................................................. 3-2 Low Flow Control .................................................................................................................. 3-2 High Flow Control ................................................................................................................. 3-2 Air/Hydraulic Circuit (Overspeed Valve) ................................................................................ 3-2

Introduction

i

BI615827

Table of Contents Air/Hydraulic Circuit (Schematic) .......................................................................................... 3-3 Boom Function Valve Compensator Pressure ...................................................................... 3-4 Drill Feed/Regulator Pressure .............................................................................................. 3-4 Feed Extend Pressure ......................................................................................................... 3-4 Boom Auto-Parallelism ......................................................................................................... 3-4 Hydraulic General Information (Schematic) ............................................................................. 3-5 Drill Operator's Maintenance Checklist ................................................................................... 3-6 Check Every Shift ................................................................................................................. 3-6 System Checks ...................................................................................................................... 3-7 Prior To Start for New or Reconditioned Machines ................................................................ 3-7 Bolt Torque Specifications ...................................................................................................... 3-8 General Preventative Maintenance ......................................................................................... 3-9 Preventative Maintenance Chart ........................................................................................... 3-10 List of Terex Air Shaft Jumbo General Fluids and Lubricants with Capacities ..................... 3-10 Daily ................................................................................................................................... 3-10 50 Hours (Weekly) .............................................................................................................. 3-11 250 Hours (Monthly)............................................................................................................ 3-11 500 Hours (3 Months) ......................................................................................................... 3-12 1000 Hours (6 Months) ....................................................................................................... 3-12 2000 Hours (1 Year) ........................................................................................................... 3-13

SECTION 4

ii

GLOSSARY

Introduction

BI615827

Section 1

Safety

Safety

1-1

BI615827

Overview of Potential Hazards OVERVIEW OF POTENTIAL HAZARDS The Jumbo is 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. Should any questions arise concerning the maintenance or operation of the machine contact Reedrill at 1-800-258-0009.

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

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

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

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

POTENTIAL HAZARD

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 operate machine in an area without good ventilation.

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

BI615827

Safety Instructions Before Operation •

Do study this manual and fully understand the controls.

•

Do be sure all safety guards are securely in place.

•

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

•

Do be sure all personnel are clear of the machine and work area before activating the air supply.

•

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

•

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

Operation •

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

•

Do provide sufficient ventilation when operating the Jumbo in the shaft. Operations can cause poisonus gasses.

•

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

•

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

•

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

•

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

After Operation •

Safety

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

1-3

BI615827

Safety Instructions Maintenance •

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

•

Do be sure each person is adequately trained to perform service and maintenance procedures.

•

Do place a warning tag on starting controls to alert personnel that someone is working on the machine and lockout the main air supply on the galloway before making repairs or adjustments to machine.

•

Do have adequate lighting when performing service.

•

Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.

•

Do be sure machine and components are well supported before servicing or replacing parts.

•

Do Not service or perform maintenance while machine is running.

•

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

•

Do Not weld or grind near oil lines.

•

Do Not leave tools or other loose objects on the unit. They could fall, injuring personnel below.

Equipment Transfer If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics: • Safety Section • Operation Instructions including: • Pre-Operation Checklist • Air System Operation • Shutdown Procedure

1-4

Safety

BI615827

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 copy of the following topics from Section 2: Pre-Operation Checklist Air System Operation Shutdown Procedure

Operating Instructions

2-1

BI615827

Pre-Operation Pre-Operation Checklist (After a longer 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.

10. Grease all grease fittings.

11. Check the oil level in each of the hydraulic tanks.

Check oil level with booms and feeds retracted.

Check the oil level indicator mounted on the oil tank.

If the hydraulic oil is low, fill it with recommended hydraulic oil, (section 3). Use the manual filling pump and the 10 micron filter. If the tank has been empty, check that the ball valve on the specified tank is open and that the line leading from the tank to the gear pump is filled with hydraulic oil. If the jumbo has not been used for a long time extend all cylinders, then retract. Recheck oil level in the hydraulic tank.

12. Check the oil level in each of the Air motors. Fill with recommended hydraulic oil (section 3).

1

Fig 2-1 Hydraulic Filler Pump Location Jumbo#2 RS

13. Check the oil level in each of the Lubricators. Fill with recommended rock drill oil (section 3).

1

3

1

2

Fig. 2-2 Hydraulic Tank (LS - Both Jumbos) 1. Hydraulic Oil Level Gauge 2. 10 Micron Filter 3. Ball Valve - (1) Per Hydraulic Tank

2-2

Fig 2-3 Filler Hose Location Jumbo #2 RS

Operating Instructions

BI615827

Setting Up for Drilling Air System Operation After the jumbo has been set up and properly chaired the (2) air, (1) water, (4) exhaust ports and the (1) cooler water must be connected to the supply ports on the galloway (fig. 2-4, 2-5).

WARNING!: Before initaial startup of Jumbo, all Drill and Boom controls should be in the neutral or off position.

Air System Check Check the air pressure. For optimum drill operation a minimum of 70 PSI (4.8 bar) is required.

Maximum pressure shall not exceed 100 PSI (6.9 bar).

Water System Check Check the water pressure. The hydraulic drilling system is water cooled (not air cooled). At least 50 PSI (3.4 bar) mine water pressure is required. For drilling use maximum 70 PSI (4.8 bar).

Activate Air Supply Be sure that all control levers are in neutral position. Activate the air by pulling up on the red estop button located on the drill operator console (fig. 2-6). This will start the hydraulic pump and activate the air supply to the drill.

4

5 1

6

7

8

2 3

Fig. 2-4 Connections - Location - Jumbo #1 - LS 1. Air Connection - Jumbo #2 2. Air Connection - Jumbo #1 3. Cooler Water - Both Jumbos 4. Water Supply - Both Jumbos

Operating Instructions

Fig. 2-5 Connections - Location - Jumbo #1 - RS 5. Exhaust - Rot. and Pwr. Pack - Jumbo #1 6. Exhaust - Rot. and Pwr. Pack - Jumbo #2 7. Exhaust - Hammer - Jumbo #2 8. Exhaust - Hammer - Jumbo #1

2-3

BI615827

I

Connection Locations, Shutdown Locations

Fig. 2-7 Fire Supression Actuator Gauge Panel on Jumbo #1

2-4

I

I

Fig. 2-6 E-Stop

Fig. 2-8 Fire Supression Actuator Gauge Panel on Jumbo #2

Operating Instructions

BI615827

Shutdown Procedures Emergency Shutdown 1.

2.

In the event of an emergency situation the machine must be shutdown immediately.

The E-Stop is located on the operator's console (fig. 2-6). You can activate the emergency shutdown system and shutdown the ENTIRE unit by depressing the red button.

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.

Fire Supression 1.

This unit is equipped with a checkfire system that will self-activate in case of fire. It is also equipped with two manual actuators located on the frame gauge panels (fig. 2-7, 2-8). Once activated take cover or move a safe distance away from the machine.

NOTE

Activating the Fire Supression WILL NOT shut down the machine.

Normal Shutdown 1.

Be sure drills are fully retracted on the feeds and all controls to the OFF or NEUTRAL position.

2.

Push the E-stop button on the operator console (fig. 2-6).

3.

Shut off and disconnect the (2) air, (1) water, (4) exhaust and (1) cooler water from the galloway.

Automatic Machine Shutdown Functions 1.

If, during operation, the unit shuts down unexpectedly the following conditions may apply: Low hydraulic fluid level.

2.

High hydraulic fluid temperature in the hydraulic reservoir.

The operator should frequently monitor all gauges and instruments, noting any unusual reading which may 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

2-5

BI615827

Drilling Procedures Setup For Drilling 1.

Lower the galloway to ensure the jumbo is close enough to the drill face so all holes can be drilled without repositioning the galloway.

2.

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.

3.

2a.

The feed is automatically kept parallel. See description of feed paralleling system.

Once selected, the angle of the feed will automatically be kept the same from hole to hole.

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, feed roll levers.

Use the feed extend lever to sting the end of the feed into 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 and feed extension cylinder at the same time.

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

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 very carefully.

4.

Push Air/Water lever forward to activate water flushing and be sure water is flowing out of the drill bit.

5.

Push the drill rotation lever forward for forward rotation (counterclockwise).The S36 rock drill has an independant rotation circuit. This allows the operator to vary the RPM of the drill without affecting the hammer.

6.

Push the drill (hammer) lever forward as desired to collar the hole.

7.

Pull the feed lever as desired to collar the hole.

8.

After the hole is collared (drill bit about 2-3" [5-7.6 cm] deep into the rock), apply full pressure to the drill hammer by pushing the drill lever fully forward. Apply appropriate feed pressure needed for ground conditions by pulling feed lever down. Maximum feed pressure can be decreased by the regulator if required.

NOTE At the end of the hole the drill operator may choose to turn the water off and turn the air on to blow the hole clean as the drill is being retracted.

9.

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

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

2-6

Operating Instructions

BI615827

Drilling Procedures 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

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

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.

Check the return filter indicator while the drill is operating. When running with clean oil and new filters the indicator should show an operating pressure of 4-6 psi. If the indicator reaches 40 psi the filters will bypass. Operating a unit with dirty filters will lead to premature failure of hydraulic components.

Operating Instructions

2-7

BI615827

Drill Control Functions Figure 2-9 Instrument Panel Jumbo #1

4

3

2

1

4

Figure 2-10 Instrument Panel Jumbo #2

3

1. Return Filter Indicator 2. Air Pressure Gauge 3. Water Pressure Gauge 4. Hydraulic Pressure Gauge 5. Hydraulic Reservoir Temp.

Gauge

2

1

5

5

Figure 2-11 Drill Control Console (same) 1. Feed Pressure Regulator 2. Feed Pressure Gauge 3. Feed 4. Centralizer 5. Feed Roll 6. Feed Extend 7. Feed Swing 8. Feed Dump 9. Boom Roll 10. Boom Extend 11. Boom Lift 12. E-Stop/Air On-Off 13. Rotation Control 14. Air/Water Valve 15. Hammer Control 16. Water Mist

2-8

14

13

15 16

2 11

12

1

3

4

5

6

7

8

9

10

Operating Instructions

BI615827

Drill Control Functions Instrument Panel(s) 1.

Return Filter Indicator - monitors life of the filter cartridge.

2.

Air Pressure Gauge - monitors air pressure so maximum drilling efficiency can be maintained by the hydraulic rock drill. Located on the instrument panel on the frame (fig. 2-9).

3.

Water Pressure Gauge - monitors flushing pressure so maximum drilling efficiency can be maintained by the hydraulic rock drill. Located on the instrument panel on the frame (fig. 2-9).

4.

Hydraulic Pressure Gauge - monitors hydraulic pressure at the pump.

5.

Hydraulic Reservoir Gauge Temp - monitors temperature of hydraulic fluid.

Drill Console(s) 1.

Feed Pressure Regulator - used to reduce maximum feed pressure in poor ground conditions. It can also be used for collaring.

2.

Feed Pressure Gauge - monitors hydraulic pressure to feed drive (may be adjusted to drilling conditions).

Hydraulic Valve (all functions are proportional)

3.

Feed - Pull down, feed extends down. Push up, feed retracts up (friction detent).

4.

Centralizer - Pull down, centralizer closes. Push up, centralizer opens.

5.

Feed Roll - Pull down, feed rolls clockwise. Push up, feed rolls counter clockwise.

6.

Feed Extend - Pull down, feed extends. Push up, feed retracts (full stroke detent).

7.

Feed Swing - Pull down, feed swings toward operator. Push up, feed swings away from operator.

8.

Feed Dump - Pull down, feed moves right. Push up, feed moves left.

9.

Boom Roll - Pull down, boom rolls clockwise. Push up, boom rolls counter clockwise.

10. Boom Extend - Pull down, boom extends down. Push up, boom retracts up.

11. Boom Lift - Pull down, boom moves right. Push up, boom moves left.

12. E-Stop/Air On-Off - Pull out, air supply (machine) on. Push in, air supply (machine) off.

Air Valve 13. Rotation Control - Push up, starts rock drill rotation in the counterclockwise direction, which is the normal direction for drilling. Pull down reverses rotation for uncoupling steel or any function requiring reverse rotation (proportional).

14. Air/Water Valve - Center position, air and water is off. Push up, water flushing activated. Pull down, air flushing activated.

15. Hammer Control - Push up starts the hammer. Hammer intensity increases as the lever is moved up. Push down decreases hammer intensity until it ceases (proportional).

16. Water Mist - Turn counter clockwise until you reach desired mist. Turn clockwise to reduce/ shut off water.

Operating Instructions

2-9

BI615827

Air Drilling Valve The drill control valve bank provides easy control of rotation, air/water and hammer functions.

Rotation The rotation section is comprised of an inlet port, two directional ports and an exhaust port.

Air/Water The air/water section is comprised of a water inlet port, and an out let port that allows for air or water to flush the drill. The air supply for the air flushing originates from the hammer section on the drill valve bank.

Hammer The hammer section is comprised of an inlet port which is shared with air flushing, and an outlet port which powers the hammer directly. Collaring can be achieved by backing off on the hammer control handle.

Fig. 2-12 Drill Control Valve

Water Mist The gate valve controls the amount of water needed for proper dust control when flushing with air. When the gate valve is closed the drill air flushing relies on the drill valve only. When the gate valve is open with air flushing on, the water can mix with the air for dust control.

2-10

Operating Instructions

BI615827

Drill Control Valve

Fig. 2-13 Drill Control Valve Schematic

Operating Instructions

2-11

BI615827

Feed Paralleling System 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 feed dump cylinder is 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 move left or right. 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 (see fig. 2-14). 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 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 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.

Fig. 2-14 Feed Parallelism System for Feed Dump

2-12

Operating Instructions

BI615827

Constant Sting Circuit (Feed Extend) This feature allows the operator to maintain constant pressure on the feed stinger while drilling.

This aids in maintaining drill steel alignment and reduces down time from stuck or broken drill steels.

The feed/boom functions valve bank is set for a maximum pressure of 2800 PSI (193.1 bar). The feed extend valve section comes with A and B port reliefs. Adjusting the A port relief (feed extend) to 1200 PSI (82.7 bar) reduces the pressure to allow stinging. B port remains at maximum pressure.

Adjustment Procedures (to be done by the maintenance department):

2.

Install a 3000 PSI (206.9 bar) gauge in the end of the hose.

3.

Start the pump.

4.

Push feed extension lever forward.

5.

Adjust valve (A port relief) to desired pressure of 1200 PSI (82.7 bar).

6.

Remove gauge and replace hose on cylinder.

b

Remove the forward direction feed extension hose at the cylinder; cap the fitting.

a

1.

Fig. 2-15 Constant Sting Circuit for Feed Extend

Operating Instructions

2-13

BI615827

Notes

2-14

Operating Instructions

BI615827

Section 3

Adjustments and Preventative Maintenance

Adjustments and Maintenance

3-1

BI615827

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.

Air Regulator: The air regulator is set at 100 PSI ( 6.9 bar) max.

Lubricator: The lubricator assembly is located in the front of the jumbo frame. The lubrication system oprates continuously with mine air. The oil reservoir holds approximately 2 gallons of rock drill oil. It should be filled daily. Both lubricator adjustments are set at 1 3/4 turns.

CAUTION: DO NOT allow lubricator resevoir to run dry while drilling or operate the jumbo without lubrication. Severe damage to the equipment will result.

Low Flow Control: Adjust to control the air motor at minimum 100 RPM.

High Flow Control: Adjust to control the air motor at maximum 1500 RPM.

Air/Hydraulic Circuit (Overspeed Valve): Adjust pilot pressure to 60 PSI (4.1 bar). Adjust Sequence valve to 1200 PSI (82.7 bar).

When any valve is centered and allowed to operate as an open center valve the sequence valve 'G' will be closed, there will be no pilot signal at air valve 'E' pilot connection allowing it to spring closed, and valve 'D' will be open just enough to allow the motor to turn at 100 rpm.

When the control valve is actuated to cause some hydraulic motion to occur, a load is put on the hydraulic pump. Sequence valve 'G' will open allowing system pressure to pressurize reducing valve 'H', which would then send a 60 psi pilot signal to air valve 'E'. This will open air valve 'E' and allow full air supply to the motor, bringing it to speed, therefore supplying full rated hydraulic pump output.

The air motor and pump have been matched so that pump imput requirements (in HP) are achieved at maximum air motor (HP) speed - which is typically half of it's rated speed. This will result in a loss of air motor torque, as the air motor tries to overspeed as well as increase in pump input requirements (in HP) as it's flow output attempts to increase. The air motor and hydraulic pump will then balance off at a safe speed.

As the hydraulic load increases and pump pressure rises, the air motor will slow down to it's optimum speed and will again balance off with pump output flow and pressure.

3-2

Adjustments and Maintenance

BI615827

Initial Machine Setup and Adjustments

Fig. 3-1 Air/Hydraulic Circuit

Adjustments and Maintenance

3-3

BI615827

Initial Machine Setup and Adjustments Boom Function Valve Compensator Pressure: The valve compensator relief is set at 2800 PSI.

Drill Feed/Regulator Pressure: The feed forward circuit is adjusted at the feed valve B port to 1100 PSI. The feed reverse circuit is adjusted at the A port to maximum system pressure (2800 PSI). This is simply a starting point 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 1100 PSI via a feed regulator valve. The forward feed for collaring can be reduced by that reducing valve, it will dump through remote port U to the tank. As with all other pressure controls on the jumbo, turning the feed regulator knob clockwise will increase the pressure, and turning the knob counter-clockwise will reduce the pressure.

The feed circuit is equipped with a counterbalance valve to hold the feed in place.

Feed Extend Pressure: The Feed extend function allows the feed guideshell (feed beam) 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 1200 PSI. The hydraulic control for this function is located on the nine section boom control valve on the drill operator's console. The Feed extend pressure is factory set at 1200 PSI on the valve section. 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 valve which controls the maximum feed extend operating pressure. The feed extend pressure is set at the factory to 1200 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. Retract is set at full system pressure.

Boom Auto-Parallelism: The boom auto-parallelism feature normally requires no adjustment. This feature utilizes a master / slave hydraulic cylinder fluid displacement design in the vertical plane 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 the vertical plane, fluid is displaced from a master cylinder in a corresponding slave cyliner ( the 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.

3-4

Adjustments and Maintenance

BI615827

Hydraulic General Information

Fig. 3-2 Hydraulic Diagram Adjustments and Maintenance

3-5

BI615827

Drill Operator's Maintenance Checklist Check Every Shift 1.

Check the oil level in the hydraulic tank by reading the oil level indicator mounted on the tank.

Only refill with the fill-pump and through the filter. Do not mix types of fluid.

2.

Check bolts on booms and look for any signs of structural damage or weld cracking. Tighten all loose bolts and have any structural damage or cracked welds repaired immediately by a qualified service person.

3.

Check to insure that the drill mounting bolts on rock drills are tight.

7.

Grease the booms at all lubricating points. * This model has 4 grease fitting manifolds provided to aid in greasing these points. One is located on Jumbo #1 -LS frame, one is on Jumbo #2 - LS frame, and there is one per boom.

8.

Grease the feeds at all lubricating points.

9.

Check rock drill side rods for proper tension. Check front bushing for excessive wear.

Fig. 3-4 Grease fitting manifold - Jumbo #1 - LH

Fig. 3-5 Grease fitting manifold - Jumbo #2 - LH

Fig. 3-6 Grease fitting manifold - Booms

3-6

Fig. 3-7 Drill Lubricator

Adjustments and Maintenance

BI615827

System Checks Prior to Start for New or Reconditioned Machines A.

Start-Up - Grease and Oil

1.

Grease all fittings - multi-purpose grease (NLGI#2)

2.

Hydraulic oil (AW46 or Equivalent)

B.

Back Out Pressure Reducing Valves for Feed Extend

C.

All Levers in Neutral

D.

Install All Gauges

1.

Pump suctions (ensure ball valve is open)

2.

Connect air, water and exhaust lines.

3.

Check for leaks.

4.

Jog pump motors and check for proper rotation.

5.

Start pump motor. Check for leaks.

6.

Observe hydraulic oil level.

7.

Run pump and cycle all functions slowly to remove any remaining air.

8.

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

9.

Check system temperature - 1200 F (490 C).

10.

System pressure (boom function relief valve 2800 PSI)

11.

Feed (forward feed 1100 PSI, feed reverse 2800 PSI)

12.

Feed extend (forward feed extend set to 1200 PSI, retract 2800 PSI)

Adjustments and Maintenance

3-7

BI615827

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

SAE Grade 5 ASTM A-449 Tightening Torque (Ft.Lbs.) Nominal Diameter K=.15 1/4 6 5/16 13 3/8 23 7/16 35 1/2 57 9/16 82 5/8 113 3/4 200 7/8 322 1 483 UNC 1-1/8 596 1-1/4 840 1-3/8 1102 1-1/2 1462 1-3/4 1714 2 2576 2-1/4 3768 2-1/2 5155 2-3/4 6996 3 9231 1/4 7 5/16 14 3/8 26 7/16 40 1/2 64 9/16 91 5/8 127 UNF 3/4 223 7/8 355 1 528 1-1/8 668 1-1/4 930 1-3/8 1254 1-1/2 1645 1-3/4 1879 2 2857 2-1/4 4127 UN 2-1/2 5726 2-3/4 7693 3 10064

SAE Grade 8 Tightening Torque (Ft.Lbs.) K=.15 9 18 33 55 80 115 159 282 455 681 966 1363 1786 2371

10 20 37 60 90 128 180 315 502 746 1083 1509 2034 2668

Note: K=.15 for plated or lubricated fasteners. K=.20 for non-lubricated fasteners. Torque values for non-lubricated fasteners can be found by multiplying the plated fastener value by 1.33.

3-8

Adjustments and Maintenance

BI615827

General Preventive Maintenance WARNING: DO NOT attempt lubrication or service while the machine is running.

BE SURE the hydraulic system is not pressurized before loosening any 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 reuse paper filters.

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

Wipe up any overspill 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 the source can be determined and repaired as part of scheduled maintenance, costly down time can be avoided later.

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 reanalysis 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 and engine hours when each maintenance was done.

Adjustments and Maintenance

3-9

BI615827

Preventive Maintenance Chart List of Terex Reedrill Air Shaft Jumbo General Fluids and Lubricants with Capacities Location

Lubricant

P/N

Capacity

Grease

NLG1 No.2 Grease

N/A

400 mg Tube

Air Motor Oil

Hydrex AW 100

N/A

4L (1 gal)

Lubricator Oil

ISO 100 grade MIN (Rock Drill Oil)

N/A

8L (2 gal.)

Hydraulic System

Cosmo Lubric 220

N/A

Reservoir = 114L (30 gal.)

Needs Repair

Repaired OK

Checked OK

2000 Hours

1000 Hours

500 Hours

250 Hours

50 Hours

Description

Daily

DAILY

Comments

Check hydraulic oil level X X X X X X Check lubricator oil level X X X X X X Inspect and lubricate boom and X X X X X X drill feed Check fire extinguisher, fire X X X X X X supression system Check all safety items: safety X X X X X X chains, etc.

To perform the following checks start the power pack and bring to operating temperature Check instrument gauges and X X X X X X lights Check for hydraulic oil leaks X X X X X X Check hydraulic return filter X X X X X X indicator (replace filter if necessary) Check hydraulic pressure filter X X X X X X indicator (replace if necessary) Check reservoir fill pump filter X X X X X X indicator (replace filter if necessary) Check Boom/Drill functions X X X X X X Inspect Drill water swivel for X X X X X X air/water leakage Check tension on feed cables X X X X X X (adjust if needed) Check hose tension on boom X X X X X X positioner (adjust if needed)

3-10

Adjustments and Maintenance

BI615827

Preventive Maintenance Chart

X X X

X

X

X

X

X

Needs Repair

X X X

Needs Repair

2000 Hours

X X X

Repaired OK

1000 Hours

X X X

Comments

Repaired OK

500 Hours

X X X

Checked OK

250 Hours

Check Air Motor oil level Lube all points on jumbo Lube hydraulic cylinder pins & pivot pins Check Operator Console for air/hydraulic leaks

50 Hours

Description

Daily

50 HOURS (WEEKLY)

Com m e nts

Adjustments and Maintenance

500 Hours

1000 Hours

2000 Hours

X X X X X

X X X X X

X X X X X

X X X X X

X X

X X

X X

X X

X X X

X X X

X X X

X X X

X

X

X

X

X

X

X

X

X X X

X X X

X X X

X X X

Checked OK

250 Hours

Hydra ulic Syste m Obtain hydraulic oil sample Inspect hydraulic tank breather Inspect hydraulic valves Inspect cylinders (wear/leaks) Inspect overall hydraulic components condition Inspect hosing condition Change hydraulic filters Inspection of old filters: Fra m e a nd Com pone nts Re cord im pa ct hours:______ Check for loose bolts Check for unusual machine wear or damage Inspect Boom and Feed Ele ctrica l (if a pplica ble ) Inspect panel (if applicable) for functionality/damage Check temperature switch Check level switch Inspect all electrical cables

50 Hours

De scription

Daily

250 HOURS (MONTHLY)

3-11

BI615827

Preventive Maintenance Chart

X X X

X X X

X

X

X

X

X

X

X

X

Needs Repair

X X X

Needs Repair

X X X

Comments

Needs Repair

X X X

Repaired OK

X X X

Repaired OK

X X X

Comments

Repaired OK

2000 Hours

X X X

Checked OK

1000 Hours

Check fire extinguisher, fire supression system Inspect fire supression system

500 Hours

Air/Water Check/clean water strainer Check/clean air strainer Check lubricator adjustments Drill Check shank Check water head Check water tube Miscellaneous

250 Hours

50 Hours

Description

Daily

250 HOURS (MONTHLY)

Comments

2000 Hours

X X

X X

X X

Checked OK

1000 Hours

Change hydraulic oil Change hydraulic filters

500 Hours

250 Hours

50 Hours

Description

Daily

500 HOURS (3 MONTHS)

3-12

X X

X X

Checked OK

2000 Hours

500 Hours

250 Hours

1000 Hours

Rebuild feed assembly Rebuild drill saddle assembly

50 Hours

Description

Daily

1000 HOURS (6 MONTHS)

Adjustments and Maintenance

BI615827

Preventive Maintenance Chart

Rebuild boom assembly Rebuild feed mount assembly Replace boom hosing

Adjustments and Maintenance

Needs Repair

Repaired OK

Checked OK

2000 Hours

1000 Hours

500 Hours

250 Hours

50 Hours

Description

Daily

2000 HOURS (1 YEAR)

Comments

X X X

3-13

BI615827

Notes

3-14

Adjustments and Maintenance

BI615827

Section 4

Glossary

Glossary

4-1

BI615827

Glossary of Terms 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 as discussed in this manual.

Belleville Washer .......... Another name for “Spring Washer”.

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

Boom ............................ Vertical structure that supports and positions the feed. One end attaches to a pivot at the boom bulkhead at the bottom of the frame, the other end attaches to the 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. A travelling centralizer is used on long feeds to support the mid-point of the drill steel.

Chaired ......................... A term that refers to the locking of the Jumbo into the galloway to ready it for drilling.

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 is also used to convey air or water for hole cleaning.

Drill Steel Coupling ......... A devise 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.

Extend .......................... To move object OUT or AWAY from machine in the 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 cable via. hydraulic cylinder drive system.

Feeds come in various lengths, depending on length of drill steel required.

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

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.

Galloway ....................... A term used for the working platform, frame or structure that houses the winches that lower the clams, Jumbo, water reservoir, ect.

4-2

Glossary

BI615827

Glossary of Terms Hammer ....................... A term sometimes used for "rock drill".

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".

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

Retract ......................... To move 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 splined end is inserted into the rock drill and engages the splines of the chuck end of the drill. The drill steel attaches to the other end by means of a coupling.

Sinking .......................... A term used to descibe the advancment of the shaft bottom.

Spring Washer .............. A cup shaped washer that, when compressed provides a “spring like” action. Also 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 contacts 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 machine as viewed from rear.

Glossary

4-3

BI615827

Notes

4-4

Glossary