Cat MD5050 Hydraulic Track Drill Operation & Maintenance Manual – PDF DOWNLOAD

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May 2012 BI006826

Operation and Maintenance Manual MD5050 Hydraulic Track Drill 426689 Rev. 02

SAFETY.CAT.COM

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PARTS ORDERING AND PRODUCT SUPPORT Use only genuine Cat® parts in the maintenance, rebuild or repair of these machines. The manufacturer shall have no liability as to any unauthorized modification of machines or parts. The manufacturer is also not obligated or liable for any machines or parts that have been improperly handled; that have not been operated, maintained or repaired according to furnished manuals or other written instructions, and that have been operated with other than genuine Cat parts or authorized OEM components.

IDENTIFICATION OF THE MACHINE Always furnish the Model Number and Serial Number when ordering parts. This information is found on the machine nameplate.

PART NUMBER AND DESCRIPTION In addition to the Model and 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 dimensional sketch or return the part to be replaced, transportation charges prepaid. Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.

SHIPMENT Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder 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.

PARTS ORDERING In North America Telephone 1-800-854-9030 or Telefax 1-800-582-6570 Telephone (903) 786-2981 Telefax (903) 786-6407

PRODUCT SERVICE AND WARRANTY In North America Telephone 1-800-258-0009 Telephone (903) 786-2981 Telefax (903) 786-6408

Caterpillar Global Mining LLC Mining Products Division 3501 S. FM Hwy 1417, Denison, TX 75020 Mining.cat.com © 2012 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Printed in U.S.A.

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Introduction Intended Use

This machine and its approved attachments are designed to drill blast holes for surface and underground quarry, mining and construction applications. Use of this machine in any other way is prohibited and contrary to its intended use.

This safety alert symbol indicates important SAFETY MESSAGES in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of personal injury or property damage.

DO NOT weld on any part of this machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. Disconnect the connections to the Electronic Control Module (ECM) on the engine before welding.

Before Starting Engine, Study Operator's Manual * Read and understand the warnings and cautions shown in Section 1 * Practice All Safety Precautions * Make Pre-Operations Check * Learn Controls Before Operating It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on machine operation and service, and to observe pertinent safety precautions, laws and regulations.

California Proposition 65 Warnings The following warning applies to equipment supplied with lead-acid batteries: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Drill Serial No. : Date Drill Delivered : Dealer : Customer : The descriptions and specifications contained in this manual were in effect at the time of printing.

We reserve the right to make changes at any time without notice or obligation.

09/2010 Introduction

i

Table of Contents

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INTRODUCTION SAFETY

SECTION 1

GENERAL DESCRIPTION

SECTION 2

OPERATOR CONTROLS

SECTION 3

START-UP, SHUTDOWN, TRAMMING AND TOWING

SECTION 4

Hazard Classification ...............................................................................................................1-2 Potential Hazards ...................................................................................................................1-3 Safety Information ...................................................................................................................1-6 Safety Sign List .......................................................................................................................1-8 Safety Sign Locations ..............................................................................................................1-9 Safety Signs .........................................................................................................................1-12

General Description .................................................................................................................2-2 Component Location ...............................................................................................................2-2 Standard Features ...................................................................................................................2-4

Graphic Symbols .....................................................................................................................3-2 Instrument Panel (non-cab machine) ..........................................................................................3-4 Tramming & Positioning Controls (non-cab machine) ...................................................................3-6 Drilling & Positioning Controls (non-cab machine) .......................................................................3-8 Auxiliary Controls...................................................................................................................3-12 Cab Controls .........................................................................................................................3-14 Component Locations ..........................................................................................................3-14 Instrument Gauge Panel .......................................................................................................3-15 Overhead Console ...............................................................................................................3-16 Right Side Console ..............................................................................................................3-18 Joystick - Drill/Tram Controls ..................................................................................................3-20 Carousel Rod Changer Controls ..............................................................................................3-22 Vertical Indicator ...................................................................................................................3-23

Pre-Start Checklist...................................................................................................................4-2 Start-up Procedure (non-cab machine) ......................................................................................4-4 Shutdown Procedure (non-cab machine) ....................................................................................4-6 Tramming Procedure (non-cab machine) ....................................................................................4-7 Start-up Procedure (cab machine) ............................................................................................4-8 Shutdown Procedure (cab machine) ........................................................................................4-10 Tramming Procedure (cab machine) ........................................................................................4-11 Towing Procedure ..................................................................................................................4-12

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Table of Contents DRILLING PROCEDURES

SECTION 5

PREVENTIVE MAINTENANCE

SECTION 6

Loading Drill Rod (manual rod rack)...........................................................................................5-2 Drill Positioning (non-cab machine) ............................................................................................5-4 Collaring the Hole (non-cab machine).........................................................................................5-5 Drilling Practices .....................................................................................................................5-6 Manual Drilling (non-cab machine) .............................................................................................5-8 Auxiliary Air Option ...............................................................................................................5-10 Smart Drill Feature...............................................................................................................5-11 Adding and Removing Drill Rod (manual rod rack) ...................................................................5-12 Linear Rod Changer (cab machine) .........................................................................................5-16 Loading Drill Rod .................................................................................................................5-17 Carousel Rod Changer (cab machine) ......................................................................................5-20 Loading Drill Rod .................................................................................................................5-21 Manual Drilling (cab machine) .................................................................................................5-24 Collaring the Hole ................................................................................................................5-25 Smart Drill Feature...............................................................................................................5-28 Adding Drill Rod (linear rod changer) .....................................................................................5-31 Adding Drill Rod (carousel rod changer) .................................................................................5-35 Removing Drill Rod (linear rod changer) .................................................................................5-39 Removing Drill Rod (carousel rod changer).............................................................................5-41 HPR1H-ATW Drill Shank Replacement ......................................................................................5-42 HPR4519 Drill Shank Replacement .........................................................................................5-44

Hydraulic Oils for Percussion Drills ............................................................................................6-2 Lubrication and Inspection .......................................................................................................6-3 Bolt Torque Specifications ........................................................................................................6-4 Maintenance Schedule .............................................................................................................6-5 Daily Operational Checklist .......................................................................................................6-6 Hydraulic Drill Accumulator Charge Pressure .............................................................................6-7 Engine Oil Filter .......................................................................................................................6-8 Engine Fuel Filter .....................................................................................................................6-9 Fuel/Water Separator ..............................................................................................................6-9 Engine Air Cleaner Filter .........................................................................................................6-10 Compressor Air Cleaner Filter.................................................................................................6-11 Compressor Oil Filter .............................................................................................................6-12 Coolant System.....................................................................................................................6-15 R20 Grease Points ................................................................................................................6-16 Maintenance Record ..............................................................................................................6-29

Introduction

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Glossary of Terms

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The following is a list of terms commonly used in the mining and construction industry. This list is not exhaustive, but pertains primarily to surface track drills as discussed in this manual.

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

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

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

Boom ............................ Horizontal structure that supports and positions the feed. One end attaches to a pivot at the boom bulkhead at the front of the machine, 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 bottom end of the feed. It has jaws that open and close around the drill steel, but allow the drill steel to pass through and rotate freely. The jaws are also used to clamp around the drill steel coupling and hold it tight for threading and unthreading of drill steel. A midpoint or travelling centralizer is used on long feeds to support the mid-point of the drill steel.

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

Detergent Tank ............... A holding tank for water and detergent solution that is sometimes pressurized, or used in conjunction with a pump. It is part of a system used to suppress dust from the hole by means of injecting water into the hole while drilling is in progress.

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 female threads or sometimes male and female threads.

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

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

Dust Collector ................ A device used to collect dust and cuttings from the hole by means of vacuum, while drilling is in progress.

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

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

Feed Mounting ................ Another name for “Feed Table” Feed Table ..................... A device that attaches to the positioner by means of a pin and hydraulic cylinder, and is used to support the feed.

Hammer(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.

Oscillation ...................... Refers to the up and down movement of the tracks. During tramming the track oscillation cylinders are unlocked to allow the tracks to move up and down according to the terrain. During drilling the track oscillation cylinders are locked, to prevent the tracks from moving.

Pickup Pot...................... A device that can be hydraulically raised or lowered over the hole and provides a means of attaching the dust collector hose to remove dust and cuttings from the hole.

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

Pre-Cleaner .................... A device used in conjunction with the dust collector, that removes large particles before they reach the dust collector.

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 IN or TOWARDS the machine in the horizontal plane, or 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.

Spring Washer ................ A cup shaped washer that, when compressed provides a “spring like” action.

Also called "belleville washer".

Sting.............................. To apply pressure to the ground 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 ground to stabilize the feed while drilling.

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

Tram .............................. To move and steer the machine from the tram station or operator’s cab.

Introduction

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Notes

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Introduction

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Section 1

Safety

Safety

1-1

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Hazard Classification

The Track Drill is a heavy moving machine with a boom capable of extending its 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 operated, inspected, and maintained. The operator's must read this manual and have been trained to use the machine in an appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer at 1-800-258-0009.

Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Safety Alert Symbol

Hazard Classification

A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard.

All are used as attention-getting devices on decals and labels fixed to the machine to assist in potential hazard recognition and prevention.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property or equipment damage.

1-2

Safety

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Potential Hazards Potential Hazard

Prevention

Safety Alert Symbol. Used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

See Operator's Manual for instructions. If you do not understand the information the manuals, consult your supervisor, the owner, or the manufacturer.

Entanglement Hazard. Death or serious injury can result from contact with rotating drill steel and drivelines.

Keep clear of rotating drill steel and drivelines. Switch off engine before performing service.

Entanglement Hazard. Rotating parts can cause personal injury.

Keep away from fan and belt when engine is running. Stop engine before servicing.

Explosion / Burn Hazard. Will cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.

Keep all open flames and sparks away.

Wear personal protective equipment, including face shield, gloves and long sleeve shirt.

READ MANUALS Read all manuals prior to operation.

Explosion Hazard. Death or serious injury can result from the use of ether or other high energy starting aids.

Do not use ether or other high energy starting aids. Engine equipped with grid heating system.

Explosion Hazard. Death or serious injury can result from the use of ether or other high energy starting aids.

Do not use ether or other high energy starting aids in compressor.

Burn Hazard. Death or serious injury can result from release of hot pressurized liquids.

Keep away from flames.

Relieve all pressure.

Allow to cool before performing service on compressor.

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Potential Hazards Potential Hazard

1-4

Prevention

Flying Object & Spray Hazard.

Death or serious injury can result from release of pressurized liquids.

Shut off live air at source, and relieve all pressure before removing filler plug.

Flying Object Hazard. Serious injury or death can occur if drill is operated without guards in place.

Use guards.

Keep in place.

Flying Object Hazard. Serious injury or death can occur if track tension is adjusted improperly.

Read and understand the procedures in the Operation and Maintenance Manual before adjusting track tension

Electrocution Hazard. Death or injury can result from contacting electric power lines.

Maintain required clearance.

Burn Hazard. Hot fluid under pressure can scald.

Allow to cool before opening.

Trip & Fall Hazard. Death or serious injury can result from tripping and falling.

Keep off top of machine.

Flying Object Hazard. Feed can contact cab and break glass. Broken and flying glass can result in serious injury or death.

Keep feed away from cab. Read manual for operating instructions.

See Table 1-1 in this manual.

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Potential Hazards Potential Hazard Inhalation Hazard. Compressor discharge air is hazardous if inhaled.

Death or serious injury may result.

Keep clear of compressor air discharge area.

Injection Hazard. Escaping fluid under pressure can penetrate skin, causing serious injury.

Relieve pressure before disconnecting hydraulic lines. Keep away from leaks and pin holes. Use a piece of cardboard or paper to search for leaks. Do not use hand.

Crush Hazard. Death or serious injury can result from contact with moving centralizer.

Keep clear of moving centralizer. Do not actuate centralizer until personnel are clear.

Crush Hazard. Death or serious injury can result from contact with moving machine.

Keep clear of moving machine.

Crush Hazard. Death or serious injury can result from contact with moving feed mast.

Read and understand operator's manual and all safety signs before attempting to remove feed mast swing pin.

Drill Feed And Table Can Fall causing serious injuries or death.

Always raise the drill feed and feed table clear of all obstacles before moving the machine. Raise them high enough to allow for rough ground or small hills.

Do Not allow anyone under the drill feed or feed table unless machine parts are not moving and are supported.

Do Not attempt to repair a pivot pin that has failed or has been sheared.

Caution. Do not use high pressure spray by electrical connections.

Safety

Prevention

1-5

Safety Information

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Before Operation •

Do study this manual and fully understand the controls.

•

Do be sure all safety guards are securely in place. Replace any damaged or missing guards.

•

Do be sure all nameplates and decals pertaining to safety, operation, and maintenance are in place and not damaged. Replace any damaged or missing nameplates or decals. Refer to decal locator drawings in this section.

•

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

•

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

•

Do attach safety chain when using towbar.

•

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

•

Do Not operate machine with: • Hydraulic or air leaks.

• Damaged hydraulic hoses or fittings.

• Broken or damaged electrical wiring.

• Damaged or missing guards and shields.

• Damaged structural members.

• Worn or damaged mechanical parts.

• Damaged or missing fasteners.

• Broken, damaged, or malfunctioning controls.

Operation •

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

•

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

•

Do keep work area clean and clear of mud, snow, ice, fluids, hand tools and other objects.

•

Do raise the drill feed before moving the machine. Raise it high enough to allow for rough ground or small hills. Drill feed can fall causing serious injury or death.

•

Do wear seat belt and operate machine with door closed on cab machines.

•

Do maintain minimum clearance from high voltage wires (see Table 1-1). Check with power company and local regulations for specific guidelines and safety information.

•

Do Not use the machine for any other purpose than what it was designed for.

•

Do Not wear loose clothing or jewelry; keep clothing and hands clear of moving parts.

•

Do Not travel on steep inclines, soft or unstable ground, or close to unsupported excavations.

•

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

•

Do Not stand directly under a boom or feed.

•

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

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Safety

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Safety Information After Operation •

Follow Shutdown Procedures given in Section 4 of this manual.

Maintenance •

Two people shall be present when performing service work, both being fully trained on 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 shall be established and understood by both persons.

•

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

•

Do use only proper tools to make repairs or adjustments.

•

Do be sure of adequate lighting when performing service work at night.

•

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

•

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 disconnect battery before making repairs or adjustments to machine.

•

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

•

Do Not service, or perform maintenance, while machine is running, or capable of being started.

•

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

•

Do Not weld or grind near oil, air, fuel lines, or batteries.

•

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

•

Do Not direct high pressure cleaning agents or water on electrical connections.

Equipment Transfer If all or part of the equipment is shipped to a new destination, always include a complete Operator's Manual or a copy of the following topics: • Safety Section • Operation Instructions including: Clearances from High Voltage Lines Pre-Start Checks Start-up Line Voltage Minimum Clearance After Start Checks 0 to 50 kv 10 ft (3 m) Shutdown Procedure 50 to 200 kv 15 ft (4.6 m) Tramming Machine 200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv

45 ft (13.7 m)

Table 1-1 Minimum safe distances from high voltage lines.

Safety

1-7

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Safety Sign List Refer to Figures 1-1 to 1-3 for locations Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Description DANGER - Electrocution Hazard WARNING - Flying Object Hazard WARNING - Operation/Maintenance, Read Manual WARNING - Flying Object & Spray Hazard DANGER - Entanglement Hazard, Rotating Drill Steel NOTICE - Hydraulic Oil Requirements DANGER - Explosion Hazard NOTICE - Fuel Type WARNING - Burn Hazard, Hot Fluid DANGER - Inhalation Hazard WARNING - Burn Hazard DANGER - Flying Object Hazard DECAL - R20 Maintenance Summary, Tier 3 WARNING - Drill Feed and Table Can Fall WARNING - Crush Hazard, Centralizer WARNING - Crush Hazard, Feed Mast WARNING - Flying Object Hazard, Boom/Feed WARNING - Fall Hazard NOTICE - Backpressure Valve WARNING - Trip & Fall Hazard CAUTION - High Pressure Spray on Elect. Connections WARNING - Crush Hazard, Centralizer (Clear) NOTICE - Gease Instructions WARNING - Explosion Hazard, Compressor WARNING - Explosion Hazard, Engine DANGER - Crush Hazard WARNING - Injection Hazard NOTICE - Do Not Weld WARNING - Entanglement Hazard, Fan & Belts

Part No. 429116 429082 428892 429141 429115 429106 428896 429471 428897 429491 429405 429119 436626 409485 429438 429084 429415 429087 429128 429548 429468 429938 427967 429493 429494 428884 428898 429489 428893

Qty. 1 2 1 2 2 1 1 1 1 1 1 2 1 1 1 1 2 1 1 2 2 1 1 1 1 4 2 2 1

(Ref. 436625 rev. B)

1-8

Safety

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Safety Sign Location

F

27

9

NOTICE DO NOT WELD

429489

7

VIEW E-E

4

28

29

VIEW D-D

F

Fig. 1-1 Rear and Top of Machine

Safety

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Safety Sign Location 2X TOP 12 AND BOTTOM

15

VIEW C-C ROTATED FOR CLARITY

20 6 16

NOTICE IN

26

26

5

VIEW F-F

2

Fig. 1-2 Right Side of Machine

1-10

Safety

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Safety Sign Location

Fig. 1-3 Left Side of Machine

Safety

1-11

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Safety Signs

429116

429141

429115

429082

428892 429106 1-12

Safety

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Safety Signs

428896

429405

429471

428898 428897 Safety

1-13

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Safety Signs

429119 409485

436626

429438 1-14

429084

429415

Safety

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Safety Signs

429087

429468

429128

429938

429548 427967

Safety

1-15

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Safety Signs

429491 429493

429494 429489

WARNING Entanglement Hazard Rotating parts can cause personal injury.

Keep away from fan and belt when engine is running. Stop engine before servicing.

428893

428884 1-16

428893 Safety

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Section 2

General Description

General Description

2-1

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General Description

The R20 Track Drill features the HPR4519 Hydraulic Rock Drill for drilling holes ranging from 2 to 3.5 in.

(50.8 to 101.6 mm) diameter. The R20 is an efficient, self-contained drill carrier featuring a simple direct driven single pump hydraulic system. The machine can be equipped with or without operator's cab and an optional carousel rod changer (not shown) in lieu of the linear rod changer.

Component Location (Cab Machine) 8

3

5

4

6

12

2 1

13

7 9 Fig. 2-1 Model R20–Right Side 1. Detergent Tank 2. Radiator/Oil Cooler 3. Dust Collector 4. Feed 5. Linerar Rod Changer

2-2

11

14

10

6. Feed Extend Cylinder 7. Feed Dump Cylinder 8. Boom Swing Cylinder 9. Track Oscillation Cylinder 10. Boom Lift Cylinder

11.

12.

13.

14.

Dust Collector Precleaner Feed Table Feed Swing Cylinder Stinger

General Description

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General Description Component Location (Cab Machine)

16

24

15

25

17

18

26 27

20

21 19

23

22 28

Fig. 2-2 Model R20–Left Side 15. Hose Reel 16. Upper Rod Rack 17. Rod Changer Driveline 18. Lower Rod Rack 19. Centralizer

General Description

20. Dust Collector Pickup Pot 21. Pendulum (plumb indicator) 22. Storage Box 23. Hydraulic Rock Drill 24. Feed Cylinder

25. Cab Air Filter 26. Fuel Fill Cap 27. Engine/Compressor Assembly 28. Main Electrical Panel

2-3

Standard Features

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Track 12 in. (30 cm) wide, overlapping, double bar (standard) grouser with mud relief hole. The track frame has 20o of oscillation for positive ground contact over rough terrain.

Track Drive Dual displacement hydraulic motor-driven compact planetary gear drives with manual disconnect for towing. Complete with hydrauluic released, spring applied automatic disc brakes.

Engine Isuzu US EPA Tier 3, 4 Cylinder, 4 Cycle Diesel OHC, 203 hp @ 2100 rpm Hydraulic System Load sense in tram mode and pressure compensated in drill mode. The system consists of one gear driven axial piston pump for all drill and tram systems with a gear driven charge loop pump.

Charge flow is fully filtered.

Air System 250 CFM Gardner-Denver Rota-Screw Compressor. Pressure capability to 150 PSI (10.3 bar).

Rock Drill HPR4519 hydraulic percussion drill with single rotation motor. For drilling holes from 2 in. to 4 in.

(50.8 to 101.6 mm) diameter, using 1-1/2 or 13/4 in. (38 or 45 mm) drill steel. Optional HPR5123 for holes from 2.5 to 5 in. (63.5 to 127 mm) diameter.

Boom A 10 ft. (3 m) swing boom with 4 ft. (1.2 m) telescoping capability. Standard on units without rod changer. Optional knuckle boom.

Cab (optional) An ergonomic cab design with rollover and/or falling object protection (ROPS/FOPS) and excellent visibility. Cab is designed for front window pushout and is equipped with an emergency stop for immediate shutdown.

Rod Changer

2-4

Linear rod changer holds 45 or 51 mm rods.

Optional carousel or single rod changers available.

General Description

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Section 3

Operator Controls

Operator Controls

3-1

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Graphic Symbol Legend Upper Panel Console

Side Panel Console

A/C ON Air INCREASE/DECREASE

Centralizer OPEN/CLOSE

Dust Collector ON/OFF Drill/Tram

Warm Oil ON/OFF 3-2

Engine FAST/SLOW

Cab Fan Speed

Lights ON/OFF

Water ON/OFF

Oscillation LOCK/UNLOCK

Feed Rate INCREASE/DECREASE

Rotation CCW

Engine Start

Feed Force INCREASE/DECREASE

Coupling Grease ON/OFF

Oscillation UP/DOWN

Cab Temp Control

Drill

Pick-Up Pot UP/DOWN

Rotation CW

Smart Drill ON/OFF Operator Controls

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Graphic Symbol Legend Left Hand Joystick Controls

Feed SWING/DUMP/EXTEND

Feed UP/DOWN

Gauge Panel

Air Pressure

Drill Pressure

Feed Pressure

Rotation Pressure

Left Track FORWARD/REVERSE

Right Hand Joystick Control

Boom LIFT/SWING/IN/OUT Right Track FORWARD/REVERSE

Operator Controls

3-3

Instrument Panel (non-cab machine)

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Fig. 3-1 Instrument Panel (located on left side of machine) 1. Ignition Switch 2. Low Oil Pressure Override Switch 3. Throttle Switch 4. Engine Tachometer/Hourmeter 5. Voltmeter 6. Water Temperature Gauge 7. Fuel Gauge 8. Drill Hourmeter 9. Engine Oil Pressure Gauge 10. Compressor Air Temperature Gauge 11. Rear Lights Switch 12. Front Lights Switch

3-4

Operator Controls

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Instrument Panel (non-cab machine) 1.

Ignition Switch -

Turn clockwise to activate engine starter, then release to ON position. Turn counterclockwise to activate glow plugs. Glow plug indicator is located to the right of the instrument panel, behind the post.

2.

Override Switch -

Hold switch up when starting engine until oil pressure is sufficient to allow engine to run.

3.

Throttle Switch -

Engage switch to raise or lower engine rpm.

With switch DOWN, engine idles at 1350 RPM. With switch UP, engine idles at 2350 RPM. Engine should be at low idle for start-up and shutdown.

Engine should be at high idle for all drilling and tramming functions.

4.

Engine Tach./Hourmeter -

Shows engine RPM and engine hours.

5.

Voltmeter -

Indicates battery charging.

6.

Engine Water Temperature Gauge -

Indicates engine water temperature.

7.

Fuel Level Gauge -

Indicates fuel level.

8.

Drill Hourmeter -

Records actual drilling time.

9.

Engine Oil Pressure Gauge -

Indicates engine oil pressure.

10. Compressor Air Temperature Gauge -

Indicates compressor discharge air temperature.

11. Rear Lights Switch -

ON/OFF

12. Front Lights Switch -

ON/OFF

Operator Controls

3-5

Tramming & Positioning Controls (non-cab)

BI006826

Fig. 3-2 Operators Tram Station (located at left front of machine) 1. Operator's Seat 2. Electric Control Panel - Tram and Positioning Functions 3. Storage Compartment

Fig. 3-3 Electric Control Panel - Tram and Positioning Functions 1. EMERGENCY STOP Button 6. Track Oscillation Switch - LOCK/UNLOCK 2. Power Light 7. Tram Switch - FAST/SLOW 3. Tram Control - LEFT TRACK 8. Selector Switch - DRILL/TRAM 4. Tram Control - RIGHT TRACK 9. Boom Lift Switch - UP/DOWN 5. Track Oscillation Switch - UP/DOWN 10. Boom Swing Switch - RIGHT/LEFT 3-6

Operator Controls

BI006826

Tramming & Positioning Controls (non-cab) Located at Tram Station 1. EMERGENCY STOP Button -

Push button to stop machine in case of emergency.

2. Power Light -

Light ON indicates electrical power to unit.

3. Tram Control - LEFT TRACK -

Controls direction and speed of left track.

4. Tram Control - RIGHT TRACK -

Controls direction and speed of right track.

5. Track Oscillation Switch - UP/DOWN -

Raises or lowers rear of machine when tramming up or down grades or over rough terrain.

6. Track Oscillation - Switch-LOCK/UNLOCK -

Switch to LOCK when drilling. This locks the hydraulic cylinders from movement.

Switch to UNLOCK when tramming. This lets the hydraulic cylinders move up and down.

7. Tram Switch - FAST/SLOW -

Switch to FAST for long distance tramming.

Switch to SLOW for precise maneuvering

8. Selector Switch - DRILL/TRAM -

Switch to DRILL for operation at drill station.

Switch to TRAM for operation at tram station.

9. Boom Lift Switch - UP/DOWN -

Raises or lowers boom.

10. Boom Swing Switch - RIGHT/LEFT -

Moves boom to right or left.

Operator Controls

3-7

Drilling & Positioning Controls (non-cab)

Fig. 3-4 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF

3-8

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

BI006826

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF

Operator Controls

BI006826

Drilling & Positioning Controls (non-cab) Located Adjacent to Feed

(refer to fig. 3-4)

1. Left Tram/Boom Control Move joystick left Move joystick right Move joystick forward Move joystick back Using joystick switch

When Selector Switch (16) is in DRILL mode: Boom swings left Boom swings right Boom lowers Boom lifts up Extends or retracts inner boom tube When Selector Switch (16) is in TRAM mode: Left track moves forward Left track moves backward Unlocks or locks track oscillation

Move joystick forward Move joystick back Using joystick switch 2. Right Tram/Feed Control Move joystick left Move joystick right Move joystick forward Move joystick back Using rocker switch Move joystick forward Move joystick back Using rocker switch

When Selector Switch (16) is in DRILL mode: Feed swings left Feed swings right Feed tilts forward Feed tilts back Extends or retracts feed When Selector Switch (16) is in TRAM mode: Right track moves forward Right track moves backward Controls track oscillation up & down

3. Feed Force -

Rotate knob clockwise to increase pressure on drill bit.

Rotate knob counterclockwise to decrease pressure

4. Feed Rate -

Used in conjunction with Smart Drill Switch (20) to adjust the speed of the feed advance.

5. Feed - UP/DOWN -

Controls speed and direction of drill feed.

6. Rotation - REVERSE/FORWARD-

Controls speed and direction of drill rotation.

Forward (normal drilling) rotation is counterclockwise as viewed from drill end.

7. Drill - WARM OIL/DRILL -

Place control in WARM OIL mode to warm hydraulic oil before drilling.

DRILL mode controls drill fluid volume.

8. Air- OPEN/CLOSE -

Toggle switch in increments to position air valve from closed to fully open.

9. Reverse Percussion -

Switch ON to provide added power to remove stuck drill steel.

10. Grease - ON/OFF -

Push switch UP to activate drill steel thread greaser when adding a piece of drill steel to the drill string.

11. Water ON/OFF -

Switch turns water ON or OFF. Water flow is then regulated by a separate metering valve (item 23).

Operator Controls

3-9

Drilling & Positioning Controls (non-cab)

Fig. 3-4 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF

Fig. 3-4a Emergency Kill Switch Pull cable to stop engine, push button to reset.

3-10

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

BI006826

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF

Fig. 3-5 Drill Station 23. Water Metering Valve 26. Hammer Pressure Gauge 24. Feed Pressure Gauge 27. Air Pressure Gauge 25. Rotation Pressure Gauge Operator Controls

BI006826

Drilling & Positioning Controls (non-cab) Located Adjacent to Feed

(refer to fig. 3-4)

continued on next page . . .

12. Rod Lock -

Switch UP to UNLOCK and DOWN to LOCK drill rod.

13. Rod Wrench -

Switch UP moves wrench IN and DOWN moves wrench OUT.

14. Carriage -

Switch UP moves carriage IN and DOWN moves carriage OUT.

15. Carriage Lock -

Switch UP to UNLOCK and DOWN to LOCK carriage.

16. Selector Switch DRILL/NEUTRAL/TRAM -

In DRILL mode, all drilling and positioning functions operate.

In TRAM mode, tramming functions ONLY operate.

Place switch in NEUTRAL position for start-up and shutdown.

17. EMERGENCY STOP Button -

Press button to stop engine in case of emergency.

Turn counterclockwise to reset.

18. Centralizer OPEN/CLOSE -

Switch opens and closes centralizer.

19. Pickup Pot UP/DOWN -

Switch raises or lowers pickup pot.

20. Smart Drill ON/OFF -

Switch ON activates automatic drilling.

21. Dust Collector ON/OFF -

Turn dust collector ON when drilling, unless detergent system is used.

22. EMERGENCY KILL SWITCH (fig. 3-4a)

Pull cable above switch to stop engine in case of emergency.

Push button on switch to reset.

See fig. 3-5 for items 23 - 27: 23. Water Metering Valve -

Controls the amount of water injected into the air stream when drilling with the detergent system.

24. Feed Pressure Gauge -

Indicates hydraulic pressure on feed cylinder.

25. Rotation Pressure Gauge -

Indicates hydraulic pressure to drill rotation motor(s).

26. Hammer Pressure Gauge -

Indicates hydraulic pressure to drill inlet.

27. Air Pressure Gauge -

Indicates blowing air pressure.

Operator Controls

3-11

BI006826

Auxiliary Controls

Fig. 3-7 Left Side Access Door 1. Auxiliary Hydraulic Controls (see fig. 3-6) 2. Swing out Electrical Panel.

3. Auxiliary 2 Manifold (see fig. 3-6a)

Fig. 3-6 Auxiliary Controls (located on left side of machine, behind operator's station or cab)

3-12

Drill Hammer

Controls oil flow to the drill.

Left Tram

Operates left track forward or back wards.

Right Tram

Operates right track forward or back wards.

Drill Feed

Controls speed and direction of drill on feed.

Drill Rotation

Controls forward and reverse drill rotation.

Boom Swing

Moves boom right or left.

Boom Lift

Raises or lowers boom.

Feed Dump

Tilts feed forward or backwards.

Feed Swing

Moves feed right or left.

Boom Extend

Extends or retracts inner boom tube.

Feed Extend

Extends or retracts feed.

Operator Controls

BI006826

Auxiliary Controls The auxiliary controls are mounted on the left side of the machine within the enclosure. These controls are not intended to be used for normal drilling or tramming, but are to be used in case of emergency or if a malfunction occurs in the electronic controls.

WARNING DO NOT tram machine up or down slopes with auxiliary tram controls, as track brakes are non-functional.

DO NOT leave brake release valve (item 1, fig. 3-6a) in DOWN position.

When valve handle is in DOWN position, the track brake system is bypassed.

Brake release valve handle MUST BE in UP position for track brakes to hold.

Fig. 3-6a Auxiliary 2 Manifold (located behind electrical panel) 1. Brake Release Valve (shown in UP position) With arrow on valve handle pointing UP, brake system is activated.

With arrow on valve handle pointing DOWN, brake system is bypassed.

Operator Controls

3-13

BI006826

Cab Controls Cab Component Locations

4

7 6 5

Fig. 3-9 Operator's Seat - Behind Right Side 10. Water Metering Valve (for detergent system) 1

2 3

Fig. 3-8 Cab Seat Components 1. Right Tram/Boom Joystick 2. Left Tram/Feed Joystick 3. Feed Control Joystick 4. Left Joystick Control Panel 5. Right Joystick Control Panel 6. Washer Switch 7. Cell Phone Plug

3-14

Fig. 3-10 Drill Lubrication Display (Located on side of RH Control Console)

Operator Controls

BI006826

Cab Controls Cab Instrument Gauge Panel DRILL PRESSURE

FEED PRESSURE

ROTATION PRESSURE

AIR PRESSURE

Fig. 3-11 Drilling Instrument Panel (ref. 438497)

Operator Controls

3-15

BI006826

Cab Controls Cab Overhead Console

1

9

8

3

11

14

0

ISUZU

100 40

3

1/2 220

80

1 2

195 170

280

100

3/4

1/4

F

E

140

DRILL HOUR FUEL

AIR TEMP

2

4

5

6

Fig. 3-12 Overhead Console (ref. 436599 rev. B) 1. Front Drill Lights ON/OFF Switch 6. Drill Hourmeter Gauge 2. Rear Drill Lights ON/OFF Switch 7. LOW/HIGH Idle Switch 3. Dust Collector ON/OFF Switch 8. Glow Plug Indicator 4. Water ON/OFF Switch 9. Engine ON/OFF Switch 5. Air Temperature Gauge 10. Engine ECM Monitor

3-16

7

12 13

10 11. Fuel Gauge 12. AC ON/OPF Switch 13. Cab Temperature Control 14. Fan Control Switch

Operator Controls

BI006826

Cab Controls Cab Overhead Console 1. Front Drill Lights ON/OFF Switch -

Turns on and off front drill lights

2. Rear Drill Lights ON/OFF Switch -

Turns on and off rear drill lights

3. Dust Collector Switch -

Switch UP turns dust collector on. With air ON, dust collector is fully operational, with air OFF, dust collector operates in pulse mode to clean dust collector filters.

4. Water ON/OFF Switch -

Switch ON, turns water on. Use metering valve, located behind operator's seat on the right side (fig. 3-9) to regulate water flow.

5. Air Temperature Gauge -

Measures outside air temperature.

6. Drill Hourmeter -

Totals hours drill is energized.

7. LOW/HIGH Idle Switch -

With switch on LOW, engine idles at 1350 RPM. With switch on HIGH, engine idle at 2350 RPM. Engine should be at low idle for start-up and shutdown. Engine should be at high idle for all drilling and tramming functions.

8. Glow Plug Indicator -

For cold starts, hold ignition switch in cold start position until glow plug indicator glows red. Then start machine.

9. Ignition Switch -

Turn clockwise to activate engine starter. Release switch when engine start.

10. Engine ECM Monitor -

Monitors engine performance and displays engine faults.

11. Fuel Gauge -

Displays amount of fuel in fuel tank.

12. AC ON/OFF Switch -

Switch up turns on the air conditioner.

13. Cab Temperatur Switch -

Controls the air temperature in the cab.

14. Fan Control Switch -

Turns on the fan and controls the volume of air discharged from the fan.

Operator Controls

3-17

BI006826

Cab Controls Cab Right Side Console 3 1

4

2 6

5

7 8

10 STOP

12

9 11

13

Fig. 3-13 Right Side Console 1. Coupling Grease Switch - ON/OFF 2. Pickup Pot Switch - UP/DOWN 3. Air Switch - OPEN/CLOSE 4. Centralizer Switch - OPEN/CLOSE 5. Rotation Control - FORWARD/REVERSE 6. Hammer Control - WARM OIL/DRILL 7. Feed Force Control

3-18

14

8. Feed Rate Control 9. Smart Drill Switch - ON/OFF 10. EMERGENCY STOP BUTTON 11. Rod Changer Switch - ROD CHANGER/SET-UP (DRILL) 12. Selector Switch - DRILL/NEUTRAL/TRAM 13. Oscillation Switch - UP/DOWN 14. Oscillation Lock Switch - LOCK/UNLOCK

Operator Controls

BI006826

Cab Controls Cab Right Side Console 1. Coupling Grease - ON/OFF -

Push switch UP to activate drill steel thread greaser when adding a piece of drill steel to the drill string.

2. Pickup Pot UP/DOWN -

Switch raises or lowers pickup pot.

3. Air - OPEN/CLOSE -

Toggle switch in increments to position air valve from closed to fully open.

4. Centralizer OPEN/CLOSE -

Switch opens and closes centralizer.

5. Rotation - REVERSE/FORWARD -

Controls speed and direction of drill rotation. Forward Rotation (normal drilling) is counterclockwise viewed from drill end.

6. Hammer Control-WARM OIL/DRILL - Place control in WARM OIL mode to warm hydraulic oil before drilling. DRILL mode controls drill fluid volume.

7. Feed Force -

Rotate knob clockwise to increase pressure on drill bit, counterclockwise to decrease pressure.

8. Feed Rate -

Used in conjunction with Smart Drill Switch (9) to adjust the speed of the feed advance.

9. Smart Drill ON/OFF -

Switch ON activates automatic drilling.

10. EMERGENCY STOP Button -

Press button to stop engine in case of emergency. Pull to reset.

11. Rod Changer Switch -

With switch in ROD CHANGER mode, the right tram/boom joystick controls the rod changer functions. With switch in SET UP mode, the right tram/boom joystick controls the boom functions.

12. Selector Switch - DRILL/NEUTRAL/TRAM - In DRILL mode, all drilling and positioning functions operate. In TRAM mode, tramming and positioning functions operate. Place switch in NEUTRAL position for start-up and shutdown.

13. Track Oscillation - UP/DOWN -

With Track Oscillation switch (14) in UNLOCK position, this switch may be used to raise or lower the rear of the machine.

14. Track Oscillation - LOCK/UNLOCK - Place switch in LOCK position for drilling. Place switch in UNLOCK position for tramming. UNLOCK positions allows cylinders to "float", enabling tracks to move up and down according to terrain.

Operator Controls

3-19

BI006826

Cab Controls Joystick - Drill/Tram Controls

Fig. 3-14 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 3-15 Right Joystick Control 5. Right Tram/Boom/Rod Changer Joystick 6. Tram Speed /Boom Extend Button 7. Boom Retract Button 8. Rod Rack Carriage Unlock (Linear Rod Changer Only) 9. Deadband Pedal

Joystick - Drill/Tram Controls 1. Feed Control - UP/DOWN -

Controls direction and speed of drill. Move forward to raise towards top of feed. Move back to lower drill towards centralizer.

2. Left Tram/Feed Control -

When Selector Switch (12) is in DRILL mode and Selector Switch (11) is in SETUP mode: Feed swings left Feed swings right Feed tilts forward Feed tilts back

Move Move Move Move

joystick joystick joystick joystick

left right forward back

3. Feed Extend -

Button extends feed

4. Feed Retract -

Button retracts feed

Linear Rod Changer Move joystick left Move joystick right 3-20

When Selector Switch (11) is in ROD CHANGER mode: Moves rod wrench IN, then clamps drill rod Moves rod wrench OUT, wrench opens, then moves out Operator Controls

BI006826

Cab Controls Joystick - Drill/Tram Controls (cont.)

Carousel Rod Changer Move joystick left Move joystick right

Rotates carousel clockwise (CW) Rotates carousel counterclockwise (CCW)

Move joystick forward Move joystick back

When Selector Switch (12) is in TRAM mode: Left track moves forward Left track moves backward

5. Right Tram/Boom/Rod Rack Control - When Selector Switch (12) is in DRILL mode and Selector Switch (11) is in SETUP mode: Move joystick left Boom swings left Move joystick right Boom swings right Move joystick forward Boom lowers Move joystick back Boom raises When Selector Switch (12) is in TRAM mode: Move joystick forward Right track moves forward Move joystick back Right track moves backward When Selector Switch (11) is in ROD CHANGER mode: Linear Rod Changer Move Move Move Move

joystick joystick joystick joystick

left right forward back

Rod Rod Rod Rod

lock bar LOCKS drill rod lock bar UNLOCKS drill rod rack carriage moves outMove joystick back rack carriage moves in

Carousel Rod Changer Move Move Move Move

joystick joystick joystick joystick

left right forward back

Carousel jaws clamp Carousel jaws unclamp Rod swing out Rod swing in

6. Tram Speed/Boom Extend -

Changes tram speed when in TRAM mode. Push button to change from slow to fast or fast to slow speed.

Extends boom when in DRILL mode.

7. Boom Retract -

Retracts boom when in DRILL mode.

8. Rod Rack Carriage UNLOCK -

Unlocks rod rack carriage when switcwill not operate.h 24 is in ROD CHANGER mode. Press and hold button to unlock carriage.

9. Deadband Pedal -

Depress pedal to activate Left Tram/Feed Control and Right Tram/Boom Control. If pedal is not depressed, functions will not operate.

Operator Controls

3-21

BI006826

Carousel Rod Changer Controls SET-UP MODE

LEFT JOYSTICK FEED DUMP UP

RIGHT JOYSTICK BOOM DOWN

FEED SWING RIGHT

FEED SWING LEFT

BOOM SWING RIGHT

BOOM SWING LEFT BOOM UP

FEED DUMP DOWN

FEED EXTEND

BOOM EXTEND

UP

OUT

DOWN

LEFT JOYSTICK

IN

ROD CHANGER RIGHT JOYSTICK MODE ROD SWING OUT

ROTATE CAROUSEL CW

ROTATE CAROUSEL CCW

JAWS CLAMP

JAWS UNCLAMP

ROD SWING IN

LEFT JOYSTICK FORWARD

LEFT TRACK

REVERSE

TRAM MODE

RIGHT JOYSTICK FORWARD

RIGHT TRACK

REVERSE

FAST / SLOW TRAM

Fig. 3-16 Decal in Cab for Carousel Rod Changer Controls

3-22

Operator Controls

BI006826

Vertical Indicator Description The angular display is connected to the sensor mounted on the feed. There are 10 display lights in each axis (Y+, Y-, X+ and X-). The maximum angle from plumb is + or - 6 degrees, thus each light represents 0.6 degrees. The lights remain lit if the feed is more than 6 degrees from plumb. The lights will go out successively as the feed approaches plumb in each direction.

Vertical Adjustment 1.

Position feed vertical (plumb) and adjust the sensor to indicate plumb (no lights on).

2.

Move feed to non-vertical position, then move back until all lights go out (plumb). Feed should be plumb within + or - 0.6 degrees.

Fig. 3-17 Vertical Indicator

Operator Controls

3-23

Notes

3-24

BI006826

Operator Controls

BI006826

Section 4

Start-up, Shutdown, Tramming and Towing

Start-up & Tramming

4-1

BI006826

Pre-Start Checklist WARNING BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in section 1.

DO NOT attempt lubrication or service while the machine is running.

BE SURE the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts.

General A.

Check underside. Look for broken or loose hoses.

Tighten any loose hose connections and any loose bolts. If dripping fuel, oil or water is evident, do not operate the machine until the leak is found and corrected.

B.

Check all grease points to insure machine is properly lubricated.

C.

Check Battery Disconnect Switch (fig. 4-6). Switch should be in the ON position.

Fig. 4-1 Radiator Overflow Tank 1. Sight Window 2. Fill Cap

Engine, Gearcases and Hydraulic Fluid Types.

A.

Check engine crankcase oil level. Add oil if necessary. Do not mix types of oil. See Section 6 for lubricant types.

B.

Check radiator coolant level (fig. 4-1). Add a 50/ 50 mixture of permanent antifreeze and water if necessary.

C.

Check battery electrolyte level and fill with distilled water if necessary. Check for clean, tight connections.

D.

Check for adequate diesel fuel (fig. 4-2). To avoid restarting problems, do not allow engine to run out of fuel. Drain water from tank prior to starting.

E.

Check oil level in track planetary drive (fig. 4-3).

Add SAE 80W-90 wt. gear oil if required. Oil should run out plug at 3 or 9 o' clock position. Be sure machine is level.

F.

Check V-Belt tension. Belts should deflect 3/8 to 1/2 in. (9.5 to 12.7 mm) maximum.

G.

Check oil level in hydraulic reservoir. Add oil if necessary (fig. 4-4).

4-2

Fig. 4-2 Fuel Tank - viewed from left side of machine.

1. Fuel Fill Cap 2. Fuel Sight Gauge

Fig. 4-3 Track Planetary Drive 1. Oil Fill Plug 2. Oil Level Plug Start-up & Tramming

BI006826

Pre-Start Checklist NOTE

Do not overfill. Do Not Mix Hydraulic Fluid Types. See Section 6 for lubricant types.

Air Compressor A.

Check oil level in compressor when oil is cold.

Level should be to top mark on the measuring rod (fig. 4-5).

Feed and Drill A.

Check for loose drill hose retainers.

B.

Check feed and feed mounting for loose bolts or fittings. Check for any damage.

C.

Chuck - Check for excessive shank side play indicating chuck wear. Grease chuck end cap after shank is inserted (see drill service manual).

D.

Shank - Inspect shank threads often. Badly worn threads can cause tight steel and premature coupling breakage.

E.

Centralizer - Check centralizer alignment with drill shank. Clamp a coupling between the centralizer jaws. Lower the drill so the shank aligns with the coupling. Adjust centralizer as necessary.

F.

Drill Accumulators - Because of Federal regulations, the accumulators on the drill cannot be charged at the factory. Both the high and low pressure accumulators on the drill must be charged before the initial round is drilled and checked periodically thereafter.

Fuel Requirements A.

Always shut off engine before refueling.

B.

Wipe up any fuel spills immediately or fire may result.

C.

Use No. 2-D diesel fuel with a minimum cetane number of 45 and sulfur content not greater than 0.5%. Fuel tank capacity is 80 gallons (303 liters).

Fig. 4-4 Hydraulic Oil Tank - view from right side 1. Hydraulic Oil Level Gauge 2. Hydraulic Oil Temperature Gauge

Fig. 4-5 Air Compressor 1. Oil Dipstick 2. Oil Sight Window

Fig. 4-6 Rear of machine 1. Battery Disconnect Switch Start-up & Tramming

4-3

BI006826

Start-up Procedure (non-cab machine) NOTE

DANGER

If engine fails to start within 10-15 seconds, release start switch. Wait for about one minute and then turn start switch CHECK FOR obstructions before moving feed or machine. again. For cold starts, hold ignition switch in COLD START DO NOT allow any part of the machine to contact or come position until glow plug indicator glows. Glow plug indicator is located to right of instrument panel behind post. Start near electrical power lines.

BE SURE the feed is high enough to clear ground obstacles engine as in step 4. and low enough to clear overhead obstacles when tramming.

5. Check main pump pressure gauge (located adja-

WARNING BEFORE starting machine BE SURE all hydraulic controls 6. are in the off or neutral position.

DO NOT operate the machine unless thoroughly familiar with controls and functions.

WEAR appropriate personal protection equipment (PPE) when on or near the machine.

7.

WEAR noise reducing ear protectors when near the machine for extended periods while the machine is running.

CHECK operation of the brakes before tramming.

REMOVE the drill steel and center the drill over the positioner before tramming over rough terrain.

cent to instrument panel). Hydraulic pump is load sense. Gauge should read about 350 psi (24 bar) with no load. Compensated pressure is about 3000 psi (207 bar).

Observe engine tachometer RPM (4) - Low idle is 1350 RPM. High idle is 2350 RPM. Switch Throttle Switch (2) to HIGH IDLE after machine has warmed up.

Turn compressor Load/Unload valve to LOAD position.

CAUTION DO NOT turn the engine switch back to start when the engine is running.

DO NOT put ether into compressor intake.

DO NOT use ether to start engine equipped with glow plugs.

KEEP the tracks clear of rocks and other debris.

After completing the pre-start checklist, use the following procedure to start the machine: Fig. 4-7 Instrument Panel (located on left side of machine) 1. Turn battery disconnect switch (located at the 1. Ignition Switch rear of the machine) to ON position.

2. Low Oil Pressure Override Switch 2.

3.

4.

4-4

3. Throttle Switch

Be sure all controls are in the OFF or NEUTRAL 4. Engine Tachometer/Hourmeter position.

5. Voltmeter Turn compressor valve (fig. 4-8) to UNLOAD posi- 6. Water Temperature Gauge tion. This allows the engine to turn over without 7. Fuel Gauge 8. Drill Hourmeter the compressor trying to make air at the same 9. Engine Oil Pressure Gauge time.

10. Compressor Air Temp. Gauge

Hold the override switch (2) in the up position. 11. Rear Lights Switch Turn ignition switch (1) to START position. When 12. Front Lights Switch engine starts, release switch to ON position. Release override switch to normal position when engine oil pressure gauge reads 20 psi (1.4 bar).

Start-up & Tramming

BI006826

Start-up Procedure (non-cab machine)

Compressor Valve Positions Fig. 4-8 Compressor Side of Machine–Compressor Load/ Unload Valve

Start-up & Tramming

4-5

Shutdown Procedure (non-cab machine)

BI006826

WARNING DO NOT operate or shutdown the machine with the feed positioned over the operator. Plant (sting) the feed prior to extended shutdowns.

1.

Set feed on ground.

2.

Place all tramming and drilling controls in the OFF or NEUTRAL position.

3.

Switch Drill/Tram switch (fig. 4-9) to TRAM position.

4.

Let engine idle at low speed for about 3 minutes, then turn ignition switch to OFF position.

5.

Turn the battery disconnect switch, located at the rear of the machine to OFF, if machine will be shut down for an extended period, of time. This will prevent excess battery drain.

Fig. 4-9 Electric Control Panel - Tram and Positioning Functions 1. EMERGENCY STOP Button 6. Track Oscillation Switch - LOCK/UNLOCK 2. Power Light 7. Tram Switch - FAST/SLOW 3. Tram Control - LEFT TRACK 8. Selector Switch - DRILL/TRAM 4. Tram Control - RIGHT TRACK 9. Boom Lift Switch - UP/DOWN 5. Track Oscillation Switch - UP/DOWN 10. Boom Swing Switch - RIGHT/LEFT

4-6

Start-up & Tramming

BI006826

Tramming Procedure (non-cab machine) WARNING DO NOT tram machine on steep inclines, or crosswise to grades; this greatly increases risk of machine rollover.

DO NOT tram machine on soft or unstable ground, or close to unsupported excavations.

CAUTION Retract the telescopic boom when tramming over rough ground and during long moves.

1.

Place the Drill/Tram switch (8) in the TRAM position.

2.

Raise feed to clear ground obstacles using the boom lift switch (9).

3.

Track oscillation switch (6) should be in the UNLOCK position for normal tramming and in the LOCKED position for drilling.

NOTE

If you must tram machine on side slopes, keep the operator station on the uphill side of machine and LOCK the track oscillation cylinders.

4.

Use the track oscillation switch (5) to raise or lower the rear of the machine as necessary.

5.

Use tram switch (7) to select FAST or SLOW tram speed. For long distance moves, use FAST position. For careful maneuvering, use SLOW position.

6.

To maneuver the machine use the left and right tram levers (3 & 4). To turn machine in its own tracks (counter rotate), push one lever forward while pulling the other lever back. Pushing both levers forward will move the machine forward, pulling both levers back will move the machine in reverse.

Fig. 4-10 Electric Control Panel Tram and Positioning Functions 1. EMERGENCY STOP Button 2. Power Light 3. Tram Control - LEFT TRACK 4. Tram Control - RIGHT TRACK 5. Track Oscillation Switch - UP/DOWN 6. Track Oscillation Switch - LOCK/UNLOCK 7. Tram Switch - FAST/SLOW 8. Selector Switch - DRILL/TRAM 9. Boom Lift Switch - UP/DOWN 10. Boom Swing Switch - RIGHT/LEFT

Auxiliary Controls If necessary, the machine can be maneuvered, using the auxiliary controls located on the left side of the machine (fig. 4-11). Refer to Section 3 for description of control functions.

Start-up & Tramming

Fig. 4-11 Left Side Access Door 1. Auxiliary Hydraulic Controls.

2. Swing out Electrical Panel.

3. Auxiliary 2 Manifold and brake release valve.

4-7

Start-up Procedure (cab machine) DANGER CHECK FOR obstructions before moving feed or machine.

DO NOT allow any part of the machine to contact or come near electrical power lines.

BE SURE the feed is high enough to clear ground obstacles and low enough to clear overhead obstacles when tramming.

BI006826

NOTE

The override switch in step 4 does not apply to Tier III engine powered machines.

NOTE

If engine fails to start within 10-15 seconds, release start switch. Wait for about one minute and then turn start switch again. For cold starts, hold ignition switch in COLD START position until glow plug indicator glows. Start engine as in step 4.

5.

WARNING BEFORE starting machine BE SURE all hydraulic controls are in the off or neutral position.

DO NOT operate the machine unless thoroughly familiar 6. with controls and functions.

WEAR a protective helmet and eye protection when on or near the machine.

WEAR noise reducing ear protectors when near the machine for extended periods while the machine is running.

7.

CHECK operation of the brakes before tramming.

REMOVE the drill steel and center the drill over the positioner before tramming over rough terrain.

Check main pump pressure gauge (located adjacent to instrument panel). Hydraulic pump is load sense. Gauge should read about 350 psi (24 bar) with no load. Compensated pressure is about 3000 psi (207 bar).

Observe engine tachometer RPM - Low idle is 1350 RPM. High idle is 2350 RPM. Switch high idle switch (7) to ON for high idle after machine has warmed up.

Turn compressor Load/Unload valve to LOAD position.

CAUTION DO NOT turn the engine switch back to start when the engine is running.

DO NOT put ether into compressor intake.

DO NOT use ether to start engine equipped with glow plugs.

KEEP the tracks clear of rocks and other debris.

After completing the pre-start checklist, use the following procedure to start the machine: 1. Turn battery disconnect switch (fig. 4-12) to ON position.

2.

Be sure all controls are in the OFF or NEUTRAL position.

3.

Turn compressor valve (4-14) to UNLOAD position. This allows the engine to turn over without the compressor trying to make air at the same time.

4.

4-8

Fig. 4-12 Rear of machine 1. Battery Disconnect Switch

Hold the override switch (non-Tier III) in the up position. Turn ignition switch to START position. When engine starts, release switch to ON position. Release override switch to normal position.

Start-up & Tramming

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Start-up Procedure (cab machine)

1

9

8

3

11

14

0

ISUZU

100 40

3

1/2 220

80

1 2

195 170

280

100

3/4

1/4

F

E

140

DRILL HOUR FUEL

AIR TEMP

2

4

5

6

Fig. 4-13 Overhead Console (ref. 436599 rev. B) 1. Front Drill Lights ON/OFF Switch 6. Drill Hourmeter Gauge 2. Rear Drill Lights ON/OFF Switch 7. LOW/HIGH Idle Switch 3. Dust Collector ON/OFF Switch 8. Glow Plug Indicator 4. Water ON/OFF Switch 9. Engine ON/OFF Switch 5. Air Temperature Gauge 10. Engine ECM Monitor

7

10

12 13

11. Fuel Gauge 12. AC ON/OPF Switch 13. Cab Temperature Control 14. Fan Control Switch

Compressor Valve Positions Fig. 4-14 Compressor Side of Machine–Compressor Load/Unload Valve

Start-up & Tramming

4-9

Shutdown Procedure (cab machine)

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WARNING BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1.

DO NOT operate or shutdown the machine with the feed positioned over the operator. Plant (sting) the feed prior to extended shutdowns.

1.

Set feed on ground.

2.

Place all tramming and drilling controls in the OFF or NEUTRAL position.

3.

Place selector switch on RH console to NEUTRAL position.

4.

Turn high idle switch OFF. Let engine idle at low speed for about 3 minutes, then turn ignition switch to OFF position.

5.

Turn the battery disconnect switch, located at the rear of the machine to OFF, if machine will be shut down for an extended period, of time. This will prevent excess battery drain.

4-10

Start-up & Tramming

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Tramming Procedure (cab machine) WARNING DO NOT tram machine on steep inclines, or crosswise to grades; this greatly increases risk of machine rollover.

DO NOT tram machine on soft or unstable ground, or close to unsupported excavations.

CAUTION Retract the telescopic boom when tramming over rough ground and during long moves.

3 1

4

2 6

5

7

NOTE

Deadband Pedal must be depressed to activate joystick tramming functions.

8

10 STOP

1.

2.

3.

Place the selector switch (12) in the DRILL position. Raise feed to clear ground obstacles using the left tram/feed joystick or the right tram/boom joystick.

After positioning the feed and boom for tramming, place the selector switch (12) in the TRAM position.

Track oscillation switch (14) should be in the UNLOCK position for normal tramming and in the LOCKED position for drilling.

NOTE

If you must tram machine on side slopes, keep cab on uphill side of machine and LOCK the track oscillation cylinders.

4.

Use the track oscillation switch (13) to raise or lower the rear of the machine as necessary.

5.

Press appropriate button on right hand joystick (see Section 3) to select FAST or SLOW tram speed. For long distance moves, use FAST position. For careful maneuvering, use SLOW position.

6.

To maneuver the machine use the left and right tram joysticks. To turn machine in its own tracks (counter rotate), push one lever forward while pulling the other lever back. Pushing both levers forward will move the machine forward, pulling both levers back will move the machine in reverse.

Start-up & Tramming

12

9 11

13

14

Fig. 4-15 Right Side Console 1. Coupling Grease Switch - ON/OFF 2. Pickup Pot Switch - UP/DOWN 3. Air Switch - OPEN/CLOSE 4. Centralizer Switch - OPEN/CLOSE 5. Rotation Control - FORWARD/REVERSE 6. Hammer Control - WARM OIL/DRILL 7. Feed Force Control 8. Feed Rate Control 9. Smart Drill Switch - ON/OFF 10. EMERGENCY STOP BUTTON 11. Rod Changer Switch - ROD CHANGER/SET-UP (DRILL) 12. Selector Switch - DRILL/NEUTRAL/TRAM 13. Oscillation Switch - UP/DOWN 14. Oscillation Lock Switch - LOCK/UNLOCK

4-11

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Towing Procedure WARNING DO NOT service, perform maintenance or make adjustments while machine is running.

The parking brake is nonfunctional when the gear drive is disengaged for towing.

BE SURE machine is on level ground and secured from movement, via tow bar to pulling vehicle or blocking tracks, prior to disengaging the gear drive and while reengaging the gear drive.

Gear Drive Disconnect Be sure machine is on level ground and secured from Fig. 4-16 Final Drive movement before disengaging the final drive.

1. Plug 1.

Unscrew plug (fig. 4-16) from gear drive cover using an 18 mm hex wrench.

2.

Remove sun gear (fig. 4-17) from gear drive and replace plug.

3.

Repeat procedure for other side.

4.

Machine is now ready to tow. Always use tow bar for towing as the brakes are nonfunctional with the sun gear removed.

5.

After towing, replace sun gear and plug BEFORE disconnecting towbar from towing vehicle.

Fig. 4-17 Final Drive 2. Sun Gear

4-12

Start-up & Tramming

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Section 5

Drilling Procedures

Drilling Procedures

5-1

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Loading Drill Rod (manual rod rack)

Fig. 5-1 Emergency Kill Switch Pull cable to stop engine, push button to reset.

Fig. 5-2 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF 5-2

Fig. 5-1a Automatic Grease Nozzle

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF Drilling Procedures

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Loading Drill Rod (manual rod rack) DANGER:

DO NOT allow any part of the machine to contact or come near power lines.

WARNING:

CHECK for obstructions before moving feed or machine.

KEEP AWAY from moving or rotating parts.

DO NOT wear loose clothing or jewelry that could get caught in moving or rotating parts.

CAUTION:

APPLY adequate lubricant to all couplings and drill rod before loading into rod rack.

Drill shank must align with centerline of centralizer.

Always stay within reach of EMERGENCY STOP button or KILL SWITCH cable (fig's. 5-1 and 5-2).

PUSH EMERGENCY STOP button or PULL KILL SWITCH CABLE to stop machine in emergency.

1.

Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean.

2.

Grease threads with coupling grease on upper end of drill rod and install coupling. With feed in vertical position, load drill rod with coupling into rod rack (up to four pieces of drill rod may be loaded). Make sure each piece of drill rod has a coupling on the upper end.

3.

Using Feed DOWN (5) position drill shank just above centralizer jaws. Adjust centralizer if necessary so it is aligned with drill shank. Position drill shank threads adjacent to auto grease nozzle (fig. 5-1a) and activate Coupling Grease Switch (10) to lubricate drill shank threads.

4.

Using Feed UP (5), Run drill up feed, higher than drill rod section.

5.

Remove a section of drill rod from rod rack and position drill rod under drill shank.

6.

Using Rotation FORWARD (6), start slow forward (counterclockwise) rotation on drill.

7.

Using Feed DOWN (5), slowly bring drill down so the shank will contact the coupling and thread itself into the coupling. Use extreme caution when working around rotating parts. Do not wear loose clothing or jewelry that could get caught in rotating parts.

7.

Stop rotation and raise drill and rod slightly.

8.

Using Centralizer Switch (18), open centralizer.

9.

Position drill rod threads adjacent to auto grease nozzle (fig. 5-1a) and activate Coupling Grease Switch (10) to lubricate threads and install drill bit.

10. Lower drill and rod until bit clears through centralizer.

11. Close centralizer around drill rod and you are ready to drill.

Drilling Procedures

5-3

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Drill Positioning (non-cab machine) WARNING:

READ and understand the warnings and cautions listed in Section 1 before attempting to operate or service this machine.

1.

Lock track oscillation cylinders using switch on tram panel or depress rocker switch on left tram/ boom control joystick (1).

2.

Use the boom (1) and feed (2) controls to locate feed at desired drilling angle and position.

3.

After desired angle is reached, extend feed to ground, using rocker switch on Feed Control (2).

4.

Firmly plant (sting) feed stinger in ground using the Feed Control (2) rocker switch to extend the feed.

Apply enough force to lift the front of the tracks off the ground slightly.

Fig. 5-2 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF

5-4

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF

Drilling Procedures

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Collaring the Hole (non-cab machine) WARNING:

KEEP all non-essential personnel away from the hole and machinery while drilling is in progress.

DO NOT re-drill a hole that has contained explosives.

DO NOT strike drill rod to dislodge it while drill is operating.

Fragmentation of the drill rod may result.

BE SURE the drill rod coupling does not unthread from both drill rod and shank. Be alert to avoid coupling should it fall free.

CAUTION:

WORN THREADS on the drill string can cause premature wear and breakage to new parts mated with the drill string.

USE sharp bits. Check for broken or loose carbides. Dull bits can cause stress in drill components.

APPLY adequate lubricant to all couplings and drill rod threads before loading.

CHECK rock conditions before operating drill rotation and feed at full throttle. Over feeding and over rotation can cause breakage of drill rotation parts and drill string.

Place DRILL CONTROL LEVER in WARM OIL position before starting to drill. Drill will not operate when oil is cold. Leave control in WARM OIL position for a few minutes until oil is warm.

Collaring the Hole

It is not normally possible to immediately start drilling a new hole at full rotation and feed pressure. At full power the bit will tend to jump around enlarging the hole and possibly changing the sting location and angle. Collaring allows accurate drilling by eliminating bit jumping. Initial drilling is performed at low rotation and feed pressure until the hole is deep enough so that the bit is guided by the hole. Hole depth should be about 3 in. (8 cm) deep in solid rock.

1.

Turn Dust Collector switch (21) to ON position or turn Water switch (11) ON and adjust metering valve to regulate water flow if using detergent system.

2.

Slowly start forward drill rotation by placing Rotation control (6) in FORWARD position about 1/2 way.

3.

Slowly engage Feed DOWN (5) to lower drill. Stop when bit contacts ground.

4.

Position Air switch (8) so blowing air is about 1/2 way open. Place Drill Control lever (7) in DRILL mode after oil has warmed up. Apply some feed pressure, using Feed DOWN (5) to collar the hole.

Stay in "collaring" mode until the hole is about 3 in. (76.2mm) deep in solid rock .

Drilling Procedures

5-5

Drilling Practices

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Here are some tips for top drilling performance.

Collaring The collar of the drill hole will directly determine the quality of the hole.

Hole Deviation The major cause of drill steel breakage is deviation of the drill hole. There is very little tolerance in the drill string for any deviation, due to the high energy output of the rock drill.

Feed Pressure "Under-feeding" is a particularly common and bad practice. Feed pressure must be kept to the bit at all times while drilling. "Free-hammering" (hammering with no load on the bit) and "under-feeding" will shorten the drill string life and the hammer seals.

Drill Pressures Feed and hammer pressures and rotation flow can and should be adjusted to suit different rock conditions. Optimum settings are reached when the maximum penetration rate is achieved with minimal heat and vibration being generated through the drill string. Incorrect drill pressure settings can be directly related to hole deviation and drill string damage and breakage.

Adjusting Drill Pressure and Monitoring the Machine The operator should attempt to maintain a 600 to a maximum of 1000 PSI (41 to 69 bar) differential between feed and hammer pressures. The reason for this is to ensure smooth drilling and maximize penetration rate by • Minimizing heat in the drill string • Eliminating "under and over feeding" • Minimizing rotation pressure Rotation flow should be increased in softer rock and decreased in harder rock as indicated by the penetration rate.

Monitoring of the machine is critical at all times. Monitoring of the machine gauges is especially critical for those unfamiliar with the drill. Increases in air and /or rotation pressures indicate developing blockage and / or jamming situations.

Plugged Bit and Stuck Drill Steel Always be alert of air and cuttings coming out of the hole, if not STOP DRILLING. If bit becomes plugged. When blowing air is stopped by a plugged bit, the drill string can become stuck quickly. Work the bit up and down the hole with hammer and rotation on until air and cuttings can be seen coming out of the hole. If bit remains plugged, raise bit out of hole and place bit against solid rock or hard wood and turn hammer on in short bursts with air on to dislodge obstruction. If bit still remains plugged, shut down machine and relieve all air pressure before removing bit. Clear bit manually and reinstall.

If drill steel becomes stuck, use the reverse percussion option (if equipped) to "hammer out" of the hole. If machine is not equipped with this option, use the feed override lever to apply extra reverse feed pressure. Work the drill string up and down using slow rotation speed with blowing air on until it is free.

Using the "smart drill" option (if equipped) will help prevent stuck steel due to bad ground. Refer to "smart drill" system operation in this section.

5-6

Drilling Procedures

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Drilling Practices

System Gauge Readings for Clay or Soft Ground.

Clay or soft ground may need lower feed pressure. To maintain the correct differential pressure between feed and hammer pressure, and to avoid shortened hammer seal and consumable life, the hammer pressure needs to lowered accordingly.

System Gauge Readings for Solid Rock.

To maximize penetration rate in solid rock, higher hammer pressure is required. To maintain the correct differential between hammer and feed pressures, and to prevent "under-feeding", the feed pressure needs to be raised accordingly.

Drilling Procedures

5-7

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Manual Drilling (non-cab machine)

Fig. 5-2 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF

Fig. 23.

24.

25.

5-8

5-2a Drill Station Water Metering Valve Feed Pressure Gauge Rotation Pressure Gauge

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF

26. Hammer Pressure Gauge 27. Air Pressure Gauge

Drilling Procedures

BI006826

Manual Drilling (non-cab machine) 1.

Once hole is collared, move Air Switch (8) to fully OPEN position.

2.

Place Rotation Control (6) to full FORWARD position.

3.

Maintain proper feed pressure. If rod starts to bow, you are using too much feed pressure. If drill starts to bounce, or excessive heating in coupling is evident, you are not using enough. Use Feed Force knob (3) to adjust feed pressure.

WARNING:

ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit.

NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury.

•

If air and cuttings stop coming out of the hole, the bit is becoming plugged and must be pulled back immediately. When the blowing air is stopped by a plugged bit, the bit and drill rod can become stuck very quickly.

•

Work the bit up and down with the drill and rotation ON until cuttings can be seen coming from the hole.

•

If the bit cannot be cleared, the drill rod and bit must be pulled out of the hole.

Try placing bit on solid rock or hard wood and turn drill ON to clear bit. If bit remains plugged, you will have to shut down the machine and let the air pressure bleed off and then remove bit and manually unclog bit and or drill rod.

•

If the downward movement of the drill rod increases suddenly, this may mean that the bit has drilled into a void, crack or some soft material. Use Feed Control (5) to slow down the forward travel of the bit.

•

If the rotation begins to slow down or stops, the bit must be pulled back immediately. Reduce the feed speed to drill through broken ground.

•

If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.

NOTE Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole.

Shut off dust collector if water is coming out of the hole. This will plug the dust collector filters. Turn dust collector on after water stops coming out of the hole.

It may be necessary to remove the dust collector hose from the pickup pot to avoid clogging the hose with mud. Connect the hose when dry drilling resumes.

4.

As drill rod coupling approaches centralizer, the centralizer must be opened to allow the coupling to pass through.

5.

When drilling cycle is complete, turn off feed, hammer, rotation and air. If required, add another piece of drill rod (described in detail, following) and continue drilling or raise drill up until bit clears the hole and move to next hole.

Drilling Procedures

5-9

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Auxiliary Air Option WARNING:

ALWAYS install a safety chain to the auxiliary air connection.

Make sure safety chain is secured to end of auxiliary air hose and to machine inlet connection.

The R20 is equipped with auxiliary air connections at the rear of the machine (fig. 5-2b).

If you are drilling large diameter holes or deep holes that require extra air for hole cleaning, you may add an outside air supply to the auxiliary air IN line (item 1, fig. 5-2b). Be sure when connecting the auxiliary air line that you attach a safety chain to the hose end and to the machine.

You may also connect an air line to the air supply OUT line (item 2, fig. 5-2b) to power air tools or blowing air.

Fig. 5-2b Auxiliary Air Connections 1. Auxiliary Air IN 2. Air Supply OUT Fig. 5-2 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF 12. Rod Lock - LOCK/UNLOCK 13. Rod Wrench - IN/OUT 14. Carriage - IN/OUT 15. Carriage - LOCK/UNLOCK 16. Function Selector Switch DRILL/NEUTRAL/TRAM 17. EMERGENCY STOP BUTTON 18. Centralizer Switch - OPEN/CLOSE 19. Pickup Pot Switch - UP/DOWN 20. Smart Drill Switch - ON/OFF 21. Dust Collector Switch - ON/OFF 5-10

Drilling Procedures

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Smart Drill Feature (non-cab machine) General Description

The "Smart Drill" feature allows for assisted drill control. The system senses rotation and air pressure changes and automatically adjusts feed force and hammer power output. It operates as an anti-jam system and greatly reduces the possibility of stuck drill rod. If the bit becomes plugged, the air pressure rises and reduces hammer pressure and reverses the direction of the feed. If the drill rotation slows, rotation pressure rises which sends a signal to the feed. The feed force is then adjusted accordingly until normal drill rotation resumes. This system greatly enhances drilling efficiency and reduces operator error. The driller can override the "Smart Drill" system by turning off the smart drill switch (20) and manually adjusting the feed force control (3).

Operation Begin drilling the same as you would for manual drilling as described previously.

1.

Once hole is collared, move Air Switch (8) to fully OPEN position.

2.

Place Rotation Control (6) to full FORWARD position.

3.

Turn Smart Drill Switch (20) ON.

WARNING:

ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit.

NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury.

•

If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.

NOTE Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole.

Shut off dust collector if water is coming out of the hole. This will plug the dust collector filters. Turn dust collector on after water stops coming out of the hole.

It may be necessary to remove the dust collector hose from the pickup pot to avoid clogging the hose with mud. Connect the hose when dry drilling resumes.

4.

As drill rod coupling approaches centralizer, the centralizer must be opened to allow the coupling to pass through.

5.

When the drilling cycle is completed, turn off feed, hammer, rotation and air. If required, add another piece of drill rod (described in detail, following) and continue drilling or raise drill up until bit clears the hole and move to next hole.

Drilling Procedures

5-11

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Adding and Removing Drill Rod WARNING:

BEFORE attempting to operate or service this machine, read the warnings and cautions listed in Section 1.

DO NOT strike drill rod to dislodge it while the drill is operating. Fragmentation of the drill rod may occur, resulting in personal injury or property damage.

BE SURE the drill rod coupling does not unthread from both the drill rod and drill shank. Be alert to avoid coupling should it fall free.

NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury.

ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit.

Fig. 5-2 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF

5-12

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF

Drilling Procedures

BI006826

Adding Drill Rod (manual rod rack) CAUTION:

USE sharp bits. Periodically check for broken or loose carbides.

Excessively worn threads on drill string can cause premature wear and breakage to new parts mated with the drill string.

DO NOT run drill in free oscillation mode (no feed pressure on drill) for extended periods of time.

After the first length of rod has been drilled to depth (coupling and drill shank is within the centralizer jaws): 1.

Stop Drilling. Place drill controls (feed, drill and rotation) in OFF position.

2.

With full blowing air and forward rotation ON, run the drill up and down full length of the feed to prevent stuck rod due to loose material above bit.

3.

Stop feed and rotation. Position bit just slightly above the bottom of the hole.

4.

Turn dust control system OFF. If using a dust collector, leave Dust Collector Switch (21) in ON mode to purge the filters of dust.

5.

Turn Drill Control (7) on and off in short bursts until rod is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the rod can be noted by change in sound in the drill string, and air escaping from around coupling threads.

6.

Close centralizer around the drill rod coupling, using Centralizer Switch (18).

7.

Turn blowing air OFF, by placing Air Switch (8) in CLOSE position. When blowing air is turned off, the air is diverted to the dust collector pulse valves to clean the filters.

8.

Use reverse rotation to unthread drill shank from coupling, while using the Feed UP (5) to raise the drill. When drill shank threads are aligned with thread grease nozzle, activate Coupling Grease Switch (10) to grease threads. Then run drill to top of feed.

9.

Add another length of rod and coupling, partially screwing the rod into the lower coupling.

Activate Coupling Grease Switch (10) to grease threads on lower end of drill rod.

10. Slowly start forward (counterclockwise) rotation and slowly lower drill shank into upper coupling. Continue rotation and feed until both couplings are tight.

11. Open centralizer, turn on blowing air and dust suppression. Adjust drilling controls to same settings used when drilling with first length of rod.

12. Close centralizer as soon as coupling has passed through. If slight bowing causes misalignment with centralizer, reduce feed pressure while closing centralizer.

13. Continue drilling to desired depth. Add more drill rod if necessary.

Drilling Procedures

5-13

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Removing Drill Rod (manual rod rack) WARNING:

CHECK for obstructions before moving feed or machine.

KEEP AWAY from moving or rotating parts.

DO NOT wear loose clothing or jewelry that could get caught in moving or rotating parts.

BE SURE the drill rod coupling does not unthread from both the drill rod and drill shank. Be alert to avoid coupling should it fall free.

When desired hole depth has been reached: (Coupling and shank are within centralizer jaws) 1.

Stop drilling, open centralizer. Place Drill Control (7) in the OFF position. With rotation and full blowing air turned ON, run the drill up and down the full length of the feed to prevent stuck rod due to loose material above the bit. Leave the bit at the bottom of the hole.

NOTE Use reverse percussion (if so equipped) to help remove stuck drill rod. If not

equipped with reverse percussion, place Drill Control in DRILL mode while feeding upward. Do not run drill in free oscillation mode (no feed pressure on hammer) for extended periods of time to prevent damage to the drill.

5-14

2.

Open and close Drill Control in short bursts until rod is loose. Use some reverse (clockwise) drill rotation and light pressure if necessary. Loosening of the rod can be noted by a change in sound in the drill string and air escaping from around the coupling threads.

3.

Turn blowing air OFF, by switching Air Switch (8) to CLOSE.

4.

Close centralizer on coupling (drill shank end of rod).

5.

Partially unscrew the drill shank from the coupling. Using both Feed Control UP (5) and Rotation Control REVERSE (6). Leave enough shank thread in the coupling so that the drill string will not fall off the shank when raising the drill up!

6.

Open centralizer. Using Feed Control (5), raise the drill string up the feed until the lower coupling is positioned within the centralizer.

7.

Close centralizer on the coupling. Place Feed Control (5) in the OFF (NEUTRAL) position. Be sure to leave the centralizer clamped! Once the drill is free from the coupling the drill string can be lost down the hole if the centralizer is opened.

Drilling Procedures

BI006826

Removing Drill Rod (manual rod rack) WARNING:

BE ALERT for falling coupling.

Be careful that upper coupling does not totally unthread from drill shank and drill rod.

8.

SLOWLY unscrew drill shank out of the upper coupling, and the rod out of the lower coupling, using Rotation REVERSE (6) and Feed UP (5). Watch upper coupling to be sure it does not totally unthread from the drill shank and drill rod! Stop rotation and finish unscrewing the rod from the lower coupling by hand. Place rod with upper coupling attached in rod rack.

9.

Advance the drill to the centralizer, using Feed Control DOWN (5), and partially engage the drill shank into the coupling held in the centralizer. Engage sufficient thread to prevent dropping the drill string.

10. Open centralizer and raise drill until next coupling is centered within the centralizer jaws. Close centralizer around coupling.

11. Repeat process to remove subsequent lengths of rod.

Fig. 5-2 Drill Control Panel 1. Left Tram/Boom Control 2. Right Tram/Feed Control 3. Feed Force Control 4. Feed Rate Control 5. Feed - UP/DOWN 6. Rotation - REVERSE/FORWARD 7. Drill - WARM OIL/DRILL 8. Air Switch - OPEN/CLOSE 9. Reverse Percussion Switch - ON/OFF 10. Coupling Grease Switch 11. Water Switch - ON/OFF

Drilling Procedures

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Rod Lock - LOCK/UNLOCK Rod Wrench - IN/OUT Carriage - IN/OUT Carriage - LOCK/UNLOCK Function Selector Switch - DRILL/NEUTRAL/TRAM EMERGENCY STOP BUTTON Centralizer Switch - OPEN/CLOSE Pickup Pot Switch - UP/DOWN Smart Drill Switch - ON/OFF Dust Collector Switch - ON/OFF

5-15

Linear Rod Changer (cab machine)

BI006826

Fig. 5-3 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button Fig. 5-4 Right Joystick and Console Controls 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Centralizer Switch - OPEN/CLOSE 10. Hammer Control - WARM OIL/DRILL 11. Rotation Control - FORWARD/REVERSE 12. Selector Switch - DRILL/NEUTRAL/TRAM 13. Rod Changer Switch - ROD CHANGER/SET-UP (DRILL)

5-16

Drilling Procedures

BI006826

Linear Rod Changer (cab machine) Loading Drill Rod WARNING

ALWAYS check for obstructions before moving feed or machine.

DO NOT allow any part of the machine to contact or come near electrical power lines.

CAUTION

Apply adequate lubricant to all couplings and drill rod threads before loading.

NOTE Three people are required to perform this procedure; one operator and two people loading drill rod.

1.

Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean.

2.

Grease threads with coupling grease on upper end of drill rod and install coupling. Make sure each piece of drill rod has a coupling on the upper end.

3.

Select DRILL position with switch (12). Select ROD CHANGER position with switch (13).

4.

Push lower left button (7) on right joystick to UNLOCK rod rack carriage. Move right joystick FORWARD to move carriage to OUT position. Use feed lever (1) run drill to bottom of feed so drill shank is positioned just above centralizer. Be sure drill shank is aligned with centralizer when it is closed, if not adjust centralizer for correct alignment. Open centralizer jaws.

5.

Tilt the feed to a suitable angle which will allow insertion of drill rod through dust collector pick-up pot and be able to align with the drill shank.

6.

Open the centralizer (9) and position drill rod through dust collector pickup pot and hold in alignment with the shank.

7.

Use forward (counterclockwise) rotation (11) to thread the shank into the coupling.

8.

Raise the drill and rod so coupling is above the rod wrench and close the centralizer.

9.

Move left joystick LEFT to swing wrench IN and clamp the drill rod. Move joystick slightly to right to open the wrench so it is not clamped on the drill rod. The wrench is now in the "guide" position for the drill rod. Continue to raise the drill up towards the top of the feed so the top coupling is above the upper rack.

Drilling Procedures

5-17

Linear Rod Changer (cab machine)

BI006826

Fig. 5-3 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button Fig. 5-4 Right Joystick and Console Controls 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Centralizer Switch - OPEN/CLOSE 10. Hammer Control - WARM OIL/DRILL 11. Rotation Control - FORWARD/REVERSE 12. Selector Switch - DRILL/NEUTRAL/TRAM 13. Rod Changer Switch - ROD CHANGER/SET-UP (DRILL)

5-18

Drilling Procedures

BI006826

Linear Rod Changer (cab machine) Loading Drill Rod (cont.)

10. Press and hold button (7) to UNLOCK rod rack carriage. Move right joystick BACK to move rod carriage IN towards feed. Position rod rack so drill rod is aligned with the outermost socket (farthest from the feed). Release button (7) lock pin will lock into next position.

11. Using the feed lever (1) lower the drill rod until the coupling is level with the upper rod rack.

12. Move the right joystick to LEFT to LOCK drill rod. This pulls the rod lock bar to lock on the coupling.

Slowly reverse the rotation and raise the drill to unthread the shank from the coupling.

13. Move left joystick RIGHT to unclamp and swing rod wrench OUT. 14. Press and hold lower left button (7) to UNLOCK carriage. Move right joystick FORWARD to move rod rack carriage OUT. 15. Using feed lever (1), run drill down the feed and repeat steps 5 -13 until all drill rod is loaded in rod rack.

16. Leave the last rod coupled to the drill. Grease the threads and install drill bit.

Drilling Procedures

5-19

Carousel Rod Changer (cab machine)

BI006826

Fig. 5-3 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button Fig. 5-4 Right Joystick and Console Controls 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Centralizer Switch - OPEN/CLOSE 10. Hammer Control - WARM OIL/DRILL 11. Rotation Control - FORWARD/REVERSE 12. Selector Switch - DRILL/NEUTRAL/TRAM 13. Rod Changer Switch - ROD CHANGER/SET-UP (DRILL)

5-20

Drilling Procedures

BI006826

Carousel Rod Changer (cab machine) Loading Drill Rod WARNING

ALWAYS check for obstructions before moving feed or machine.

DO NOT allow any part of the machine to contact or come near electrical power lines.

CAUTION

Apply adequate lubricant to all couplings and drill rod threads before loading.

NOTE Three people are required to perform this procedure; one operator and two people loading drill rod.

1.

Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean.

2.

Grease threads with coupling grease on upper end of drill rod and install coupling. Make sure each piece of drill rod has a coupling on the upper end.

3.

Select DRILL position with switch (12). Select ROD CHANGER position with switch (13).

4.

Move right joystick FORWARD to swing jaws OUT. Use feed lever (1) run drill to bottom of feed so drill shank is positioned just above centralizer. Be sure drill shank is aligned with centralizer when it is closed, if not adjust centralizer for correct alignment. Open centralizer jaws.

5.

Tilt the feed to a suitable angle which will allow insertion of drill rod through dust collector pick-up pot and be able to align with the drill shank.

6.

Open the centralizer (9) and position drill rod through dust collector pickup pot and hold in alignment with the shank.

7.

Use forward (counterclockwise) rotation (11) to thread the shank into the coupling.

8.

Raise the drill and rod so coupling is above the centralizer and close the centralizer.

9.

Continue to raise drill and rod until top coupling is just below the top carousel can.

10. Move right joystick back to swing jaws IN and then move left to clamp the drill rod.

Drilling Procedures

5-21

BI006826

Carousel Rod Changer (cab machine)

Fig. 5-3 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button Fig. 5-4 Right Joystick and Console Controls 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Centralizer Switch - OPEN/CLOSE 10. Hammer Control - WARM OIL/DRILL 11. Rotation Control - FORWARD/REVERSE 12. Selector Switch - DRILL/NEUTRAL/TRAM 13. Rod Changer Switch - ROD CHANGER/SET-UP (DRILL)

5-22

Drilling Procedures

BI006826

Carousel Rod Changer (cab machine) Loading Drill Rod (cont.)

11. Move left joystick RIGHT until carousel stops turning momentarily.

12.

Slowly reverse the rotation and raise the drill to unthread the shank from the coupling.

13. Push the right joystick FORWARD and swing rod into carousel.

14. Using feed lever (1), run drill down the feed and repeat steps 5 -13 until all drill rod is loaded in the carousel.

15. Leave the last rod coupled to the drill. Grease the threads and install drill bit.

Drilling Procedures

5-23

BI006826

Manual Drilling (cab machine) Fig. 5-5 Overhead Console 1. Front Drill Lights ON/OFF Switch 2. Rear Drill Lights ON/OFF Switch 3. Dust Collector ON/OFF Switch 4. Water ON/OFF Switch 5. Air Temperature Gauge 6. Drill Hourmeter Gauge 7. LOW/HIGH Idle Switch 8. Glow Plug Indicator 9. Engine ON/OFF Switch 10. Engine ECM Monitor 11. Fuel Gauge

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE 5-24

14. Hammer Control - WARM OIL/DRILL 15. Feed Force Control 16. Feed Rate Control 17. Smart Drill Switch - ON/OFF 18. EMERGENCY STOP BUTTON 19. Rod Changer Switch - ROD CHANGER/SET-UP 20. Selector Switch - DRILL/NEUTRAL/TRAM 21. Oscillation Switch - UP/DOWN 22. Oscillation Lock Switch - LOCK/UNLOCK Drilling Procedures

BI006826

Manual Drilling (cab machine) WARNING:

KEEP all non-essential personnel away from the hole and machinery while drilling is in progress.

DO NOT re-drill a hole that has contained explosives.

DO NOT strike drill rod to dislodge it while drill is operating.

Fragmentation of the drill rod may result.

CAUTION:

WORN THREADS on the drill string can cause premature wear and breakage to new parts mated with the drill string.

USE sharp bits. Check for broken or loose carbides. Dull bits can cause stress in drill components.

APPLY adequate lubricant to all couplings and drill rod threads before loading.

CHECK rock conditions before operating drill rotation and feed at full throttle. Over feeding and over rotation can cause breakage of drill rotation parts and drill string.

Place HAMMER CONTROL (14) in WARM OIL position before starting to drill. Drill will not operate when oil is cold. Leave control in WARM OIL position for a few minutes until oil is warm.

Collaring the Hole It is not normally possible to immediately start drilling a new hole at full rotation and feed pressure. At full power the bit will tend to jump around enlarging the hole and possibly changing the sting location and angle. Collaring allows accurate drilling by eliminating bit jumping. Initial drilling is performed at low rotation and feed pressure until the hole is deep enough so that the bit is guided by the hole. Hole depth should be about 3 in. (76.2mm) deep in solid rock.

1.

Turn dust collector switch (3, fig. 5-5) to ON position or turn water switch (4, fig. 5-5) ON and adjust metering valve (behind seat) to regulate water flow if using detergent system.

2.

Slowly start forward drill rotation by placing rotation control (13, fig. 5-7) in FORWARD position about 1/2 way.

3.

Slowly engage feed DOWN (1, fig. 5-6) to lower drill. Stop when bit contacts ground.

4.

Position air switch (11, fig. 5-7) so blowing air is about 1/2 way open. Place hammer control (14, fig.

5-7) in DRILL mode after oil has warmed up. Apply some feed pressure, using feed DOWN (1, fig. 56) to collar the hole. Stay in "collaring" mode until the hole is about 3 in. (76.2mm) deep in solid rock.

Drilling Procedures

5-25

BI006826

Manual Drilling (cab machine) Fig. 5-5 Overhead Console 1. Front Drill Lights ON/OFF Switch 2. Rear Drill Lights ON/OFF Switch 3. Dust Collector ON/OFF Switch 4. Water ON/OFF Switch 5. Air Temperature Gauge 6. Drill Hourmeter Gauge 7. LOW/HIGH Idle Switch 8. Glow Plug Indicator 9. Engine ON/OFF Switch 10. Engine ECM Monitor 11. Fuel Gauge

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE 5-26

14. Hammer Control - WARM OIL/DRILL 15. Feed Force Control 16. Feed Rate Control 17. Smart Drill Switch - ON/OFF 18. EMERGENCY STOP BUTTON 19. Rod Changer Switch - ROD CHANGER/SET-UP 20. Selector Switch - DRILL/NEUTRAL/TRAM 21. Oscillation Switch - UP/DOWN 22. Oscillation Lock Switch - LOCK/UNLOCK Drilling Procedures

BI006826

Manual Drilling (cab machine) 1.

Once hole is collared, move air switch (11, fig. 5-7) to fully OPEN position.

2.

Place rotation control (13, fig. 5-7) to full FORWARD position.

3.

Maintain proper feed pressure. If rod starts to bow, you are using too much feed pressure. If drill starts to bounce, or excessive heating in coupling is evident, you are not using enough. Use feed force control (15, fig. 5-7) to adjust feed pressure.

WARNING

ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit.

NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury.

•

If air and cuttings stop coming out of the hole, the bit is becoming plugged and must be pulled back immediately. When the blowing air is stopped by a plugged bit, the bit and drill rod can become stuck very quickly.

•

Work the bit up and down with the drill and rotation ON until cuttings can be seen coming from the hole.

•

If the bit cannot be cleared, the drill rod and bit must be pulled out of the hole.

Try placing bit on solid rock or hard wood and place hammer lever (14, fig. 5-7) in DRILL mode to clear bit. If bit remains plugged, you will have to shut down the machine and let the air pressure bleed off and then remove bit and manually unclog bit and or drill rod.

•

If the downward movement of the drill rod increases suddenly, this may mean that the bit has drilled into a void, crack or some soft material. Use feed lever (1, fig. 5-6) to slow down the forward travel of the bit.

•

If the rotation begins to slow down or stops, the bit must be pulled back immediately. Reduce the feed speed to drill through broken ground.

•

If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.

NOTE Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole.

Shut off dust collector if water is coming out of the hole. This will plug the dust collector filters. Turn dust collector on after water stops coming out of the hole.

It may be necessary to remove the dust collector hose from the pickup pot to avoid clogging the hose with mud. Connect the hose when dry drilling resumes.

4.

As drill rod coupling approaches centralizer, open centralizer (12, fig. 5-7) to allow the coupling to pass through.

5.

When drilling cycle is complete, turn off feed, hammer, rotation and air. If required, add another piece of drill rod (described in detail, following) and continue drilling or raise drill up until bit clears the hole and move to next hole.

NOTE If extra air is needed for drilling large diameter or deep holes, you may add an auxiliary air source. See "Auxiliary Air Option" in this section.

Drilling Procedures

5-27

BI006826

Smart Drill Feature (cab machine) Fig. 5-5 Overhead Console 1. Front Drill Lights ON/OFF Switch 2. Rear Drill Lights ON/OFF Switch 3. Dust Collector ON/OFF Switch 4. Water ON/OFF Switch 5. Air Temperature Gauge 6. Drill Hourmeter Gauge 7. LOW/HIGH Idle Switch 8. Glow Plug Indicator 9. Engine ON/OFF Switch 10. Engine ECM Monitor 11. Fuel Gauge

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE 5-28

14. Hammer Control - WARM OIL/DRILL 15. Feed Force Control 16. Feed Rate Control 17. Smart Drill Switch - ON/OFF 18. EMERGENCY STOP BUTTON 19. Rod Changer Switch - ROD CHANGER/SET-UP 20. Selector Switch - DRILL/NEUTRAL/TRAM 21. Oscillation Switch - UP/DOWN 22. Oscillation Lock Switch - LOCK/UNLOCK Drilling Procedures

BI006826

Smart Drill Feature (cab machine) General Description

The "Smart Drill" feature allows for assisted drill control. The system senses rotation and air pressure changes and automatically adjusts feed force and hammer power output. It operates as an anti-jam system and greatly reduces the possibility of stuck drill rod. If the bit becomes plugged, the air pressure rises and shuts off the hammer and reverses the direction of the feed. If the drill rotation slows, rotation pressure rises which sends a signal to the feed. The feed force is then adjusted accordingly until normal drill rotation resumes. This system greatly enhances drilling efficiency and reduces operator error. The driller can override the "Smart Drill" system by turning off the smart drill switch (17, fig. 5-7) and manually adjusting the feed force control (15, fig. 5-7).

Operation Begin drilling the same as you would for manual drilling as described previously.

1.

Once hole is collared, move air switch (11, fig. 5-7) to fully OPEN position.

2.

Place rotation control (13, fig. 5-7) in full FORWARD position.

3.

Turn smart drill switch (17, fig. 5-7) ON.

WARNING:

ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit.

NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury.

•

If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.

NOTE Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole.

Shut off dust collector if water is coming out of the hole. This will plug the dust collector filters. Turn dust collector on after water stops coming out of the hole.

4.

As drill rod coupling approaches centralizer, the centralizer must be opened to allow the coupling to pass through.

5.

When the drilling cycle is completed, turn off feed, hammer, rotation and air. If required, add another piece of drill rod (described in detail, following) and continue drilling or raise drill up until bit clears the hole and move to next hole.

Drilling Procedures

5-29

BI006826

Linear Rod Changer (cab machine) Fig. 5-5 Overhead Console 1. Front Drill Lights ON/OFF Switch 2. Rear Drill Lights ON/OFF Switch 3. Dust Collector ON/OFF Switch 4. Water ON/OFF Switch 5. Air Temperature Gauge 6. Drill Hourmeter Gauge 7. LOW/HIGH Idle Switch 8. Glow Plug Indicator 9. Engine ON/OFF Switch 10. Engine ECM Monitor 11. Fuel Gauge

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE 5-30

14. Hammer Control - WARM OIL/DRILL 15. Feed Force Control 16. Feed Rate Control 17. Smart Drill Switch - ON/OFF 18. EMERGENCY STOP BUTTON 19. Rod Changer Switch - ROD CHANGER/SET-UP 20. Selector Switch - DRILL/NEUTRAL/TRAM 21. Oscillation Switch - UP/DOWN 22. Oscillation Lock Switch - LOCK/UNLOCK Drilling Procedures

BI006826

Linear Rod Changer (cab machine) Adding Drill Rod After the first length of drill rod has been drilled to depth (coupling and shank even with top of centralizer jaws): 1.

With full blowing air ON, raise the bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it.

NOTE It is a good idea to run the bit up and down the hole a few times with full blowing 2.

air on and forward rotation on. This will clear the hole of loose cuttings to prevent stuck drill rod.

Place feed lever (1, fig. 5-6) in OFF (NEUTRAL) position and place air switch (11, fig. 5-6) in CLOSE position.

3.

Place rotation control (13, fig. 5-7) and hammer control (14, fig. 5-7) in OFF (NEUTRAL) position.

4.

Open and close hammer using hammer control in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound (hammer frequency) of the drill string.

5.

Use the centralizer switch (12, fig. 5-7) to close centralizer around the drill rod coupling.

6.

Use reverse (clockwise) rotation using the rotation control to unthread drill shank from coupling, while using the drill feed lever to raise the drill. When drill shank is in line with automatic thread grease nozzle (fig. 5-8), activate coupling grease switch (9, fig. 5-7) to grease drill shank thread.

7.

Raise drill towards top of feed, so drill shank is above upper rod rack.

Fig. 5-8 Automatic Grease Nozzle

Drilling Procedures

5-31

Linear Rod Changer (cab machine)

BI006826

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE

5-32

14.

15.

16.

17.

18.

19.

20.

21.

22.

Hammer Control - WARM OIL/DRILL Feed Force Control Feed Rate Control Smart Drill Switch - ON/OFF EMERGENCY STOP BUTTON Rod Changer Switch - ROD CHANGER/SET-UP Selector Switch - DRILL/NEUTRAL/TRAM Oscillation Switch - UP/DOWN Oscillation Lock Switch - LOCK/UNLOCK

Drilling Procedures

BI006826

Linear Rod Changer (cab machine) Adding Drill Rod (cont.)

The rod changer switch (19) MUST be in the ROD CHANGER position for the right

NOTE joystick to control the rod changer functions.

8.

Press and hold carriage unlock button (7) to UNLOCK rod rack carriage. Move right joystick BACK to move carriage IN towards feed to position first drill rod under drill shank. Release carriage unlock button; locking pin will automatically locate the drill rod position.

9.

Slowly start forward (counterclockwise) rotation (13), use feed lever (1) to slowly lower drill shank into the coupling. Continue rotation and feed until coupling is tight.

10. Move left joystick to left to move Rod Wrench to IN position. This swings wrench into position and clamps around the drill rod. Move joystick back to right slightly to open the wrench so it is not clamped on the drill rod. The wrench is now in the "guide" position for the drill rod.

11. Raise the drill to clear the coupling from the upper rod rack.

12. Move right joystick to RIGHT to UNLOCK drill rod. This moves the lock bar IN towards feed to release the drill rod.

13. Press and hold carriage unlock button (7) to UNLOCK rod rack carriage. Move the right joystick FORWARD to move rod carriage OUT. Release carriage unlock button; the locking pin will automatically engage in next position in the rod rack.

14. Move right joystick to LEFT to LOCK drill rod. This moves the lock bar OUT away from feed to lock the drill rod in place.

15. Lower the drill until the threads of the drill rod are in line with the automatic thread grease nozzle (fig. 5-8), activate coupling grease switch (9) to grease threads.

16. Use feed lever (1) to slowly lower drill rod into coupling. Use forward (counterclockwise) rotation (13) and feed until all couplings are tight.

17. Place centralizer switch (12) in OPEN position and resume drilling. When coupling clears the centralizer, close centralizer and swing rod wrench out of the way by pressing lower left button.

18.

Repeat the above steps for all additional rods to be added.

Drilling Procedures

5-33

BI006826

Carousel Rod Changer (cab machine) Fig. 5-5 Overhead Console 1. Front Drill Lights ON/OFF Switch 2. Rear Drill Lights ON/OFF Switch 3. Dust Collector ON/OFF Switch 4. Water ON/OFF Switch 5. Air Temperature Gauge 6. Drill Hourmeter Gauge 7. LOW/HIGH Idle Switch 8. Glow Plug Indicator 9. Engine ON/OFF Switch 10. Engine ECM Monitor 11. Fuel Gauge

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE 5-34

14. Hammer Control - WARM OIL/DRILL 15. Feed Force Control 16. Feed Rate Control 17. Smart Drill Switch - ON/OFF 18. EMERGENCY STOP BUTTON 19. Rod Changer Switch - ROD CHANGER/SET-UP 20. Selector Switch - DRILL/NEUTRAL/TRAM 21. Oscillation Switch - UP/DOWN 22. Oscillation Lock Switch - LOCK/UNLOCK Drilling Procedures

BI006826

Carousel Rod Changer (cab machine) Adding Drill Rod After the first length of drill rod has been drilled to depth (coupling and shank even with top of centralizer jaws): 1.

With full blowing air ON, raise the bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it.

NOTE It is a good idea to run the bit up and down the hole a few times with full blowing 2.

air on and forward rotation on. This will clear the hole of loose cuttings to prevent stuck drill rod.

Place feed lever (1, fig. 5-6) in OFF (NEUTRAL) position and place air switch (11, fig. 5-6) in CLOSE position.

3.

Place rotation control (13, fig. 5-7) and hammer control (14, fig. 5-7) in OFF (NEUTRAL) position.

4.

Open and close hammer using hammer control in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound (hammer frequency) of the drill string.

5.

Use the centralizer switch (12, fig. 5-7) to close centralizer around the drill rod coupling.

6.

Use reverse (clockwise) rotation using the rotation control to unthread drill shank from coupling, while using the drill feed lever to raise the drill. When drill shank is in line with automatic thread grease nozzle (fig. 5-8), activate coupling grease switch (9, fig. 5-7) to grease drill shank thread.

7.

Raise drill towards top of feed, so drill shank is above upper carousel.

Fig. 5-8 Automatic Grease Nozzle

Drilling Procedures

5-35

Carousel Rod Changer (cab machine)

BI006826

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE

5-36

14.

15.

16.

17.

18.

19.

20.

21.

22.

Hammer Control - WARM OIL/DRILL Feed Force Control Feed Rate Control Smart Drill Switch - ON/OFF EMERGENCY STOP BUTTON Rod Changer Switch - ROD CHANGER/SET-UP Selector Switch - DRILL/NEUTRAL/TRAM Oscillation Switch - UP/DOWN Oscillation Lock Switch - LOCK/UNLOCK

Drilling Procedures

BI006826

Carousel Rod Changer (cab machine) Adding Drill Rod (cont.)

NOTE

The rod changer switch (19) MUST be in the ROD CHANGER position for the right joystick to control the rod changer functions.

8.

Move the right joystick RIGHT to ensure jaws are opened fully. Push right joystick FORWARD to ensure jaws are in position to accept a rod.

9.

Move the left joystick RIGHT and position first rod against jaws.

10. Move right joystick LEFT to clamp the rod. Then move joystick BACK and swing rod under drill.

11. Slowly start forward (counterclockwise) rotation (13), use feed lever (1) to slowly lower drill shank into the coupling. Continue rotation and feed until coupling is tight.

12. Slightly move right joystick RIGHT to loosen grip. The jaws are now used as a guide wrench to remove the drill rod clamped in the centralizer.

13. Lower the drill until the threads of the drill rod are in line with the automatic thread grease nozzle (fig. 5-8), activate coupling grease switch (9) to grease threads.

14. Use feed lever (1) to slowly lower drill rod into coupling. Use forward (counterclockwise) rotation (13) and feed until all couplings are tight.

15. Place centralizer switch (12) in OPEN position and resume drilling. When coupling clears the centralizer, close centralizer and swing carousel jaws out of the way by pushing the right joystick FOWARD. 16. Repeat the above steps for all additional rods to be added.

Drilling Procedures

5-37

Linear Rod Changer (cab machine)

BI006826

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE

5-38

14.

15.

16.

17.

18.

19.

20.

21.

22.

Hammer Control - WARM OIL/DRILL Feed Force Control Feed Rate Control Smart Drill Switch - ON/OFF EMERGENCY STOP BUTTON Rod Changer Switch - ROD CHANGER/SET-UP Selector Switch - DRILL/NEUTRAL/TRAM Oscillation Switch - UP/DOWN Oscillation Lock Switch - LOCK/UNLOCK

Drilling Procedures

BI006826

Linear Rod Changer (cab machine) Removing Drill Rod When desired hole depth has been reached: 1.

With full blowing air ON, raise bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it.

NOTE

Use reverse percussion (if so equipped) to help remove stuck drill rod. If not equipped with reverse percussion, place hammer control (14) in DRILL mode while feeding upward. Do not run drill in free oscillation mode (no feed pressure on hammer) for extended periods of time to prevent damage to the drill.

2.

Place feed control (1) in OFF (NEUTRAL) position.

3.

Place drill rotation control (13) and hammer control (14) in OFF (NEUTRAL) position.

4.

Open and close hammer (14) in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound of the drill string and air escaping from around coupling.

5.

Raise the drill until the coupling below the last drill rod is aligned with the centralizer jaws. Do not close centralizer jaws.

6.

Place Air Switch (9) in CLOSE position.

7.

Swing the rod wrench into position around the drill rod by moving left joystick LEFT. The wrench will clamp drill rod automatically. Slowly begin forward (counterclockwise) rotation (13) to slightly tighten the upper coupling on the drill rod.

8.

Place centralizer switch (12) in CLOSE position around the coupling.

9.

Swing rod wrench out of the way by moving left joystick RIGHT. Slowly begin reverse (clockwise) rotation (13) at the same time utilizing the feed UP (1) to unthread drill rod from coupling in centralizer and raise the drill and rod until the coupling on the shank clears the upper rack level. Stop feed and rotation.

10. Press carriage unlock button (7) on right joystick to UNLOCK the rod rack. Move right joystick BACK to move rod rack IN towards feed and position the last empty socket of the rod rack in line with the drill rod. Release unlock button (7); locking pin will automatically engage in next position. Use the feed lever (1) lower the rod until the coupling is level with the upper rod rack.

11. Move right joystick to LEFT to engage lock bar on the coupling. Slowly reverse the rotation and raise the drill to unthread the drill shank from the coupling.

12. Press carriage unlock button (7) on right joystick to UNLOCK the rod rack. Move right joystick FORWARD to move rod rack OUT away from feed. Release carriage unlock button and locking pin will automatically engage in next position.

13. Using feed DOWN (1), run drill down the feed and use forward (counterclockwise) rotation (13) to thread the drill shank into the coupling in the centralizer. When shank is threaded into coupling, open centralizer and raise drill up until next coupling is centered between centralizer jaws.

14. Repeat steps 7 - 13 until all of the drill rod has been removed from the hole.

Drilling Procedures

5-39

BI006826

Carousel Rod Changer (cab machine)

Fig. 5-6 Left Joystick Control 1. Feed Control - UP/DOWN 2. Left Tram/Feed Joystick 3. Feed Extend Button 4. Feed Retract Button

Fig. 5-7 Right Joystick Control Side Console 5. Tram Speed /Boom Extend Button 6. Boom Retract Button 7. Rod Rack Carriage Unlock (Linear Rod Changer Only) 8. Deadband Pedal 9. Coupling Grease Switch - ON/OFF 10. Pickup Pot Switch - UP/DOWN 11. Air Switch - OPEN/CLOSE 12. Centralizer Switch - OPEN/CLOSE 13. Rotation Control - FORWARD/REVERSE

5-40

14.

15.

16.

17.

18.

19.

20.

21.

22.

Hammer Control - WARM OIL/DRILL Feed Force Control Feed Rate Control Smart Drill Switch - ON/OFF EMERGENCY STOP BUTTON Rod Changer Switch - ROD CHANGER/SET-UP Selector Switch - DRILL/NEUTRAL/TRAM Oscillation Switch - UP/DOWN Oscillation Lock Switch - LOCK/UNLOCK

Drilling Procedures

BI006826

Carousel Rod Changer (cab machine) Removing Drill Rod When desired hole depth has been reached: 1.

With full blowing air ON, raise bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it.

NOTE

Place hammer control (14) in DRILL mode while feeding upward. Do not run drill in free oscillation mode (no feed pressure on hammer) for extended periods of time to prevent damage to the drill.

2.

Place feed control (1) in OFF (NEUTRAL) position.

3.

Place drill rotation control (13) and hammer control (14) in OFF (NEUTRAL) position.

4.

Open and close hammer (14) in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound of the drill string and air escaping from around coupling.

5.

Raise the drill until the coupling below the last drill rod is aligned with the centralizer jaws. Do not close centralizer jaws.

6.

Place Air Switch (9) in CLOSE position.

7.

Swing the carousel jaws into position around the drill rod by moving right joystick BACK. Then move right joystick LEFT to clamp rod. Slowly begin forward (counterclockwise) rotation (13) to slightly tighten the upper coupling on the drill rod.

8.

Place centralizer switch (12) in CLOSE position around the coupling.

9.

Slightly move right joystick RIGHT to loosen grip on rod. Slowly begin reverse (clockwise) rotation (13) at the same time utilizing the feed UP (1) to unthread drill rod from coupling in centralizer and raise the drill and rod until the coupling on the shank is just below the top carousel can. Stop feed and rotation.

10. Move right joystick LEFT to clamp rod.

11. Slowly reverse the rotation and raise the drill to unthread the drill shank from the coupling.

12. Move right joystick back to swing rod in carousel.

13. Move right joystick RIGHT to unclamp rod.

14. Move left joystick LEFT and rotate carousel one position away from jaws.

15. Using feed DOWN (1), run drill down the feed and use forward (counterclockwise) rotation (13) to thread the drill shank into the coupling in the centralizer. When shank is threaded into coupling, open centralizer and raise drill up until next coupling is centered between centralizer jaws.

16. Repeat steps 7 - 15 until all of the drill rod has been removed from the hole.

Drilling Procedures

5-41

BI006826

HPR1H-ATW Drill Shank Replacement CHUCK END COVER CHUCK

WATER SWIVEL HOUSING SHANK

FRONT END BUSHING THRUST PLATE CHUCK DRIVER BUSHING CHUCK DRIVER

BEARING PLATE SHANK BUSHING THRUST WASHER

Fig. 5-9 HPR1H-ATW Drill Front End (ref. 407201)

5-42

Drilling Procedures

BI006826

HPR1H-ATW Drill Shank Replacement WARNING

DO NOT attempt lubrication or service while the machine is running.

BE SURE the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts.

Two people are required to change the drill shank when the drill is mounted on the feed.

KEEP AWAY from moving or rotating parts.

DO NOT wear loose clothing or jewelry that could get caught in moving or rotating parts.

1.

Lower the boom and feed while keeping the feed as horizontal as possible. Remove the drill rod by unthreading the coupling from the drill shank and then sliding the drill rod down the feed channel onto the ground. Always place drill rod on wood blocks, keep threads clean.

2.

Lay the feed on the ground.

3.

Position the drill on the feed at a height above the ground that will allow working on the drill's front end comfortably (without excessive bending or reaching).

4.

Turn off the engine and bleed any remaining air from system (open blowing air valve).

5.

Remove the air/water hose from the water swivel housing.

6.

Remove the front-end side rod nuts.

7.

Slide off the water swivel housing and thrust plate.

8.

Remove the shank.

9.

Inspect drill front end parts for wear. See drill service manual for detailed instructions and wear tolerances. Pay particular attention to chuck splines, thrust plate, thrust washer, shank bushing and front end bushing. Shank mis-alignment can cause rapid wear of hammer face.

10. Apply grease (we recommend PG55, P/N 312810) to rear diameter of shank and shank splines.

NOTE Before installing a new shank, remove the rust prevention coating on the bearing and seal surfaces, using steel wool or fine sandpaper. If this is not done, the coating will build up on the seals, causing them to heat up an wear out rapidly.

11. Install a new drill shank into the drill chuck, being sure to align the splines on the shank with those in the chuck and being careful not to damage the seal in the bearing plate behind the chuck driver.

Install thrust plate (fig. 5-9).

12. Slide the water swivel housing into position.

13. Tighten side rod nuts. Torque to 500 ft. lbs. (680 Nm).

14. Connect air/water hose to connection on water swivel housing.

15. Apply a liberal coat of coupling grease to the drill shank threads before attaching the drill rod.

NOTE Be sure to keep rotation housing of drill greased well (every 2 hours with a hand grease gun). If automatic lubrication system is used, check reservoir daily.

Drilling Procedures

5-43

BI006826

HPR4519 Drill Shank Replacement

BEARING PLATE PINION GEAR CHUCK END COVER WATER SWIVEL HOUSING SHANK

FRONT END BUSHING THRUST PLATE CHUCK

SHANK BUSHING THRUST WASHER

CHUCK DRIVER Fig. 5-10 HPR4519 Drill Front End (ref. 407596)

5-44

Drilling Procedures

BI006826

HPR45 Drill Shank Replacement WARNING:

DO NOT attempt lubrication or service while the machine is running.

BE SURE the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts.

Two people are required to change the drill shank when the drill is mounted on the feed.

1.

Lower the boom and feed while keeping the feed as horizontal as possible. Remove the drill steel by unthreading the coupling from the drill shank and then sliding the free steel down the feed channel onto the ground.

2.

Lay the feed on the ground.

3.

Position the drill on the feed at a height above the ground that will allow working on the drill's front end comfortably (without excessive bending or reaching).

4.

Unload the hydraulic pump (make sure the hydraulic system gauge goes to zero). Turn off the engine and bleed any remaining air by opening the drill air valve at the drill console or in cab.

5.

Remove the air/water hose from the water swivel housing.

6.

Remove the four bolts and lock nuts that retain the water swivel to the chuck end using 1-7/16 and 1-1/2 wrenches.

7.

Slide off the water swivel housing and thrust plate.

8.

Remove the shank.

9.

Inspect drill front end parts for wear. See drill service manual for detailed instructions and wear tolerances. Pay particular attention to chuck splines, thrust plate, thrust washer, shank bushing and front end bushing. Shank mis-alignment can cause rapid wear of hammer face.

10. Apply grease (we recommend PG55, P?N 312810) to rear diameter of shank and shank splines.

NOTE

Before installing a new shank, remove the rust prevention coating on the bearing and seal surfaces, using steel wool or fine sandpaper. If this is not done, the coating will build up on the seals, causing them to heat up an wear out rapidly.

11. Install a new drill shank into the drill chuck, being sure to align the splines on the shank with those in the chuck and being careful not to damage the seal in the bearing plate behind the chuck driver.

Install thrust plate (fig. 5-10).

12. Slide the air swivel into position.

13. Install the four bolts, spring washers and lock nuts. Torque to 483 ft. lbs. (657 Nm).

14. Connect air/water hose to connection on water swivel housing.

15. Apply a liberal coat of coupling grease to the drill shank threads before attaching the drill steel.

Drilling Procedures

5-45

Notes

5-46

BI006826

Drilling Procedures

BI006826

Section 6

Preventive Maintenance

Preventive Maintenance

6-1

BI006826

Hydraulic Oils for Percussion Drills

In general, oils recommended or approved by hydraulic pump manufacturers are suitable for operating hydraulic percussion drills. Optimum viscosity in a temperature stabilized system is 150 to 300 SUS (extended range is 500 SUS) for continuous operation.

The following oils meet the requirements: ISO EQUIVALENT ISO 150/220

OIL TYPE Mobil DTE 19M

ISO 100

Mobil DTE 18M

ISO 46

Mobil DTE 15M

OPTIMUM RANGE o o Between 175 F and 135 F o o Between 79.4 C and 57.2 C o o Between 145 F and 115 F o o Between 62.7 C and 46.1 C o o Between 110 F and 80 F o o Between 43.3 C and 26.7 C

EXTENDED RANGE o o 115 F (46.1 C) o

o

100 F (37.8 C) o

o

60 F (15.6 C)

If stabilized system temperatures have not been established, the oil can be selected based on anticipated ambient temperature range.

AMBIENT OPERATING TEMPERATURE o o 90 F (32.2 C) or higher o o o o 32 F to 90 F (0 C to 32.2 C) o o o o -20 F to 32 F (-28.9 C to 0 C) o o Under -20 F (-28.9 C)

OIL SELECTION

ISO EQUIVALENT

DTE 19M or equivalent DTE 18M or equivalent DTE 15M or equivalent Consult Factory

ISO 150/220 ISO 100 ISO 46

These selections assume "normal operating conditions" as expected in quarry or quarry-like operations. Pioneering and secondary drilling normally result in a lower than average operating temperature; the necessity to drill out of the hole to remove stuck steel, as found in badly broken ground, will result in higher than normal operating temperatures.

NOTE

Since the determining factor for safe and efficient operation is the viscosity of the oil, final selection for the oil (or changing the oil) should be based on the stabilized oil temperature in your specific drilling application.

In addition to the viscosity at stabilized oil temperature, we also have to consider viscosity at start-up conditions.

Limitations are cavitation of the pumps and sluggish controls, and extended warm-up periods that may be required to avoid pump cavitation and to provide adequate control. Oils with high viscosity index (above 120) are better able to cover a wide range of temperatures. Oils with lower viscosity index may need more frequent change of oil based on ambient temperature or may require an oil heater to improve start-up conditions o

o

In general, cold starts may be made at a temperature of at least 30 F (16.9 C) warmer than the pour point of the fluid. All cold starts should be made at low pressure, low flow, and low speed.

6-2

Preventive Maintenance

BI006826

Lubrication and Inspection WARNING:

BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1.

DO NOT service or perform maintenance while machine is running.

NOTE

Since the determining factor for safe and efficient operating is the viscosity of the oil, final selection for the oil (or changing of the oil) should be based on the stabilized oil temperature in your specific drilling application.

To avoid unnecessary machine repairs, keep the following in mind when handling fuel 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 no dust is in the air.

•

Never reuse paper filters.

•

Wash metal parts of filters with clean oil. Do not wipe the parts with a 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 misadjustment. If the source can be determined and repaired as a part of scheduled maintenance, costly down time can be avoided later.

•

Ensure that clean fuel of correct grade for winter/summer is used.

Bolt Maintenance WARNING:

BE SURE all bolts are tight and not damaged. Pay particular attention to critical areas, such as; feed mounting, boom pivot, boom mounting, drill mounting slide or any areas where loose bolts could cause a component to fall and cause injury.

Check torque on bolts after first 50 hours of machine operation. Retorque any bolts that are less than the specified value as listed in the Bolt Torque Specifications sheet in this section, or as specified on the assembly drawing. Pay particular attention to critical mounting areas, such as; feed mounting, boom pivot, boom mounting, drill mounting slide, or any areas where loose bolts could cause a component to fall and cause injury or machine damage. Refer to drill service manual for bolt maintenance on drill.

Periodically inspect bolts for damage and replace as necessary. Check torque and retorque as required.

Preventive Maintenance

6-3

BI006826

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.

Nominal Diameter

UNC

UNF

UN

SAE Grade 5 ASTM A-449 Tightening Torque (Ft. Lbs.) K = .15

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

6 13 23 35 57 82 113 200 322 483 596 840 1102 1462 1714 2576 3768 5155 6996 9231 7 14 26 40 64 91 127 223 355 528 668 930 1254 1645

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

1879 2857 4127 5726 7693 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.

6-4

Preventive Maintenance

BI006826

R20 Maintenance Schedule Interval Hours Every 2 Hours

10 Hours or Daily

Every 50 Service Hours or Weekly

Every 250 Service Hours

Every 500 Service Hours

Service Points

Every 2000 Service Hours Every 4000 Service Hours

Lubricant/Notes

Drill Chuck End

Lubricate with Grease Gun, unless fitted with oil lubrication.

PG55 Grease (Part No. 312810) 14oz. tube

Engine Oil (Isuzu US EPA Tier 3)

Check Level - Refill as Required

*SAE 15W-40 +5o F (-15o C) and up o o SAE 10W-30 -22 F + 86 F o o (-30 C + 30 C)

Pump Drive Gearbox Fuel Tank Engine Coolant Engine Belts Fuel/Water Separator-Engine Hydraulic Oil Air Compressor Oil

Check Level - Refill as Required Check Level - Refill as Required Check Level - Refill as Required Check and Adjust Check. Drain if Required Check Level - Refill as Required Check Level - Refill as Required

Engine Air Filter Air Compressor Air Filter Hydraulic Oil Filters Radiator / Oil Cooler Cylinder / Boom Pivots Feed Cylinder Sheaves or Sprockets Drill Steel Centralizer Batteries Drill Oil Lube Reservoir (if used)

Check - Clean if Required Check - Replace if Required Check - Replace if Required Check - Clean if Required Lubricate and Inspect Lubricate and Inspect Lubricate and Inspect Check Level - Refill as Required Check Level - Refill as Required

Track Chain Tension Feed Table Pivot Pin and Bolts Rock Drill Side Rods and Mounting Bolts Drill Slide Wear Pads Feed Table Wear Pads Dust Collector Filters Detergent System Strainer Engine Oil and Filter Engine Air Filter Drill Accumulators Track Drive Gear Case Oil Air Compressor Air Filter Air Compressor Oil Filter Engine Oil and Filter Pump Drive Gearbox

Check and Adjust Check and Tighten

Feed Table Bushing Hydraulic Oil Filters Fuel Filter Engine Fan Drive Bearing Fuel Priming Pump Strainer (see Section 3 of Service Manual) Compressor Oil Every 1000 Service Hours

Service or Maintenance

Pump Drive Gearbox Engine Coolant Conditioner Track Drive Gear Case Oil Hydraulic Oil Compressor Oil Separator Element Engine Coolant

*HD 80W-90 Gear Oil No. 2 Diesel Fuel Water/Anti-freeze, 50/50 mix ––––––– ––––––– *Chevron AW MV, ISO 46 *Chevron Tegra Synthetic Compressor Oil, ISO 68 ––––––– ––––––– ––––––– ––––––– EP - NLGI No. 2 Grease EP - NLGI No. 2 Grease EP - NLGI No. 2 Grease Distilled Water Extreme Pressure Rock Drill Oil Chevron Vistac ISO 32 EP - NLGI No. 2 Grease –––––––

Check, Torque HPR1H side rods to 355 - 500 ft. lbs. (483 - 680 Nm) Check and Adjust ––––––– Check and Adjust ––––––– Check - Clean or Replace if Required ––––––– Check - Clean if Required ––––––– Drain Oil and Replace (initial change) *15W-40 Replace ––––––– Check Charge Pressure see Drill Service Manual Drain Oil and Replace (initial change) *HD 80W-90 Gear Oil Replace ––––––– Replace ––––––– Drain Oil and Replace Filter *15W-40 Drain Oil and Replace *HD 80W-90 Gear Oil Initial change at 500 hours, then every 6 months.

Inspect and Replace (if necessary) ––––––– Replace ––––––– Replace ––––––– Grease Special Purpose Grease (SPG) Clean and Replace ––––––– Drain Oil and Replace Drain Oil and Replace Replace Drain Oil, Flush and Replace Drain, and Replace Oil Replace Replace, Clean and Flush System

*Chevron Tegra Synthetic Compressor Oil, ISO 68 *HD 80W-90 Gear Oil *HD 80W-90 Gear Oil *Chevron AW MV, ISO 46 ––––––– Water/Anti-freeze, 50/50 mix

Capacity –––––––

21.7 Qt. / 20.5 L 4.5 Qt. / 4.3L 80 Gal. / 303 L **32.8 Qt./31 L ––––––– ––––––– 100 Gal. / 380 L 9.5 Qt. / 9 L – – – – – – –

– – – – – – –

– – – – – – –

– – – – – – –

– – – – – – –

– – – – – – –

– – – – – – –

2.1 Qt./ 2 L

–––––––

––––––– ––––––– ––––––– ––––––– 21.7 Qt./20.5 L ––––––– ––––––– 2.5 Qt./2.4 L ––––––– ––––––– 21.7 Qt./20.5 L 4.5 Qt. / 4.3 L – – – – –

– – – – –

– – – – –

– – – – –

– – – – –

– – – – –

– – – – –

9.5 Qt. / 9 L 4.5 Qt. / 4.3 L 2 quarts / 1.9 L 2.5 Qt./2.4 L 100 Gal. / 380L ––––––– **32.8 Qt./31 L

* Filled at factory unless special request. **Cooling capacity of system - including Radiator 14 Qts. (13.2 L), Shunt Tank 4 Qts. (3.8 L) and Engine 14.8 Qts. (14 L)

NOTE

See pages 6-24 to 6-36 for grease fitting locations.

Preventive Maintenance

6-5

BI006826

Daily Operational Checklist Daily Operational Checklist CAUTION

DO NOT direct high pressure cleaning agents or water on electrical connections.

In addition to the daily scheduled maintenance items indicated on page 6-5, several mechanical checks should be added to ensure long, safe and trouble-free operation. Each day the minimum items to be checked include: •

All daily checkpoint items on maintenance chart.

•

Check underside. Look for broken or loose hoses. If dripping fuel, hydraulic oil or coolant is evident, do not continue until leak is found and corrected.

•

Check that tracks are tensioned properly. Clear any rocks, mud or snow from tracks to prevent overtensioning or other damage.

•

Check for clean, tight battery connections. Check that the battery is fully charged.

With the ignition switch in the Accessory or Run position, the battery voltmeter should indicate 24-25 volts. When the engine is running, the voltage should increase slightly to indicate alternator charging.

•

Look for loose or missing bolts. Replace all missing bolts and tighten loose bolts.

Tighten bolts per torque specification on page 6-4 unless otherwise stated in the parts manual.

•

Lubricate chuck end of drill every two hours during drilling.

•

Look for excessive play due to worn wear pads on the boom, drill and feed.

•

Check fill caps, tank covers and dipstick. They should be in place and seated properly.

•

Check the engine intake and exhaust clamps, be sure they are tight to prevent damage to the turbocharger.

Hydraulic System The hydraulic system is filled at the factory with Chevron AWMV ISO 46.

Any other oils used, must meet the specifications listed on page 6-2.

Diesel fuel or kerosene used as dilutants for cold weather operation are not recommended, as they are not sufficiently refined products.

Do not use any fire resistant fluids or non-petroleum oils without consulting the manufacturer.

6-6

Preventive Maintenance

BI006826

Hydraulic Drill Accumulator Charge Pressure - Check Monthly •

The drill accumulators must be charged with dry nitrogen before drilling.

•

Check accumulator charge pressure monthly. Each time charge pressure is checked, a little charge pressure is lost, therefore don't check any more than necessary.

•

If drill hoses vibrate excessivly, this is an indication that charge pressure is low, and must be checked and recharged.

•

Refer to drill service manual for correct procedure for checking and charging accumulators. Or, refer to charging instructions (318147) that comes with drill charge kit (316120).

•

The two primary drills used on the R20 track drill are the HPR1H-ATW and the HPR4519. The two drills are shown below and the accumulators identified.

HPR1H-ATW Hydraulic Drill 1. Low Pressure Accumulator Charge Valve (closest to rear of drill) 2. High Pressure Accumulator Charge Valve (closest to front of drill)

HPR4519 Hydraulic Drill 1. Low Pressure Accumulator Charge Valve (left side of drill as viewed from rear of drill) High Pressure Accumulator is on right side of drill, opposite.

Preventive Maintenance

6-7

BI006826

Engine Oil Filter WARNING:

BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1.

SHUT DOWN machine and relieve pressure before attempting lubrication or service.

AVOID prolonged and repeated skin contact with used engine oil. Prolonged and repeated contact with used oil can cause serious bodily injury. Use only authorized waste disposal facilities to dispose of used engine oil and other lubricants.

The engine oil filter is the spin-on type. To replace: 1.

Shut down engine and clean area around filters.

2.

Spin off and properly discard used oil filter. Use caution to avoid burns from hot oil. Clean mounting base and be sure old gasket is not stuck to base.

3.

Lubricate the gasket on the new filter with engine oil. Spin on the new filter, tighten 3/4 of a turn further after the filter gasket makes contact with filter base.

4.

Add oil through fill tube. Check oil level with dipstick in fill tube.

Fig. 6-1 Engine Oil Filter OIL FILLER CAP

OIL LEVEL DIPSTICK

Fig. 6-2 Engine - Top Side

6-8

Preventive Maintenance

BI006826

Engine Fuel Filter The engine fuel filter is a spin-on filter located at the right rear of the machine.

To replace: •

Shut down the engine, clean area around the filter, flange.

•

Spin off and discard the old filter and rubber gasket. Clean mounting base and be sure old gasket is not stuck to base.

•

Lubricate the filter gasket with clean diesel fuel, or oil.

•

Spin on a new filter, tightening 3/4 turn after the gasket has contacted the base.

•

If necessary, open the fuel priming pump valve by unscrewing the top and then pump to prime the system. Screw top back on tight.

Fuel/Water Separator • Drain water from fuel water separator daily.

Fig. 6-3 Fuel Filter and Fuel/Water Separator 1. Fuel Filter 2. Fuel/Water Separator

Preventive Maintenance

6-9

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Engine Air Cleaner Filter

The engine air cleaner should be cleaned when the service indicator (fig. 6-2a) indicates the filter is clogged (check daily or every 10 hours). There is a service window on the indicator that will gradually turn red as the filter restriction increases to a maximum of 30" of H20. After cleaning the filter, reset the service window to green by pressing the rubber diaphragm on top of the service indicator.

CAUTION:

DO NOT clean the safety element. The safety element should be replaced once a year or sooner, if required.

To replace or clean the engine air cleaner filter 1. Shut down the machine.

2.

Undo the clamps and remove the filter cover.

3.

The primary and safety element are a press fit inside the housing. Carefully move the primary element from side to side and slide the element from the air cleaner housing to avoid dislodging dust from element when removing. Be careful not to knock the element against the side of the housing. Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a poor seal.

Check seal area of housing for foreign material or damage.

4.

Remove safety element in the same manner.

5.

Clean the inside of the housing and vacuator valve with a clean cloth.

6.

Fig. 6-4 Service Indicator Clean the primary element (up to 6 times) with water, household detergent or compressed air. Do not use more than 40 PSI (2.8 bar) water or 90 PSI (6.2 bar) air.

Install new safety element (if need be) and primary element. Push all the way in and be sure the elements are seated against the back of the housing. Install cover and secure with clamps.

7.

Fig. 6-5 Engine & Compressor Air Filters 1. Engine Air Filter 2 Vacuator Valve 3. Compressor Air Filter 6-10

Preventive Maintenance

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Compressor Air Filter The compressor air cleaner should be cleaned when the service indicator, indicates the filter is clogged. There is a service window on the indicator that will gradually turn red as the filter restriction increases to a maximum of 30" of H20. After cleaning the filter, reset the service window to green by pressing the rubber diaphragm on top of the service indicator.

The compressor air filter service indicator is mounted on the rear of the air filter housing.

• Check filter indicator daily or every 10 hours.

CAUTION:

DO NOT clean the safety element. The safety element should be replaced once a year or sooner, if required.

To replace the compressor air cleaner filter 1. Shut down the machine.

2.

Loosen the clamp ring and remove the filter cover.

Remove the rubber dust cover inside the filter cover and empty out dust. Clean inside of filter cover with a clean cloth and replace rubber dust cover.

3.

Unscrew the wing nut and carefully slide the primary element from the air cleaner housing to avoid dislodging dust from element when removing. Be careful not to knock the element against the side of the housing.

Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a poor seal. Check seal area of housing for foreign material or damage.

4.

Clean the inside the of the housing with a clean cloth.

5.

Install safety element (if removed) and primary element and secure with wing nuts. Be sure to install filter cover with arrow pointing up and secure with clamp.

Preventive Maintenance

Fig. 6-6 Compressor Air Filter

6-11

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Compressor Oil Filter WARNING:

BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in section 1.

SHUT DOWN machine and relieve pressure before attempting lubrication or service.

Allow compressor to cool down before starting any work.

CAUTION:

Use recommended oil type only; do not mix different oils.

Dispose of waste oil according to local regulations regarding handling of waste oil.

Fig. 6-7 Air Compressor 1. Oil Filter 3. Sight Glass 2. Measuring Rod 4. Oil Drain Plug (bottom side)

6-12

1.

Remove filter element with filter wrench. Have a cloth handy to catch any oil that may drain from filter. Clean mounting base and be sure old filter gasket is not stuck to base.

2.

Lubricate sealing ring on new filter element with clean oil.

3.

Screw on new filter element and tighten by hand only.

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Compressor Oil Check/Change WARNING:

BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in section 1.

SHUT DOWN machine and relieve pressure before attempting lubrication or service.

Allow compressor to cool down before starting any work.

CAUTION:

Use recommended oil type only; do not mix different oils.

Dispose of waste oil according to local regulations regarding handling of waste oil.

Adding Oil 1.

Shut down machine and wait for pressure to relieve. Let oil cool before checking. Unscrew the oil measuring rod. Add oil up to the top mark on the oil measuring rod. USE ONLY Chevron Tegra Synthetic Compressor Oil, ISO 68 or equivalent.

2.

Screw in the oil measuring rod tight.

Changing Oil o

o

o

o

1.

Run the compressor until the oil temperature is 104 F to 122 F (40 C to 50 C).

2.

Shut down machine and wait for pressure to relieve. Unscrew the oil measuring rod. Place a suitable container under the drain plug and remove drain plug (item 4, fig. 6-7) located at the front right hand corner of the compressor. Dispose of used oil according to local regulations.

NOTE

Compressor sump oil capacity is 9.5 quarts (9 liters). This does not include oil required to fill the lines and oil cooler.

3.

Replace drain plug and tighten and add oil up to top mark on measuring rod.

4.

Replace measuring rod and tighten.

5.

Start machine, check for leaks and run for a few minutes.

6.

Shut down machine and recheck oil level after oil has cooled down.

Preventive Maintenance

6-13

Notes

6-14

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Preventive Maintenance

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Coolant System

WARNING:

DO NOT check coolant level when coolant is hot.

KEEP AWAY from rotating fan and belts.

DO NOT wear jewelry or loose fitting clothing when working around machinery.

•

Check the radiator, hydraulic oil and compressor oil coolers daily. Clean out any accumulation of dirt, leaves and other debris that would block air flow through the coolers and cause overheating of the engine.

•

Check coolant level through sight glass (2) daily. Add coolant to overflow tank (1 to proper level if required.

Fig. 6-8 Right Rear of Machine 1. Radiator Overflow Tank 2. Sight Glass

Preventive Maintenance

6-15

R20 Grease Points

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Fig. 6-9 R20 - Right Side

Fig. 6-10 R20 - Left Side 6-16

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R20 Grease Points The general area's for greasing are shown in fig's. 6-9 and 6-10. Detailed drawings are provided to illustrate specific grease points.

Establish a pattern for greasing the machine and stick with it. That way, you won't miss any grease points by skipping around. The following table starts out with greasing the drill, then all the feed points, then the feed table, positioner and boom points. Finally, grease the track oscillation cylinders and track pivot points, also, the dust collector pivot points.

SERVICE LOCATION

FREQUENCY

NOTES

HPR4519 Rock Drill Front End 4 HPR1H-ATW Rock Drill Front End 6 Centralizer 4 Feed Cylinder Sheaves 4 Chain Feed (optional) - includes the next 3 items: Lower Feed Chain Sprocket 1 Feed Drive Sprocket 1 Upper Feed Chain Sprocket 1 Lower Rod Rack 7

Every 2 hours Every 2 hours Daily Daily

Polytech PG55 grease recommended Polytech PG55 grease recommended

Rod Wrench Rod Rack Driveline, Midpoint Upper Rod Rack

2 2 9

Daily Daily Daily

Feed Table

4

Daily

Positioner Feed Dump Cylinder Boom Lift Cylinder Boom Swing Cylinder Boom Pivot

4 3 2 3 4

Daily Daily Daily Daily Daily

Track Oscillation Cylinders (2) Track Frame Pivot Points Dust Collector Pivot Engine Fan Drive Bearing

4 4 2 1

Daily Daily Daily 500 hours or 6 months

Preventive Maintenance

LUBE POINTS

Daily Daily Daily Daily

2 upper, 2 lower

4 rollers, 2 driveline bearings, 1 rod lock pin 1 coupling, 1 bearing 4 rollers, 2 driveline bearings, 1 rod lock pin, 1 driveline to motor coupling 2 feed swing cylinder, 2 feed extend cylinder 2 at trunnion, 1 at rod end 1 each end 1 rod end, 2 base end & clevis top & bottom of pivot pin, and 1 each side of boom clevis 1 each end Located under frame use Special Purpose Grease (SPG) with a polyurea thickener.

6-17

Rock Drill Grease Points

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Fig. 6-11 HPR4519 Rock Drill - 4 Grease Points

2X

3X

Fig. 6-12 HPR1H-ATW Rock Drill - 6 Grease Points

6-18

Preventive Maintenance

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Centralizer & Feed Sheaves Grease Points

Fig. 6-13 Centralizer - 4 Grease Points

Fig. 6-14 Feed Drive Cylinder - 4 Grease Points 1 place each sheave.

Preventive Maintenance

6-19

Chain Feed & Feed Drive Grease Points

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Fig. 6-15 Chain Feed (optional) - 2 Grease Points

Fig. 6-16 Chain Feed Drive Sprocket - 1 Grease Points

6-20

Preventive Maintenance

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Lower Rod Rack Grease Points

Fig. 6-17 Lower Rod Rack - 7 Grease Points

Preventive Maintenance

6-21

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Rod Wrench & Driveline Grease Points

Fig. 6-18 Rod Wrench - 2 Grease Points All other pivot points are lubed with Never-Sieze® at assembly.

Fig. 6-19 Rod Rack Driveline - 8 Grease Points See Upper and Lower Rod Racks for additional points.

6-22

Preventive Maintenance

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Upper Rod Rack Grease Points

Fig. 6-20 Upper Rod Rack - 9 Grease Points

Preventive Maintenance

6-23

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Feed Table Grease Points

Fig. 5-21 Feed Table - 4 Grease Points

6-24

Preventive Maintenance

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Boom Assembly Grease Points

Fig. 6-22 Boom Assembly - 16 Grease Points Preventive Maintenance

6-25

Track Frame Grease Points

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Fig. 6-23 Track Oscitllation Cylinders and Pivot - 8 Grease Points

6-26

Preventive Maintenance

Dust Collector Pivot Grease Points

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Fig. 6-24 Dust Collector Swing Arm - 2 Grease Points

Preventive Maintenance

6-27

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Engine Fan Drive Bearing Grease Point

Fig. 6-25 Engine Fan Drive Bearing - Grease 1 place every 500 hours or 6 months.

Use Special Purpose Grease (SPG) with a polyurea thickener.

6-28

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Maintenance Record

DATE

HOUR METER

Preventive Maintenance

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

6-29

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Maintenance Record

DATE

6-30

HOUR METER

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

Preventive Maintenance

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Maintenance Record

DATE

HOUR METER

Preventive Maintenance

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

6-31

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Maintenance Record

DATE

6-32

HOUR METER

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

Preventive Maintenance

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Maintenance Record

DATE

HOUR METER

Preventive Maintenance

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

6-33

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Maintenance Record

DATE

6-34

HOUR METER

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

Preventive Maintenance

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