Onboard Inspection Items

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.

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

7. Close and lock all electrical cabinet doors.

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

8. 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

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: 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.

15. 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.

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.

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.

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.

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.

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: 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.

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.

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.