CAT Rotary Track Drill 59HR Blast Hole Drill Operator's Manual - PDF DOWNLOAD

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OPliRAJrOR'S MANIUAIL Manual No.

10836 SN: 141426

□ Bucyrus International, Inc. 1100 Milwaukee Ave.• P.O.Box 500 • South Milwaukee, Wisconsin 53172-0500 USA

BI619852

Bucyrus International, Inc. 59HR Blast Hole Drill

Manual No. 10836

October 2009

BI619852

Bucyrus International, Inc. 59HR Blast Hole Drill

DANGER: THIS MANUAL PROVIDES INFORMATION AND DATA FOR THE MAINTENANCE AND OPERATION OF THIS MACHINE. ALL ELECTRICAL EQUIPMENT MUST BE SERVICED

BY QUALIFIED INDIVIDUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH VOLTAGE SYSTEMS, VARIABLE FREQUENCY AC DRIVES, AND/OR WARD LEONARD LOOP DC DRIVES. FAILURE TO COMPLY COULD RESULT IN PERSONAL INJURY OR DEATH.

DANGER: DO NOT ATTEMPT MECHANICAL OR ELECTRICAL MAINTENANCE ON THIS MACHINE WITHOUT A FULL UNDERSTANDING OF EACH COMPONENT’S OPERATION AND FUNCTION. COMPONENTS UTILIZING ELECTRICAL POWER, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND ISOLATED PRIOR TO DISASSEMBLY. The FEEDER CABLE must contain a provision for a ground connection, especially whenever 2,300 volts or greater are used. At the substation, the power line must terminate (see paragraph on ground circuits) to a suitable permanent ground. At the machine, the power line must securely terminate through a bolted connection to the machine frame. This provides a constant ground for the machine and its electrical equipment. Failure to provide this adequate ground endangers employees and equipment.

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

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

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Manual No. 10836

October 2009

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Bucyrus International, Inc. 59HR Blast Hole Drill

59HR Blast Hole Drill Operator’s Manual Manual No. 10836 Lot 16; sn: 141426 Table of Contents GENERAL INFORMATION ............................................................................................................ 5 SAFETY ........................................................................................................................................ 6 SAFETY PRECAUTIONS ........................................................................................................ 7 FIRE PREVENTION CONSIDERATIONS .................................................................................... 10 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS .............................. 11 MACHINE PLACARDS ................................................................................................................. 14 Stored Energy Signs ................................................................................................................. 15

OPERATION NEAR ELECTRICAL TRANSMISSION LINES .................................................. 16 MACHINE OVERVIEW ................................................................................................................. 17 PROPEL MACHINERY .......................................................................................................... 17 MAINFRAME AND DECKS .................................................................................................... 18 MACHINERY HOUSE ............................................................................................................ 20 MAIN AIR SYSTEMS ............................................................................................................. 21 HYDRAULIC SYSTEM .......................................................................................................... 22 OPERATOR’S CAB ............................................................................................................... 23 MAST .................................................................................................................................... 24 ROTARY/PULLDOWN MACHINERY ..................................................................................... 25 ROTARY GEARCASE ........................................................................................................... 26 PULLDOWN GEARCASE ...................................................................................................... 26 DRILL TOOL STRING ASSEMBLY ........................................................................................ 27 BREAKOUT WRENCH .......................................................................................................... 28 CABLE REEL ......................................................................................................................... 28 CONTROLS - LOCATION AND FUNCTION ................................................................................ 29 OPERATOR’S CONTROL CONSOLE ................................................................................... 30 Operator’s Control Console - Overall View .............................................................................. 30

MAIN CONTROL PANEL ....................................................................................................... 31 Main Control Panel ................................................................................................................... 31

HOIST/PULLDOWN RHEOSTAT .................................................................................... 32 ROTARY RHEOSTAT ...................................................................................................... 32 DRILL/PROPEL CONTROLS ON AND OFF PUSHBUTTON .......................................... 32 HOIST/PULLDOWN SPEED SELECTOR SWITCH ........................................................ 33 ROTARY SPEED SELECTOR SWITCH .......................................................................... 33 HOIST BRAKE SWITCH .................................................................................................. 34 IMPORTANT NOTE This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

© 2009 Bucyrus International, Inc. All Rights Reserved.

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PIPE RACK SELECTOR SWITCH ................................................................................... 34 PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL) ...................................................... 34 WINCH/MAST SELECTOR SWITCH............................................................................... 35 MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL) ............................................... 35 TOOL WRENCH SWITCH ............................................................................................... 36 DUST CURTAIN SWITCH ............................................................................................... 36 BIT VIEW HATCH SWITCH ............................................................................................. 36 PROPEL CONTROL PANEL ................................................................................................. 37 Propel Control Panel ................................................................................................................ 37

EMERGENCY STOP PUSHBUTTON ............................................................................. 37 PROPEL SPEED SELECTOR SWITCH .......................................................................... 37 COMPRESSOR STOP PUSHBUTTON .......................................................................... 38 COMPRESSOR VENT/DRILL SWITCH ........................................................................... 38 HEATER/VENT/AIR CONDITIONER CONTROLS ........................................................... 38 OPERATING MODE SELECTOR SWITCH ..................................................................... 38 PROPEL JOYSTICKS ...................................................................................................... 38 SELECTOR SWITCH PANEL ................................................................................................ 39 Selector Switch Panel .............................................................................................................. 39

BREAKOUT WRENCH SWITCH ..................................................................................... 40 PIPE POSITIONER SWITCH ........................................................................................... 40 DUST SEAL SWITCH ...................................................................................................... 40 A-FRAME LOCK SWITCH ............................................................................................... 40 MAST BRACE LOCK SWITCH ........................................................................................ 40 MAST LOCK SWITCH ..................................................................................................... 41 BOARDING STAIRS SWITCH .......................................................................................... 41 PEDESTAL HEATER SWITCH ........................................................................................ 41 FIRE SUPPRESSION SYSTEM INDICATORS ................................................................ 41 RADIO .............................................................................................................................. 41 LEVELING CONTROL PANEL ............................................................................................... 42 Leveling Control Panel ............................................................................................................. 42

MANUAL LEVELING JOYSTICKS .................................................................................... 43 AUTOMATIC LEVELING SWITCH ................................................................................... 43 WATER INJECTION ON/OFF SWITCH ........................................................................... 43 WATER INJECTION FLOW CONTROL ........................................................................... 43 HORN PUSHBUTTON .................................................................................................... 44 DEPTH INDICATOR RESET PUSHBUTTON .................................................................. 44 PROGRAMMED DRILL CONTROL SWITCH................................................................... 44 EMERGENCY STOP PUSHBUTTON ............................................................................. 44 OPERATOR’S DISPLAY TERMINAL ..................................................................................... 45 Operator’s Display Panel ......................................................................................................... 45

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MACHINERY HOUSE CONTROLS ....................................................................................... 46 LIGHTING LOAD CENTER .............................................................................................. 46 CONTROLS ON THE LOW VOLTAGE START CABINET ............................................... 46 CONTROLS ON THE LOW VOLTAGE CABINET ............................................................ 47 Low Voltage Cabinet (Typical) .................................................................................................. 47

CONTROL ON THE PROGRAMMABLE CONTROLLER CABINET ................................ 47 Programmable Control Cabinet ................................................................................................ 47

HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ................................. 48 Hoist Pulldown and Rotary Drive Cabinets .............................................................................. 48

CONTROLS ON OR NEAR THE AIR COMPRESSOR .................................................... 50 Air Compressor Mounted Controls .......................................................................................... 50

MISCELLANEOUS CONTROLS ...................................................................................... 51 PORTABLE REMOTE PROPEL STATION (OPTIONAL) ................................................. 51 Portable Remote Propel Station (Optional) .............................................................................. 51

HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL ........................................ 52 Hydraulic Reservoir Remote Fill Control Panel ....................................................................... 52

LUBE CONTROL PANEL ................................................................................................ 52 Lube Control Panel ................................................................................................................... 52

PRESTART CHECKS .................................................................................................................. 53 EXTERNAL INSPECTION ...................................................................................................... 53 Daily Inspection Items ............................................................................................................. 54

ONBOARD INSPECTION ...................................................................................................... 56 Onboard Inspection Items ........................................................................................................ 56

PRESTART LUBRICATION ................................................................................................... 59 START-UP ................................................................................................................................... 59 MACHINE START-UP ............................................................................................................ 59 MACHINERY CHECK ...................................................................................................... 61 BREAK-IN OF NEW COMPONENTS .............................................................................. 61 ROTARY DRIVE UNIT BREAK-IN .............................................................................. 61 HOIST/PULLDOWN GEARCASE BREAK-IN ............................................................. 61 ELECTRIC MOTOR BREAK-IN ................................................................................. 61 MAINTENANCE DURING OPERATION ....................................................................................... 62 PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK .............................................. 63 OPERATION ................................................................................................................................ 63 PROPELLING ........................................................................................................................ 64 DEFINITIONS .................................................................................................................. 64 PROPEL PROCEDURE ................................................................................................... 65 Operator Controls - Propel .......................................................................................................

Propel - Forward or Reverse ....................................................................................................

Propel - Gradual Right Hand Turn ............................................................................................

Propel - Gradual Left Hand Turn ..............................................................................................

Propel - Counter-Rotation Left Hand Turn ...............................................................................

Gradual Turns - 15° Increments ..............................................................................................

66 67 67 68 68 69

TOWING PROCEDURE .................................................................................................. 70 Tow Bar Detail .......................................................................................................................... 70

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CABLE REEL OPERATION ................................................................................................... 71 Cable Reel ............................................................................................................................... 71

LEVELING ............................................................................................................................. 72 Machine Orientation ................................................................................................................. 72 Controls for Leveling the Machine ............................................................................................ 74

MAST RAISING AND LOWERING ......................................................................................... 74 MAST RAISING ................................................................................................................ 74 Controls for Raising or Lowering the Mast ............................................................................... 75

MAST LOWERING .......................................................................................................... 76 Controls for Angle Drilling ......................................................................................................... 77

PULLDOWN MACHINERY OPERATION ............................................................................... 78 Controls for Hoist / Pulldown ................................................................................................... 78

AUXILIARY WINCH OPERATION........................................................................................... 79 Controls for Operating the Winch ............................................................................................ 79

PIPE RACK OPERATION ................................................................................................ 80 Controls for Operating the Pipe Racks .................................................................................... 81

TOOL HANDLING .................................................................................................................. 84 PIPE LOADING AND UNLOADING .................................................................................. 84 DRILL TOOL STRING ASSEMBLY .................................................................................. 86 Stabilizer Installation ................................................................................................................

Controls for Drill Pipe Installation ............................................................................................

Installing Drill Pipe ...................................................................................................................

Stabilizer Installation ................................................................................................................

Bit Installation ..........................................................................................................................

87 87 88 90 91

BREAKOUT WRENCH OPERATION .................................................................................... 92 DRILL TOOL STRING DISASSEMBLY .................................................................................. 93 ADDING ADDITIONAL DRILL PIPE .................................................................................. 95 REMOVAL OF MULTIPLE SECTION DRILL PIPE ............................................................ 96 ANGLE DRILLING .................................................................................................................. 97 Jib Crane .................................................................................................................................. 98

DUST SUPPRESSION SYSTEM OPERATION ..................................................................... 98 DRILLING .............................................................................................................................. 99 VERTICAL DRILLING ....................................................................................................... 99 Controls for Normal Drilling ..................................................................................................... 100

STARTING THE HOLE (COLLARING) .................................................................... 100 NORMAL DRILLING ................................................................................................. 101 ENDING THE HOLE ................................................................................................ 103 ENDING THE HOLE (MULTIPLE PIPE SECTIONS) ................................................ 104 DRILLING DIFFICULT FORMATIONS ............................................................................ 104 UNCONSOLIDATED MATERIALS ................................................................................. 105 WET OR STICKY FORMATIONS .................................................................................. 107 ANGLE DRILLING .......................................................................................................... 108 PROGRAMMED DRILL CONTROL DRILLING ............................................................... 109 Controls for Programmed Drill Control .................................................................................... 109

PREPARING TO MOVE ................................................................................................. 110

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MACHINE SHUTDOWN ...................................................................................................... 112 SHUTDOWN PROCEDURE .......................................................................................... 112 SHORT TERM STORAGE ............................................................................................ 113 LONG TERM STORAGE ............................................................................................... 114 ATTENDED LONG TERM STORAGE ........................................................................... 115 UNATTENDED LONG TERM STORAGE ...................................................................... 115 TOOL RECOVERY .................................................................................................................... 116 PIPE SIZE LIMITATIONS ..................................................................................................... 118 Drill Pipe Limitations ............................................................................................................... 118

DRILL STABILITY CHARTS ................................................................................................. 119 Drill Stability Chart - Special Propel Conditions ..................................................................... 119 Drill Stability Chart - Typical Propel Conditions ......................................................................120

TYPICAL MACHINE SPECIFICATIONS ..................................................................................... 121 Machine Dimensions ............................................................................................................... 122

COMPONENT SYSTEMS ......................................................................................................... 125 GENERAL ESTIMATED COMPONENT WEIGHTS ................................................................... 126

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59HR Blast Hole Drill Operator’s Manual

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

Safe operation of the machine minimizes production delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual. Safety guidelines are intended to prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon the use of good judgment and the alertness of the entire mining crew.

Throughout this manual, the use of the terms “LEFT, RIGHT, FRONT, and REAR” refer to machine locations as viewed by the operator sitting in the operator’s seat in the cab.

THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied for this purpose.

Periodic additions or revisions may be made to this manual. Should you require additional information or factory service assistance, contact your regional service representative or:

Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin, USA Telephone (414) 768-4000

53172-0500

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

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

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

Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definition.

In the event you question your ability to safely perform any of the enclosed maintenance and operational procedures contact your regional Bucyrus service representative or the factory.

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

NOTE:

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

CAUTION:

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

DANGER:

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

DANGER:

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

Operating, maintaining or servicing this machine can be dangerous unless performed properly.

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

CAUTION:

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

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

• Check limit switches for proper operation.

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

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

• Use proper interior and exterior lighting.

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

• Perform functional tests of all safety circuits.

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

• Use extreme caution when working around drilled holes.

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

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

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

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

• Never utilize the machine air or hydraulic systems for support when working on the machine.

Deactivate or isolate the entire system prior to performing maintenance.

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

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

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

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

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

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

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

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

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

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

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

• Protective eye goggles should be worn at all times when working on the air conditioning system.

Work on the air conditioning system only in a well ventilated area.

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

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

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Operating Precautions: • Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa • When in doubt about the noise level, wear approved hearing protection.

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

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

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

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

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

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

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

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

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

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FIRE PREVENTION CONSIDERATIONS •

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

•

DO NOT smoke while handling flammables or when near batteries.

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

•

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

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STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS These signals are derived from ANSI-B30.5-1868 and are intended to provide standardization to the signaling used in communication between maintenance personnel and crane operators during the maintenance cycle.

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

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

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

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

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

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

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

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

DOG EVERYTHING Clasp hands together in front of body.

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

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

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

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

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

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

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

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

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

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

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

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MACHINE PLACARDS The images below depict an example of the warning placards mounted on the machine as it was delivered from Bucyrus International. These hazard warning placards convey information to operators, maintenance personnel, and anyone who will be on, or near, the machine. The information is designed to help prevent situations which will result in injury to personnel, or damage to the machine.

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Stored Energy Signs

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

CAUTION:

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

Working in the vicinity of electrical power lines presents a very serious hazard and special precautions must be taken. For purposes of this manual you are considered to be working in the vicinity of power lines when the machine, in any position, can reach to within the minimum distance specified by local, state and federal regulations.

Safe operating practices require that you maintain the maximum possible distance from the lines and never violate the minimum clearances.

Be certain to comply with all local, state and federal regulations regarding working in the vicinity of power lines.

Before working in the vicinity of power lines, always take the following precautions: 1.

Always contact the owners of the power lines or the nearest utility before beginning work.

2.

You and the electric utility representative must jointly determine what specific precautions must be taken to insure safety.

3.

It is the responsibility of the user and the electric utility to see that the necessary precautions are taken.

4.

Consider all lines to be power lines and treat all power lines as energized even though it is known that the power is shut off and the line is visibly grounded.

5.

Slow down the operating cycle. Reaction time may be too slow and distances may be misjudged.

6.

Caution all ground personnel to stand clear of the machine at all times.

7.

Use a signal person to guide the machine into close quarters. The sole responsibility of the signal person is to observe the approach of the machine to the power line. The signal person must be in direct communication with the operator and the operator must pay close attention to the signals.

CAUTION:

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

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MACHINE OVERVIEW The machine is designed and constructed to provide efficient service under the most severe conditions.

The machine is built to the highest possible standards and will provide trouble free operation if properly maintained.

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PROPEL MACHINERY The propel system of this machine is a chainless hydraulic drive system which will allow the separate tracks to counter-rotate. This capability provides the machine with the capacity to turn completely around within it’s own length. Each track is driven by a hydraulic motor and a planetary gearbox equipped with a hydraulically released, spring activated brake. The machine is capable of 2 different propel speed ranges. The lower speed range is used for maneuvering in close spaces while the high speed range is used for tramming in open areas, over long distances.

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MAINFRAME AND DECKS The machine mainframe consists basically of two I-beams tied together with bracing and covered on the top surface with deck plates.

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MACHINERY HOUSE

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MAIN AIR SYSTEMS The screw compressor is located within the machinery house just forward of the hydraulic pump gearcase. The rotary screw compressor is an oil flooded, single stage twin screw type compressor.

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HYDRAULIC SYSTEM Hydraulic pressure for operation of this machine is provided by four separate pumps. These pumps are driven by the electric motor located in main machinery house, forward of the hydraulic filters and reservoir.

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

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

The auxiliary control console is within reach to provide access to additional functions of the machine.

The cab is provided with dual doorways to the main deck.

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MAST The mast is a fabricated structure made of steel tubes and formed plates. The structure is formed by four vertical tubes tied together on three sides with tubular lacing. The fourth side is open to allow the rotary drive unit to be raised and lowered the length of the mast.

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ROTARY/PULLDOWN MACHINERY

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ROTARY GEARCASE

PULLDOWN GEARCASE

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DRILL TOOL STRING ASSEMBLY

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BREAKOUT WRENCH

CABLE REEL

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CONTROLS - LOCATION AND FUNCTION Regardless of previous experience, the new operator of any machine must become familiar with the location and function of all of the operating controls before he can begin to operate the machine.

Since this manual covers all possible controls that could be used on the machine, he should familiarize himself with both this manual and the particular machine being operated.

For the purpose of this manual, the operating controls have been divided into three groups, depending upon their location. These three groups are: 1.

Operator’s Console Controls.

2.

Machinery House Controls.

3.

Miscellaneous Controls.

CAUTION:

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Read and become familiar with this manual before attempting to operate any of the machine controls. Pay particular attention to the caution and warning statements, and any federal, state, local or company safety rules relating to the machine. Failure to be aware of and understand the hazards associated with the operation of the controls may lead to death, personal injury or serious machine damage.

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OPERATOR’S CONTROL CONSOLE NOTE:

The controls on the operators console are all electric. The switches operate electric controls, electromechanical or electrohydraulic valves on the machine. For purpose of describing the controls, the console will be broken down into panels and the controls on each panel described. The panels of the console are: main controls, propel controls, selector switches, leveling controls and Operator’s display terminal.

Operator’s Control Console - Overall View

NOTE:

The panels with controls as shown on the following pages are typical of what could be included on a console. Individual machines will vary depending upon customer requirements.

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MAIN CONTROL PANEL

Main Control Panel

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HOIST/PULLDOWN RHEOSTAT The hoist/pulldown rheostat (1) controls the speed and direction of the hoist-pulldown motor for hoisting or lowering the rotary drive unit.

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

Turning the rheostat in the pulldown direction from the “0” position will lower the rotary drive unit.

Maximum speed is available at full counterclockwise position.

NOTE:

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

ROTARY RHEOSTAT The rotary rheostat (2) controls the speed and direction of the rotary motor which in turn drives the machinery to rotate the tool string.

Turning the rheostat clockwise from the “0” position will turn the tool string in a clockwise direction.

Maximum rotary speed is achieved at full clockwise position.

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

NOTE:

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

DRILL/PROPEL CONTROLS ON AND OFF PUSHBUTTON The drill/propel controls on (3) and off (4) push-buttons are used to energize or de-energize the control levers and switches of the machine.

When the operating mode selector switch is in the DRILL position, depressing the ON pushbutton will energize the hoist/pulldown and rotary drives if all appropriate circuit breakers are closed; no drive or power system faults exist, and master switches are in NEUTRAL. When the operating mode selector switch is in the PROPEL position, depressing the ON pushbutton will enable the propel controls if all appropriate circuit breakers are closed, compressor motor is operating normally, and no power system faults exist.

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

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HOIST/PULLDOWN SPEED SELECTOR SWITCH The hoist/pulldown speed selector switch (5) is located above the hoist/pulldown rheostat and is used to determine the speed range of the hoist/pulldown rheostat. The switch is a four-position switch with the following designations: PULLDOWN, HOIST HIGH, HOIST LOW, and PIPE RACK/ JOINT. In the PULLDOWN setting, which is used for normal drilling, full pulldown force is available but the speed range for both pulldown and hoisting is limited to about 25 FPM (7.62 MPM).

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

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

In the HOIST HIGH position maximum head speed capability is allowed for both hoisting and lowering.

However, force capability in the lowering direction is limited to the weight of the rotary head/pipe combination. No additional downforce is allowed to the drive which reduces the chance of equipment damage during lowering operation.

As a result of obtaining a higher speed, the hoist force capability at full speed is not as large as is obtainable in the HOIST LOW position.

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

NOTE:

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

ROTARY SPEED SELECTOR SWITCH The rotary speed selector switch (6) is a three position switch located above the rotary rheostat.

This switch determines the speed/torque range of the rotary motor. In the LOW position, the motor has the highest torque capability but is limited in speed to about 85-100 RPM at the bit. In the HIGH position, the motor has a higher speed capability (110-140 RPM range) but motor torque will be less (typically 68% to 74%). The MEDIUM position provides for operation between the HIGH and LOW positions.

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

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HOIST BRAKE SWITCH The hoist brake switch (7) is a two-position switch. It is used to set or release the hoist brake.

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

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

PIPE RACK SELECTOR SWITCH The pipe rack selector switch (8) is a four-position switch used to determine which pipe rack will be operated. For machines without a pipe rack or with only one pipe rack, this switch is not used.

PIPE RACK JOYSTICK (Left Crawler Propel) This joystick (9) will operate the pipe rack or the left crawler (secondary propel control). For the joystick to control the pipe rack, the operating mode selector switch on the propel control panel must be in the DRILL position and the hoist/pulldown speed selector switch (5) in the PIPE RACK/JOINT position.

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

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

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

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WINCH/MAST SELECTOR SWITCH The winch/mast selector switch (10) is a two-position switch. Turning the switch to the WINCH position will activate the winch circuit. The joystick associated with this switch can then be used to operate the winch. Turning the switch to the MAST position will activate the mast hoist cylinder circuit and the associated joystick is used to raise or lower the drill mast.

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

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

MAST/WINCH JOYSTICK (Right Crawler Propel) This joystick (11) is used to raise or lower the mast, operate the auxiliary winch or right crawler.

For the joystick to control the mast raising and lowering operation, the operating mode selector switch on the propel control panel must be in the DRILL position and the mast/winch selector switch (10) must be in the MAST position.

For the joystick to control the auxiliary winch, the operating mode selector switch on the propel control panel must be in the DRILL position and the mast/winch selector switch (10) must be in the WINCH position.

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

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

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

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

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

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TOOL WRENCH SWITCH The tool wrench switch (12) is a three-position spring return switch. Turning the switch to the EXTEND position will cause the tool wrench to extend to clamp the drill pipe. Turning the switch to the RETRACT position will retract the wrench, releasing the drill pipe. This switch is functional whenever the hydraulic pumps are running.

DUST CURTAIN SWITCH The dust curtain switch (13) is a three-position switch. Turning the switch to the UP position will raise the dust curtains. Turning it to the LOWER position will lower the dust curtains.

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

BIT VIEW HATCH SWITCH This is a two-position switch (14) that is used to move the hatch for viewing the drill bit on the ground. Moving the switch to the CLOSE position will close the hatch. Turning the switch to the OPEN position will open the hatch.

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PROPEL CONTROL PANEL

Propel Control Panel

EMERGENCY STOP PUSHBUTTON The emergency stop pushbutton (1) is a large red mushroom head pushbutton switch. Depressing the pushbutton will cause the power to the machine from the power source to be disconnected. The pushbutton is tied to the power source ground check circuit.

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

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COMPRESSOR STOP PUSHBUTTON This pushbutton (3) is used to shutdown the compressor motor. The compressor will have to be restarted from the machinery house.

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

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

One switch (5) selects the mode being used and has the following positions: OFF, FAN, HEAT, and COOL. The other switch (6) controls fan speed for vented air and circulated air. The four positions are: VENT HIGH, VENT LOW, CIRCULATE HIGH, and CIRCULATE LOW.

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

PROPEL JOYSTICKS For the joysticks (8 & 9) to control the crawlers, the operating mode selector switch (7) must be in the PRIMARY PROPEL position. Pushing the right (8), left (9), or both joystick levers forward will cause the machine to move forward, straight, right, or left, depending upon which lever(s) were pushed. Moving the levers to the rear will cause the machine to move rearward, straight, right, or left, depending upon which lever(s) were moved.

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

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SELECTOR SWITCH PANEL

Selector Switch Panel

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

PIPE POSITIONER SWITCH The pipe positioner switch (2) is a three-position spring-return switch. Turning the switch to the OVER HOLE position will retract the positioner alignment cylinders. When fully retracted it will then extend the positioner jaw cylinder to clamp the drill pipe. Turning the switch to the STORE position will retract the jaw cylinder, then extend the positioner alignment cylinders. This switch is functional whenever the hydraulic pumps are running.

DUST SEAL SWITCH This is a three-position spring-return switch (3) which is used to initiate movement of the drill deck dust seal. Turning the switch to the rear position will cause the dust seal mechanism to move toward the rear of the machine. Turning the switch to the forward position will cause the dust seal mechanism to move toward the front of the machine. This switch is functional whenever the hydraulic pumps are running, and is only used on machines with the angle hole drilling package.

A-FRAME LOCK SWITCH The A-frame lock switch (4) is a three-position spring-return switch. Turning the switch to the LOCK position will extend the A-frame lock pin cylinder. Turning the switch to the UNLOCK position will retract the cylinder. For this switch to be functional, the hydraulic pumps must be running, the mast/ winch selector switch must be in a vertical position with mast lock pins in place. When the machine is drilling at an angle, these pins are in the UNLOCKED position. This switch is only used in machines equipped with the angle hole drilling package.

MAST BRACE LOCK SWITCH The mast brace lock switch (5) is a three-position spring-return switch. Turning the switch to the LOCK position will extend the mast brace lock pin cylinder. Turning the switch to the UNLOCK position will retract the cylinder. For this switch to be operable, the hydraulic pump must be running and the mast/winch selector switch must be in the MAST position. This will allow the switch to function in the LOCK position. To function in the UNLOCK position, the rotary head assembly must be at the lower limit point. This additional restriction, of having the rotary head assembly at the lower limit, is not required for machines with the angle hole drilling feature.

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MAST LOCK SWITCH The mast lock switch (6) is a three-position spring-return switch. Turning the switch to the LOCK position will extend the mast lock cylinder. Turning the switch to the UNLOCK position will retract the cylinder. Before this switch can become operable the hydraulic pumps must be running and the mast/winch selector switch must be in the MAST position. For the switch to be functional in the UNLOCK position, the rotary head assembly must be at the lower limit point. On machines with the angle hole drilling feature, the A-frame locking pins must also be in place before this switch can become operable.

BOARDING STAIRS SWITCH The boarding stairs switch (7) is a two-position switch. A like switch is located at the stairs. Depending upon the position of the stairs, the switch must be moved from its present position to the opposite position for the stairs to change position.

PEDESTAL HEATER SWITCH The pedestal heater switch (8) is a two-position switch used to turn the heater ON or OFF.

FIRE SUPPRESSION SYSTEM INDICATORS The fire suppression system indicators (9) show the status of the fire suppression system.

RADIO The radio (10) is standard equipment.

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LEVELING CONTROL PANEL

Leveling Control Panel

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

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MANUAL LEVELING JOYSTICKS The four two-directional joysticks (1, 2, 3, & 4) are used to manually raise or lower the leveling jacks.

Moving a joystick forward will extend the corresponding jack cylinder and raise that corner of the machine. Pulling the joystick toward the operator will retract the corresponding leveling jack cylinder and lower that corner of the machine. These joysticks are not functional if the automatic leveling switch is being used.

NOTE:

The joysticks should be moved in pairs. Single joysticks may be used for the final adjustment of leveling jacks. All four leveling jack joysticks should not be moved at the same time.

AUTOMATIC LEVELING SWITCH The automatic leveling switch (5) is a three-position spring return switch. Turning the switch to the EXTEND position will extend the leveling jack cylinders and raise the machine. Turning the switch to the RETRACT position will retract the cylinders and lower the machine. When this switch is being used, the manual leveling joysticks are not functional.

NOTE:

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

WATER INJECTION ON/OFF SWITCH The water injection on/off switch (6) is a two-position switch used to start-up or shut-off the water injection system. When the switch is turned to the OFF position, it will stop the pump.

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

WATER INJECTION FLOW CONTROL The water injection flow control (7) is a potentiometer used to regulate the water flow. Full counterclockwise rotation of the control will shut off water flow. Full clockwise rotation of the control will supply maximum flow of water.

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HORN PUSHBUTTON The horn pushbutton (8) is used to sound the warning horn of the machine.

DEPTH INDICATOR RESET PUSHBUTTON The depth indicator reset pushbutton (9) is used to zero out the depth meter, as shown on the Operator’s display terminal Operator’s Display screen, when one hole is completed and another is to be started. This function can also be performed on the operator’s display terminal keypad.

PROGRAMMED DRILL CONTROL SWITCH The programmed drill control switch (10) is used to activate or deactivate the programmed drill control system on the machine. This function can also be performed on the operator’s display terminal keypad.

EMERGENCY STOP PUSHBUTTON The emergency stop pushbutton (11) is a large red mushroom head pushbutton switch. Depressing the pushbutton will cause the power to the machine from the power source to be disconnected. The pushbutton is tied to the power source ground check circuit.

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

The operator’s Display Terminal displays status information for all PLC controlled machine functions. Some machine setup parameters may be entered using the keypad.

Refer to the topic at the end of this section for further operational procedures for the Operator’s Display Terminal.

Operator’s Display Panel

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MACHINERY HOUSE CONTROLS NOTE:

The controls shown on the following illustrations are typical of the controls on a machine.

Because of the variations of controls that can be supplied for customers needs, be sure to become acquainted with the controls on the cabinets of your machine. All controls will be identified with nameplates.

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

The lighting load center contains the breakers to control the interior and exterior lights and various auxiliary functions.

Each breaker is labeled as to its particular function on any particular machine.

The controls are three-position lever operated circuit breakers. Moving the lever in one direction (ON) will close the circuit, while moving it in the opposite direction (OFF) will open the circuit. The center position is the tripped position.

The breaker may be reset by moving the lever to the OFF position and then back to the ON position.

CONTROLS ON THE LOW VOLTAGE START CABINET The low voltage start cabinet contains the breaker for the main compressor. Turning the breaker to the ON position will activate the compressor circuits, allowing the compressor to be started.

Main Air Compressor Breaker

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CONTROLS ON THE LOW VOLTAGE CABINET The low voltage cabinet contains most of the breakers for the auxiliary equipment on the drill.

Because of the variations of equipment supplied on a particular drill, a list of typical controls which might appear on the cabinet is shown in figure.

Low Voltage Cabinet (Typical)

CONTROL ON THE PROGRAMMABLE CONTROLLER CABINET The typical programmable controller cabinet contains controls as shown in figure.

Programmable Control Cabinet

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HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS Typical controls on the Hoist/Pulldown and Rotary Drive Control cabinets are shown in the figure below.

Hoist Pulldown and Rotary Drive Cabinets

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CONTROLS ON OR NEAR THE AIR COMPRESSOR A typical set of controls, monitors and indicators located on or near a screw type air compressor are shown in figure.

Air Compressor Mounted Controls

NOTE:

For the exact controls located on a screw type air compressor on a particular machine refer to the compressor manufacturer’s manual.

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MISCELLANEOUS CONTROLS Located about the machine are various miscellaneous controls and monitors which would be used with optional equipment or do not fit in the previously described groups.

PORTABLE REMOTE PROPEL STATION (OPTIONAL) The portable remote propel station is located in an enclosure under the operator’s cab on the right side of the machine. In addition to storing the portable station the enclosure includes 40 feet of cable and an enabling switch to energize or de-energize the station. Another enabling switch and plug in socket are located at the front right corner of the drill main frame.

The station includes two joysticks, one for each crawler frame; an emergency stop pushbutton; a propel speed selector; and a red indicator which will light up when the station is energized.

Portable Remote Propel Station (Optional)

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HYDRAULIC RESERVOIR REMOTE FILL CONTROL PANEL The hydraulic reservoir remote fill control panel is used to monitor the reservoir as it is being filled.

The instructions for use of these controls are printed directly below the controls.

Hydraulic Reservoir Remote Fill Control Panel

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

Lube Control Panel

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PRESTART CHECKS Before starting the drill, inspect it to ensure it is ready to be put into operation. Failure to make such a routine check could result in unnecessary downtime. For example, an undetected oil leak could result in a dry gear case, which would lead eventually to excessive gear wear or destruction, seized bearings, or other mechanical problems. A few minutes spent inspecting the machine often results in considerable savings in time and machine efficiency. This inspection should be performed before each shift.

EXTERNAL INSPECTION 1.

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

2.

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

3.

Check the drive tumbler gearcase, hydraulic motor and hoses for leaks. Check the lubricant level in the drive tumbler gearcase.

4.

Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and bolts.

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Daily Inspection Items

5.

Check the dust curtains for tears. Be sure that the curtains are not frozen to the ground or covered with cuttings.

6.

Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp rocks. Have an electrician inspect the strain relief device and the condition of the cable where it enters the machine.

CAUTION:

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

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7.

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

8.

Inspect the leveling jack spuds for proper lubricant covering. Inspect the leveling jack pads for cracks, broken or missing pins, or excessive dirt accumulation.

9.

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

CAUTION:

Use a safety belt and lanyard to protect against falls when climbing on the mast braces or working on the machinery house roof.

10.

Inspect the mast hinge pins for loose or missing keepers or bolts. Replace missing or damaged parts immediately. Check the pins for sufficient lubrication and lubricate if necessary.

11.

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

12.

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

13.

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

14.

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

15.

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

16.

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

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ONBOARD INSPECTION 1.

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

2.

Check the condition of the air compressor intake filter. Replace the filter cartridge if the red flag is visible in the service indicator. Empty the dust hopper and clean the pre-cleaner element.

Inspect the housing and ductwork for damage or leaks. Repair or replace leaking components.

3.

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

4.

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

5.

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

Onboard Inspection Items

6.

7.

Inspect the automatic lubrication central pumping stations for proper operation. Check the supply of lubricant and change or refill drums as necessary.

Close and lock all electrical cabinet doors.

CAUTION:

8.

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

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

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9.

Check the operator’s display terminal for any faults.

10.

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

NOTE:

Do not use compressed air to clean the machinery house. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the machine. Failure to clean the inside of the machinery house will cause damage to many of the components located there.

11.

Inspect the auxiliary winch and auxiliary winch line.

12.

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

13.

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

14.

Inspect the operator’s cab for housekeeping and cleanliness. Clean dirt and debris from the cab. Clean the windows to give full visibility for proper operation.

NOTE:

15.

Do not use compressed air to clean the operator’s cab. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the cab.

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

CAUTION:

Before working near or under the rotary drive/pulldown unit, make sure all of the operator’s controls are off and tagged and the hoist brake set to prevent movement of the unit. Serious personal injury or death could result should the rotary drive/pulldown unit fall when personnel are working near or under it.

16.

Inspect the automatic breakout wrench for free operation, broken or missing parts, proper lubrication, lubricant leaks or excessive dirt accumulation. Repair or replace parts as necessary.

Be certain that the breakout wrench is retracted.

17.

Inspect the pipe racks for broken or missing parts, proper operation, dirt accumulation, or lubricant leaks. Be certain that the upper gate is closed and that the rack is in the stored position.

18.

Inspect the guide bushing for excessive wear or dirt accumulation. Also inspect the retainer lugs to be sure they are intact. Do not operate the machine without both retainer lugs intact and securely welded to the deck.

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19.

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

20.

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

21.

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

22.

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

23.

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

24.

Check the hoist brake for proper operation.

25.

Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation.

The deflector should seal around the drill pipe securely.

26.

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

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PRESTART LUBRICATION Lubrication of the machine is an extremely important job. Most drills come equipped with automatic lubrication systems that lubricate most of the necessary points at regular intervals. These systems, although automatic, are not foolproof. Broken lines, dirty lubricant, faulty feeders, and a whole range of other problems can cause wearing parts to loose lubrication. For this reason, it is important that all lubrication points be inspected every shift to verify that they are receiving lubrication. Also, there are several points for lubrication that either need lubrication very infrequently, or are not possible to pipe into the automatic system. These points will need lubrication applied manually.

The lube charts in Appendix 3 gives the location and frequency of lubrication.

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

When using a manual gun wipe each fitting and the grease gun fitting before injecting the lubricant.

Use clean containers and funnels for lubricant for transferring to the gear cases or reservoirs. Do not allow water to enter any gear case, reservoir or container. Wipe off all fill caps before removing them.

START-UP Start-up of this machine is a very important operation. Improper start-up could cause various safety and operating difficulties as well as damage to the machine. Following the step-by-step procedure listed below to start the machine will help reduce the possibility of accidental injury or machine damage.

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

1.

Go into the operator’s cab and verify that all controls on the operator’s console are in the off or neutral position. Be sure that the EMERGENCY STOP pushbutton is in the pulled-up position.

NOTE:

On some machines there are two or more Emergency Stop push-buttons. Be sure ALL Emergency Stop push-buttons are in the RELEASED (UP) position.

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2.

Go to the machinery house to the low voltage start cabinet. Turn ON the main compressor breaker.

3.

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

4.

On the programmable controller cabinet verify that the lockout control pushbutton is in the RELEASED position. Turn the house pressurization fan switch to the desired operating position.

Verify that the operator’s display terminal power supply, PLC input and PLC output breakers are in the ON position,

5.

Press the air compressor start pushbutton on the programmable controller cabinet to start the main compressor.

NOTE:

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

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

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MACHINERY CHECK The following is a list of points and equipment that should be checked for proper operation immediately following start-up of the drill. If operating difficulties are not found during this procedure, they probably will not be noticed until some point in time at which the system or component will cease to function and cause serious damage to the machine.

1.

Check the main air system for leaks.

2.

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

3.

Check for leaks in the hydraulic system.

BREAK-IN OF NEW COMPONENTS When a machine is new, is returned to service after a long period of storage, or is returned to service after major repairs, certain precautions must be taken upon initial start-up and for a time following the start-up. These precautions are necessary to insure that the full service life of the components is realized.

ROTARY DRIVE UNIT BREAK-IN Break-in of the rotary gear case is limited to reduced loading during the first 100 hours of operation and a complete oil change at the end of the break-in period.

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

HOIST/PULLDOWN GEARCASE BREAK-IN Break-in for the hoist/pulldown gearcase is limited to reduced loading during the first 100 hours of operation and a complete oil change at the end of the break-in period.

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

ELECTRIC MOTOR BREAK-IN Break-in of the rotary and hoist/pulldown motors is limited to reduced loading and inspection for the first 8 hours of operation. This break-in period is intended to spot any problems in the motors before they lead to serious damage to the motors or the machine. Inspection should include monitoring the motor temperature and listening for unusual noises which might indicate a problem. Inspection should also include verifying that all blower vents and intake openings are open.

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MAINTENANCE DURING OPERATION Safety requirements dictate that all machines in active service be inspected at regular intervals for proper adjustment of operating mechanisms, excessive wear of components, system cleanliness and any other defects. In-operation deficiencies should be carefully investigated. It should be determined if a safety problem exists. Remember that maintenance is vital to safe operation. It should be performed systematically by competent personnel.

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the machine is running. Obviously, there are some maintenance procedures, such as gear tooth inspection and compressor maintenance, which require machine shut down.

However, many support duties can be safely and effectively handled at shift change when the machine is still activated.

Some parts of the machinery may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

DANGER:

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MAKE SURE ALL GUARDS, COVERS OR OTHER SAFETY DEVICES ARE PROPERLY INSTALLED BEFORE OPERATING THIS EQUIPMENT AFTER PERFORMING MAINTENANCE OR REPAIRS. FAILURE TO HEED, COULD RESULT IN SERIOUS INJURY OR DEATH. A REPAIR OR MAINTENANCE TASK IS NOT COMPLETE UNTIL ALL GUARDS, COVERS OR OTHER SAFETY DEVICES REMOVED TO PERFORM THE TASK HAVE BEEN PROPERLY REINSTALLED.

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PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK The operator must be sure the equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a yielding support surface.

Before beginning repair or adjustment, the operator shall: • • • •

Secure the rotary drive unit and tool string.

Set all brakes.

De-energize and tag control functions.

Do whatever else is necessary to prevent accidental movement of the machine.

DANGER:

ALL PERSONNEL MUST BE CLEAR OF ELECTRICAL, MECHANICAL AND HYDRAULIC COMPONENT HAZARDS WHILE THE MACHINE IS OPERATING, OR WHILE USING THE CONTROLS DURING A REPAIR ACTIVITY.

Prior to beginning any work, maintenance personnel must notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the engine must be shut off, the engine key switch in the “OFF” position with the key removed, and the controls should be tagged.

The machine should only be returned to service when the maintenance personnel have completed all maintenance and have notified the appropriate personnel.

Approved protection equipment such as hard hats, gloves and safety glasses should always be worn around the machine. When the engine is running, hearing protection should be worn.

While performing maintenance, the awkward positions encountered often increase injuries due to handling heavy parts. As a precautionary measure, use mechanical lifting and handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials, ladders and scaffolding. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

DANGER:

Many of the components of the machine are heavy, bulky items.

EXTREME CAUTION SHOULD BE USED WHEN LIFTING. Personnel should be certain of the weights of components before attempting to lift them, either manually or with some lifting device. FOLLOW ALL APPLICABLE SAFETY RULES WHEN USING CRANES OR OTHER LIFTING EQUIPMENT. BE SURE OF THE LOAD, LIFTING HEIGHT AND RADIUS, AND CAPACITY OF THE LIFTING DEVICE BEFORE LIFTING. Failure to follow all applicable safety rules when lifting can cause serious injury or death.

CAUTION:

USE EXTREME CAUTION WHEN STRIKING METAL PARTS WITH A SLEDGEHAMMER AS CHIPS MAY FLY OFF WITH GREAT FORCE AND POSSIBLY CAUSE SERIOUS INJURY. WEAR ADEQUATE PROTECTIVE CLOTHING INCLUDING A FACE SHIELD. Alternate methods of removal might involve using a ductile metal hammer or a hydraulic jack with suitable fixtures.

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OPERATION Operation of this machine is, in principle, the same as the operation of any other machine. But just because the machines operate using the same in principles does not mean they operate the same in all respects. For this reason it is important that the operator become familiar with the particular machine that is being operated.

The purpose of this section of the operator’s manual is to detail the procedures involved in operating many of the major components and preparing to drill a hole. The actual drilling procedure is detailed later within this section.

Become familiar with the controls and learn to operate at reduced speeds. As the machine and drilling cycle become more familiar, increase speeds gradually to the full operating capability of the machine.

The most important reason to operate slowly at first is safety. Operating at full speed means that things happen quickly, perhaps more quickly than expected. This unexpected operation of equipment can very easily lead to an accident.

For the purpose of this manual, we will assume that the drill has been left in the proper condition for operating. If this is not the case, complete the prestart checks and start the machine using the procedures as outlined.

PROPELLING

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

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

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

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PROPEL PROCEDURE Before beginning the propel operation, the operator should first inspect the travel route for large rocks, deep ruts, or uneven contours. When working on a grade, verify the slope and compare to the allowable maneuvering slope limits (see APPENDIX 5).

CAUTION:

Do not attempt to maneuver or steer the machine on grades which exceed the allowable maneuvering slopes without consulting the special propel LIMITATIONS CHARTS AT THE END OF THIS SECTION. Failure to follow these instructions could result in a machine tip-over, damaging the equipment and resulting in possible serious injury or death.

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

Once it has been verified that the travel route is in good condition, the machine is now ready to propel.

NOTE:

The drill should only be propelled with the mast fully lowered, fully raised and locked, or locked at an ANGLE HOLE setting.

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

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

All of the stability values shown are based on a fully loaded machine (i.e. full water tank, cable on cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by the Customer and shipped by Bucyrus International, Inc. The machine is propelled using the controls on the operator’s console in the operator’s cab or radio controlled from the remote propel station outside the machine.

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Operator Controls - Propel

1.

Verify that the hoist brake is set. Verify that the tool string is clamped with the tool wrenches to prevent the tools from moving during the propel operation. Also, verify that the tool string is hoisted to a position to avoid striking the ground when the machine is propelled. Verify that the leveling jacks are fully retracted and that the dust curtains are fully raised. Verify that the boarding stair is raised.

2.

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

3.

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

4.

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

NOTE:

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

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

5.

To propel straight forward lift up on both joysticks to unlatch them and release the propel brakes, then move both joysticks slowly forward. Speed is increased as the levers are moved forward. To propel straight in reverse pull both joysticks slowly to the rear. Speed is increased as the levers are pulled.

Propel - Forward or Reverse

6.

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

Propel - Gradual Right Hand Turn

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Propel - Gradual Left Hand Turn

7.

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

8.

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

Propel - Counter-Rotation Left Hand Turn

9.

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

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Gradual Turns - 15° Increments

CAUTION:

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

NOTE:

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

NOTE:

The ability of the machine to turn sharply is dependent on the surface on which the machine is setting. A soft surface will cause the crawlers to dig in and machine to bog down.

NOTE:

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

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TOWING PROCEDURE CAUTION:

Be sure crawlers are securely blocked before disengaging gearbox clutch for towing.

1.

Secure the machine by blocking crawlers.

2.

Secure the tow bar to the towing vehicle.

Tow Bar Detail

3.

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

4.

Disconnect the drive tumbler gearbox from the propel motor as follows: a.

Ensure that the propel pump controls are in neutral position

b.

Loosen shifter lever lock screw

c.

Pull out shifter lever to disengage clutch

d.

Tighten shifter lever lock screw

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5.

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

NOTE:

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

NOTE:

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

6.

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

CABLE REEL OPERATION When the cable reel switch is in the AUTO position, is designed to pick up trail cable as the drill moves toward its power source. It is not designed to drag the trail cable over the ground.

Cable Reel

The line pull is proportional to operating pressure. The correct line pull is when there is sufficient pull on the cable to wind it on the reel, but not too great to put unnecessary strain on the trail cable.

The line speed is dependent on the volume of hydraulic oil flowing through the system. The correct line speed is slightly faster than the travel speed of the drill.

To manually operate the cable reel, proceed as follows: 1.

Start the main air compressor motor or turn ON the external cable reel switch. This will automatically start the cable reel hydraulic system motor. Allow the oil to circulate for about 5

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minutes.

2.

To spool the trail cable onto the reel, turn the cable reel switch to the REEL IN position.

3.

To spool the trail cable off of the reel, turn the cable reel switch to the REEL OUT position.

LEVELING To level the drill, proceed as follows: 1.

Place the machine in the proper location to drill the required hole. Verify that the leveling jack pads will rest on solid footing. Cut or fill or reposition as necessary to achieve solid footing.

Maximum angle for jack pad is 17°.

2.

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

NOTE:

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

Machine Orientation

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3.

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

4.

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

5.

Lower all four leveling jacks until they are resting on the ground. Then, starting with the low side (left or right) of the drill, slowly lower the jacks until the weight of the machine is resting on them. The leveling jack controls should be operated in pairs while doing this operation. This reduces the twisting of the drill frame. Once the weight of the machine is resting on the downhill side leveling jacks, slowly lower the uphill side leveling jacks until the machine weight is resting on them. The machine need not be raised a great deal during this operation, since the purpose is only to get the weight of the machine resting on the leveling jacks.

CAUTION:

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

6.

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

7.

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

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Controls for Leveling the Machine

MAST RAISING AND LOWERING The mast is normally left in the raised position for most situations including propelling from hole to hole on a blast pattern. Lowering the mast is necessary under three conditions: 1.

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

2.

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

3.

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

MAST RAISING CAUTION:

Raising or lowering the mast is a two-person job. Do not attempt to raise or lower the mast without the assistance of a helper familiar with the procedures involved.

CAUTION:

During the mast raising procedure personnel should be kept clear of the machine and the area immediately surrounding the machine, especially the front of the machine. No one is to be allowed on the mast, operator’s cab roof, or machinery house roof while the mast is in the air. Failure to heed this caution may result in the death or serious injury of personnel struck by the mast should it fall for some reason.

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CAUTION:

Limitations exist as to the length, diameter, wall thickness and number of drill pipes that may be stored in the pipe racks when raising or lowering the mast. Refer to the pipe size limitation chart in the appendix before attempting to raise or lower the mast. Failure to comply with these limitations will overload the mast, mast support and hydraulic system possibly causing loss of control of the mast.

1.

Inspect the mast and machine exterior to ensure that all wires, hoses, cables, etc. are clear of the machine to prevent damage to the machine or equipment during the raising procedure.

Check that the mast cylinder pins, mast hinge pins, and mast brace pins are in place and secured. Verify on the operator’s display terminal operator’s display screen that no reference to A-frame pins is shown. Verify that the operating mode selector switch is in the DRILL mode.

2.

The main air compressor motor must be energized. Move the winch/mast selector switch to the MAST position. Slowly raise the mast by lifting and then slowly pushing the mast/winch joystick, located on the main control panel, forward. As the mast reaches an angle of 70 degrees it will begin to go over center and tend to come into the vertical position by itself. Care should be used once the mast has gone over center since the speed of the mast will increase sharply.

CAUTION:

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

Controls for Raising or Lowering the Mast

NOTE:

Pay close attention to the hoses, wires and cables that run between the mast support and the mast to prevent damage to the machine as the mast is being raised. Have a helper watch from a safe position on the left side of the machine as the mast is going up.

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3.

Once the mast is vertical, move the mast lock switch to the LOCK position to lock the mast in the vertical position. Return the lever to the neutral position when the latch is in position.

Blinking (Mast Pins Out) on operator’s display terminal operator’s display screen will disappear when mast is locked in position. Turn the mast brace lock switch to the LOCKED position to secure the mast and brace in the vertical position.

NOTE:

When moving the mast for angle hole drilling, on machines with mast lengths of 65 ft. (19.8 M) or more, the drill pipe must be stored in the racks and the rotary head lowered to its lowest position.

4.

If the mast is to be set up for angle drilling move the A-frame lock switch and the mast brace lock switch to the UNLOCK position to release the A-frame front leg lock pin and mast brace lock pins. The readout (A-frame Pins Out and Mast Brace Pin Out) will show up on the bottom of operator’s display screen of the operator’s display terminal.

5.

Verify that the winch/mast selector switch is still in the mast position, then lift and pull the mast joystick slowly to the rear. Slowly lower the mast to the desired drilling angle, then turn the mast brace lock switch to the LOCKED position to secure the mast and brace in the desired position.

MAST LOWERING NOTE: Refer to the cautions at the beginning of MAST RAISING. To lower the mast: 1.

Remove the drill pipe from the rotary drive unit and store it in the pipe racks. Remove the bit and stabilizer from the machine. Clear the drill deck of all tools and materials which could fall off during the lowering procedure. Secure the auxiliary winch hook. Be sure the auxiliary winch line is secured to the mast. Raise the dust curtains. Lower the rotary/pulldown unit to its lowest position. Verify that the machine is level.

2.

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

3.

If the machine is set up for angle drilling and the mast is at an angle proceed to step 4. If the machine is set up for vertical drilling proceed to step 5.

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Controls for Angle Drilling

4.

Turn the mast brace lock switch to the UNLOCK position to release the mast lock pins, then raise the mast to the vertical position (figure 4-13). Turn the A-frame lock switch to the LOCK position to lock the A-frame front leg. The readout (A-frame Pins Out) on the operator’s display terminal will disappear when the A-frame pins are in the LOCKED position. Now proceed to step 5 to lower the mast.

5.

If the mast lock pins and/or mast brace lock switch have not been released, turn the switches to the UNLOCK position to release the pins. A blinking readout (Mast Pins Out and Mast Brace Pins Out) will appear on the operator’s display terminal when the pins are released.

6.

Slowly lower the mast by lifting and then pulling the joystick to the rear (figure 4-13). As the mast moves away from the vertical position, its speed will increase. Gently reduce the lowering speed by moving the joystick toward neutral.

CAUTION:

NOTE:

The joystick should be moved away from and returned to the neutral position very slowly. Sudden starts and stops can be damaging to the mast hydraulic system. Be extremely cautious as the mast approaches the mast rests, as only a slight movement of the control is necessary to cause motion in the mast. Lay the mast in the mast rests gently to prevent damage to the mast or machine house.

Pay close attention to the hoses, wires and cables that run between the mast support and the mast to prevent damage to the machine as the mast is being lowered. Have the helper observe the machine from a safe position on the left side of the machine as the mast is coming down.

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

7.

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

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PULLDOWN MACHINERY OPERATION Use of the pulldown machinery is necessary during the tool handling and the drilling procedures.

The pulldown machinery supplies power to either raise or lower the rotary/pulldown unit. Power is supplied to the pulldown gearbox by an electric motor.

Controls for Hoist / Pulldown

To operate the hoist/pulldown machinery proceed as follows; 1.

Move the operating mode selector switch to the DRILL position.

2.

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

For this procedure, turn the switch to the PULLDOWN position. For a review of each switch position, refer to Hoist/Pulldown Speed Selector Switch.

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3.

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

4.

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

5.

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

6.

Rotate the pulldown force rheostat in the pulldown direction to lower the rotary/pulldown unit.

The farther the rheostat is turned to the left the faster the unit will be lowered.

7.

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

CAUTION:

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

AUXILIARY WINCH OPERATION

Controls for Operating the Winch

To operate the auxiliary winch proceed as follows: 1.

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

2.

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

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3.

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

4.

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

PIPE RACK OPERATION The machine can be equipped with 1 to 4 pipe racks and depending upon the number of pipe racks the pipe rack configuration and operation will be different.

•

On a machines with one pipe rack, the rack will be on a swing out arm and will be in #1 position .

•

On a machine with two pipe racks, the racks will be on swing out arms and will be in #1 and #4 positions.

•

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

•

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

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Controls for Operating the Pipe Racks

The general method of operating the pipe racks is as follows: 1.

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

2.

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

3.

Select the desired pipe rack.

4.

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

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

1.

One pipe rack configuration. a.

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

b.

Operate the rack as described under general procedure.

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2.

Two pipe rack configuration. a.

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

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b.

NOTE:

3.

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

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

Three pipe rack configuration. a.

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

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

The carousel configuration of pipe racks one and two requires a special sequence.

Position #1 of the selector switch will allow, when the joystick is pulled to the rear, the carousel with pipe racks to be swung out over the guide bushing hole.

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

NOTE:

4.

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

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

Four pipe rack configuration. a.

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

b.

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

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TOOL HANDLING This section describes the procedures necessary to load, unload, handle, assemble and disassemble the drill tools.

The procedures detailed in this section are intended to be as universally applicable as possible. It is, however, impossible to prepare a procedure that will take into account every possible machine option or tool vendors’ products. For this reason it is important that the operator not only become familiar with these procedures, but with the machine and the particular tools being handled.

PIPE LOADING AND UNLOADING Loading pipe onto the drill is necessary when the drill is new and has not yet had the pipe installed or when the pipe has been removed for change out or for maintenance to the mast. The procedure in this manual, unlike some more commonly used procedures, requires that the mast be in the horizontal or lowered position to load the drill pipe. This is necessary for safety.

This procedure, while not the most expedient for machines requiring pipe change out while the mast is in the drilling position, is quite efficient while the mast is in the stored position. Proper scheduling of maintenance and production requirements against pipe life will allow using this procedure while reducing the downtime of the machine.

CAUTION:

Limitations exist as to the length, diameter, wall thickness and number of drill pipes that may be stored in the tool racks when raising or lowering the mast. Refer to the pipe size limitation chart in the appendix of this manual before loading pipe onto the machine with the mast down and before raising or lowering the mast. Failure to comply with these limitations will overload the mast, mast support and hydraulic system possibly causing loss of control of the mast.

Refer to the appendix of this manual for an alternate method of loading and unloading pipe from the machine in order to comply with the mast raising and lowering limitations.

To load drill pipe onto the drill, proceed as follows: 1.

If the mast is in the vertical or drilling position, lower the mast and store it in the mast rests.

Refer to the appropriate topic in this manual for the exact operating procedures.

2.

Obtain a crane with suitable capacity and reach to place the drill pipe into the pipe racks with the mast in the stored position. Normal placement of the crane is on the left side of the drill since this allows the shortest reach and greatest boom angle.

CAUTION:

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

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3.

Position the pipe to be installed in such a position so as to be accessible to the crane. Normal placement of the drill pipe is on the left side of the machine, laying at right angles to the machine. This allows the crane to lift the pipe and swing without excessive boom hoisting and lowering. The pipe may be stored on suitable blocking on the ground, or on a truck or trailer.

CAUTION:

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

4.

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

5.

Using suitable rigging, attach the crane to the drill pipe. The pipe should be rigged so that it will remain horizontal while being lifted. Attach suitable tag lines to the pipe. Remove the thread protectors and clean and lubricate the threads and shoulders on each end of the pipe.

Install an approved lifting bell to the pin (upper) end of the pipe. Lift the pipe into position over the mast.

6.

Using a tag line guide the pipe into the desired pipe rack. Place suitable blocking beneath the pipe to allow the sling to be removed from the pipe.

CAUTION:

Block the pipe securely to prevent it from moving unexpectedly.

7.

Remove the slings from the pipe. Attach a sling to the lifting bell on the pin end of the pipe and lift the pipe sufficiently to remove the blocking.

8.

Slide the pipe down the pipe rack until it rests on the bottom of the pocket. Lay the pipe in the pipe rack and remove the sling and lifting bell.

9.

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

10.

Repeat the procedure for additional lengths of pipe.

11.

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

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

To install the stabilizer proceed as follows: 1.

Place the stabilizer to be installed in a position so as to be accessible to the auxiliary inch line. Clean and lubricate the threads and shoulders on each end of the stabilizer.

Install a lifting bell on the pin (upper) end of the stabilizer and lift it onto the drilling deck with the auxiliary winch line. Securely block the stabilizer horizontally on blocking sufficient enough to place the stabilizer 8-10 inches above the drill deck. Remove the auxiliary winch line.

2.

Remove the guide bushing from the hole in the drill deck.

Place the guide bushing on the upper end of the stabilizer with the tapered end of the bushing toward the lower (box) end of the stabilizer. Reattach the auxiliary winch line to the lifting bell.

3.

Install the stabilizer and drill bushing in the hole in the drill deck. Make sure the drill bushing is seated properly.

Lower the stabilizer until the slots in the stabilizer are aligned with the tool wrenches. Extend the tool wrenches to hold the stabilizer in place.

4.

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

NOTE:

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

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Stabilizer Installation

Controls for Drill Pipe Installation

To install a single section of drill pipe proceed as follows: 1.

Lower the rotary/pulldown unit until the pipe coupling on the unit can be reached from the drill deck. Set the hoist brake and depress the drill/propel control OFF pushbutton. Clean the inside threads on the coupling to remove any dirt or old lubricant. Apply a coat of drill thread compound to the threads and shoulder of the coupling.

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Installing Drill Pipe

NOTE:

Use only drill pipe thread compound on the pipe threads. Drill pipe thread compound contains material that will prevent the threads from seizing and galling under the severe pressure encountered on the pipe threads.

2.

Depress the drill/propel control ON pushbutton and release the hoist brake. Raise the rotary/ pulldown unit to a position on the mast so as to clear the pipe rack as it comes into place. Set the hoist brake.

3.

Verify that the main compressor/hydraulic pump motor is running, the hoist/pulldown speed selector switch is in PIPE RACK/JOINTS position, the operating mode selector switch is in DRILL position, and on the operator’s display terminal that the head is clear of pipe rack. Place the pipe rack selector switch in #1 position. The pipe rack joystick will now control only the #l pipe rack.

4.

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

5.

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

6.

Turn the rotary rheostat clockwise until the rotary drive unit coupling begins to turn at approximately 5 RPM as shown on operator’s display terminal operator’s display screen.

Release the hoist brake and carefully lower the rotary drive unit until the coupling contacts the drill pipe. Allow the rotary/pulldown unit to lower under gravity while the coupling is threading onto the pipe.

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7.

When the drill pipe begins to turn with the rotary coupling, stop the rotary motion and check the joint between the coupling and the pipe. The shoulders on the pipe and coupling must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the pipe is removed from the rack. If the shoulders of the pipe and coupling are contacting, the joint is made up.

CAUTION:

The threads on the drill pipe are tapered to make assembly and disassembly of the pipe easier. The threads are designed to disengage after only a few revolutions of the pipe. Failure to have the pipe shoulders contacting may result in the pipe joint uncoupling and the pipe falling from the rotary/pulldown unit.

There is no provision made for holding the pipe stationary in the rack while the joint is tightened. If the joint does not tighten using the above procedure it may be necessary to apply a small amount of hoist power to the rotary/pulldown unit to lift it slightly to remove the pressure from the drill threads.

CAUTION:

Do not lift the drill pipe. Lift the rotary/pulldown unit only enough to relieve the pressure on the threads. Lifting the unit enough to lift the pipe will not only put pressure on the other side of the threads, but may also allow the pipe rack upper gate to open. Should the joint uncouple at this point, the drill pipe may fall out of the rack, causing death, serious injury or serious machine damage.

If the pipe joint does not make up by relieving the weight of the drive unit from the threads it will be necessary to inspect and/or repair the threads on the rotary coupling and the drill pipe. Inspect the threads for rough surfaces and burrs and apply a liberal coat of thread compound to them. The threads should have a smooth finish and no burrs or dirt that will hinder joint make-up. The joint shoulders should also be clean and smooth and should have compound applied.

After cleaning and repairing the threads, try making the joint again. If the joint cannot be made, either the drill pipe or the coupling is defective. Replace the pipe or coupling as necessary.

8.

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

9.

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

NOTE:

Verify that the upper gate on the pipe rack is open before retracting the pipe rack.

Retracting the pipe rack with the gate closed will cause damage to the pipe rack.

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10.

Once the pipe rack has been stored the pipe should be cleaned out using the bailing air.

Remove all personnel from the area and turn on the bailing air for a moment. After cleaning the pipe, clean and lubricate the threads and shoulder on the lower end of the pipe and the upper end of the stabilizer.

CAUTION:

Before working around the tool string set the hoist brake. Depress the drill/propel control OFF pushbutton.

Stabilizer Installation

11.

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

12.

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

13.

When the stabilizer begins to turn with the drill pipe, check the joint between the stabilizer and the pipe. The shoulders on the pipe and stabilizer must be together. If there is clearance between the shoulders, it will be necessary to tighten the joint some more before the stabilizer is released. If the shoulders of the pipe and stabilizer are contacting, the joint is made up.

Installation of the drill bit is the last step in preparing the tool string.

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To install the bit, proceed as follows: 1.

Hoist the completed drill pipe/stabilizer assembly 2 to 3 ft. (0.6 to 0.9 M) off the drill deck.

Place the bit basket (furnished with machine) into the hole left by the guide bushing in the drill deck.

Remove all personnel from the drilling deck and the immediate area. Turn on the main air stream to blow any contaminants from the drill pipe and stabilizer.

Bit Installation

2.

Place the bit into the bit basket. Coat the threads and shoulders of the bit and stabilizer with drill pipe thread compound.

3.

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

4.

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

5.

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

6.

Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck.

Set the hoist brake and depress the drill/propel control OFF pushbutton. The tool string is now complete for single pass drilling or for the first pass of multiple pass drilling.

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BREAKOUT WRENCH OPERATION CAUTION:

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

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

To break a joint with the breakout wrench, proceed as follows: 1.

If a pipe joint between pipe sections or between the stabilizer and the pipe is to be broken, align the slots in the lower pipe to be broken with the tool wrench jaws. Close the tool wrench by turning the tool wrench control switch to the EXTEND position. Make sure the lower tool is held securely by the tool wrench and that the slots in the tool are aligned with the tool wrench jaws.

CAUTION:

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

2.

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

3.

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

4.

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

5.

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

CAUTION:

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The joint must uncouple freely while using the rotary unit. If the joint does not uncouple freely, repeat the procedure using the breakout wrench until it does. Constantly observe the joint between the rotary coupling and the first section of pipe when running the rotary motion in reverse. If this joint begins to uncouple, stop the rotary motion immediately and retighten the joint. If this joint uncouples the pipe will fall, possibly causing death or serious injury to personnel.

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6.

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

DRILL TOOL STRING DISASSEMBLY The tool string is disassembled in reverse of assembly, that is the bit is removed first, then the drill pipe and lastly the stabilizer.

To remove the bit from the tool string, proceed as follows: 1.

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

3.

Using the breakout wrench, break the joint between the stabilizer and the bit. After breaking the joint, use rotary power to disassemble the joint. Use a slight amount of hoist power to lift the tool string off of the bit to facilitate the disassembly.

4.

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

5.

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

To remove the drill pipe from the rotary drive unit, proceed as follows: 1.

Lower the tool string until the slots on the upper end of the stabilizer are aligned with the tool wrench. Clamp the stabilizer in the tool wrench. Using the breakout wrench to break the joint between the stabilizer and the drill pipe. After breaking the joint, use the rotary unit to disassemble that joint completely. Raise the rotary/pulldown unit and drill pipe 2 to 3 ft. (0.6 to 0.9 M).

2.

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

3.

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

4.

After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4,

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swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.

5.

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

6.

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

NOTE:

7.

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

If the joint does not break, it will be necessary to index the slots on the drill pipe so as to allow the rotary drive unit to build up speed before stopping the drill pipe. This is done by rotating the drill pipe in the forward direction until the slots in the pipe are almost aligned with the pawls in the sockets. This allows the drill pipe to rotate almost one-half turn before being stopped by the pawls.

After indexing the pipe to allow the one-half turn rotation, repeat step 6 above to break the joint.

Repeat this procedure as many times as is necessary to break the joint.

8.

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

9.

When the joint completely unscrews, the pipe will drop to the bottom of the pipe rack pocket.

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

10.

Swing the pipe rack into the stored position.

To remove the stabilizer, proceed as follows; 1.

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

2.

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

3.

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

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ADDING ADDITIONAL DRILL PIPE Installation of additional sections of drill pipe is necessary when the depth of the hole is to be greater than the total length of one section of pipe. Installation of the second and third sections of pipe is essentially the same procedure as installation of the first. The rotary/pulldown unit is raised above the pipe racks, a pipe rack with pipe moved over the hole, the rotary coupling threaded to the pipe, and the pipe removed from the rack and the rack stored.

To add an additional section of drill pipe, proceed as follows: 1.

The first part of the hole should be drilled as deep as possible with the first section of pipe.

The hole should be drilled deep enough to place the joint between the rotary drive unit and the top of the first section of the pipe even with the top of the tool wrench. After completing this section of the hole, turn the main air stream off.

2.

Raise the tool string until the slots in the top of the first section of pipe are aligned with the tool wrench. Clamp the tool wrench firmly around the drill pipe.

3.

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

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

4.

If the joint does not break, it will be necessary to index the slots on the drill pipe so as to allow the rotary drive unit to build up speed before stopping the drill pipe. This is done by rotating the drill pipe in the forward direction until the slots in the pipe are almost aligned with the tool wrenches. This allows the drill pipe to rotate almost one-half turn before being stopped by the tool wrenches. The spring loaded inserts in the tool wrench allow the pipe to rotate while being clamped by the wrench.

After indexing the pipe to allow the one-half turn rotation, repeat step 3 above to break the joint.

Repeat this procedure as many times as is necessary to break the joint.

5.

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

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6.

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

7.

Once the new section of pipe is attached to the rotary unit and the pipe rack stored, lower the pipe until it is approximately 3 feet above the drilling deck. Set the hoist brake. Place a cover over the threads on the pipe held by the tool wrench. Clear all personnel from the area and turn the main air stream on to blow away any dirt from inside of the pipe attached to the rotary unit. After turning off the main air stream, remove the cover from the lower pipe and clean and lube both the pin threads on the lower pipe and the box threads on the upper pipe.

8.

After cleaning and lubricating the threads, turn the rotary rheostat until the drill pipe is rotating at approximately 5 RPM as shown on the operator’s display terminal operator’s display screen.

Lower the rotary/pulldown unit slowly by gravity until the threads begin to contact. Once the threads begin to join the two pipes, attempt to minimize the pressure on the threads by allowing the joint to close slightly while holding the upper pipe in position with the hoist brake, then allowing the upper pipe to descend slightly to keep the tool wrench from losing its grip on the lower pipe. Once the joint is tight, stop the rotary motion.

NOTE:

9.

Be sure that the joint is made properly before attempting to unclamp the lower pipe.

Should the joint not be made properly and fail, the lower pipe will fall into the hole and be difficult to recover.

Unclamp the tool wrench and retract it fully. The second section of pipe is now installed.

To install the third section of pipe, follow the procedure for installation of the second section of pipe, except that the third section of pipe is now installed between the rotary unit and the second section of pipe.

REMOVAL OF MULTIPLE SECTION DRILL PIPE Disassembly of multiple section pipe strings is essentially the same as disassembly of a single section of pipe. The difference is that instead of the stabilizer being held by the tool wrench, it is the first or second section of pipe.

The tool string is disassembled to reverse order of assembly. First, the last section of pipe to be installed is removed, followed by the second section of pipe installed, and then the first. In each case the lower section of pipe is held by the tool wrench while the joint is broken by the breakout wrench. The joint is then disassembled by the rotary motion and the pipe stored in the pipe rack.

The procedure is then repeated as necessary to remove all, or part of the tool string.

NOTE:

For normal operation it is not necessary to completely disassemble the tool string to move from hole-to-hole within the drill pattern as long as the stability limitations are not exceeded. Do not disassemble the tool string more than necessary.

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ANGLE DRILLING All tool handling procedures are carried out the same way either in angle drilling or in standard vertical drilling. The only addition to the procedures is the use of the pipe positioner to hold the drill pipe to be threaded together in position and a mast A-frame with adjustable front legs. It also includes an adjustable pipe seal which can be moved to align with the drill pipe.

During angle drilling the deck remains horizontal providing a horizontal surface to work from. The drill pipe, however, is laying at the angle of the mast. In order to make a joint at the drilling deck, such as when adding the stabilizer, bit or drill pipe or when removing these components, it is necessary to hold the drill pipe in position so as to line up with the drill pipe or component being held on the drill deck. This is the function of the pipe positioner.

The pipe positioner is moved into position by hydraulic cylinders. The pipe positioner jaws are opened by a single hydraulic cylinder.

NOTE:

Do not operate the rotary machinery except at low speeds to make and break joints while the jaws are closed around the pipe. Operating the rotary machinery at high speeds or drilling while the pipe positioner jaws are closed around the pipe will damage the jaws and positioner structures.

To make a joint with the pipe positioner, proceed as with normal joint assembly. When the pipe rack has been moved into position, retract the positioner into place and lock the jaws around the pipe.

Proceed as normal to make the joint. Once the joint is made, open the positioner jaws and extend the positioner to the stored position.

To break a joint both the pipe positioner and the breakout wrench are utilized. The pipe positioner is used to hold the pipe in position to be loaded into the pipe rack. The breakout wrench is used to break the joint.

To break a joint, proceed as normal with joint disassembly. Proceed as normal with joint disassembly.

Before breaking the joint completely, clamp the pipe with the pipe positioner. After breaking the joint, hoist the drill pipe and lower the pipe rack, release the jaws and extend the positioner. Proceed as normal with the pipe joint disassembly procedure.

NOTE:

THE CASING TONG JIB CRANE IS DESIGNED SO THAT IT CAN BE EXTENDED FROM 4 TO 7 FEET. FOR VERTICAL DRILLING, THE CRANE SHOULD BE EXTENDED TO THE 5 FOOT POSITION. FOR ANGLE DRILLING OF 30 DEGREES THE CRANE SHOULD BE EXTENDED TO THE 6.5 FOOT POSITION.

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Jib Crane

DUST SUPPRESSION SYSTEM OPERATION Most machines are equipped with some sort of dust control system. This system may be either a dry type filter or a water injection system. Dust control is necessary to contain the dust generated by drilling from escaping to the environment. All machines are equipped with dust control curtains and dust seal to contain the dust around the drill hole as standard equipment. The dust seal must be adjusted to the pipe angle when angle hole drilling.

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There are two ways to suppress dust generation or prevent the escape of the dust to the atmosphere.

The two methods cannot be used at the same time as they are not compatible. One method to suppress the generation of dust is to inject water into the main air stream as it passes to the bit.

The water serves to conglomerate the dust particles into larger particles that may be treated as cuttings. The other method to suppress the dust is to contain the dust in the dust curtain enclosure then draw off the lighter particles and filter them out of the air before returning the air to the atmosphere.

The filtering is done by a filter unit, which forces the dust laden air through filters where the dust is removed. In the filter system, the dust must remain dry as wet material will plug the filters.

NOTE:

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

DRILLING

VERTICAL DRILLING Once the drill has been inspected and started, positioned, leveled, and the tool string assembled, it is now ready to begin drilling. There are two methods of drilling, vertical drilling and angle drilling.

Vertical drilling is, as the name implies, drilling a vertical hole. Angle drilling is drilling the hole at some angle from vertical (up to 30 degrees). This section of the Operator’s Manual details the procedures involved in the drilling of vertical holes.

CONTROLS UTILIZED WHILE DRILLING The actual drilling procedure involves three main sections: 1.

Starting the hole (collaring).

2.

Drilling the hole.

3.

Cleaning or reaming the hole.

Many types of formations are found in mining areas. Formations that are drilled may range from a wet clay to solid taconite. Each formation, and the parts of the hole within each formation, requires drilling techniques, expressly for that formation. A hole drilled through fragmented limestone is not drilled the same way that a hole is drilled through consolidated taconite. For this reason it is important that the operator not only become familiar with the basic drilling procedures and the specific machine being operated, but that he also become familiar with the formation being drilled.

For the purpose of this section of the Operator’s Manual it is assumed that the hole will be drilled in a consolidated rock formation. This is probably the simplest formation to drill in. Special circumstances will be taken into account in the Drilling In Difficult Formations section of this manual. It is also assumed that the operator is familiar with the location and operation of all of the controls on the machine and that the machine is in good repair.

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Controls for Normal Drilling

During the actual drilling the operator’s display terminal should be turned on and the operator display screen shown on the monitor. All of the drilling parameters noted in the following paragraphs will appear on the operator’s display screen.

NOTE:

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

STARTING THE HOLE (COLLARING) Since the first few feet of a hole are usually in unconsolidated material, the procedure for drilling through this material will be different than for the remainder of the hole. This procedure is commonly referred to as collaring the hole.

To begin, or collar the hole, proceed as follows: 1.

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

2.

Place the operating mode selector switch in the DRILL position. Place the hoist/pulldown speed selector switch in the PULLDOWN position. Depress the drill/propel control ON pushbutton. Release the hoist brake and allow the tool string to lower so that the guide bushing is firmly seated in the hole in the drill deck. Make sure that the slots in the bushing align with the lugs on the drill deck. Reset the hoist brake.

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3.

Turn the rotary speed selector switch to LOW position. Turn the rotary rheostat clockwise until the rotary speed bar graph on the operator’s display terminal screen indicates that the tool string is turning at approximately 25 RPM.

4.

Lower the dust curtains and turn on the dust control system. Place the main compressor vent/ drill switch in the DRILL position to supply bailing air to the bit.

NOTE:

5.

While the bit is passing through the unconsolidated material laying on the top of the formation, the pulldown speed sufficient to cause penetration of the bit is provided by turning the hoist/pulldown rheostat slightly in the pulldown direction.

Release the hoist brake and allow the drill bit to contact the ground. Monitor the vibration coming from the tool string. To reduce vibration slow the rotary speed with the rotary rheostat.

Keep the vibration to a minimum. As the vibration lessens, increase the rotary speed and the pulldown speed while monitoring the rotary current bar graph and the air pressure bar graph on the operator’s display terminal screen.

The objective is to penetrate the formation as fast as possible without damaging the machine or plugging the hole with cuttings. Monitoring the rotary current, and keeping the load in the lower portion of the bar graph (green) will eliminate damage to the rotary motor. Reducing the load on the motor is accomplished by reducing the pulldown force on the bit. Reducing the pulldown force will, in most instances, accomplish this. In some cases it may even be necessary to hoist the tool string slightly to reduce the loading. Monitoring the air pressure graph will indicate the condition of the hole. If penetration is too fast and the bailing air cannot remove the cuttings as fast as they are generated, the hole will plug and the air pressure will rise. Varying the penetration rate will vary the air pressure. Keep the air pressure in the normal working range (30 PSI for machines with water injection and 40 PSI for machines with dry-type dust control) by increasing or reducing the penetration rate. Keep the vibration levels to a minimum by varying the rotary speed and the pulldown force.

6.

When the bit passes through the fragmented material (approximately 3-5 ft. [0.9-1.5 M]) and into the consolidated material underneath, the vibration and loading will reduce drastically.

When this occurs, the hole has been collared and normal drilling may commence.

NORMAL DRILLING After the bit has passed through the unconsolidated material at the top of the hole, it is no longer necessary to reduce the load on the bit to reduce vibration and rotary motor loading. More rapid penetration and increased pulldown force may now be used to complete the hole as fast as possible with minimum vibration. This is the normal drilling condition for the machine.

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Normal drilling follows the same guidelines as collaring the hole. Penetration is increased to the maximum determined by the rotary motor load, the vibration of the tool string, and the air pressure.

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

To begin normal drilling proceed as follows: 1.

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

Apply enough pulldown force to allow the bit inserts to chip the material being drilled, rather than pulverizing it. If the pulldown force is not sufficient enough, the bit will ride over the top of the material being drilled and will not create chips. This condition can be observed by monitoring the cuttings. If the cuttings are finely pulverized material, the pulldown force is not enough. Another cause of poor cutting is a worn bit. If pulldown force is high, but the cuttings are fine and penetration is slow, change the bit.

2.

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

3.

Monitor the vibration of the tool string and the machine. Keep the vibration to a minimum by varying the pulldown speed and the rotary speed. If vibration increases, reduce the rotary speed first. If this does not reduce the vibration to an acceptable level, reduce the pulldown speed until the vibration is acceptable.

NOTE:

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

Monitor the air pressure. Keep the pressure in normal working range to eliminate compressor overheating. Pressures above normal working range (30 PSI [206.85 kpa] for machines with water injection and 40 PSI [275.8 kpa] for machines with dry-type dust control) indicate that the hole is starting to plug with cuttings. Stop the pulldown by returning the hoist/pulldown rheostat to the “0” position. Set the hoist brake. Wait a moment and if the pressure starts to decrease, let the hole clear before returning to drilling. If the pressure does not start to decrease it will be necessary to hoist the tool string to clear the hole. To do this release the hoist brake and turn the hoist/pulldown selector switch to the LOW position and the hoist/pulldown rheostat in the hoist direction. Hoist the tool string until the hole is cleared. Leave the rotary motion activated since this will help clear the hole. If the pressure is noticed slowly rising during drilling, reducing the penetration rate momentarily may eliminate the need to cease pulldown and hoist the tool string.

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4.

Continue normal drilling until the hole is at the desired depth. It may be necessary to add drill pipe to complete the hole. Refer to the appropriate sections in this manual for the procedures necessary for adding drill pipe.

The operator’s display screen on the operator’s display terminal will show the hole depth in feet.

5.

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

ENDING THE HOLE Once the finished hole depth is reached normal drilling ceases. It is now necessary to ream the hole before preparing the drill to move to the next hole. Reaming the hole removes cuttings that have fallen to the bottom of the hole and also straightens and increases the diameter of the hole.

As the bit and tool string are cutting through the formation, the bit may tend to wander slightly. This wandering is due to the fact that the stabilizer cannot be exactly the same diameter of the bit or it would wear out quickly and create operation problems. The stabilizer tends to keep the bit on course, but it cannot keep the hole exactly straight. Reaming the hole straightens the hole and therefore increases the diameter of the hole slightly. Reaming the hole also removes any cuttings that are lodged in the hole. These cuttings must be removed or they will eventually fall to the bottom of the hole, reducing the drilling depth.

To complete the drilling procedure the hole is reamed as follows: 1.

When the hole is drilled to the finished depth, leave the main air stream on and the rotary rheostat to the MINIMUM position and the motion activated. Return the hoist/pulldown rheostat to the “0” position and set the hoist brake. Allow the tool string to rotate and the air to bail the hole for a moment. This removes all of the cuttings in suspension from the hole.

2.

Turn the hoist/pulldown speed selector switch to the LOW HOIST position and the hoist/ pulldown rheostat in the HOIST direction while simultaneously releasing the hoist brake. Slowly hoist the tool string out of the hole. If resistance is met, or if vibration increases, return the hoist/pulldown rheostat to “0” position and set the hoist brake. Allow the obstruction to be removed by the bit before continuing. If the hole is very crooked (indicating a worn stabilizer) it may be necessary to repeat this procedure of hoisting, then stopping and allowing the bit to clear, many times before reaching the top of the hole. This procedure straightens the hole and allows the tool string to be removed.

3.

Once the tool string has been removed and the hole reamed, it must now be cleaned out.

Reaming the hole loosens cuttings that have become lodged in the side of the hole. These cuttings, and most of the cuttings generated during reaming will fall to the bottom of the hole.

This filling of the hole may reduce the actual depth of the hole significantly, so it is necessary to remove these cuttings from the hole. To do this, release the hoist brake and turn the hoist/ pulldown rheostat slowly in the pulldown mode.

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Leave the air on and the tool string turning at 25-30 RPM. When the bit reaches the point where the cuttings have accumulated on the bottom of the hole, these cuttings will be forced out of the hole.

When the cuttings have been cleaned out of the bottom of the hole, the bit will contact the undrilled formation at the bottom of the hole and stop penetrating. Once the flow of cuttings out of the hole stops and the tool string stops penetrating, the hole is clean.

4.

After cleaning the hole the tool string may be raised to the top. Turning the hoist/pulldown rheostat control in the HOIST direction and the hoist/pulldown speed selector switch in the HOIST HIGH position will hoist the tool string.

ENDING THE HOLE (MULTIPLE PIPE SECTIONS) Reaming the hole with multi-section tool strings is the same as reaming with single pipe section strings. The reaming procedure must be done in stages as the pipe sections are removed.

While removing the drill pipe the cuttings dislodged from the sides of the hole and the cuttings generated by reaming will fall to the bottom of the hole. To effectively clean the hole, it would be necessary to reassemble the tool string and lower it to the bottom of the hole. This is not desirable as it is time consuming. One method to eliminate the need to clean the hole is to overdrill the depth and allow cuttings to fill the hole to the desired finishing depth. Experience in this area will show how much to overdrill the hole. A good practice is to overdrill the hole by 1 to 2 feet (0.3 to 0.6 m) over the estimated finished hole depth. This way, if the estimate is wrong, the hole will be 1 to 2 feet (0.3 to 0.6 m) too deep. This can easily be corrected by a few shovels full of cutting thrown into the hole.

Underestimating, on the other hand will require that the tool string be reassembled and the hole cleaned.

DRILLING DIFFICULT FORMATIONS For the purpose of explanation, the drilling procedure given in the Drilling section of the manual assumes that drilling takes place in consistent, consolidated rock formation. Unfortunately, not all drilling is in this type of formation. This section of the Operator’s Manual will detail, in general, some typical drilling difficulties encountered.

The main cause of difficult drilling are unconsolidated material or wet sticky material. Unconsolidated material causes vibration far greater than experienced in consolidated formation, and if severe enough, may also decrease the bailing velocity of the main air stream. Wet, sticky material causes problems with cleaning the hole since the material may coat the hole and the drill pipe, increasing the air pressure above the working range. Wet material may also plug the bit orifices, freeze the bit cones, or compact into balls that refuse to be bailed out of the hole. The general procedure for drilling in difficult formations is the same as the procedure for drilling in good formations. The hole is collared, drilled, reamed, and cleaned using the standard operating procedures. Monitoring of the machine is, however, critical while drilling in difficult formations.

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NOTE:

Failure to closely monitor the machine and its bar graphs as shown on the operator’s display terminal operator’s display screen will result in damage to the machine or a stuck drill pipe.

UNCONSOLIDATED MATERIALS Drilling unconsolidated materials may present two problems. The first, and most severe, is the vibration encountered if the penetration rate is too fast. As the bit rotates the cones pass over the material and the teeth or inserts chip away at the material being drilled. Unconsolidated material, however, has voids in it. When the bit passes over a void in the material it only contacts part of the bottom of the hole. As each roller passes through the void, the tool string moves down, as the roller falls into the void, and then back up as the roller climbs out. This continual up and down motion results in shock loads being transmitted from the bit, through the tool string, to the machine.

To drill through an unconsolidated formation it is necessary to reduce the load on the bit as it is passing over the voids. It is also helpful to isolate the shock loading to the tool string. This is accomplished by first reducing the pulldown speed. If reducing the pulldown speed does not reduce the vibration to the machine to an acceptable limit, it may even be necessary to hoist the bit above the void and then lower the bit a small amount at a time so as to chip away at the sides of the void a little at a time. Reduction of the rotary speed will also help reduce the vibration of the tool string. This is the last procedure that should be tried since if the pulldown speed is left high and the rotary speed diminished, the vibration will be just as severe, only at a different frequency.

Unconsolidated material presents another problem due to the fact that the voids in the material may allow the bailing air to escape through the sides of the hole, rather than passing along the drill pipe and exiting through the top of the hole. This loss of air reduces the volume of air available to bail the hole, causing the cuttings to fall to the bottom of the hole and be reground by the bit. This further reduces the penetration rate since these cuttings must be ground up by the bit and bailed out of the hole or they will plug the hole. Unconsolidated material may also cause the hole to cave in. This creates problems due to the sudden addition of material into the hole and the resultant loss of bailing velocity due to the increased diameter of the hole.

If unconsolidated material is causing the loss of bailing air volume or caving of the hole it is necessary to continually clean the hole as the recycled cuttings or the caved material will plug the hole. Closely monitor both the bailing air pressure and the flow of cuttings from the hole. If the air is being lost the air pressure will remain constant but the flow of cuttings will stop or drastically decrease while penetration does not decrease. Continue drilling for a few feet to try and get past the leak. If the bailing air pressure starts to rise, the hole is plugging. Immediately hoist the tool string until the pressure drops and allow the drill string to rotate for a few moments to clear itself. Then lower the tool string to the bottom of the hole and clean it out. It may be necessary to regrind the cuttings to make them small enough to seal the leak and be bailed out of the hole by reduced air volume. Once the hole is clean, repeat the hoisting and lowering procedure every 2 to 3 feet (0.3 to 0.6 m) to keep it so.

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If the material tends to cave in from the sides of the hole, the tool string can become stuck in the hole quickly. If the caved material is small, it will fit between the cones of the roller and fall to the bottom of the hole. The hole can then be cleaned out using the same procedure as for a leaky hole. If the caved material is large it will be necessary to pull the tool string out of the hole and then redrill the caved material.

NOTE:

Be very cautious when drilling in formations which tend to cave in easily, especially if the material caves in large blocks. Should the material that caves into the hole be too large to lift with the rotary drive unit or too hard to break with the top of the bit, the tool string will have to be abandoned in the hole.

Experience will dictate what procedure to follow when encountering material which tends to cave in.

When the formation is unfamiliar always be cautious. Caution may result in lower production, but it could save a great amount of work and a complete tool string should the tool string become stuck.

Always clean the hole often and monitor the air pressure constantly. If the air pressure starts to climb, hoist the tool string immediately — do not wait to see if the pressure will level off or not. By the time it is determined what the air pressure will be, the hole is plugged. Cleaning the hole often accomplishes two things.

First, it removes the caved in materials from the hole. Second, it loosens any potentially hazardous material and causes it to cave in while the stool string is being hoisted. If the hole caves in while in the hoist mode there is a better chance of recovering from the cave in.

If the hole should become plugged there are two ways to recover the tool string. Each method depends upon what type of material has plugged the hole. If the material that is plugging the hole is small (less than 6 inches [15.2 cm] square), it is possible to grind the material sufficiently to allow it to pass between the lobes of the bit and fall to the bottom of the hole. This condition can be observed if the bailing air pressure increases over normal working range. Large, chunky material will let the bailing air through, while fine material won’t. Also, when attempting to hoist out of the hole the tool string will not vibrate greatly, due to the small size of the material. Large material will cause the tool string to be shocked every time a lobe on the bit strikes the block.

To recover the tool string from a hole plugged with smaller material hoist the bit until it runs into the plug and stops hoisting. With rotary motion turning at approximately 50-60 RPM keep high hoist loading on the bit and allow the bit to work its way through the plug. Monitor the rotary motor loading (current) and reduce the hoist loading (force) to keep the load in the lower portion of the bar graph.

Once the plug is passed, clean the hole and return to drilling. The main air pressure may or may not exceed the safety valve setting and cause the main air compressor to overheat. If the safety valve opens when the hole is plugged, continue to attempt to free the tool string. The safety valve will close when the plug has been removed. If the compressor overheats and shuts down continue to attempt to free the tool string without the compressor. Allow the compressor to cool for a few minutes and restart it. Continue this procedure until the tool string is free.

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If the material plugging the hole is large it will be necessary to try and force the material back into position enough to let the bit go past, and then try and redrill through the plug. Large material is indicated when the tool string experiences severe vibration when being hoisted. To free the tool string apply maximum hoist power. If the plug does not clear itself within a few moments lower the tool string a few feet if possible and try again.

If the plug does not clear itself after repeated attempts at clearing it, there are two options available.

The tool string can be abandoned immediately without further trial or an attempt to drill through the plug using the top of the bit can be made. In either case the hole being drilled will have to be abandoned. In the first case the cost of the abandoned tool string is known, while in the second case a gamble is being taken as the bit and stabilizer will almost certainly have to be scrapped and there is no guarantee that the rest of the drill pipe will be recovered. If it is decided to abandon the tool string, attempt to unscrew a section of pipe to recover some of the tool string. If this cannot be done, lower the tool string to the bottom of the hole and then, using a suitable burning torch, cut the drill pipe at ground level. It will be necessary to move over an existing hole to remove the stub of pipe from the rotary drive unit.

CAUTION:

Before cutting the drill pipe verify that the main air compressor is shut down.

Burning the pipe with the main air compressor running may cause a fire or explosion as hot slag is introduced to the main air stream or may cause hot material to be blown back onto the torch operator.

If an attempt is to be made to free the drill string by drilling with the top of the bit, apply only enough hoist pressure to keep the vibration and rotary motor load levels in an acceptable range. Vary the hoist pressure by alternately placing the hoist/pulldown selector in the hoist and neutral positions.

Vary the rotary speed to help reduce vibration. Drilling through a large block with the top of the bit can be a lengthy procedure and it is important to prevent damage to the rest of the machine. Once the tool string is free, check the bit and stabilizer as well as the drill pipe for damage. Replace components and move to a new location for the hole. Do not try and drill the same hole again as this will almost certainly cause the tool string to become stuck again.

WET OR STICKY FORMATIONS Drilling in wet or sticky formations presents three possible problem areas. The three problems that may be encountered are coating of the hole and pipe with material, conglomeration of the material into pieces too large to remove with the bailing air stream and caving of the hole. Either of these problems may be present, or any combination of the three may be present at the same time.

Drilling in wet formations follows the same practices as drilling any other formation. Drilling wet formations, however, requires that particular attention be paid to the bailing air pressure and penetration rates. Wet formations are more susceptible to plugging the hole, but recovering the tool string from the plugged hole is easier than with unconsolidated material.

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In the case where the material is adhering to the drill pipe and coating the sides of the hole it is necessary to ream and clean the hole every 5 to 10 feet (1.5 to 3.0 m) to remove the offending material. It is also necessary to clean the drill periodically to remove the caked on material. This can be accomplished by removing the tool string from the hole and allowing the material to be scraped off by the guide bushing. It is important then, if the guide bushing is to be used to clean the tool string, that the bushing be kept in good repair.

In the case where the material is conglomerating into large pieces, these pieces fall back down to the bottom of the hole and are recycled through the bit to be broken up. If the amount of recycled material is too great it will accumulate at the bottom of the hole and restrict the main air stream. To keep this material at a minimum, clean the hole periodically. When hoisting the tool string, allow the material to be ground by the bit and fall to the bottom of the hole before cleaning the hole.

In the case where the material is caving from the sides of the hole, treat the formation as unconsolidated and drill according to the procedure detailed in this manual for unconsolidated material.

It is important when drilling through difficult formations to constantly monitor the machine and tool string. Allowing the tool string to become stuck is an expensive mistake and can be avoided by cautious drilling practices. Reaming and cleaning the hole may only take a few moments, but it could be the difference between an abandoned hole and tool string and a successfully completed hole.

ANGLE DRILLING NOTE:

When moving the mast for angle hole drilling on machines with mast lengths of 65 ft. or more, the drill pipe must be stored in the racks and the rotary head lowered to its lowest position.

Angle drilling follows the same general drilling procedures as vertical drilling. The main difference in the drilling procedures, besides the fact that the hole is at an angle, is the need to monitor the condition of the different systems more closely while angle drilling. The differences in the operating procedures for the different systems on the machine are limited to handling the tool string and raising and lowering the mast to the proper drilling angle.

When drilling an angle hole, monitoring of the system indicators such as the drilling air pressure, the rotary load and the machine vibration, becomes more critical than when drilling a vertical hole. The reason these monitors become more important is the fact that an angle hole will tend to wander downward as the hole is being drilled. This wandering is due to the drill steel assuming a natural camber as it is being extended past the guide bushing. This camber is unavoidable and becomes worse as the angle of the hole approaches 30 degrees.

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The force of gravity continually acts upon the tool string causing it to bend downward. This downward bending is known as the camber of the drill pipe. This camber causes the hole to be drilled with a gradual bend in it. This causes the drill pipe to contact the side of the hole, increasing the load on the rotary motor. This also tends to inhibit the bailing of the hole since the cuttings are not flowing vertically. The flow of the bailing air (and suspended cuttings) must be diverted around the points that the drill pipe is resting on the side of the hole. This contributes to the increased air pressures needed to drill an angle hole. The vibration of the tool string will be increased while drilling at an angle, due to the tool string resting on the side of the hole, rather than on the bottom.

PROGRAMMED DRILL CONTROL DRILLING PDC drilling is similar to normal drilling in that the machine must be positioned, leveled and set up manually by the operator. The actual drilling operation will be controlled by the automated system.

To start the automated system use the following start-up sequence.

Controls for Programmed Drill Control

1.

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

2.

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

3.

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

4.

Place the operating mode selector switch in the DRILL position.

5.

Press the drill/propel control ON pushbutton.

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6.

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

7.

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

8.

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

9.

Place hoist brake control in the RELEASE position.

10.

On the operator’s display terminal with operator’s display showing, depress keypad button F5 to turn on PDC The readout above the F5 key will then read “PDC on.”

After the above start-up procedure has been initiated the automatic controls will take over the actual drilling of the hole. Water injection (if so equipped) will be shut off at preset depth. When the total depth of the hole is reached, as preset, the tool string will be automatically hoisted and when the bit approaches the top of the hole, the control will stop the bit, shut off the air and set the hoist brake.

If problems arise in the PDC functions, the system will have to be corrected by a qualified electrician.

In most cases, if a malfunction occurs in the automated system, the automated system can be turned off and the drilling completed manually.

PREPARING TO MOVE Once the hole has been completed and the tool string removed from the hole it is necessary to move the drill to the next hole location to prepare to drill the next hole. Preparing to move the drill consists of proper storage of the tool string, lowering the machine to the ground, and inspection of the machine and travel route prior to propelling.

To prepare the drill to move, proceed as follows: 1.

Upon completion of the current hole, hoist the tool string from the hole. If using multiple pipe sections, remove and store all pipe necessary to remove the entire tool string from the hole.

Turn off the dust control system and raise the dust curtains.

2.

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

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CAUTION:

3.

Do not propel with the tool string in a position where it will be struck against the ground while propelling. Should the tool string hit the ground while propelling, damage to the machine and tool string will result.

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

NOTE:

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

4.

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

5.

Once the machine is touching the ground, it may be lowered completely. To lower the machine completely, first lower the uphill side or end of the machine to the ground, then lower the downhill side or end to the ground. It is important that the machine be lowered in stages to minimize both the angle of the machine and the bending stresses placed on the machine.

CAUTION:

6.

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

NOTE:

7.

While manually lowering the machine to the ground it is imperative that the machine be kept as level as possible. It may be necessary to lower the machine in stages to keep it as level as possible.

When manually lowering the machine be sure that the leveling jacks are fully retracted before propelling the machine. Propelling the machine with a leveling jack not fully retracted will result in serious damage to the jack and machine structures.

Inspect the machine, travel route as outlined in the Propelling topic in this manual. After completing the inspections the machine is ready to propel.

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

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

SHUTDOWN PROCEDURE To shut down the machine, proceed as follows: 1.

Complete the hole, if any, currently being drilled. If the hole is not completed before the machine is shut down, it will be necessary to abandon the hole and drill another in its place. Do not try to place the machine over an existing hole.

2.

Remove the tool string from the hole. If multiple pipe sections are used, remove and store pipe sections as necessary to remove the entire tool string from the hole.

NOTE:

Do not shut the machine down with the tool string in the hole. To do so may cause damage to the drill pipe and may lead to the abandonment of the tool string and the hole.

3.

Determine the length of time the drill is to be idle. Refer to the appropriate storage topic in this manual for the degree to which the tool string must be disassembled. If necessary, disassemble and store the tool string at this time.

4.

If possible lower the rotary drive unit to its lowest position and set the hoist brake. If the tool string is not to be removed, clamp the stabilizer with the tool wrench and set the hoist brake.

5.

Following the procedures in the Preparing To Move topic in this manual, lower the drill to the ground. Place the leveling jack pads on the ground, but do not place any weight on them.

6.

Shut off the main air compressor. Place all controls in the off or neutral position.

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7.

Go to the machinery house and turn off all breakers. If the machine is to be shut down for a short period of time and it is necessary to leave the lights on, it is permissible to leave the lighting breaker and lights on.

8.

Inspect the machine for obvious damage or wear. Make note of any operating difficulties discovered while drilling and any problems discovered during this inspection. Report the difficulties to the appropriate personnel.

9.

Close all doors and windows tightly.

SHORT TERM STORAGE If the machine is to be shut down for more that 3 eight hour shifts, but less than 3 weeks, short term storage precautions are necessary. These precautions are necessary to insure that the machine is not damaged or does not deteriorate during the storage period.

Short term storage is primarily concerned with placing all components in a safe position and providing additional protective lubrication to normally lubricated components.

To store the machine for a maximum of 3 consecutive weeks, proceed as follows: 1.

If not already done so previously, complete all shut down procedures as detailed in the Machine Shut Down topic in this manual. During the shut down procedure it is necessary to remove and store the complete tool string. Remove the bit from the stabilizer and store it in a protected place. Coat the bit with a suitable oil to prevent rusting while stored. As the drill pipe is being disassembled, clean and lubricate the threads on each end of the pipe before storing in the pipe racks.

2.

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

3.

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

4.

Manually cycle the lube system and verify that all points on the mast are receiving lubricant. If the auto lube system is not functioning properly, repair or replace components as necessary.

5.

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

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6.

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

7.

If the air compressor motor is equipped with anti-condensation heaters, turn them on at this time. If the motor is not equipped with heaters, have a qualified electrician install heaters or a suitable substitute. Cover the motor with a waterproof tarp or cover.

8.

Close and lock all electrical cabinet doors.

9.

Fill the radiator to the top with the proper oil on machines equipped with screw compressors.

10.

Manually cycle the auto lube system to verify that all points on the machine are receiving lubricant. Repair the system as necessary to lube all points.

11.

Lube all manual lube points.

12.

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

13.

Close and lock all windows and doors.

LONG TERM STORAGE Long term storage procedures are necessary any time the machine is to be left for a period exceeding 3 weeks. Long term storage includes all procedures necessary for short term storage, and depending on the situation, some additional precautions.

There are two procedures involved in long term storage of the drill, the choice of which depends upon whether the machine can be attended to while in storage. If the machine can be started and the majority of the machinery operated once a month during the storage period, much less protective work is necessary. If the machine must remain unattended, special precautions are necessary to prevent damage to the machine.

NOTE:

If the machine is to be unattended during the storage procedure the procedures necessary to store the machine properly will take considerable time and restoring the machine to production will take even longer. Do not utilize the unattended long term storage procedure unless absolutely necessary.

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ATTENDED LONG TERM STORAGE The attended long term storage procedure combines the short term storage procedure with monthly start-up and running periods. To store the machine for a long period of time it is necessary to complete the procedures listed in the Short Term Storage topic in this manual. Then, once a month for the duration of the storage period, complete all start-up inspection and lubrication procedures listed in this manual and start the drill. Run all of the gear trains for 10-20 minutes to distribute the oil over the gears and bearings. Hoist and lower the rotary/pulldown unit the full length of the mast 4-6 times to distribute lubrication to the mast and rotary/pulldown unit components. Cycle the tool racks 2-3 times. Run the air compressor for 1 hour. Propel the drill at least 6 times the length of the machine. After running the machine components, follow the short term storage procedure once again and store the machine for another month. Repeat this procedure every month until the machine is returned to service.

UNATTENDED LONG TERM STORAGE It is not within the scope of this manual to detail the procedures involved in the long term storage of a drill. These procedures will involve disassembly of the major units on the drill, duties that are not usually performed by operating personnel. Refer to the Mechanical Maintenance Manual for details concerning the long term storage of the machine.

The procedure listed here is an outline intended only to give a general idea of the effort involved in proper storage of the machine. To store the unattended machine for an extended period of time, proceed as follows: 1.

Complete all short term storage procedures.

2.

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

3.

Completely fill the rotary and pulldown gear cases with an approved oil. Both cases can be filled completely by adding the oil through the breather openings. Remove all water from the cases.

4.

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

5.

Remove the auxiliary winch line.

6.

Cover the rotary gear case and hoist/pulldown gear case with a waterproof tarp.

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7.

Remove the air compressor from the machine and store in an attended heated building.

8.

Close and completely seal all electrical cabinets.

9.

Close and completely seal the operator’s cab.

10.

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

11.

Completely drain the compressor coolant system.

12.

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

13.

Block the leveling jacks in the full retracted position.

14.

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

TOOL RECOVERY Normally the drill tools are always either connected to the rotary drive unit or are held by the tool wrench. Mistakes, however, do happen and the drill tools may be dropped down the hole. Tool recovery (or tool fishing) is the procedure used to recover these tools.

There are two situations where the tool recovery procedures are necessary and each situation dictates the procedure to be used. The first situation is when the tools have been uncoupled and have fallen below the guide bushing. It is possible in this situation to recover the tool string and, if no damage was done, return to drilling. The other situation is where the drill pipe has broken and has either fallen below the guide bushing or cannot be handled normally.

If the tools have uncoupled and the upper end of the tool string is still above the guide bushing, recouple the tools as would normally be done for tool joint make-up. Clamp the tool string with the tool wrench to aid in making the joint. When the tools are coupled, remove the tool string from the hole, remove the bit and turn the main air on momentarily to clean the inside of the drill pipe. Clean and reinstall the bit and return to drilling.

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If the tools have uncoupled and the upper end of the tool string is below the guide bushing but still above ground level, re-couple the tool string as would normally be done to tool joint make-up, except use caution when making the joint. Caution is necessary when making the joint as the tools in the hole will now be at an angle with respect to the tools on the drill. Cross threading of the joint is possible in this situation and should be avoided since it will not only damage the threads but result in an unreliable joint. One method to realign the tools would be to attach a suitable pulling device to the tools in the hole and center the tools with blocking (make sure it doesn’t fall down the hole). This would allow normal joint make-up without abandoning the hole. If this is not possible, the leveling jacks may be adjusted to align the tools. Be sure that the stability limits of the machine are not exceeded. It will be necessary to abandon the hole since the drill cannot be repositioned in the exact same orientation as before losing the tools. When the tools are recovered, clean the pipe and bit as detailed in the first procedure of this section and return to drilling.

If the tool string has uncoupled and the upper end of the lost tool string is below ground level, there are two methods of recovering the lost tools. One method is to attempt to make the joint using the drill pipe still connect to the rotary drive unit. The other method is to use special equipment (not supplied by Bucyrus) to recover the tools.

If the top of the lost tool string is not reachable from ground level, very gently lower the remaining tool string until it contacts the tools in the hole. Using very slow rotary speed and low torque, attempt to re-make the joint. If the joint can be made, very gently raise the tools to a position where the top of the recovered tools can be clamped in the tool wrench. Rebreak the joint and inspect the threads on both sections of pipe. Repair the threads if necessary before continuing. When the tool string is repaired, remove the bit and clean both it and the drill pipe to remove any dirt that may have entered while the joint was uncoupled.

If the joint cannot be made using the above procedures, or if the pipe has been broken or been damaged to an extent that it cannot be handled normally, it will be necessary to use special equipment and techniques to continue drilling or recover the lost tools. It is not within the scope of this manual to detail the procedures necessary to handle broken or lost tools, and the use of these tools should be described by the manufacturer.

CAUTION:

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WHEN PERFORMING SPECIAL PROCEDURES NOT DETAILED IN THIS MANUAL, ALWAYS FOLLOW THE RECOMMENDATIONS OF THE TOOL MANUFACTURER AND PRUDENT SAFETY GUIDELINES. FAILURE TO FOLLOW SAFE PROCEDURES MAY RESULT IN THE DEATH OR SERIOUS INJURY OF PERSONNEL OR SERIOUS DAMAGE TO THE MACHINE

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PIPE SIZE LIMITATIONS The limitations shown in table below are necessary to prevent overloading of the mast and mast support structures as well as the machine hydraulic system by long, heavy drill pipe.

CAUTION:

Failure to comply with these limitations will result in overloading of the mast, mast support and hydraulic system - possibly causing serious machine damage and resulting in possible loss of control of the mast.

Before raising or lowering the mast, always determine the pipe diameter, wall thickness and length and compare the results against the table. If the pipe on the machine falls within the limitations set forth in the table, the mast may be raised or lowered following the procedures detailed in this manual. If the pipe on the machine falls outside of these limitations DO NOT RAISE OR LOWER THE MAST. Either remove the pipe from the machine or consult with the Bucyrus International, Inc. Service Department before raising or lowering the mast.

CAUTION:

Always remove all drill pipe from the rotary drive unit and store it in the tool racks before lowering the mast. Always lower the rotary drive unit to its lowest position and rest it on the lower stops before raising or lowering the mast.

Drill Pipe Limitations

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DRILL STABILITY CHARTS

Drill Stability Chart - Special Propel Conditions

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Drill Stability Chart - Typical Propel Conditions

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TYPICAL MACHINE SPECIFICATIONS

DIMENSIONS: • • A B C D E F G H I J K L M N O P Q R S • •

Hole Diameter ........................................................................ 10 ¾” To 17 ½” Hole Depth (Single Pass) ............................................................... 60’-00” Ground to Top of Deck ....................................................................... 7’-2” Ground to Bottom of Rear Jack Pads ................................................. 1’-9” Ground to Top of Machinery House .................................................. 15’-8” Ground to Top of Machinery House Pressurizing Unit ...................... 17’-4” Ground to Top of Cable Reel ............................................................ 10’-9” Ground to Bottom of Front Jack Pads ................................................ 2’-2” Diameter of Jack Pads ...................................................................... 3’-8” C/L Hole to C/L Rear Jacks ................................................................ 0’-0” Overall Length of Crawlers ............................................................... 25’-5” C/L Rear Jacks to C/L Front Jacks .................................................. 41’-8” Overall Length of Machine without Cable Reel .................................. 53-’2” Overall Length of Machine with Cable Reel ....................................... 65’-0” Overall Length of Machine with Mast at Rest .................................. 106’-7” Ground to High Point with 60 Ft. (18.29m) Mast at Rest ................... 31’-6” Overall Width of Machine ................................................................. 25’-1” C/L Machine to Left Side ................................................................ 12’-10” C/L Machine to Right Side ............................................................... 12’-3” C/L Machine to Left Outside Edge of 36 Inch (914mm) Track ........... 11’-4.5” C/L Machine to Right Outside Edge of 36 Inch (914mm) Track ........ 10’-6.5” C/L Machine to C/L Left Rear Leveling Jack ...................................... 7’-9” C/L Machine to C/L Right Rear Leveling Jack .................................... 7’-9”

(273-444mm) (18.29M) (2.18M) (0.53M) (4.77M) (5.28M) (3.28M) (0.66M) (1.12M) (0.0mm) (7.75M) (12.70M) (16.21M) (19.81M) (32.49M) (9.60M) (7.65M) (3.91M) (3.73M) (3.47M) (3.21M) (2.36M) (2.36M)

WEIGHTS:* BASIC MACHINE 350,000 lbs. (158,730 kg) AVERAGE WORKING WEIGHT 405,000 lbs. (183,673 kg) (*) Type and number of machine options will affect weight.

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Machine Dimensions

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MAST COMPONENTS: STANDARD MAST FOR DRILL PIPE AND ONE RACK 60’-0” (18.29M) Computer Analyzed, tubular lattice construction with back braces.

RAISING and LOWERING Two-9” (220mm) diameter hydraulic cylinders (1) ANGLE HOLE DRILLING to 25º off-center in 5º increments HOIST/PULLDOWN: Chainless rack and pinion driven by head-mounted excavator grade DC motor.

BIT LOADING UP TO: 140,000 lbs. (63,500 kg) FEED RATE UP TO: 25 fpm (7.62m/min) HOIST RATE UP TO: 100 fpm (30.48m/min) LOWERING RATE UP TO: 100 fpm (30.48m/min) AUXILIARY WINCH STANDARD CAPACITY: 12,000 lbs.

(5,433 kg) PIPE RACKS: SINGLE RACKSTANDARD 1 PIPE RACK 10.75” TO 17.5” 2 PIPE RACKS 10.75” TO 17.5” 4 PIPE RACKS to 10.75”

(273-445mm) (273-445mm) (273mm)

ROTARY DRIVE: CONTINUOUS OUTPUT MAXIMUM BIT SPEED

205 hp (153kw) 120 rpm

AIR COMPRESSOR: A-C Compressor Corporation KS46AC Screw Type 4,600 CFM (130.2m3/min) free air @ 80 psi (552 kPa) (2) or A-C Compressor Corporation KS40AC Screw Type 3,600 CFM (101.9m3/min) free air @ 70 psi (483 kPa) (2)

LEVELING JACKS: AUTOMATIC LEVELING SYSTEM Standard JACK SIZE 9” (229mm) diameter x 66” (1.67M) stroke JACK PAD DIAMETER 44” (1.18M) MACHINE LIFT REAR 45” (1.14M) FRONT 40” (1.01M) OPERATING LEVELING GRADE TO 19%

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LUBRICATION: Automatic Centralized System Standard CRAWLER MOUNTING: DUAL AXLES Fixed Rear/Pivoting Front OVERALL LENGTH 25’-5” (7.75M) OVERALL TREAD WIDTH (standard) 21’-11” CRAWLER BELT WIDTHS STANDARD 36” (914mm) OPTIONAL WIDE LINKS 42” (1.06M) PROPEL: Chainless hydraulic drive with counter-rotation capability Crawler mounted disc brakes with brake release for towing Propel Speed up to 0.9 mph (11.45kph) Operating Propel Grade 25% (3) ELECTRICAL: EQUIPMENT Static DC – Variable Output POWER REQUIREMENTS 3 phase, 60 Hz, 4,160V (4) AIR COMPRESSOR/AC INDUCTION MOTOR Dual Shaft, 800 – 1,000 hp (597-746 kw) @ 460V ROTARY DRIVE DC Motor (205 continuous hp output) 195 hp MAIN HYDRAULIC OIL PUMPS Driven by main air compressor motor 250 hp nominal COMPRESSOR RADIATOR FAN AC-TEFC Motor 20 hp (15kw) @ 460V MACHINERY HOUSE PRESSURIZATION 25,000 CFM (708m3/min) 25 hp (19 kw) @ 460V OPERATOR’S CAB PRESSURIZATION W/HEATER and AIR CONDITIONER Self contained unit manufactured by SIGMA LIGHTING and CONTROL 120V NOTES: (1) (2)

(3) (4)

With optional angle hole drilling equipment.

Standard conditions = Sea Level @ 80oC (26.7oC) inlet temperature. 60 Hz electrical power.

Can be stability limited.

For alternate power sources consult Bucyrus International.

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COMPONENT SYSTEMS PROPEL MACHINERY: The propel system of the machine is a chainless hydraulic drive system which will allow the separate tracks to counter-rotate. This capability provides the machine with the capacity to turn completely around within it’s own length. Each track is driven by a hydraulic motor and a planetary gearbox equipped with a hydraulically released, spring activated brake. The machine is capable of 2 different propel speed ranges. The lower speed range is used for maneuvering in close spaces while the high speed range is used for tramming in open areas, over long distances.

MAIN FRAME AND DECKS: The machine main frame is of welded box type construction with integrally placed mast supports and jack towers.

MAST: The machine mast is a fabricated structure of steel tubes and formed plates. The major structure is composed of vertical tubes welded together with back bracing. The mast functions to provide the mounting and guide for the equipment required to operate the drilling function of the machine. The mast is capable of being positioned at any 5o increment within it’s operating range from 65 degrees through 90 degrees (vertical). The mast can be raised and lowered by 2 (two) 8.00 inch (203mm) hydraulic cylinders.

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

HYDRAULIC SYSTEM: Hydraulic pressure for operation of the machine is provided by four separate pumps. These pumps are driven by the electric motor located in main machinery house, forward of the hydraulic filters and reservoir. The machine has 2 separate, though not completely independent hydraulic systems, the OPEN and CLOSED circuits. Both draw fluid from a common reservoir.

OPERATOR’S CAB: The sound insulated operator’s cab of the machine provides a sealed, comfortable enclosure from which the operator can perform the tasks involved with the operation of the machine. The location and design of this compartment have been structured to provide the optimum viewing angles with immediate accessibility. The swivel mounted chair provides easy access to all required controls. The auxiliary control console is within reach to provide access to additional functions of the machine. The cab is provided with dual doorways to the main deck.

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Bucyrus International, Inc. 59HR Blast Hole Drill

GENERAL ESTIMATED COMPONENT WEIGHTS

Qty.

Weight Ea. (Lbs.)

Lower Works Frame, R.H. Crawler .......................................................... 1 ..................... 11,025 Frame, L.H. Crawler ........................................................... 1 ..................... 11,025 Axle, Crawler Front Equalizer ............................................. 1 ....................... 3,980 Axle, Crawler Rear ............................................................. 1 ..................... 12,100 Tumbler, Crawler Drive ....................................................... 2 ....................... 1,090 Tumbler, Take-Up ............................................................... 2 ....................... 1,255 Gearbox, Planetary Drive ................................................... 2 ....................... 2,750 Link, Crawler ..................................................................... 86 ......................... 300 Pin, Link ..................................................................... 172 .......................... 10 Motor, Propel Drive ............................................................ 2 .......................... 195 Roller, Upper / Lower ........................................................ 20 ......................... 345 Shaft, Take-Up Tumbler ..................................................... 2 .......................... 295 Shaft, Lower Roller ............................................................ 18 ........................... 90 Shaft, Lower Roller-Front ................................................... 2 .......................... 110 Support, Take-Up Tumbler ................................................. 4 .......................... 140 Bearing Block, Rear Axle .................................................... 2 .......................... 775 Guard, Lube, Center .......................................................... 8 ............................ 40 A-Frame Leg, Front A-Frame ............................................................

Leg, Rear A-Frame .............................................................

Cylinder, Mast Latch ...........................................................

Pin, A-Frame Lock ..............................................................

Pin, Mast Pivot ...................................................................

Pin, Upper Front Leg ..........................................................

Pin, Lower Front Leg ..........................................................

2 .......................... 920 1 ....................... 2,930 1 ............................ 25 2 ............................ 25 4 ............................ 40 2 ............................ 40 2 ............................ 40

Main Frame Main Frame ........................................................................ 1 ..................... 55,005 Casing Assembly, Left Rear Jack ................................. 1 ....................... 2,270 Casing Assembly, Right Rear Jack ............................... 1 ....................... 5,750 Cylinder Assembly, Leveling Jack ................................. 4 .......................... 810 Cylinder, Jack ............................................................... 4 .......................... 845 Spud, Jack ................................................................... 4 .......................... 660 Shoe, Spud .................................................................. 2 .......................... 530 Pump Drive Assembly .............................................................................................

Gearcase, Pump Drive ................................................. 1 .......................... 175 Pump, Tandem ............................................................. 1 ............................ 45 Pump, Propel ............................................................... 2 .......................... 145 Coupling, Gearbox ....................................................... 1 ............................ 65 Guard, Coupling ........................................................... 2 ............................ 20 Pump, Gear .................................................................. 1 ............................ 40

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Bucyrus International, Inc. 59HR Blast Hole Drill

Qty. Air Compressor Assembly ...................................................

Valve, Butterfly .............................................................

Coupling .......................................................................

Receiver .......................................................................

Cooler, Oil ....................................................................

Motor, Air Compressor ..................................................

Reservoir, Hydraulic ...........................................................

Cover, Plain ..................................................................

Cover, Header ..............................................................

Filter, Return ................................................................

Header, Suction ............................................................

Valve, Butterfly .............................................................

Manifold, Return Piping ................................................

Reservoir, Lube ..................................................................

MCC, Low Voltage #1 .........................................................

MCC, Low Voltage #2 .........................................................

MCC, Main Compressor .....................................................

Cabinet, Hoist/Pulldown .....................................................

Panel, Static DC Drive Control .....................................

Cabinet, Drill Hoist .............................................................

Cabinet, PLC ......................................................................

Transformer, Main Power ...................................................

Transformer, Lighting .........................................................

Air Conditioner ...................................................................

Tank Assembly, Water ........................................................

Tank, Water ..................................................................

Pump, Water Injection ..................................................

Pump, Water.............................................................

Valve Assembly, 3-Station ...................................................

Valve Assembly, 10-Station .................................................

Jack Valve Stand Assembly ................................................

Valve, Direct, 4-Spool .........................................................

Valve Assembly, 5-Station ...................................................

Valve Assembly, 7-Station ...................................................

Valve, Spool, 3-Section ......................................................

Valve Assembly, 6-Station ...................................................

Jaw, Breakout Wrench .......................................................

Arm, Tong, Breakout Wrench .......................................

Cylinder, Clamping .......................................................

Cylinder Assembly, Positioning .....................................

Cylinder Assembly, Breaking ........................................

Wrench, Bit ........................................................................

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Weight Ea. (Lbs.)

1 ..................... 20,080 1 ............................ 20 1 .......................... 160 1 .......................... 300 1 .......................... 565 1 ....................... 4,270 1 .......................... 795 1 ............................ 50 1 ............................ 55 2 ............................ 20 1 ............................ 35 1 ............................ 20 1 ............................ 30 1 .......................... 560 1 ....................... 1,000 1 .......................... 550 1 ....................... 1,050 1 .......................... 600 1 .......................... 210 1 .......................... 600 1 .......................... 800 1 ....................... 4,000 1 .......................... 275 1 .......................... 930 1 ....................... 5,625 1 ....................... 5,540 1 .......................... 225 1 ............................ 70 1 ............................ 60 1 ............................ 35 1 .......................... 500 1 .......................... 190 1 ............................ 60 1 ............................ 75 1 ............................ 65 1 ............................ 45 1 .......................... 765 1 ....................... 1,005 1 .......................... 120 1 .......................... 400 1 .......................... 355 1 .......................... 105

October 2009

BI619852

Bucyrus International, Inc. 59HR Blast Hole Drill

Qty.

Weight Ea. (Lbs.)

Box, Pipe Handling ............................................................. 1 .......................... 145 Box, Bit Handling ................................................................ 1 ............................ 60 Extender, Drill Pipe ............................................................. 1 ....................... 1,700 Cylinder, Tool Wrench ........................................................ 2 .......................... 470 Dust Curtain ...................................................................... 18 ........................... 10 Dust Seal ........................................................................... 1 ............................ 20 Cone, Chip Deflector .......................................................... 1 .......................... 110 Stairway, Boarding ............................................................. 1 .......................... 270 Cable Reel Assembly ......................................................... 1 ....................... 6,600 Reducer, Right Angle .................................................... 1 ............................ 50 Arm, Upper Support ...................................................... 2 ............................ 50 Collector Rings, Cable Reel ......................................... 1 .......................... 185 Machinery House Wall, Machinery House R.H. ..............................................

Wall, Machinery House Front .............................................

Extension, Left ...................................................................

Cove, Hydraulic ..................................................................

Panel, Center Roof .............................................................

Panel, Rear Roof ...............................................................

Wall, Machinery House Left ................................................

Door, Service, Machy House, 30” ......................................

Door, Service, Machy House, 34” ......................................

Door & Frame Assy, L.H. ....................................................

Door, LH Extension (large) .................................................

Door, LH Extension (small) .................................................

Hatch, Pressurization Unit Roof .........................................

Enclosure, Dynavane Bleed Fan ........................................

Duct, Pressurization Unit Transition ...................................

Duct, Upper Bleed Fan Discharge ......................................

Duct, Lower Bleed Fan Discharge ......................................

Shroud, Pressurization Unit Rain .......................................

Filter, Air/Bleed Air Duct ......................................................

Fan, Vane Axial ...................................................................

Blower & Motor ..................................................................

Operator Cab Structure ......................................................

Hatch, Bit View ...................................................................

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1 ....................... 3,000 1 ....................... 1,000 1 ..................... 10,000 1 ....................... 1,800 1 .......................... 710 1 .......................... 670 1 ....................... 1,700 2 .......................... 170 2 .......................... 300 1 .......................... 250 2 .......................... 285 1 .......................... 145 1 .......................... 375 1 .......................... 275 1 .......................... 280 1 ............................ 90 1 .......................... 100 1 .......................... 120 1 ....................... 1,000 1 .......................... 825 1 .......................... 230 1 ....................... 5,000 1 .......................... 180

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BI619852

Bucyrus International, Inc. 59HR Blast Hole Drill

Qty. Mast Braces Brace, Mast ........................................................................

Sleeve, Mast Brace ............................................................

Support, Front Brace ..........................................................

Eyebolt ...............................................................................

Pin, Lock ............................................................................

Cylinder, Brace Lock ..........................................................

Pin, Pivot ............................................................................

Cylinder, Mast Hoist Hydraulic ...........................................

Weight Ea. (Lbs.)

2 ....................... 2,810 2 .......................... 805 2 ....................... 1,205 2 ............................ 50 2 ............................ 25 2 ............................ 25 2 ............................ 20 2 ....................... 1,470

Mast Assembly Mast Structure .................................................................... 1 ..................... 34,845 Mast Rack ................................................................... 44 ......................... 105 Frame, Auxiliary Winch ....................................................... 1 .......................... 815 Rope, Auxiliary Winch ......................................................... 1 .......................... 175 Sheave, Auxiliary Winch ..................................................... 2 ............................ 35 Winch, Auxiliary .................................................................. 1 .......................... 415 Support Arm, Up LH Safety Sling ....................................... 1 .......................... 375 Support Arm, RH Safety Sling ............................................ 2 .......................... 175 Hose, Lower Air .................................................................. 1 .......................... 300 Hose, Upper Air .................................................................. 1 .......................... 470 Hose, Cable Retaining ....................................................... 1 .......................... 340 Pipe Rack, Single ............................................................... 2 ....................... 3,625 Cylinder, Rack .............................................................. 2 .......................... 100 Cylinder, Rack Gate ..................................................... 2 ............................ 10 Cylinder, Rack Lock ..................................................... 2 ............................ 10 Guide Frame ...................................................................... 2 ....................... 2,005 Spreader, Guide Frame ................................................ 2 ............................ 65 Guard, Gearcase .......................................................... 1 .......................... 100 Housing, Bearing - Right .............................................. 1 .......................... 690 Guide Rollers, Lower .................................................... 2 ............................ 50 Guide Rollers, Upper .................................................... 2 .......................... 150 Roller Assembly ........................................................ 4 ............................ 40 Roller, Track ............................................................ 12 ........................... 10 Shaft, Guide Roller Shipper .......................................... 1 ....................... 1,170

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Bucyrus International, Inc. 59HR Blast Hole Drill

Qty. Mast Machinery Gearcase & Cover, Pulldown .............................................

Support, Gearcase .......................................................

Shaft, Intermediate .......................................................

Gear, Intermediate ........................................................

Shaft, Shipper ..............................................................

Gear, Output ................................................................

Shaft, Input ...................................................................

Coupling .......................................................................

Brake, Pulldown ...........................................................

Motor, Pulldown ............................................................

Gearcase, Rotary ...............................................................

Cover, Inspection ..........................................................

Pinion, Rotary Motor ....................................................

Gear, Intermediate ........................................................

Shaft, Intermediate .......................................................

Cover, Lower Bearing ...................................................

Gear, Drive ...................................................................

Bearing, Drive Shaft, Main ...........................................

Shaft, Rotary Drive .......................................................

Housing, Upper Seal ....................................................

Carrier, Drive Shaft Bearing .........................................

Motor, Rotary ...............................................................

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Weight Ea. (Lbs.)

1 ....................... 2,155 1 ....................... 1,500 1 .......................... 195 1 ....................... 2,005 1 ....................... 1,170 1 ....................... 1,050 1 .......................... 100 1 ............................ 40 1 .......................... 160 1 ....................... 2,650 1 ....................... 5,165 1 ............................ 40 1 ............................ 80 1 .......................... 175 1 .......................... 105 1 ............................ 15 1 .......................... 695 1 .......................... 155 1 .......................... 565 1 ............................ 25 1 .......................... 400 1 ....................... 2,780

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Bucyrus International, Inc. 59HR Blast Hole Drill

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October 2009