Cat Jumbo Drill Operating Manual Mark III Hydraulic Jumbo (BI009875) - PDF DOWNLOAD

BI009875

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI009875

BI009875

OPERATING MANUAL FOR MARK III HYDRAULIC JUM BOS Th is manual provides in-depth coverage of the specifications . set -up and starting procedures . operating instruct ions . and maintenance recommendations for the Gardner-Denver two-800m . All - Hydraulic Mark III Jumbo . It also includes troubles hoot ing guides and complete details of the operator procedures for tramming. setting up to drill. drilling and re moval of the Jumbo. The purpose of this manual is to help you understand the functions of this unit a:ld also to help you operate and maintain it more efficiently . Operating and maintenance personnel should become th o roughly familia r w ith the contents of this manu al for optimum operating efficiency. It is very important that you read and unders tand the Mark III operator 's man ual compl etely and keep it on hand for la ter reference .

OPERATOR MUST READ OPERATOR MANU AL

BI009875

GARDNER-DENVER COMPANY

The Gardner-Denver Company has a long-established tradition - since 1859 - in the mining industry. We' re "The Wo rld-Wide Drill Team l " Our reputation is founded on our history of manufacturing the best drilling equipment for loday 's needs while developing tomorrow 's technol ogy ... all backed by the industry's mos t knowledgeable , reliable , an d res pected service organization.

Th e Mark III Hydraulic Jumbo drilling unit described in this literature is manufactured to Gardner-Denver's exacting standards. It is designed to do the job faster and eas ier than any previous pneumatic drilli ng rig .

For max imum utilization of the equipment and efficiency in operating this equipment, we urge you to thoroughly read th e entire contents of this manual before you begin to drill with th e Mark III jumbo.

FOR MORE INFORMATION Fo r additional sales and service information. parts lists . serv ice data . etc ., contac t your nearest Gardner- Denver Sales O ffi ce.

CO PYRIGHT ' 1977 / Gardner-Denver Co mpany . Denver . Colorad o/ First Edit ion / All Ri g hts rese rved .

ii

Litho in U SA

BI009875

MARK III HYDRAULIC JUMBO

TABLE OF CONTENTS Introduction Mark III - General Description

Section 1 1-1

OPERATOR INSTRUCTIONS Precautionary Notices

Section 2

Operator Warnings

1-1

Diesel Engine Caution Statemen t

2-1

Equipment Cautions

3-1

Emergency Shutdown

4-1

Tramming

Section 3

Tramming Controls

1-1

Tramming Checklist

2-1

Tramming Procedures

3-1

Maneuvering the Jumbo

4-1

Drilling

Section 4

Drilling Controls

1-1

Drilling Checklist

2-1

Drilling Procedures

3-1

Shutdown Procedures

4-1

Pullback from Face

5-1

iii

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MAINTENANCE Lubrication

Section 5

Carrier Lubrication

1-1

Boom, Feed, & Positioner Lubrication

2-1

Drill Lubrication

3-1

Checklist

4-1

Preventive Maintenance

Section 6

General

1-1

Drill & Feed

2-1

Changing the Shank

3-1

Checklist

4-1

Troubleshooting

Section 7

General Troubleshooting Guide

1-1

Electric Troubleshooting Guide

2-1

Hydraulic Troubleshooting Guide

3-1

Diesel Engine Troubleshooting Guide

4-1

Specifications

Section 8

Jumbo Carrier

1-1

Electrical Diagram

2-1

Booms, Feeds, & Positioners

3-1

Drills

4-1

General

5-1

Drilling Coverage Pattern

6-1

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SECTION 1

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INTRODUCTION Mark III

Section 1

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I SECTION

I PAGE

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1 1-2

INTRODUCTION

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• Fig . 1-2. Tramming Console and Controls.

Fig . 1-4. Hydraulic-operated Cable Reel (optional) with mine power connection .

Fig. 1-3. Emergency Electric Shutoff .

Fig. 1-5.

• Operator's drilling and positioning console .

BI009875 SECTION 1

INTRODUCTION

PAGE

1-1

MARK III Th e Gardner-Denver Mark III is a two-boom all-hydraulic operated Jumbo drilling rig mounted on a heavy-duty car riag e for stability and efficiency in drilling undergro und through hardrock. The rig is easily maneuverable in most drilling situations .

The Mark I II utilizes a highly efficient hydraulic drilling tea m . the Model HPR -1 Hydraulic Drill and HFM Hydraulic Feed . This combination is designed for faster rock penetration for hole sizes from 1-1 / 2" to 2-1 / 2" (38 mm to 64 mm). The Mark III with HPR-1 features fully automatic blowing air and hole-cleaning water with manual over-ride capability, plus automatic drill return .

Powered by a Duetz Diesel engine, the Mark III Jumbo can be trammed into position , then connected to mine air, w ater, and elect ric power for drilling.

The o perato r's drilling console is fully illuminated with controls grouped for efficiency and ease. Warning lights and gaug es are conveniently locat ed to provid e th e operator with drilling and maneuvering pressures, filte r bloc kage , etc. The tramming console includes engin e operating gauges and controls for engin e oi l pressure, motor temperature, and fu el level.

A rOllover-type boom provides maximum maneuverability in positioning to drill the face. Drill positioning is accomplished by moving the boom lift, boom rollover , feed dump, feed swing , and feed extension cylinders to cover a pattern approx imately 19 fee t high by 32 feet wide (5 .79m x 9.75m) .

The following photographs highlight features , controls , and compon ents of the Mark III that are covered in detail in the sections that follow .

POSITIONING & DRILLING CONSOLE TRAMMING CONSOLE

HFM FEED

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OPTIONAL CABLE REEL JUMBO CARRIER Fig. 1-1 . Mark III Hydraulic Jumbo with Hyd raulic Drills and Feeds

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SECTION 2

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OPERATOR INSTRUCTIONS Precautionary Notices

Section 2

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OPERATOR INSTRUCTIONS

SECTION

2

PAGE

1-1

6 WARNINGS Your first consideration, when operating your Mark III Jumbo, must be your personal protection and that of others.

Correct operation of the Mark III Jumbo is a matter of being completely familiar with your machine and the job it is to do. Carefully read the warnings listed below; and most of all, remember to apply good common sense at all times.

1. DO NOT ATTEMPT TO OPERATE THIS JUMBO UNLESS YOU HAVE READ THIS MANUAL COMPLETELY AND ARE THOROUGHLY FAMILIAR WITH THE FUNCTIONS.

11. DO NOT MANEUVER BOOMS IF JUMBO IS IN AN UNSTABLE POSITION. 12. BE AWARE AND REPORT ANY CUTS ABRASIONS TO THE MAIN POWER CABLE.

OR

2. BE THOROUGHLY FAMILIAR WITH THE EMERGENCY ELECTRICAL SHUT-DOWN PROCEDURES - SEE SECTION 2, PAGE 4-1.

13. REPORT ANY LOOSE CONDUIT AT CONDULET FITTINGS.

3. DO NOT OPERATE THE JUMBO ON GRADES IN EXCESS OF 35%.

14. DO NOT OPERATE JUMBO WITH ELECTRICAL PANEL COVERS OPEN.

4. BE SURE TRANSMISSION IS IN NEUTRAL POSITION BEFORE ATTEMPTING TO START ENGINE.

15. WEAR NOISE-REDUCING EAR PROTECTORS WHEN NEAR JUMBO WHILE DRILLING. 16. WEAR EYE PROTECTION WHILE DRILLING.

5. SELECTOR VALVE MUST BE IN POWER STEERING MODE WHEN TRAMMING THE JUMBO. 6. DO NOT ATTEMPT TO MOVE JUMBO WITH OBSTRUCTED VISABILITY. 7. DO NOT ATTEMPT TO MOVE THE JUMBO IN A POTENTIALLY UNSTABLE CONDITION. 8. ALWAYS DRIVE JUMBO DOWN GRADES. DO NOT DISENGAGE CLUTCH AND COAST. 9. DO NOT TRAM OVER ELECTRICAL CABLE OR ALLOW ANY OTHER VEHICLE TO DO SO AT ANY TIME. 10. MAIN POWER SWITCH AT JUMBO AND JUNCTION BOX SHOULD BE OFF AND PANEL BOXES CLOSED BEFORE PLUGGING IN.

17. KEEP SHIELDS AND GUARDS IN PLACE. 18. BE SURE TO DEPRESSURIZE THE HYDRAULIC LINE BY BLEEDING IT OFF BEFORE REMOVING ANY FITTING. 19. DO NOT REMOVE GREASE ZERK FROM HOSE REEL TENSION DEVICE. BLEED PRESSURE WITH BLEED VALVE ONLY. 20. KEEP HANDS, CLOTHING, AND TOOLS AWAY FROM MOVING PARTS. 21. ENGAGE BRAKE SYSTEMS BEFORE LEAVING JUMBO FOR ANY REASON.

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I SECTION OPERATOR INSTRUCTIONS I PAGE

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2-1 J

ENGINE CAUTION STATEMENT Bureau of Mines Schedule 24 Approval No. 24-168-1 for Deutz Air-Cooled Diesel Engine THIS ENG I NElS APPROVED ONLY WHEN

MAINTAINED UNDER THE FOLLOWING CONDITIONS:

1. General Safety

4. Battery and Cables

This diesel-powered machine is approved only for use In non-coal mines. Such mines are defined as those in which the material being mined is incombustible or contains at least 65% by weight of incombustible material. and in which the underground atmosphere in any open workings contains less than 0.25% by volume of flammable gas.

Tunneling operations in which underground conditions conform with the foregoing. may be considered in the same category as noncoal mines.

The battery top must be kept clean and free of dirt and electrolyte. All terminals and connectors must be kept clean and tight. Any wire or cable with damaged insulation must be replaced. The battery box cover must be kept in place during operation.

Frequent inspection must be made to see that all engine intake and exhaust parts. and all electrical components. including wiring connectors and all other equipment. are in proper operating condition. There must be no openings in any part of the engine exhaust system other than the exhaust outlet originally provided.

All fuses for overload protection in the electrical circuits must be maintained in approved condition.

Change in. or additions to. this approved diesel carrier must not be made without the prior approval of the U.S. Bureau of Mines. Branch of Electrical-Mechanical Testing. Pittsburgh. Pennsylvania 15213.

2. Fastenings All bolts. nuts. screws. and other means of fastening electrical enclosures must be kept in place. properly tightened. and secured. Similiarly. fastenings for the engine cylinder head. intake and exhaust systems must be kept in place. properly tightened and secured.

3. Repairs and Renewals Special care must be taken in making repairs and renewals. Use new parts exactly like those furnished by the manufacturer of the original machine. Use only new gaskets of the same type as furnished by the manufacturer and having all mating surfaces clean and in proper condition.

5.

Intake System

Free flow of air to the Intake must not be restricted in any way. The maximum pressure (Vacuum) through the intake system at full throttle. no load. 2.000 rpm. should not exceed ten inches (254 mm) of water. The intake air cleaner must be inspected at regular. frequent intervals. and cleaned when necessary. Never use more oil in the air cleaner than specified.

6. Engine Fuel injectors. fuel pumps. or other parts of the fuel injection system. when found to be faulty. must be replaced with exact duplicates of original equipment and set so that the maximum fuel injection rate is not changed.

The fuel pump adjustment and governor must be sealed.

7.

Exhaust System

The exhaust piping must be kept tight at all times. and must not be restricted by foreign material. The maximum back pressure (pOSitive) of the exhaust system at full throttle. no load. 2.000 rpm. should not exceed 34 Inches (864 mm) of water.

8. Exhaust-Gas Conditioner Drain. flush. and inspect the exhaust-gas conditioner at regular. frequent intervals. and clean when necessary. Fill the conditioner with clean water at the beginning of each shift.

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SECTION

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PAGE

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OPERATOR INSTRUCTIONS

9. Fuel

11.

Use only diesel fuel recommended by the engine manufacturer that gives satisfactory engine operation.

The flash point must not be less than 140 0 F (60 0 C) or the sulfur content greater than 0.5 percent by weight. Keep fuel clean. Precautions should be taken to keep the fuel clean and free from dirt and water.

The amount of fresh moving air for ventilation at any place underground, where this machine is working, must be 7,200 cfm (204 m 3 /m), or more, with the governor set for 2,000 r.p.m. full load, per machin(; of this type. This ventilation must be supplied in addition to that required for other diesel machines and other requirements. Shut off the engine whenever underground ventilation is interrupted for any reason.

When necessary to fill fuel tank underground, fuel should be transported in strong, tight. metal containers with positive closing devices. Store fuel containers in closed compartments constructed of incombustible matenals while awaiting transfer to fuel tank of the diesel carrier.

Keep fuel in well-ventilated places.

10. Fuel Rate The maximum fuel injection rate for approved operation of this diesel carrier (Deutz Model F6L-912W engine) at various altitudes is:

FUEL INJECTION RATE Altitudes 1

1 2

Maximum Fuel Injection Rate 2

Zero to 1000 (0- 305 m)

30.0 (13.6 kg)

2,000 ( 610m)

29.0 (13.2 kg)

3,000 ( 914 m)

27.9(12.7kg)

4,000{1219m)

26.8 (12.2 kg)

5,000 (1524 m)

25.8 (11.7 kg)

6,000(1829m)

24.9(11.3kg)

8,000 (2438 m)

23.1 (10.5kg)

10,000 (3048 m)

21.3(9.7kg)

12,000 (3658 m)

19.8 (9.0 kg)

14,000 (4267 m)

18.3 (8.3 kg)

Indicates feel/meters above sea level.

Indicates pounds/kilogram per hour at 2000 RPM maximum load.

Fig. 2-1. Fuel usage chart.

General Ventilation

It is recommended that the engine be shut off when the carrier IS not in use. Do not idle engine for excessively long periods.

12.

Fire ExtingUishers

Each diesel carrier should carry at least one fire extinguisher of C02 type (5 pound, 2.3 kg size) or dry type, pressurized (2 pound, .9 kg size) at all times.

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OPERATOR INSTRUCTIONS

SECTION

2

PAGE

3-1

CAUTIONS Following are good practices to observe for protecting the equipment, dnlls, etc. from damage, and to provide IllaXIi11urn life of the Mark III Jumho drilling unit.

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PERIODICALLY INSPECT ALL BOLTS, NUTS, BELTS AND CHAINS FOR WEAR OR LOOSENESS. CHECK HOSES FOR PROPER TENSION

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BE SURE TO ENGAGE SERVICE BRAKE. THEN DISENGAGE BOTH EMERGENCY AND PARKING BRAKE SYSTEMS BEFORE PUTTING TRANSMISSION IN GEAR TO TRAM.

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WHEN MOVING JUMBO BE CERTAIN OUTRIGGERS CLEAR GROUND AND BOOMS CLEAR RIBS WHILE TURNING.

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DO NOT IDLE DIESEL ENGINE FOR EXCESSIVELY LONG PERIODS OF TIME

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CHECK FOR RED WARNING LIGHT WHEN AIR PRESSURE DROPS BELOW 40 PSI AIR PARKING BRAKES WILL NOT RELEASE WHEN AIR PRESSURE

DROPS BELOW 40 PSI (276 kPa).

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DO NOT OPERATE JUMBO WITH ANY GAUGES INDICATING A MALFUNCTION.

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BE SURE HYDRAULIC RESERVOIRS ARE ALWAYS FILLED TO THE RECOMMENDED LEVELS WITH THE PROPER TYPE HYDRAULIC FLUID DO NOT MIX DIFFERENT TYPES OF OIL

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USE ONLY DIESEL FUEL, LUBRICATION GREASE AND HYDRAULIC OIL RECOMMENDED - SEE SECTION 5, LUBRICATION AND SECTION 6, PREVENTIVE MAINTENANCE

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IMMEDIATELY SHUT DOWN ENGINE WHEN MOTOR TEMPERATURE INDICATES OVER-HEATING.

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SECTION

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PAGE

4-1

OPERATOR INSTRUCTIONS

EMERGENCY SHUTDOWN PROCEDURE Electrical

I

If for any reason a serious electrical problem should arise. it is essential for the operator to know the location and operating procedure of two emergency devices. One is the emergency shut-off switch. and the other is the dry chemical fire extinguisher.

The emergency power shut-off switch is located on the cover of the rear-facing electrical power panel on the right of the driver's seat. This control is painted red so it can be readily located. It can be easily reached from the operator's platform or the ground. The switch is connected directly to the main circuit breaker and will Immediately cut off all electrical current into the Jumbo.

This function should be used if there is immediate danger to anyone in contact with the Jumbo. or if there is Immediate potential damage to the Jumbo itself. In case of a fire on the Jumbo. immediately depress the emergency shut-off switch and use the dry chemical fire extinguisher located to the immediate right of the driver's seat.

I

( Fig. 2-3. Emergency diesel engine shutoff.

Hydraulic In the event of Hydraulic Line rupture. depress the Stop button that controls the boom and drilling functions on the malfunctioning side of the drill operator's console.

ThiS control shuts off the electric motor that provides charge pressure for the Hydraulic System. If a major hydraulic supply line ruptures, shut off both electric Stop buttons on the operator's console.

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HYDRAULIC ~ STOP

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.~~~ Fig. 2-2. Electric Emergency Switch and Fire Extinguisher.

RIGHT ...SIDE. ...t , HYDRAULIC

Diesel Engine Emergency shut-off of the diesel engine is accomplished by shutting off the fuel supply to the engine. Pull the control marked I:ngine Stop located on the right side of the tramming control console.

LEFT SIDE Fig. 2-4. Hydraulic shut-off controls.

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SECTION 3

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OPERATOR INSTRUCTIONS Tramming

Section 3

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SECTION

3

PAGE

1-1

OPERATOR INSTRUCTIONS

TRAMMING

Fig. 3- 1. Tramming control console .

Fig . 3-2. Driver's seat, gear and steering controls .

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1Fig. 3-3. Tramming Area.

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r SECTION OPERATOR INSTRUCTIONS I PAGE

1 1-2 I 3

TRAMMING CONTROL FUNCTIONS 1. Starter Switch - activates pre-start heater when turned clock-wise to the first position . When this switch is turned clock-wise to the second position, the engine will start.

2. Glow Plug Indicator Light - indicates when engine is ready to start.

3. Light Switch - this is a four position switch . Turn counter-clockwise to the first position for front lights only. Turn to second position for rear lights only. Turn to third position for both front and rear lights. Switch handle in 6 o'clock position turns all lights off.

4. Ammeter Gauge - should read just slightly plus zero during normal operating conditions.

5. Engine

Oil

Pressure

Gauge

-

should

show

approximately 40 to 60 PSI (276 - 414 kPa) during normal operating conditions .

6. Motor Temperature Gauge - shows a green section when engine temperature is in the normal range.

Shows a Red section when the engine is over-heated.

When red, the engine should be immediately shut down. f. -·-Tachometer - while idling after an appropriate warmup period, the gauge should read 800 to 1000 RPM .

Normal tramming gauge range is determined by the engine speed.

8. Fuel Gauge - shows the amount of diesel fuel in the fuel tank.

9. Horn - should be used each time the Jumbo is moved to alert pedestrians .

10. Engine Stop Cable - the engine can be shut down by pulling this handle all the way out or toward the ope rator.

11 . 4-Speed Transmission Gear Control- determines the tramming speed of the Jumbo .

12. Direction Gear Control- this designates the direction in which the Jumbo will tram.

13. Throttle - regulates the RPM of the engine.

14. Transfer Case - low range transfer case is standard equipment . Dual high and low range with shift control is optional.

15. Air Parking Brake - push-p ull contro l. When the handle is pushed Down , it engages parking brakes.

When pulled Up , it releases parking brakes. This brake will automatica lly actuate when the system air pressure drops below approximately 40 PSI (276 kPa).

16. Selector Valve - this push-pull control provides power steering for tramming when pushed in. The pulled out position allows boom movement. At no time will you have both functions at the same time. Be sure this control is in the pushed-in position for tramming.

(This control is replaced by a lever located beneath the Air Parking Brak e Control when the optional cable reel rewind is installed.)

17. Clutch Pedal - depressing this pedal will disengage the clutch, allowing you to change gears .

18. Service Brake Pedal- depressing this pedal applies air pressure to the brake system, engaging the brakes to stop the Jumbo.

19. Emergency Brake - this handle in the down position engages the brake band on the drive shaft.

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OPERATOR INSTRUCTIONS

SECTION

3

PAGE

2-1

TRAMMING CHECKLIST Do not operate the Mark III Jumbo unless you are thoroughly familiar with controls and functions and have read all the CautIOns and Warnings listed in Section 2.

1. Check oil levels in Engine and Transmission.

2. Inspect Belts and Hoses for indication of wear, loosensess, or damage.

3. Make sure Transmission is in neutral position when starting the engine.

4. Be sure to warm up Engine with heater switch before cold starts.

5. Always use a reputable brand of diesel fuel, and observe strict cleanliness while filling.

6. Periodically check the oil level in the Injection Pump and Governer unit. They must be filled with the same grade oil as used in the Engine itself.

7. Be sure both Emergency and Parking Brake Systems are disengaged before putting Transmission in gear to tram.

8. Do not attempt to move the Jumbo with obstructed visability.

9. Make sure Jacks are clear from ground and are in an upright position before moving the Jumbo.

10. Keep hands, clothing, and tools away from moving parts.

11. Feeds and Booms must be off the ground and within the width of the console, not higher than the console when t~amming.

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OPERATOR INSTRUCTIONS

SECTION

3

PAGE

3-1

TRAMMING PROCEDURES The Mark III Jumbo can be moved from on e location to anoth er easi ly and quickly once th e tramming procedures have been learned . Foll ow thes e step -by-step procedures until you become thoroughly familiar with them .

1. Check all oil levels . If refilling is necessary only use the rec ommended grade and type specified in th e Maintenance Section o f th e manual.

LIGHTS

2. Check the fuel level.

3. Check condition of th e battery.

4. Put the Direction Gear Control in the neutral position .

5. Put the 4-speed Transmission Gear Control in th e neutral posi ti o n.

6. Sli ght ly increase the Throttle by moving it toward th e Fast pos ition .

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ENGINE STOP EMERGENCY BRAKE

TRANSMISSION

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TRANSFER CASE

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(Optional)

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Fig . 3-5. Engin e start controls .

9. Make sure the Jacks are clear from the ground and are in the straight up position . Jacks are maneuvered by pulling back on the Jack control handle on both the 8-Bank and 9- Bank Cont rol Valve located at the Op erator's Drilling Console. Step -by-step procedures are outlined in Section 4, Page 3-2.

Fig . 3-4. Position of gears for starting .

7. If engin e is cold, put the starter switch in the pre- heat posi tion by turning th e switch clockwise to the right until you feel resistance . Hold the switch in this positio n until the coil in the indicator is glowing red.

This process should take approximately 30 to 45 seconds.

8. Turn Starter to Start engine position by continuing to turn the switch past the first resistance to the right.

The engine should turn over almost im mediately . If it does not start the first time, do not hold the switch in the Start position for more than .; 5 seconds. Let the battery recover for at least one minute; then try again .

Fig . 3-6. Driller's operating controls (right side)

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3 3-2

OPERATOR INSTRUCTIONS

10. Put the Selector Valve In the power steering position by pushing the control forward. This control must be kcpt In the forward position while tramming.

12. Depress the Service Brake pedal so the Jumbo will not roll when you release the Air Parking Brake

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I I~ 3-7 Power steering/Boom controls.

11

Release the Emergency Brake by pulling up on the handle and placing it in a vertical position.

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LIGHTS

START

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13. Then release the Air Parking Brake by pulling up on the Control handle. This brake will not release unless there is at least 40 PSI (276 kPa) air pressure in the brake system. This pressure can be monitored on the Air Pressure Gauge located to the right of the steering wheel.

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PRESSURE GAUGE!

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HORN ENGINE STOP EMERGENCY BRAKE

Fig 3-8. Emergency Brake in released position.

;PAR KING B!R!A!K!E!'

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Fig. 3-10. Air Parking Brake and pressure gauge.

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3

PAGE

3-3 I

OPERATOR INSTRUCTIONS

14. Turn the light switch counter-clockwise to the third position. This will engage both front and rear lights for tramming. The second position IS for tramming lights on the engine end of the Jumbo only. and the first position will allow lights at the boom end only

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SECTION

dHROTTLE TRANSFER CASE

HORN

(Optional)

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SLOW

Fig. 3-B. Gears In tramming position.

ENGINE STOP EMERGENCY BRAKE

18 Release Clutch pedal slowly and adjust Throttle to the deSired engine speed

Fig. 3-11. Tramming lights on.

19 Shift the Transfer Case Control from high to low range when tramming on steep grades.

15 Depress cl utch pedal.

20 Booms and Feeds should be positioned Within the width and not higher than the console during the tramming function.

A blinking red warning light will appear when air pressure In this brake system is too low to release the Air Parking Brake While tramming. if this light comes on. stop the Jumbo and correct the malfunction before resuming movement of the ng

Fig. 3-12. Clutch operates similar to automobile.

16. Put Direction Gear Control Into Forward or Reverse position depending on the direction you want to travel. Reverse is toward the t.oom end of the Jumbo. Forward is toward the ennine. If you are going to tram a considerable distance, it is preferable to tram with the engine end of the Jumbo toward the direction of travel, or the control in the Forward position.

17. Put transmission in first gear. A higher gear can be used if you are on level. smooth ground. But always tram in first gear on a grade or incline.

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OPERATOR INSTRUCTIONS

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4-1

MANEUVERING THE JUMBO While tramming, it will at times be necessary to make turns with the Jumbo that require careful attention to the following procedures: 1. When approaching a tunnel Intersection, make a turn into the intersection as far as possible. Make sure the feeds do not come in contact with the walls of the tunnel.

4 Reposition Booms 9nd Feeds at an angle necessary to complete the turn, again making sure of wall clearance.

2. Stop the Jumbo; put Direction Gear and Transmission in Neutral; engage Parking Brakes.

5. Put the Selector Control in Push position for Power Steering and resume tramming until Jumbo is headed straight into the desired tunnel.

3. Put the Selector Valve in Boom Function's Pull position. Note that you will not have power steering for tramming except with the optional cable reel.

6. If necessary, readjust Boom and Feeds, repeating steps 2, 3, and 4 to clear tunnel walls during further Jumbo maneuvering.

Fig. 3-14. Illustration of procedure for turning the Jumbo in mine tunnel intersection.

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SECTION 4

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OPERATOR INSTRUCTIONS Positioning and Drilling

Section 4

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SECTION

4

PAGE

1-1

OPERATOR INSTRUCTIONS

D RILLING

11

9

8

~-.... ~ -------

/- - - - -

- - - - - -- -1-- - - - - -1- - 1 - - -1- - - - - -- - - 1 - - - - - - - - - - - - -

3 4

4

5 6

Fig . 4- 1. O pe rator's Control Console with drilling and positioning control s indi ca ted.

5 6

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SECTION

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OPERATOR INSTRUCTIONS

DRILLING & POSITIONING CONTROLS AND FUNCTIONS These controls, when duplicated , operate right and left drilling and positioning functions respectively.

1. Feed Pump Control - activates stroking cylinder attached to the feed and rotation pump control arm, which controls delivery of hydraulic power to all functions supplied by that pump .

2. Drill Pump Control - activates the stroking cylinder control to cause the pump to deliver hydraulic power to the drill.

3. Drill Stroke Control - variable pressure regulating valve - regula tes blows per minute and foot-pound blow.

13. Pressure Gauge Selector Valve - provides hydraulic pressure reading from stroke control , rotation , or boom functions depending on position of handle.

14. Stroke, Rotation, Boom Pressure Gauge - 3,000 PSI (20682 kPa) - shows hydraulic pressure of drill stroke, rotation , or boom function .

15. Selector Valve - provides air or water pressure gauge readings from either left or right side depending on the position of the handle.

4. Feed Controller - regulates the amount of feed pressure supplied to the feed cylinder.

16. Air/Water Pressure Gauge - 200 PSI (1379 kPa) shows air or water pressure of both left and right side of drill depending on the position of selector valve .

5. Rotation Speed Valve - regulat es the speed, or RPM , of the drill rotation motor. This valve only operates when drill steel is being rotated counter-clockwise.

17. Drill Pressure Gauge - 4000 PSI (27576 kPa) indicates hydraul ic pressure of the drill wh en Drill Control Valve is activated in On position .

6. 8-Bank Control Valve - controls all Boom , Feed, and Jack functions . Al so controls Drill rotation . (The 9th control, on the right bank, raises and lowers the op tional , adjustable canopy.)

18. Feed Cylinder Pressure Gauge - 3000 PSI (20682 kPa) shows hydraulic pressure of feed cylinder.

7. Start Buttons - activates 75 hp electric motor which drives the hydraulic pumps .

8. Stop Buttons - turns off electric cu rrent to the 75 hp electric motor .

9. Green Indicator Light - indicates 75 hp electric motor is operating.

10. Drill and Panel Lights Switch - two-way elec trical switch that turns drilling and console control lights on or off. These lights can only be operated with the main elec trical power to the Jumbo .

11 . Filter Warning Light - shows red light when filters are plugged or malfunctioning , and a hydraulic oil back pressure is developing .

12. Selector Valve - allows operator to select manual control of water only, automatic air and water, or both systems Off .

19. Fan Indicator Light - shows green when automatic cooler fan is operating.

20. Panel Lights - Illuminates console controls and gauges.

SECTION

4

PAGE

2-1

BI009875

• OPERATOR INSTRUCTIONS '.

I

-'

~

l--··~·

... \

\

l________~----------------------------------------~1

Fig . 4-2 . Dril ling and positi oning cont rol s.

~0 1ERATOR INSTRUCTIONS I

BI009875

SECTION

4

PAGE

2-2

,

I

DRILLING AND POSITIONING CHECKLIST Do not operate the Mark III J um bo unless you are thoroughly fami I iar with controls and fu nctions and have read all the Cautions and Warnings listed in Section 2.

1. Do not operate drilling controls unless you are thoroughly familiar with functions.

2. Always wear noise reduction ear protectors when near Jumbo while drilling .

3. Check for cuts or abrasions to the main power cable, and report them to the proper mine personnel.

4. Check for loose conduit at condulet fittings.

Note : Because of Federal regulations, the accumulators on the drill cannot be charged at the factory. This procedure will have to be done before the initial start-up at the mine site.

Both the high and low pressures of the accumulators on the drill must be properly charged before the initial first round is drilled and periodically thereafter. Figure 4-3 shows Accumulator checkpoints. Refer to Service and Maintenance Manual fC?r procedures.

5. Immediately report any bare copper wire outside the electrical panel boxes .

6. Main power switch at Jumbo and junction shoufd be off, and panel boxes closed, before plugging in.

7. Blow or flush air and water supply lines before connecting to Jumbo .

8. Make sure all pump control valves on console are in the Off position.

7. Check for proper tension of the hose reel to prevent slack in hoses.

8. Make sure reservoir shut-off valves are in the open position .

9. Check for leaks in the hydraulic system.

10. Frequently check all bolts, nuts , and hoses for proper tension.

11 . Do not maneuver booms until outriggers are in down position.

12. Check hydraulic reservoirs and add any factoryapproved hydraulic fluid when needed . Refer to Maintenance, Section 5.

Fig. 4-3. Locations checkpoints .

of

Hydraulic

Drill

accumulator

CAUTION • DO NOT OPERATE THE HPR-1 HYDRAULIC DRILLS UNTIL ACCUMULATORS HAVE BEEN CHARGED.

r SECTION

4

l PAGE

3-1 I

BI009875

1

OPERATOR INSTRUCTIONS

i

. .- r·---·· ....::. --"--:~\ V-1 . - ~' 'db [3 "'.

1

6

Fig . 4-4 . Drilling and positioning controls.

,~ .

1

6

BI009875

)

OPERATOR INSTRUCTIONS

.

SECTION

4

PAGE

3-2

I

l

DRILLING

& POSITIONING PROCEDURES

Positioning to drill

Just as in tramming, moving the booms, positioners, and feeds into position for drilling can be done smoothly, once th e operator becomes familiar with the controls and gains experience in their use .

1. Turn on drilling lights by moving lights switch (10) from left to right in a clockwise direction .

2. Press both Start buttons (7) to start motors. Always start one at a time, with at least one second between.

4. Set Jacks by pushing forward the Jack control handles on both the 8-Bank Valves (6). Lift evenly and be sure you have the majority of the weight of the boom end of the Jumbo off the tires.

5. Position booms to first hole by moving the following five handles, on the 8-bank directional valves, either forward or back, as described below . .. a. Boom lift - forward will lower boom assembly; back will lift boom assembly. b. Boom swing - forward will swing boom to the left; back will swing boom to the right . c. Boom rotation - forward will rotate positioner and feed assemblies counter-clockwise to the left; back will rotate the positioner and feed assemblies clockwise to the right. d . Feed dump - forward will dump front of feed down and lift back of feed up; back will dump back of feed down and front of feed up.

Fig . 4-5. Right Drill Lights and Hydraulic Motor controls.

e. Feed swing - forward will swing front of feed to the left; back will swing front of feed to the right.

3. Engage both feed pump controls (1) by moving handles to On. DRill

DO WN

DO WN

CANOPY

R IG HT JA C K

UP

UP

RO TATION

FEED

BOOM

ON

0" S WIN G

ON PUMP

ROT ATE

OU MP

SWIN G

".

MADE UNDER O NE O R MORE OF THE FO LLOWIN G U S PATENTS

us PATENT 3.995.700

OFF GARDNER - DENVER CO

Fig. 4-7. Operator Control Valves (right side).

Fig . 4-6. Feed Pump controls in ON position.

BI009875

SECTION

4

PAGE

3-3

OPERATOR INSTRUCTIONS

15

6

Fig. 4-8 . Drilling and positioning controls .

6

J

BI009875

I SECTION 4 OPERATOR INSTRUCTIONS I PAGE 3-4

Drilling Procedures

Drilling with the Mark III Jumbo is highly automated and includes a special adjustable stroke feature that is controlled at the console. For best performance and optimum drilling efficiency carefully follow the procedures as listed.

After moving the boom and feed into the desired drilling position you are ready to advance the drill.

Stinging The Face

6. Sting face by moving the Feed Extension Control Valve handle on the 8-Bank Control Valve (6) forward. This valve function is detented and should be left in the forward position. It will apply constant stinging pressure to the face at approximately 1000 - 1200 PSI (6894 - 8273 kPa).

DRill ROTATION

BOOM L IrT

SWING

ROTATE

DOWN

DOWN

CANOPY

RIGHT JACK

UP

UP

BOOM

DOWN

DOWN

CANOPY

RIGHT JACK

UP

UP

FEED OFF

lifT

"WING

ROTATF

DUMP

SWING

'Xl

Fig. 4-10. Contois for collaring.

8. Engage automatic air and water system by turning the 3-way Selector Valve (12) handle clockwise 90° so it is facing to the right.

Fig. 4-9. Controls for stinging.

9. The Air or Water pressure can be read on the center gauge (16) by turning the 3-way valve (15) directly below it 90° to the right for the right drill.

Collaring The Hole

7. Engage forward rotation of the drill by moving forward the Rotation Control on the 8-bank Control Valve. This is also a detented valve function and should be kept in the forward pOSition. Pulling the handle back will reverse the rotation.

RH AIR & WATER

..

CAUTION--- -.. _-_. _._ ....... -

Fig. 4-11. Drilling water and air controls.

BI009875 ~ECTION

4

PAG E

3-5

OPERATOR INSTRUCTIONS

14

14

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l______________________________~ Fig . 4-12 . Drillin g and positioning control s.

BI009875

OPERATOR INSTRUCTIONS

SECTION

4

PAGE

3-6

10. Start the drill by moving the Drill Control Valve (2) to On. The drill pressure gauge (17) will indicate approximately 2000 PSI (13788 kPa). It will initially read slightly higher because of the low viscosity of the hydraulic oil, but will stabilize as soun as the oil reaches normal working temperature.

11. Feed bit to face by gradually moving the Feed Controller (4), causing the drill to move up the feed.

As the bit reaches the face and is collaring in, you should observe a reading of approximately 500 - 600 PSI (3447 - 4136 kPa) on the Feed Cylinder Pressure Gauge (18). Hold that pressure until the hole is securely collared, then continue to move the Feed Controller Forward until the feed pressure reads approximately 800 - 1000 PSI (5515 - 6894 kPa), depending on the hardness of the rock.

Fig. 4-14. Panel of gauges for drilling pressures.

13 Adjust the rotation speed of the steel by moving the Rotation Speed Control (5) handle clockwise to the right to slow down the speed of rotation; or counterclockwise, to the left, to speed it up, depending on the substance and consistency of the rock. It would be preferable to use more rotation in softer rock and less in harder rock.

Fig. 4-13. Drill controls in operating position.

Drilling 12. Turn the Pressure Gauge Selector Valve (13) to the number two position on the console, which is straight up and down. This selection will give you a rotation pressure reading on the Stroke, Rotation, Boom Gauge (14). This reading should show approximately 500 - 600 PSI (3447 - 4136 kPa) with no restriction on the bit, and approximately 900 - 1200 PSI (6205 - 8273 kPa) during drilling.

14. When the drill reaches the end of the Feed, the drill Will automatically shut off. The water will also automatically shut off, and the blowing air will automatically come on The drill will then return up the feed. When the drill is completely retracted, the blowing air will automatically shut off. You will also note that the Feed Controller (4) handle will automatically shift from the forward position, clockwise, to the reverse position. The return feed pressure reading on the Feed Pressure Gauge (18) should show approximately 1500 PSI (10341 kPa).

Repositioning Feed and Drill to next hole.

15. Remove feed from face. Reposition the feed to your next hole by moving boom and feed functions. Sting the face and repeat drill steps #10, #11, and #13.

16. The length of stroke that the piston in the drill travels can be adjusted by turning the Drill Stroke Control Valve (3). By turning it clockWise, you can lengthen the stroke; and by turning it counter-clockwise, you can shorten it. It is recommended to use a longer stroke in harder rock, and a shorter stroke In soft rock.

(1000 PSI (6894 kPa) -long stroke; 750 PSI (5171 kPa) semi-long; 500 PSI (3447 kPa) - semi-short; 250 PSI (1724 kPa) - short.} 17. While drilling, you can also observe the length of stroke the drifter is in by moving the Pressure Gauge Selector Valve (13) to the number one position, and reading the Stroke, Rotation, Boom Pressure Gauge (14).

BI009875

SECTION

4

PAGE

4-1

OPERATOR INSTRUCTIONS

\

1

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I i

I

I

\

1

· - - -1 -- - -

---1-===1-----1--- ------1 ------,

I 1

4

6

Fig . 4- 15. Drilling and positionin g controls.

4

6

\

BI009875

4

PAGE

4-2 J

- --

OPERATOR INSTRUCTIONS

I

SECTION

SHUTDOWN PROCEDURES The drill round has been completed and the Jumbo is now ready for shutdown. The same care in following the stepby-step procedure as previously outlined must be exercised, both for protective reasons and to assure readiness of the equipment for the next drilling round.

1. After completing the drill round. put the feeds and booms in a tramming position: preferably inside the Width of the console and not higher than the top of the console.

2. Lift Jacks off the ground and put them in the complete upright position.

5. Shut off electric motors by depressing the red Stop button (8) at the top sides of the console, directly behind the 8-bank directional valves (6).

6. Switch off drilling lights by turning the Switch (10) from right to left. This sWitch is located on the same panel as the filter warning light.

3. Disengage the feed rotation pumps by pulling back on the Feed Pump Control handle (1).

4. Make sure all other pump controls are in the off position and the Feed Controllers (4) are in the neutral or Off position.

/j ~8 W"-

flrp Uff

UI"

Fig. 4-17. Shutdown controls for lights and hydraulic system.

Fig. 4-16. Drilling Controls in OFF position.

BI009875

- - -

~----

--

~----

BI009875

OPERATOR INSTRUCTIONS

SECTION

4

PAGE

5-1

PULLBACK FROM FACE Upon completion of the drilling process, you will need to pull the Jumbo back from the face to move to another drilling location or parking area. The following is a guide for proper removal of the Jumbo.

1. Switch off main power at the mine switch box.

2 As you back out of the heading just drilled, simultaneously retract the cable reel by moving the Cable Reel Control (see Fig. 4-18) Up, rewinding the main electric cable as you go.

3. When you have backed to the main switch box, unplug the cable and finish winding on the reel.

4. To move the Jumbo out of the heading, follow the same steps as in the tramming procedures. Make sure you pull out slowly and carefully so as not to interfere with other traffic or pedestrians.

5. Tram the Jumbo to the next heading, or to a parking area. making sure lights are off and brakes are set before you leave the Jumbo.

Fig. 4-18. ReWinding of power cable during pullback.

BI009875

BI009875

SECTION 5

BI009875

BI009875

MAINTENANCE Lubrication

Section 5

BI009875

SECTION

5

PAGE

1-1

MAINTENANCE

CARRIER LUBRICATION

o

V

UNDER NO R.... A L l SAGE GREASE EvERY 30 DAYS. uS( GRADE 2 ALL PURPOSE CREASE .

a--. .\) ['R AULIC RE ">E ~IR C HECK LE v EL E ACH [.\A\ ~J REFILL N IT H D E ~RO N T rPE

AU T O ... '" TIC

I HA " SM I 5S ION OIL .

.' l\ REV ER SI NC TRAN S ... ,">S,ON DRAIN A ND R(fI LL EVERY

\W T 'M) MONT H S wITH ST RAICHT MIN[RAL OIL Lu BP IC A1IT 5. A .E. 14 0 . DO NOT loA I X LU B RIC ANT S.

fi\ DHII E A I\LE DRA IN AND REFILL EvER\

IX MONTH S

~ WITH S . A£. 90 ...uUI - PURPO S[ CUR _u BRICANT.

a\ ~"' NY l C ASf DRA IN AND REFIL L E . I .." T we. \W ...orn H S VI TH <, TRAICH '7 '-' INERAL OI L Ld- "_ ANT ~ .A.I .

4 C . JC NOT .... ,X Lu BRI CA NTS.

{j\ I f<UNl AAU . :..:RAIN AND REFILL EVERy SIX 1oA 0 NTH S ~ :.IT .... SAL 9 :

,V 0

'A.LT I-PURPOs( GE AR LUBRIC ANT.

f,AT T[RY O1ECK wEEKLY AN D R(fILL A "> REQUIRED : . IT H DISTILL ED WATER.

Fig . 5-1. Carrier Lubrication .

~ ~Mr\f CYU NDER .

Cr£CK WEEKLY AN D R(FI L A S REOLA RED >'11TH 5. A .E HEAv y DJTY 70RI HYDR"'-lliC BRAK( fLUID.

l " r.1< l ' (.HANCE OIL (VERY

12CJ HOUR S "" rH "> .... (

20 w

CAL BATH AIR ClEANER. ~MAL C()N)ITIONS USE 5 A .E . 20W . CHANCE WHEN ENGINE CRANK CASE OIL 15 O1AN ('ED . NI'i:R E WST IS EXCESSivE Crl AN CE ONCE OR TWIC E DAILY. NHEEL BEARINC5: CLE AN AND R(PACK wITH SINCLAIR LlTHJlI NE "' . P. (,RLA'>E ONCE ~ YEAR . RE....cNE AL L OLD CJ\E A ')C AND P/lC.K WITH FRESH (flEAS(. DO NOT '>PIN BEARINC WITH A IR ROoAo..t: ALL SOLvENT PRIOR TO REPAC.KI~. "'U M " ) R vE GE. Ai> BO~ : DRAIN AND REFILL EvE R Y ':, .X Met TH <. NIT ....

S A E 90 E P. G EA"I LuB R CANT.

BI009875

MAINTENANCE

SECTION

5

PAGE

1-2

GENERAL LUBRICATION RECOMMENDATIONS FOR JUMBO CARRIER One of the primary causes of mechanical problems, whether it be at the carrier, the boom, the positioners and feed, or the drill itself, is lack of, or improper lubrication The most significant factor in hydraulic equipment breakdown is contamination of the hydraulic fluid.

Stnct observance of the guidelines set down in the next three sections for proper lubrication time tables will provide longer life, and keep the equipment operating at peak performance.

Refer to Fig. 5-1 in this section for location of lubrication fittings. Also, refer to LUbrication Check list.

Lubncation Instructions for Brakes, Diesel Engine. Axles, Transmission, etc. are included in Figure NO.5-I and on the Checklist Hand Greased Pressure Fittings: Lubncate every 30 days uSing grade 2 all-purpose grease.

Hand Oiled Parts: Lubricate every 30 days with SAE 20011 Hydraulic Reservoir: Check level at beginning of each shift. Refill with factory-approved hydraulic flUid

Cable Reel (Option) lubrication The optional cable reel that holds the mine electric power cable has two grease POints. These are located at each end of the center support shaft. Lubricate every 30 days with Grade 2 all-purpose grease.

BI009875

I SECTION

5

PAGE

2-1

MAINTENANCE

BOOMS, FEEDS, POSITIONERS LUBRICATION

._------------------------------_._------------,

NOTE

There are 28 total grease pornts on each side, 4 on each Feed, 24 on each Mountrng Bracket, Boom and POSitioner

Fig. 5-2. Booms, Feeds, Positioner

d Mounting Brae

UNDER NORMAL USAGE, GREASE EVERY 30 DAYS USE GARDNER-DENVER GD-1 GREASE, OR FACTORY-APPROVED EQUIVALENT ONLY GD-1 IS AVAILABLE FROM GARDNER-DENVER. ORDER PART NO 1JTI455

) Lubrication

\

•

BI009875

SECTION -~----"--

MAINTENANCE

LUBRICATION

PAGE

5 2-2

RECOMMENDATIONS FOR FEEDS, BOOMS & POSITIONERS

The JTIHD rollover type booms and DPU positioners mounted on the Mark III Jumbo have replaceable bushings at all swivel pin joints. All major joints are eqUIpped with zerk fittings. aooms and Positioners have a total of 24 grease fittings for each side of the Mark III. The HFM feeds have 4 grease pOints each. Location of the fittings is shown in the diagram on Page 2-1 of this Section.

To insure maximum service life, inspect all swivel joints frequently and lubricate daily using GD-1 grease, or factory-approved equivalent.

Check level of Hydraulic Reservoir each day and refill with any factory-approved Hydraulic fluid.

6 WARNING DO NOT REMOVE GREASE ZERK FROM HOSE REEL TENSION DEVICE. BLEED PRESSURE WITH BLEED VALVE ONLY.

Note: Grease zerk located on Hose Reel Tension Device is used to adjust slack from Feed Hoses. Refer to Section 6, Page 2-1 for procedure.

BI009875

BI009875

I SECTION MAINTENANCE I PAGE

LU9RICATION OF THE HPR-1 HYDRAULIC DRILLS The chuck end of the HPR-1 is sealed and grease lubri cated . The drill has one grease fitting located at the c huck end that must be serviced weekly .

In ad d ition . grease must be applied each timea new shank is installed .

Add approximately 20 squirts of grease with a hand-held greas e gun . Apply to zerk fittings located on the right side of the drill at the chuck end section .

Fig . 5-3. HPR- 1 Dri" Lubrication .

5 3-1

BI009875

, BI009875

I

SECTION

5

PAGE

4-1

MAINTENANCE

LUBRICATION CHECK LIST Location

Procedure

Interval

Engine o il

Check & Fill. 4 cyl. 7 qt. 1 pt . (7.1 liters) SAE20W 6 cyl. 12 qt. 1 pt . (11.8Iiters)

Daily

Oil Bath Air Cleaner

Check & Fill. SAE 20 W

Engine oil

Change & Fill. 4 cyl. 7 qt. 1 Pt. (7.1 liters) SAE20W 6cy1.12qt . 1 pt. (11 .8Iiters )

120 Hours

Oi l Filter

Change. Use Oi I Fi Iter no. 88x20x 117H4119

120 Hours

Oil Bath Ai r Cleaner

Change & Fill. SAE 20 W

120 Hours

Farr Air Cleaner

Change Cartridge 4 cyl P9, 6 cyl P12

120 Hours

Inj ection Pump

Check Oil Level

120 Hours

Tie Rod Ends

Low p ressure gun - using Grade 2 - allpu rpose grease

120 Hours

Drag Link Joints

Low pressure gun - us ing Grade 2 - allpurpose grease

120 Hours

King Pin

Low pressure gun - using Grade 2 - allpurpose grease

120 Hours

Univen::al joints

Low pressure gun - using Grade 2 - allpurpose grease

120 Hours

Ax le Cradle Pin

Low pressure gun - using Grade 2 - allpurpose grease

120 Hours

Master Cylinder

Check & fill with heavy duty brake fluid to within W' (12.7mm) to %" (9.5mm) of top

120 Hours

Linkage

Adjust & Lubricate

120 Hours

Hydraulic

Check . Use only Factory-approved hydraulic fluid

120 Hours

Normal 120 Daily when in excessive dust

BI009875

5 .........._

MAINTENANCE

.....4_-2_

LUBRICATION CHECKLIST Location

Procedure

Hydraulic Strainer

Change strainer (in tank)

Hydraulic oi l

Change. Use only draulic fluid

Hydraulic Filter

Change filter

Transmission

factory-approved

Interval

720 Hours hy-

Funk 1024 type A automatic transmission fluid 23 qt. (21.8 liters) Funk 1014 type A automatic transmission fluid Warn er T -18-L2 use only straight mineral oil SAE 140 Warner T- 9-L2 use only straight mineral oil SAE 140

720 Hours 720 Hours

720 Hours

T ransfer Case

Rockwell T221 grade 140 4 Pts. (1.9 liters) Rockwell T223 grade 140 5 Pts. (2.4 liters) Rockwell T226 grade 140 7 Pts . (3.3 liters) Funk E-15 90W Warner T-98 SAE 140 8 Pts . (3.8 liters)

720 Hours

Fue l Filter

Change filter

1.200 Hours

Di fferential & Wheel End

Drain & fill . SAE 90 Multi-purpose Gear Lubricant

6 months

Wheel Bearing

Check & Repack with Grade 2 all-purpose grease

Annually

Air Compressor - Engine driven

Check & Fill with 20 W hydraulic fluid

Daily

BI009875

SECTION 6

BI009875

BI009875

MAINTENANCE Preventive

Section 6

BI009875

-'

BI009875

MAINTENANCE

SECTION

6

PAGE

1-1

PREVENTIVE MAINTENANCE - GENERAL A regular program of examining and servicing the equipment should be followed and only trained maintenance personnel should work on the hydraulic equipment. A more detailed checklist on procedures can be found in the Maintenance Manual.

There are many areas of concern that are important to the trained operator. Many of these checks should be made frequently for preventive maintenance purposes.

The operator can help control contamination of the hydraulic fluid by making sure that all removable reservoir covers fit well, and are gasketed and tightly bolted. Watch for leakage. Static joint leakage occurs at tube fittings, connecting pipe threads and joints, and at flexible hose couplings. Other sites include cylinder heads, valve caps, manifold joints, filters, pumps, and motor casings.

Operator should shut-off the equipment when a hose or hydraulic line breaks.

Time spent in preventive maintenance cannot be over emphasized. Worn parts, leaks, and other potential problems that can be detected early, or avoided all together, will save much time and money and prevent damage to the equipment.

BI009875

,

.'

BI009875

MAINTENANCE

PREVENTIVE MAINTENANCE In addition to the attention that must be given to the hydraulic system, preventive maintenance procedures of the hydraulic drill and feed should be carefully followed.

Side rod adaptors and nuts must be kept tight. Frequent checks should be made on all nuts and bolts for tightness.

Be sure the drill rod is in correct alignment. In the HPR1 with sealed chuck-end, the problem of dirt getting inside the drill is eliminated, nevertheless it is good practice to clean off the outside of the drill, feed, and hoses frequently to keep dirt from clogging up moving parts.

6 WARNING DO NOT REMOVE GREASE ZERK FROM HOSE REEL TENSION DEVICE. BLEED PRESSURE WITH BLEED VALVE ONLY.

6

PAGE

2-1

'.

The Drill & Feed

Tension of Hose Reels must be visually checked daily and adjusted when needed. To tighten tension, inject grade 2 all-purpose grease into the Hose Tension Device located in the feed hose bulkhead - see photograph, Figure 6-1. If tension is to be released, open Bleed Valve to allow reduction of pressure.

SECTION

I

I/) I' Fig, 6-1. Hose Reel tension adjusting.

BI009875

BI009875

MAINTENANCE

I SECTION

6

I PAGE

3-1

CHANGING THE SHANK Following is the procedure for changing the shank whenever the shank becomes worn or damaged.

Note: Always inspect the condition of the end of the water tube before replacing shank . Refer to the Mainten ance Manual if the water tube needs replacement.

1. Rattle the steel to loosen the coupling from the shank .

This can be done by turning the drill on and running the drill up and down the feed approximately five feet a few times without the rotation on. Bring the drill back to the rear of the feed and screw the coupling off the shank .

2. Remove the tw01-1 / 4" (32 mm)adapter nuts by turning

them to the left (counter-clockw ise) .

3. Sl ide the end cap forward off the end of the shank .

Fig . 6-2. Photo of HPR-1 shank end.

4. Pull the shank out of the drill and replace it with th e new one. Make sure there is a cup seal installed in the new shank before replacing . If there is grease available, it would be preferable to hand grease the spline section of th e new shank , .also. If not, insert grease throu gh zerk fitting after change-out is completed .

5. Replace end cap by sliding back over shank on to drill .

6. Replace the two adaptor nuts and turn clockwise to tighten . Be sure to tighten these two nuts evenly to approximately 150 Ib- ft torque (20.8 kg - m).

BI009875

BI009875

MAINTENANCE

SECTION

6

PAGE

4-1

CHECKLIST - PREVENTIVE MAINTENANCE, CARRIER -

r----

Location Engine Mounts

---

Procedure Check for wear and damage

,

Interval

1 Month

Check Torque Wheel Lug Nuts

5/8" (15.9 mm) 120 ft.-Ibs. (16.6 kg-m) 3/4" (19.1 mm) 200 ft.-Ibs. (27.7 kg-m)

Daily & at 120 hours

Tires

Check Tire Pressure

Dally & at 120 hours

Electrical

Check lights and fuses

Daily

Cooling Fins

Clean by a dry method

120 hours, or when necessary

Belts

Check and Tighten

120 Hours

Battery

Check & Fill, use distilled water.

Clean battery terminals.

120 Hours

Check Torque 3/8" (9.5 mm) U-Bolt.

150 ft.-Ibs. (20.8 kg-m) Axle Mounting

3/4" (19.1 mm) U-Bolt.

150 ft.-Ibs. (20.8 kg-m) 3/4" (19.1 mm) Bolt.

296 ft.-Ibs. (40.9 kg-m)

120 Hours

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SECTION 7

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MAINTENANCE Troubleshooting

Section 7

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GENERAL TROUBLE SHOOTING GUIDE If troubles occur, these will be frequently due to incorrect operation, lubrication, or maintenance. Thoroughly re-read all appropriate maintenance schedules. If you cannot identify the cause of the trouble, or are unable to correct it, contact your Gardner-Denver representative.

Problem

A. Water coming from ports in chuck end of drill.

Probable Cause

Solution

Cup seal in shank damaged or missing.

Replace cup seal in shank.

B. Drill won't automatically retract.

Cam block or cam valve on feed is not positioned properly. Orifice setting on yellow knob valves under console is wrong, not allowing oil to pass through.

Reposition cam block or cam valve on feed. Readjust orifice valves under console.

C. Continual breakage of feed chainS.

Tension is either too tight or too loose.

Feed pressure force is too great.

Replace the broken chain, check the tension of the feed chains. Reduce the feed pressurewhiledrilling, but not to the point where couplings begin to heat.

D. Couplings are heating up and breaking.

Feed pressure at which you are drilling is too low.

Increase feed pressure while drilling until the couplings stop over-heating.

plugging and mudding up continually.

E. Steel

Water pressure is too low.

Check the mine water pressure at the gauge. It should be a minimum of 60 PSI (414 kPa) working. If it isn't, a booster pump Will have to be used.

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ELECTRIC TROUBLESHOOTING GUIDE Problem

Probable Cause

Solution

A. Electric motors will not remain running after started, or one motor will run but both shut off when trying to start the second.

Low supply voltage.

Call electrician to confirm voltage from transformer or power may have to be increased if insufficient.

B. Electric motors will not remain running unless start switch is held in.

Supply power is not in proper phase and phase relays are functioning to protect motors.

Mine voltage supply is insufficient.

Call electrician to make necessary trailing cable hook up changes or check voltage.

C. Motors will not start.

Valve on oil reservoir to suction filters is shut off. Bad start switch. Bad control relay. Bad motor starter coil. Loose control wiring.

Call electrician to have components and circuit continuity checked, and repair or replace problem component.

D. Electric motors tripping out.

Reservoir on-off valve kicked shut.

Turn reservoir valve back on.

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HYDRAULIC TROUBLESHOOTING GUIDE Problem

Probable Cause

A. Total loss of Hydraulic power

in feed, boom, and rotation circuits & drill pump won't go to collaring level.

Low pressure relief stuck open.

Solution

Replace low pressure relief valve in control manifold or remove, disassemble, polish internal spool. Reassemble & replace adjusting to 200 PSI (1379 kPa).

B. Drill won't come up to pressure. Collaring or drilling pressure is too low.

Drill pump control arm is not fully stroked due to either sticking control stroking cylinder, or blocked line to cylinder.

C. Total loss of feed control.

Plugged flow control supplying hydraulic fluid to feed controller valve.

Remove blocking particles from flow control within main feed control valve.

D. Loss of feed control in one direction only.

Port in, or supply line to feed controller blocked.

Remove blocking particle by flushing, back flushing, or disassembly & removal.

Cam on traveling hose reel out of adjustment. Rear cam valve on feed stuck.

Valve actuating spring broken.

Adjust, replace, or repair problem component.

Flow control (yellow knob) valves out of adjustment or plugged.

Adjust or unplug flow control.

G. Drill suddenly looses power.

Accumulator bladder ruptured.

Drill pump malfunction.

Have mechanic replace accumulator diaphragm & recharge. Troubleshoot drill pump.

H. Blowing air will not shut off when drill stops at rear when automatic air & water is used.

Cam on traveling centralizer out of adjustment. Front cam valve stuck. Spring on front cam valve bent or broken.

Adjust, replace, or repair problem component.

I. Drill and hoses bounce and

The high pressure accumulator has lost pressure.

Shut down immediately, check and recharge, using the proper procedure.

E. Drill will not shut off, flushing water will not shut off, & feed

will not reverse automatically when drill reaches forward end of feed.

F. Feed will not automatically reverse.

vibrate excessively

Try to free it manually. If it continues to stick, it will have to be removed, disassembled & cleaned. If it is internally damaged, it will have to be replaced.

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ENGINE TROUBLESHOOTING GUIDE Problem

A. Engine fails to start

B. Engine is difficult to start

Probable Cause

,

Solution

Fuel tank empty

Fill fuel tank and air-vent.

Shut-off valve closed

Open shut-off valve and air-vent if necessary

Starter in fuel lift pump blocked

Clean strainer

Fuel filter blocked in winter through fuel clouding

Renew filter and then airvent; use winter-grade fuel.

Fuel lines leaking

Check all fuel line connections for tightness

Charging pilot lamp fails to light although bulb is functional.

Turn switch key clockwise to first detent, tighten terminals on battery, check wiring

Battery low, battery terminals loose or oxidized causing starting motor to turn slowly

Have battery inspected, clean terminals, tighten and coat with acid-free grease

Grade of motor oil used is too viscous (applies particularly in winter)

Choose grade of motor oil suited to temperature conditions

Fuel supply not sufficient; in winter blockage by clouding

Fuel supply not sufficient

C. Engine gives poor performance Valve clearance out of adjustment, valve spring broken Nozzle needle sticking

Renew fuel filter and then air-vent. Clean strainer in fuel lift pump, check fuel line connections for tightness, use winter-grade fuel Renew fuel filter and airvent, clean strainer of lift pump, tighten fuel line connections Readjust valve clearances, fit new valve spring Have inspected by specialist

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MAINTENANCE

ENGINE TROUBLESHOOTING GUIDE I

Problem

Probable Cause

Too much oil in sump

F. Engine oil pressure too low (Shut down engine immediately)

G. Charging indicator lamp lights up while engine is running

Drain off until level reaches top mark on dipstick

Oil level in oil bath air cleaner too high

Reduce level to agree with fill mark

Inefficient compression due to sticking or broken compression rings or incorrect valve clearances

Have compression rings and pistons inspected by specialists, readjust valve clearances

Cooling fins on cylinders and cylinder heads very dirty

Clean cooling fins, particularly the vertical ones on the cylinder heads

Injectors not operating

Have inspected by specialists

Injection pump delivery out of adjustment

Have adjusted by specialist

Insufficient cooling air input to blower

Make sure that aircan enter blower freely

Blower V-belt broken

Replace V-belt

Leaks in lubricating oil system

Check connections on pump, lines filter, pressure gauge and cooler for tightness

Excessive main bearing clearance

Have adjusted. specialists

Generator speed too low

Check V-belt tension

Generator not charging battery because generator or tension regulator not functioning

Have inspected by specialists

D. Exhaust smokes badly

E. Engine overheats causing temperature indicator to display "STOP". Shut down engine immediately

Solution

Consult

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SECTIONS

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SPECIFICATIONS Technical Data Section 8

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8

SE(:TlON

f1 PAGE

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SPECIFICATIONS

~

MARK III JUMBO CARRIER DIMENSIONS 476 " (12 .1 m)

229 " - - - - - - -1-- - - - - -

~ I"

(5.8 m)

93" (2.4

~

/"

m)/,

90" (2.3 m) ,

215" (5.5 m)

TURNING ~ RADIUS \

'\

96" (2.4 m)

!

Fig . 8-1.

Ir(1 74,,1 .9m)j--·- -

Dimensions of Mark " '

247"

(6.3 m)

'·1

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SPECIFICATIONS

8

J

1- 2 I,--PA_G_E....I....- J1

CARRIER A . Basic Configuration Universal Hydraulic Two Boom Drill Jumbo with 9 ft.

(2 .74 m) wheel base and hydraulic outriggers for stability when drilling.

B. Drive Train 1. ENGINE : Duetz Diesel Model F6L912W with 86 hp at 2300 rpm 2. CLUTCH: Rockford Model 12" (305 mm) TT CLA1537-AB with 430 lb . ft. torque (59.5 kg .m) capacity .

3. TRANSMISSION: Warner Model T 18-L2 4-speed full-reversing .

4. TRANSFER CASE : Rockwell speed. (optional)

Model

T-226

2-

5. AXLES : a. Rear

planetary

drive-steer: Rockwell

Model PS-114-HX1 with 16" x 2-1 / 2" (406 x 64 mm) hydraulic drum brakes. b. Front planetary

rigid drive : Rockwell

Model PR-114-PX1 with 16-1 / 2" x 5" (419 x 127 mm) air spring brake chamber actuated drum brakes .

C . Miscellaneous Equipment 1. TIRES : 15.00 x 22.5 x 16 ply rated tubeless Firestone rock Grip Duplex.

2. POWER STEERING: Char-Lynn orbitrol UK-01 steering supplied by Vickers VTM 42 power steering pump and controlling two steering cylinders .

3. AIR COMPRESSOR : Bendix Westinghouse TUFLO 300 piece no. 277886.

4. ALTERNATOR: Delco #1100577 43 ampere, 12 volt with integral regulator.

5. BATTERY : Delco No. 1980759-C 12 volt, 150 amphour rated U.S.B.M. approved exhaust condition er.

6. EXHAUST SYSTEM: a. Oxy-Catalyst cat alyt ic ex haust conditioner. b. Water batch condition er - optional.

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SPECIFICATIONS

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CARRIER - ELECTRIC DIAGRAM

HEAD

INST.

LIGHT SWITCH

ENGINE TEMPERATURE

LOW AIR PRESSURE SWITCH FUEL

REAR

FLASHER

REAR LIGHTS

FRONT LIGHTS

SWITCH

AMMETER

START SWITCH

BATT.

STARTER

ALTERNATOR

HEATER INDICATOR

TO HEATER PLUGS

+ BATTERY

Fig . 8-2. Mark III Jumbo Carrier electric switching diagram .

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SPECIFICATIONS

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BOOM, POSITIONERS, FEEDS 102 mm

6.S"

t 173 mm

~========'i===(?a-=i==~===~1~ ;'; =1aiSG1:.. t 9"

229mm

mm

~----------------------------------OVERALLLENGTH

A ----------------------------------~~

The HFM IS an all-hydraulic feed system designed to be used with the HPR-1 Hydraulic Drill The two units mount on the Gardner-Denver MARK III Ail-Hydraulic Jumbo making a complete underground hydraulic dnlling team. The fef' :~ available In five lengths.

SPECIFICATIONS eVERALL LENGTH. DIM A

HFM8 .'.: ..•. HFM10 16' 7" 505 m

1R' 7' 566 fTl ---~-

HFM12 -~:.~.:AFM;t~ .

HFM16

20' 7" 627 m

;>2'7"

688 m

24' 7" 749 m

----

DRILL TRAVEL. DIM B

8' 9" 267 m

10' 9" 328 m

12' 9" 389 m

14' 9" 450 m

16' 9" 511 m

NOMINAL HOLE DEPTH

8' 244 m

10' 305 m

12' 366 m

14' 427 m

16' 488 m

DRILL ROD LENGTH

10' 305 m

12 366 m

16' 488 m

18' 549 m

1100lbs 499 kg

1200lbs 544kg

14' 427 m ------1300lbs 590 kg

1400 Ibs 635 kg

1500 Ibs 680 kg

~-----

APPROXIMATE WEIGHT Includes baSIC feed plus drill mounllng. hosps. hose reel and centralizers Does not Include drill and drill string

-

Fig. 8-4. Dimensions of HFM Feed.

Booms

Feeds

Two Model JTI Series Booms. These are 12 or 14 ft. (3.66 or 4.27 m) nominal length with 4-3/4" (121 mm) bore rollover cylinders for 270 0 coverage and 6" (152 mm) bore lift cylinders.

Hydraulic cylinder channel construction feed with removable end centralizer. traveling centralizer. and hose reel. Drill travel is 153" (3886 mm) maximum to allow for the use of 14 ft. (4.27 m) long steel, to enable drilling of holes to a full 12 ft. (3.66 m) depth. Optional drill travels of 129" (3277 mm) and 177" (4496 mm) are available.

Drill Positioners Two DPU series drill positioners with 5 ft. (1.52 m) stroke feed extend cylinders.

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r:r=1~*t?~

__t -

SPECIFICATIONS

DRILLS _~_ _ _ _ _ _ _ __ _ _ 43.75 " _ _ _ _ _ _ _ _ _ _ _ _..

• 1 1111 mm

_ _ _--.-_ __

f 11 .20" 284mm--

124 mm

6.31 " 160 mm

t f-o- - - - - - - - - 34 " - - - - - - - - -_ 863 mm

TOP OF FEED

The HPR-1 is an all-hydraulic percussion rock drill used fo r underground drilling . The hol e size range is 1 '12" t02 '12" . The drill is mounted on the Gardner-D en ver HFM Hyd rau lic Feed . The two unit s mount on th e Garnd er- Denv er Ma,'k III All-Hydraulic Jumbo making a comple te und erg round hydraulic drilling team .

•

SPECIFICATIONS METRIC WEIGHT

3251bs

147 kg

IMPACT ENERGY

125 - 200 ft-Ibs

170 - 27 1 J

IMPACT FREQUENCY

4000 - 2500 BPM

OPERATING PRESSURE

3000Ibs / ln ?(Max)

OIL FLOW-OSCILLATOR

25 gal / min (Max)

ROTATION SPEED

0 - 200 RPM

ROTATION TORQUE

250 Ibs- feet (M ax)

339 Nm (Max)

FEED FORCE

2000 - 3000 Ibs

8.9 - 13.3 kN

FLUSHING WATER

20 gal / min

76 I/ mln

RECOMMENDED WATER PRESSURE

75 - 120 Ibs/ in 2

5 - 8 bar 500 - 800 kPa

TOTAL CONNECTION POWER REQUIRED DURING DRILLING

50 kw

Fig . 8-5. Dimensions of HPR- 1 Drill .

204 ba r (Max) 20.400 kPa 95 I/ min (Max )

Two Mod el HPR-1 Hydraulic Drills. The drills are designed to give a constant energy output of 500,000 ftIb/ min . Th e drill has a means by which the drill hammer stroke and blow frequency may be varied to adjust to drilling conditions to achieve a ma ximum drilling rate .

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GENERAL SPECIFICATIONS Hydraulic Power Supply Units

Misc. Hydraulic Circuit Features

A. Basic Configuration There will be two supply units, one mounted on each side of the Jumbo Carrier between the front and rear axles. Each unit will have one 75 hp electric motor driving two variable displacement piston pumps through a double pump gear case drive. One pump will supply the drill hammer only; the other pump will supply drill rotation , the feed, and the boom positioning components. The pumps will be remote controlled.

A . Drill Rotation -feed force interfacing A feature is incorporated which decreases the feedi ng force on the drill as the drill rotational torque increases . This feature will allow drilling throug h "vuggy" area rather than sticking the drill steel.

B. Motors 75 hp, 460 VAC ., 60 HZ, 3-phase, 86 ampere rating, 1780 rpm, severe duty and NEMA B design .

Other approved voltages and frequencies are optional.

C . Reduced power to drill during reverse feeding A feature is incorporated that will allow the drill to be operated only under reduced power when in the reversing mode, thus preventing damage to the drill, which could occur if operated under full power with no load for prolonged periods.

C . Pump Drive Funk Model 28102 Doubl <:! Pump drive.

D. Pumps 1. Drill hammer supply : Dynapower Model 45 phase IV design standard variable volume axial piston pump with long differential , consta nt input, torque controller set to 43 hp at 1750 rpm. Cut-off or compensated pressure set to 3400PSI(23440 kPa) .

2. Feed and Rotation supply: Dynapower Model 45 phase IV design standard variable volume axial piston pump with long differential, constant input, torque controller set to 15 hp at 17.50 rpm. Pressure set to 2100 PSI (14477 kPa) . Cut-off compensated .

B. Filtration 10 Micron suction filters and 3 micron absolute pressure line filters, all with dirt alarms , are used to minimize circuit particle contamination .

D . Gau ges Gauges are provided for monito ring the drill hammer circuit pressure, boom pressure, feed cylinder pressure, air pressure, water pressure, rotation pressure, and drill stroke pressure.

E. Oil Cooling Oil cooling is accomplished by passing the oil through an oil-to-air cooler. Air is blown through the coolers by a fan mounted to a thermostatically controlled 7.5 hp electric motor.

Electric Circuit Features

A. Control Panels 1. Two control panels are mounted in two separate weather-proof control panel boxes .

2. An externally switch able main breaker is supplied , as well as individual breakers, for each motor inside panel boxes.

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Boom must be rotated to drill in sh aded areas.

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16

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6

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DRILLING COVERAGE PATTE RN

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