CAT Rotary Track Drill MD5125 Hydraulic Track Drill Operation and Maintenance Manual - PDF DOWNLOAD

November 2015 EM006181-03-EN

Operation and Maintenance Manual MD5125 Hydraulic Track Drill SEZ1-up

SAFETY.CAT.COM

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

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

PART NUMBER AND DESCRIPTION In addition to the Model and Serial Number, always give the part number and description of each part ordered. If there is any doubt as to the correct part number and description, furnish a dimensional sketch or return the part to be replaced, transportation charges prepaid. Your cooperation in furnishing as much information as possible will assist us in filling your orders correctly and in the shortest possible time.

SHIPMENT Unless otherwise instructed, all shipments will be made via motor freight collect, freight forwarder or UPS prepaid and charged on our invoice. Shipments cannot be made on open account until your credit has been approved by our accounting department.

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

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

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

Printed in U.S.A.

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Introduction WARNING:

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

Failure to do so may result in dangerous practices which can cause equipment damage, serious personal injury or death.

BOTH operator and service personnel must read this manual, particularly the warnings and cautions listed in Section 1.

This manual contains instructions regarding operation of the Model SCH5000 Hydra-Trac® track drill carrier. It is intended to help you understand how the system operates and the precautions that should be observed. Read and understand this manual before operating or servicing this unit. This manual must be read and interpreted to non-English speaking personnel. Keep it handy for future reference.

For maximum utilization and efficiency in operating this equipment, we urge you to thoroughly read the entire contents of this manual before you begin to drill or service this machine.

CAUTION:

DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) from the engine before welding.

Fig. i-1 Caterpillar C10 Engine 1. Electronic Control Module (ECM) 2. Plug-Ins - Disconnect from ECM BEFORE welding.

Fig. i-1a Caterpillar C11 Engine 1. Electronic Control Module (ECM) 2. Plug-Ins - Disconnect from ECM BEFORE welding.

Specifications are subject to change without notice.

Information contained in this manual was up to date at the time of printing.

Introduction

i

General Information

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Fig. i-2 SCH5000CL - Left Side View

Fig. i-3 SCH5000CL - Right Side View

ii

Introduction

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General Information The SCH5000 series Hydra-Trac and HPR518 (HPR2-C1) drill make an ideal drilling package for a wide range of mining and construction applications. The SCH5000 Hydra-Trac is easy to operate, maneuverable, and efficient. A fully self-contained drill carrier, the Hydra-Trac consists of the following main components: 1.

D-4 type track assemblies with 15 inch triple-bar grousers.

2.

Prime mover - Caterpillar model C11 ACERT, Tier 3 electronic diesel engine rated at 325 B.H.P. @ 1800RPM.

3.

Hydraulic system, consisting of three (3) hydraulic pumps driven by the prime mover thru an elastic coupling to the pump drive gearbox.

4.

Drill/right-hand tram pump - Rexroth A11VLO. Compressor/left-hand tram pump - Rexroth A11VLO. Drill rotation pump - Vickers PVE-19

5.

400 C.F.M. compressor driven by a piston hydraulic motor provides plenty of blowing air for large hole sizes.

6.

A 12' chain feed (20' Model SCH5000CL) powered by a hydraulic piston motor, complete with a hydraulic powered, scissors type centralizer, an automatic linear rod changer, rack, and hose reel system.

7.

Model HPR5128 (HPR2-C1) hydraulic percussion drill complete with nitrogen charge kit. The HPR5128 Hydra-Drill is a high performance hydraulic rock drill that produces 3 1/2 inch (8.9 cm) and larger holes in medium to hard rock.

The SCH5000C/SCH5000CL operator cab is sound suppressive pressurized, with air conditioning.

The cab encloses control consoles for tramming, drilling, and positioning, and is mounted on the left side of the carrier. The SCH5000 (non-cab machine) is equipped with a drill console mounted on a hydraulically movable arm for safety and comfortable operation.

Machines equipped with optional dust collector incorporate an additional pump dedicated for operation of the dust collector fan.

The heavy duty 3' extendable telescoping boom is installed on all SCH5000/5000C model machines. The boom has large wear pads and all externally mounted cylinders, which combine for long component life and easy access for service areas. The combination of the telescoping boom and the 12' feed system provide accurate and fast set-up for all drilling functions. A massive non-extendable boom is provided on SCH5000CL machines. This boom system combines with a 20' feed system that can satisfy all high production demands.

The heavy duty construction and low center of gravity make this self contained carrier a highly stable drilling platform.

Overlapping track pads and track frame with + 8% oscillation provide positive ground contact when tramming over rough terrain.

SCH5000 Model machines are equipped with an automatic engine throttle system which provides full engine power only at drilling operation for energy saving and economic operation.

Introduction

iii

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Table of Contents SECTION 1

SAFETY

SECTION 2

OPERATOR CONTROLS

SECTION 3

OPERATING PROCEDURES

SECTION 4

DRILLING PROCEDURES

Overview of Potential Hazards .............................................................................................. 1-2 Before Operation ................................................................................................................. 1-3 Clearance from High Voltage Lines ....................................................................................... 1-3 Operation and After Operation .............................................................................................. 1-4 Maintenance and Equipment Transfer .................................................................................... 1-5 Stability Limits ..................................................................................................................... 1-6

Tram / Drill Positioning Controls........................................................................................... 2-2 Instrument Panel - Non-Cab with 3306 Engine ........................................................................ 2-4 Instrument Panel - Non-Cab with C11 Engine .......................................................................... 2-6 Drilling Controls - Non-Cab Machine ....................................................................................... 2-8 Instrument Panel - Cab Machine .......................................................................................... 2-12 Drilling Controls - Cab Machine ........................................................................................... 2-14 Tramming Controls - Cab Machine ...................................................................................... 2-16 Drill Positioning Controls - Cab Machine .............................................................................. 2-18 Air Ride Seat Adjustment .................................................................................................... 2-20

Personal Safety ................................................................................................................... 3-2 Walk-Around Checks ............................................................................................................ 3-3 Pre-Start Checklist ............................................................................................................... 3-4 Engine and Gearcases ........................................................................................................ 3-5 Pneumatic System ............................................................................................................. 3-5 Feed Table Pivot Pin ........................................................................................................... 3-6 Weekly Checks................................................................................................................... 3-6 Boom, Feed and Drill .......................................................................................................... 3-7 Drill Accumulators .............................................................................................................. 3-7 Daily Maintenance Checklist .................................................................................................. 3-8 Mounting & Dismounting Machine ......................................................................................... 3-9 Start-Up Procedure ............................................................................................................ 3-10 Cold Weather Starting ...................................................................................................... 3-11 Tramming-Preliminary Checks and Warnings ........................................................................ 3-12 Tramming from Operator's Cab .......................................................................................... 3-13 Tramming from Tram Station ............................................................................................. 3-14 Shutdown Procedure.......................................................................................................... 3-16

Loading Drill Steel ................................................................................................................ 4-2 Drill Positioning Procedure ................................................................................................... 4-4 Position Feed for Vertical Drilling ......................................................................................... 4-6 Vertical Indicator (optional) .................................................................................................. 4-6 Position Feed for Angle Drilling ........................................................................................... 4-7 Repositioning Feed or Lowering Feed to Horizontal Position ................................................. 4-7 iv

Introduction

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Table of Contents SECTION 4

DRILLING PROCEDURES

Final Checks ...................................................................................................................... 4-9 Drilling Procedure .............................................................................................................. 4-10 Collaring the Hole ............................................................................................................ 4-10 Collaring Circuit ............................................................................................................... 4-13 Normal Drilling ................................................................................................................... 4-13 Drilling Practices ................................................................................................................ 4-14 Collaring .......................................................................................................................... 4-14 Hole Deviation .................................................................................................................. 4-14 Feed Pressure ................................................................................................................. 4-14 Drill Pressures ................................................................................................................. 4-14 Adjusting Drill Pressure and Monitioring the Machine .......................................................... 4-14 Plugged Bit and Stuck Drill Steel........................................................................................ 4-14 Anti-Jam System (optional) .................................................................................................. 4-16 Reverse Percussion (optional) ............................................................................................. 4-18 Adding and Removing Drill Steel .......................................................................................... 4-20 Adding Drill Steel .............................................................................................................. 4-20 Removing Drill Steel ......................................................................................................... 4-21 Drill Shank Replacement ..................................................................................................... 4-23 Indexing the Swing Cylinder ................................................................................................ 4-24

SECTION 5

PREVENTIVE MAINTENANCE

Hydraulic Oils for Percussion Drills........................................................................................ 5-2 Lubrication and Inspection .................................................................................................... 5-3 Engine Oil ............................................................................................................................ 5-3 Bolt Maintenance ................................................................................................................. 5-4 Bolt Torque Specifications .................................................................................................... 5-5 Preventive Maintenance Chart ............................................................................................... 5-6 SCH5000 Grease Points - Overall Machine ............................................................................. 5-8 Grease Point Chart .............................................................................................................. 5-9 Grease Points - Drill & Centralizer...................................................................................... 5-10 Grease Points - Feed & Feed Drive .................................................................................... 5-11 Grease Points - Lower Rod Rack & Rod Wrench ................................................................. 5-12 Grease Points - Rod Rack Driveline .................................................................................... 5-13 Grease Points - Upper Rod Rack & Hose Reel .................................................................... 5-14 Grease Points - Feed Table ................................................................................................ 5-15 Grease Points - Positioner (12 Ft. Feed) ............................................................................ 5-16 Grease Points - Positioner (20 Ft. Feed) ............................................................................ 5-17 Grease Points - Boom Assembly ....................................................................................... 5-18 Grease Points - Drill Console Boom (non-cab) ..................................................................... 5-19 Grease Points - Cab Mounting ........................................................................................... 5-20 Grease Points - Track Assembly ........................................................................................ 5-21 Grease Points - Headrest for 20 Ft. Feed .......................................................................... 5-22 Grease Points - Fan Drive, Caterpillar C10 & 11 Engine ...................................................... 5-22 Maintenance Record .......................................................................................................... 5-23 Introduction

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Table of Contents SECTION 6

DRILL MAINTENANCE

SECTION 7

DUST CONTROL

SECTION 8

GLOSSARY

Charging the Accumulators .................................................................................................. 6-2 Requirements .................................................................................................................... 6-2 Procedure ......................................................................................................................... 6-3 Checking the Accumulator Charge Pressure .......................................................................... 6-4 Accumulator Charge Kit ....................................................................................................... 6-6 Drill Lubrication .................................................................................................................... 6-7 Grease Lubrication with a Hand Grease Gun ........................................................................ 6-7 Grease Specifications ......................................................................................................... 6-7 Automatic Lubrication ......................................................................................................... 6-7 Automatic Grease Lubricator Operation ............................................................................... 6-8

Health Hazard Warning ......................................................................................................... 7-1 Dust Collector Assembly ...................................................................................................... 7-2 Function of Dust Collector .................................................................................................. 7-3 Detailed Function of Components........................................................................................ 7-3 Initial Start-up and Tuning .................................................................................................... 7-4 Dust Collector Valve Adjustment (3306 engine) .................................................................... 7-5 Dust Collector Valve Adjustment (C10 & C11 engine) ............................................................ 7-6 Air Pressure Regulator Adjustment ...................................................................................... 7-7 Timer Adjustment ............................................................................................................... 7-8 Fan Speed Adjustment ........................................................................................................ 7-8 Filter Elements ................................................................................................................. 7-10 Dust Collector Efficiency .................................................................................................. 7-10 Operational Variables ........................................................................................................ 7-11 Fine Tuning ....................................................................................................................... 711 Manometer Setup Instructions .......................................................................................... 7-13 Timer Installation ............................................................................................................. 7-14 To Set Timer ................................................................................................................ 7-14 Control Circuit (Hydraulic, Electric and Air) ......................................................................... 7-15 Fan Removal and Installation ............................................................................................. 7-16 Troubleshooting Hints ...................................................................................................... 7-17

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Introduction

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Section 1

Safety

Safety

1-1

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Overview of Potential Hazards

The Track Drill is a heavy moving machine with a boom capable of extending its reach vertically and horizontally. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly inspected and maintained. The operators should read this manual and have been trained to use the machine in an appropriate and safe manner. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer at 1-800-258-0009.

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

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

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

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

POTENTIAL HAZARD

EFFECT

PREVENTION

Electrical Contact

DANGER: Will cause serious injury or death.

Maintain minimum clearance from high voltage power lines (refer to table 1-1). Do Not drill near underground power lines.

Machine is NOT insulated.

Contaminated Air

DANGER: WILL cause serious injury or death.

Do Not run machine in an area without good ventilation.

Silica Dust

WARNING: Health Hazard Can cause silicosis, as serious and sometimes fatal disease.

Always use dust collector or water suppression to control dust.

Unit Overturn

WARNING: Can cause serious injury or death.

Do Not travel on steep inclines or tram crosswise to grades.

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

Moving Boom or Parts

WARNING: Can cause serious injury or death.

Do Not operate machine or boom until all people are clear of the area. Do Not lubricate or service while machine is running.

High Pressure Air or Fluid

WARNING: Can cause serious injury or death.

Relieve pressure on hydraulic and pneumatic systems before loosening hoses or connections.

1-2

Safety

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Safety Instructions Before Operation •

Do notify the owner of overhead or underground power lines before drilling. Be sure to comply with all local regulations regarding safe operating distances from power lines. See table 1-1 for general guidelines for safe distances from high voltage lines.

•

Do study this manual and fully understand the controls.

•

Do be sure all safety guards are securely in place.

•

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

•

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

•

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

•

Do attach safety chain when using towbar.

•

Do Not operate machine with: • Hydraulic or air leaks • Broken or damaged electrical wiring or components • Damaged hydraulic hoses or fittings • Worn or damaged parts Clearances from High Voltage Lines Voltage Minimum Clearance 0 to 50 kv

10 ft. (3 m)

50 to 200 kv

15 ft. (4.6 m)

200 to 350 kv 350 to 500 kv

20 ft. (6.1 m) 25 ft. (7.6 m)

500 to 750 kv

35 ft. (5.2 m)

750 to 1000 kv

45 ft. (13.7 m)

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

Safety

1-3

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Safety Instructions Operation •

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

•

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

•

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

•

Do place feed in horizontal position with feed resting on feed rest (if equipped) when tramming over rough ground or during long moves. When moving from hole to hole, be sure feed is high enough to clear ground obstacles. If feed hits something while tramming, feed can fall causing serious injury or death.

•

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

•

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

•

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

•

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

•

Do Not stand directly under a boom or feed.

•

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

After Operation •

1-4

Follow Shut Down Procedures as listed in Operator's Manual.

Safety

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Safety Instructions Maintenance •

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

•

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

•

Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.

•

Do have adequate lighting when performing service work at night.

•

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

•

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

•

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

•

Do make sure no tools or other loose objects are left on the engine or drive mechanisms. They could be thrown by this equipment with a powerful force.

•

Do Not service or perform maintenance while machine is running.

•

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

•

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

•

Do Not weld or grind near oil lines.

•

Do Not attempt to remove radiator cap when engine is hot or has overheated.

Equipment Transfer If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics: • Safety Section • Operation Instructions including: • Pre-Start Checks • Start-up • After Start Checks • Shutdown Procedure • Tramming Machine

Safety

1-5

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Stability Limits

1-6

Safety

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Stability Limits

Safety

1-7

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Stability Limits

1-8

Safety

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Stability Limits

Safety

1-9

Notes

1-10

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Safety

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Section 2

Operator Controls

Operator Controls

2-1

Tram/Drill Positioning Controls

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Fig. 2-1 Tram Station

2-2

Operator Controls

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Tram/Drill Positioning Controls WARNING:

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

1.

Track Oscillation Allows manual control of track oscillation cylinders.

2.

Feed Extend Moves feed up or down on the feed table.

3.

Boom Extend Extends or retracts the boom (Not available on fixed boom machines).

4.

Feed Swing Swings the feed left or right.

5.

Boom Swing Swings the boom left or right.

6.

Feed Dump Tilts the feed forward or back.

7.

Boom Lift Raises or lowers the boom.

8.

Left Tram Activates the left track to enable forward or backward motion.

9.

Right Tram Activates the right track to enable forward or backward motion.

10. Throttle Allows the manual control of 3306 engine rpm. C-10 engines are electronically controlled.

NOTE

An "Automatic Throttle Control System" controls engine rpm during drilling operation (standard equipment). The engine will automatically run at full speed whenever the blow air valve is turned on. The engine will automatically resume at low idle speed when the blow air valve is turned off. Pulling the throttle lever out will override the automatic throttle control system and keep the engine running at higher constant rpm which is only required for fast tramming conditions. Keeping the throttle control knob at low idle position during normal drilling operations will provide economical machine operation and longer engine life. The 3306 engine has been set at 1400 RPM low idle speed and 1900 RPM full load speed.

11. Left/Right Track Oscillation Lock Switch selector that allows the operator independent, manual control of the left and right track oscillation. Normally, when tramming, place oscillation switch in UNLOCK position and when drilling switch to LOCK position.

12. Drill/Tram Selector Switch Selector switch allows adjustment of the machine hydraulic system for drilling or tramming operation.

13. Tram Motor Speed Switch This switch changes the displacement of the tram motors: Low Position - increases motor displacement to provide higher torque and lower speed.

High Position - decreases motor displacement to provide lower torque and higher speed.

Operator Controls

2-3

Instrument Panel - Non-Cab

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with 3306 Engine

Fig. 2-2 Instrument Panel used with 3306 Engine

13. Tachometer/Hourmeter Indicates the engine speed and hours of operation.

Low Idle - 1400 RPM Full Load - 1900 RPM 14. Circuit Breaker Circuit breaker for Ignition System 2-4

Operator Controls

Instrument Panel - Non-Cab

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with 3306 Engine

15. Circuit Breaker Circuit breaker for Electric Controls 16. Circuit Breaker Circuit breaker for Drill Lights.

17. Circuit Breaker Circuit breaker for Angle Inclinator.

18. Air Temperature o o Indicates compressor air temperature. 235 F(112.7 C) maximum.

19. DC Volts Voltmeter gauge indicates the amount of battery voltage available when the ignition switch is "ON".

20. Engine Water Temperature o Gauge indicates engine water temperature. Water temperature should not exceed 205 F o (96.1 C).

21. Engine Oil Pressure Gauge indicates engine oil pressure. Normal operating pressure is 40-60 psi (2.8-4.1 bar).

NOTE

Engine oil pressure must be more than 15 psi (1 bar) for operation.

22. Drill Lights On/Off switch activates the drill lights (Optional Equipment).

23. Electric Inclinator Activates the power supply to the angle inclinator.

24. Dust Collector Not used.

25. Electric Defroster Not used.

26. System Failure (early machines) Indicator light warns of low engine oil pressure, high engine water temperature, or high compressor air temperature.

26. Override Switch (late machines) Hold switch UP while cranking engine. Continue to hold until oil pressure is above 15 PSI (1 bar).

Machine will automatically shut down if engine oil pressure is low, engine water temperature is high or air compressor temperature is high.

27. Ignition Off/On/Start Main electrical power supply switch.

Off - Ignition and accessory are off.

On - Accessory circuit is "ON", and ignition circuit is "ON".

Start - Starter engages when switch is turned to this position.

28. Cold Start Push button switch to control ether injection into engine to improve "Cold Starting" capabilities.

(Optional Equipment) Operator Controls

2-5

Instrument Panel - Non-Cab

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with C-10/11 Engine

Fig. 2-2a Instrument Panel used with C10 Electronic Engine

2-6

Operator Controls

Instrument Panel - Non-Cab

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with C-10/11 Engine

1.

Tachometer/Hourmeter Indicates engine speed and hours of operation.

2.

Cold Start Button (optional) Activates ether starting aid when required for cold weather starting.

3.

Circuit Breakers Provide protection for electronic circuits. Refer to electrical schematics in service manual.

4.

Engine Water Temperature o o Gauge indicates jacket coolant temperature. Normal range is 190 to 215 F (88 to 102 C). o o Maximum allowable is 220 F (105 C).

5.

Compressor Air Temperature o o Indicates compressor discharge air temperature. 235 F (112.7 C) maximum.

6.

Ignition Off/On/Start Main electrical power supply switch.

Off - Ignition and accessory are off.

On - Accessory circuit is "ON", and ignition circuit is "ON".

Start - Starter engages when switch is turned to this position.

7.

Engine Speed Switch Switch in DOWN position is SLOW engine speed.

Switch in UP position is FAST engine speed.

8.

DC Volts Voltmeter gauge indicates the amount of battery voltage available when the ignition switch is "ON".

9.

Engine Oil Pressure Gauge indicates engine oil pressure. Normal operating pressure is 35 to 70 psi (2.4 to 4.8 bar) at rated speed with SAE 10W30 or 15W40 engine oil. Oil pressure will be somewhat lower at low idle speed.

10. ECM Diagnostic Light Light will flash to indicate the diagnostic code. The codes are stored in the Electronic Control Module (ECM). When ignition switch is turned ON the lamp will come on for five seconds. This checks the operation of the lamp. The lamp will then go out. When the lamp comes on during normal operation, this indicates an active fault in the engine system. The lamp will flash to indicate a two-digit code. Count the number of flashes for the first digit. The lamp will pause for one second between digits and two seconds between codes. Count the number of flashes for the second digit. Refer to Caterpillar Operation & Maintenance Manual for C10 and C11 engines for a listing of codes. In most cases service from an authorized Caterpillar dealer will be required. It is not necessary to have the engine running to retrieve the codes. Turn ignition switch to ON position and the ECM diagnostic light will flash the code(s).

Operator Controls

2-7

Drilling Controls - Non-Cab Machine

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Fig. 2-3 Drilling Console - Non Cab Machine

2-8

Operator Controls

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Drilling Controls - Non-Cab Machine CAUTION:

Always keep the rod lock in "locked" position when not loading or unloading the drill steel.

29. Rod Lock Lock position clamps drill steel top coupling in upper rack. Use when tramming or repositioning the feed. Unlock position unclamps the drill steel to allow for loading or unloading the drill steel.

30. Rod Wrench Swing rod wrench in to clamp and guide the drill steel, or swing rod wrench out to load drill steel.

31. Carriage Controls Enables carriage to move in and out to load or unload drill steel.

32. Carriage Lock Carriage lock holds carriage in a fixed position and prevents any misalignment.

33. Centralizer Controls opening and closing of centralizer.

34. Dust Collector Switch Three position rotary switch Off/Purge/Drill - activates dust collection system. Purge mode allows air to purge dirt from filters. Drill mode activates fan and purging.

35. Blow Air Adjustable and proportional flow control switch, allowing operator to adjust the blow air flow output. On / Off lever for blow air is located in front of drill console (not shown).

36. Water System Controls Meters the amount of water injected into the drilling hole.

37. Water System Controls On / Off control of water system.

38. Coupling Grease Push button to lubricate the coupling connections.

39. Drill Rotation Flow Control Adjustable flow control which sets the maximum drill rotation speed. Simplifies the drilling procedure.

40. Air Pressure Gauge Indicates the blow air pressure.

41. Feed Pressure Gauge Indicates feed pressure. During normal operation the feed pressure is adjustable from 900 -1800 psi (62-124.1 bar).

42. Rotation Pressure Gauge Indicates drill rotation pressure, 800-1500 psi (55.2-103.4 bar) during normal operation. Pressure will vary with hole size, bit type, feed pressure, and ground conditions.

43. Hammer Pressure Gauge Indicates drill hammer pressure - 2600 psi (179.3 bar) during normal operation.

Operator Controls

2-9

Drilling Controls - Non-Cab Machine

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Fig. 2-3 Drilling Console - Non Cab Machine

2 - 10

Operator Controls

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Drilling Controls - Non-Cab Machine 44. Feed Pressure Adjustment Sets the feed pressure at the desired level to maintain proper feed rate and drill penetration.

45. Feed Override Provides "Feed Drive System" full system pressure to maximize the power available when removing the drill steel from the hole.

46. Feed Control Lever Controls speed and direction of drill travel on the feed.

47. Rotation Control Lever Controls speed and direction of drill steel rotation.

48. Hammer Control Lever Controls the hammer percussion impact and speed.

49. Movable Dust Pot Raises and lowers dust pot to provide operator greater visibility when collaring the hole and improves dust control features of the SCH5000.

50. Drill Console Lift / Swing Raises, lowers, or swings the drill console for ease of operation.

51. Feed Dump / Feed Swing Feed Dump - Tilts the feed forward or back.

Feed Swing - Swings the feed left or right.

52. Feed Extend / Boom Extend Feed Extend - Moves feed up or down on the feed table.

Boom Extend - Extends or retracts the boom. (Not available on fixed boom machines.)

53. Boom Lift / Boom Swing Boom Lift - Raises or lowers the boom.

Boom Swing - Swings boom to left or right.

Operator Controls

2 - 11

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Instrument Panel - Cab Machine

Fig. 2-4 Engine Control Panel - early models with 3306 engine.

WARNING:

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

1.

Circuit Breakers Circuit breakers for Ignition System, Electric Controls, Drill Lights, Angle Inclinator (optional), Wiper System, Floor Heater, AC Heater, and Electric Defroster.

2.

Engine RPM Indicates the engine speed and hours of operation.

3.

Engine Oil Pressure Gauge indicates engine oil pressure. Normal operating pressure is 40-60 psi (2.8-4.1 bar).

NOTE

Engine oil pressure must be more than 15 psi (1 bar) for operation.

4.

DC Volts Voltmeter gauge indicates the amount of battery voltage available when the ignition switch is "ON".

5.

Engine Water Temperature Gauge indicates engine water temperature. Water temperature should not exceed 205oF o (96.1 C).

6.

System Failure Warning Light (early machines with 3306 engine) Indicator light warns of low engine oil pressure, high engine water temperature, or high compressor air temperature.

2 - 12

Operator Controls

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Instrument Panel - Cab Machine

Fig.2-4a Engine Control Panel - late models with C10 engine.

6.

Override Switch (later machines with 3306 engine) Hold switch UP while cranking engine. Continue to hold until oil pressure is above 15 PSI (1 bar).

Machine will automatically shut down if engine oil pressure is low, engine water temperature is high or air compressor temperature is high.

6.

ECM Diagnostic Light (late machines with C10 engine) See fig. 2-4a. Light will flash to indicate the diagnostic code. The codes are stored in the Electronic Control Module (ECM). When ignition switch is turned ON the lamp will come on for five seconds. This checks the operation of the lamp. The lamp will then go out. When the lamp comes on during normal operation, this indicates an active fault in the engine system. The lamp will flash to indicate a two-digit code. Count the number of flashes for the first digit. The lamp will pause for one second between digits and two seconds between codes. Count the number of flashes for the second digit. Refer to Caterpillar Operation & Maintenance Manual for C10 and C11 engines for a listing of codes. In most cases service from an authorized Caterpillar dealer will be required. It is not necessary to have the engine running to retrieve the codes. Turn ignition switch to ON position and the ECM diagnostic light will flash the code(s).

7.

Ignition Switch Off - Ignition and accessory are off.

On - Accessory circuit is on, and ignition circuit is on.

Start - Engages starter.

8.

Cold Start Push button switch to control ether injection into engine to improve "Cold Starting" capabilities.

(Optional Equipment)

9.

Gauge Lights Enables illumination of instrument gauges for greater visibility.

10. Wiper System Controls There are two (2) dedicated wiper systems, the "Front" and "Right". The wiper rotary switch has three (3) positions. Depress the wiper switch for washer operation.

Off - First Position.

High - Second Position Low - Third Position NOTE

Prolonged operation of the washer without fluid may damage the pump mechanism.

Operator Controls

2 - 13

Drilling Controls - Cab Machine

BI006828

Fig. 2-5 Drilling Controls

Fig. 2-5a Air and Water Controls - Located to the right of operator seat on lower panel.

2 - 14

Operator Controls

BI006828

Drilling Controls - Cab Machine 11. Detergent On-Off Valve Turns water supply on or off.

11a.Detergent Metering Valve Regulates the amount of water injected into the air stream.

12. Blowing Air On-Off Valve Turns air supply on or off.

13. Collaring Circuit Switch Activates collaring system which automatically lowers feed and hammer pressure for starting hole penetration.

13a.Anti-Jam Switch (optional) Activates anti-jam automatic drilling system.

13b.Reverse Percussion Switch (optional) Activates reverse percussion to aid in removing stuck drill steel.

14. Dust Collector Switch Three position rotary switch Off/Purge/Drill - activates dust collection system. Purge mode allows air to purge dirt from filters. Drill mode activates fan and purging.

15. Centralizer Switch Controls the opening and closing of the centralizer.

16. Movable Dust Pot Switch Raises and lowers dust pot to provide operator greater visibility when collaring hole and improves dust control features.

17. Hammer Control Lever Controls the hammer percussion. (Impact and speed).

18. Rotation Control Lever Controls speed and direction of drill steel rotation.

19. Feed Control Lever Controls speed and direction of drill travel on the feed.

20. Feed Pressure Override Provides "Feed Drive System" full system pressure to maximize the power available when removing drill steel from the hole.

21. Hammer Pressure Adjustment (Older Machines-up to mid 2007) Adjusts the hammer pressure to drilling requirement.

22. Drill Rotation Flow Control Adjustable flow control which sets the maximum drill rotation speed. Simplifies the drilling procedure.

23. Feed Pressure Adjustment Sets the feed pressure at the desired level to maintain proper feed rate and drill penetration.

24. Coupling Grease Switch Push button down to lubricate the coupling connections. Improves the assembly and disassembly of drill steel. To insure proper operation of coupling grease system, use only Bit/Coupling Grease (part no. 1416254, 5 gallon bucket).

Operator Controls

2 - 15

Tramming Controls - Cab Machine

BI006828

Fig. 2-6 Tramming Controls - early models with 3306 engine.

Fig. 2-6a Tramming Controls - late models with C-10/11 engine.

Note throttle switch (item 31) in place of throttle cable.

2 - 16

Operator Controls

BI006828

Tramming Controls - Cab Machine 25. Rotation Pressure Gauge Indicates drill rotation pressure, 800-1,500 psi (55.2-103.4 bar) during normal operation. Pressure will vary with hole size, bit type, feed pressure, and ground conditions.

26. Hammer Pressure Gauge Indicates drill hammer pressure - 2,500 ± 100 psi (172.4 ± 6.9 bar) during normal operation.

27. Feed Pressure Gauge Indicates feed pressure. During normal operation the feed pressure is adjustable from 600 -1,900 psi (41.4-131 bar).

28. Left Tram Activates the left track to enable forward or backward motion.

29. Right Tram Activates the right track to enable forward or backward motion.

30. Track Oscillation Allows manual control of track oscillation cylinders when oscillation switches (33) are in the UNLOCK position.

31. Throttle Control Cable (early models with 3306 engine) Allows the manual control of engine rpm.

NOTE

An "Automatic Throttle Control System" controls engine rpm during drilling operation (standard equipment). The engine will automatically run at full speed whenever the blow air valve is turned on. The engine will automatically resume at low idle speed when the blow air valve is turned off. Pulling the throttle lever out will override the automatic throttle control system and keep the engine running at higher constant rpm which is only required for fast tramming conditions. Keeping the throttle control knob at low idle position during normal drilling operations will provide economical machine operation and longer engine life.

31. Throttle Control Switch (late models with C10/11 engine) Place switch in FAST position for tramming or drilling. Place switch in SLOW for idling and shutdown of machine.

32. Drill/Tram Selector Switch Selector switch allows adjustment of the machine hydraulic system for drilling or tramming operations.

32a. Motor Speed Switch This switch changes the displacement of the tram motors: Low Position - increases motor displacement to provide higher torque and lower speed.

High Position - decreases motor displacement to provide lower torque and higher speed.

32b. Tram Control Switch This switch affects the sensitivity of the tram control levers (28 & 29).

Normal Position - the levers function at 100% capacity for full speed tramming.

Fine Position - the levers function at 50% capacity for precise positioning of machine.

33. Left/Right Track Oscillation Lock Switches lock or unlock track oscillation cylinders.

NOTE

Oscillation lock should be in UNLOCK position during normal tramming operation, and in LOCK position when set-up for drilling.

Operator Controls

2 - 17

Drill Positioning Controls - Cab Machine

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Fig. 2-7 Drill Positioning Controls

34. Drill Lights On/Off Provides light source for drilling operations in a dark environment.

35. Defrost On/Off Two speed blower fan to defrost or defog the two main drilling/operation windows.

36. Floor Heater Temperature Pull out lever to control the temperature of the air discharged from the heater/defroster blower.

37. Floor Heater On/Off On/Off switch to control two speed heater blower fan that provides a floor heat supply in the cab.

38. Feed Dump / Feed Swing Feed Dump - Tilts the feed forward or back.

Feed Swing - Swings the feed left or right.

39. Feed Extend / Boom Extend Feed Extend - Moves feed up or down on the feed table.

Boom Extend - Extends or retracts the boom. (Not available on fixed boom machines.)

40. Boom Lift / Boom Swing Boom Lift - Raises or lowers the boom.

Boom Swing - Swings boom to left or right.

2 - 18

Operator Controls

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Drill Positioning Controls - Cab Machine 41. Air Pressure Indicates pressure in the blow air system. Normal drilling pressure is 70-110 psi (4.8-7.6 bar).

42. Compressor Discharge Air Temperature o o Indicates compressor air temperature (235 F [112.7 C] maximum).

43. Cab/Boom Position Warning Light Indicator light, when illuminated, informs operator that the cab and boom are too close to each other, which may damage machine components. When light is ON the boom swing LEFT and cab boom swing RIGHT are rendered inoperative.

CAUTION:

For machines with 20 ft. feed, always keep the feed dump cylinder centered in the "cradle" on top of the boom when lowering the feed or damage to machine may result.

44. Feed Rest and Feed Dump Cylinder Warning Light On machines equipped with 20 ft. feed, this warning light has two functions: 1. Light comes ON when feed is on the feed rest at the rear of the machine. When light is ON the positioner dump UP and boom lift UP functions are rendered inoperative.

2. Light comes ON if positioner dump cylinder contacts the proximity switch mounted to the right of the feed dump cylinder cradle on top of the boom. When light is ON the positioner dump UP and boom lift UP functions are rendered inoperative.

45. Cab Lift / Cab Swing Raises and Lowers the operator cab, and swings cab left or right.

CAUTION:

Always keep the rod lock in LOCKED position when not loading or unloading the drill steel.

46. Rod Wrench / Rod Lock Rod Wrench - Swing rod wrench in to clamp and guide drill steel, or out to load drill steel.

Rod Lock - Lock position clamps drill steel in upper rack. Use when tramming or repositioning the feed. Unlock position unclamps the drill steel to allow for loading or unloading the drill steel.

CAUTION:

Always keep the carriage lock in LOCKED position when not loading or unloading the drill steel.

47. Carriage Lock and Controls Carriage control moves carriage in and out to load or unload drill steel. Locked position holds carriage in a fixed position and prevents any misalignment. Unlocked position enables carriage to move in and out to load or unload drill steel.

Operator Controls

2 - 19

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Air Ride Seat

An air ride seat is standard equipment on later model SCH5000 units. Below is a description of adjustments that can be made for optimum operator comfort.

A.

Weight and Height Adjustment To adjust, push air valve knob IN to RAISE seat, and pull OUT to LOWER seat. When adjusted properly, the seat should not top nor bottom against the end limits of the vertical travel under normal operating conditions.

B.

Fore and Aft Seat Position Adjustment.

Hold lever to left to adjust seat position forward or backward a total of 7.5 inches (190 mm).

C.

Back Angle Adjust.

Lean forward slightly to remove your weight from seat back. Hold handle rearward to adjust to any position within range.

Fig. 2-8 Air Ride Seat 2 - 20

Operator Controls

BI006828

Section 3

Operating Procedures

Operating Procedures

3-1

BI006828

Personal Safety WARNING:

Wear an approved protective helmet, safety boots, hearing, and eye protection when on or near the machine.

BE SURE all personnel are clear of the machine before moving.

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

Inspect hose retainers and hoses for indication of wear, looseness, cracking or fraying at regular intervals.

CHECK all bolts, nuts, and adjustments for proper tension.

Keep the tracks clear of rocks and other objects.

•

Your personal safety and the safety of others around you must be your first priority.

•

Always wear personal safety equipment when working on or near the machine, this includes: • Safety Helmet (Hard Hat) • Safety Glasses • Hearing Protection • Safety shoes (steel toed) • Leather work gloves

•

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

Keep long hair tied up to prevent getting caught in rotating machinery.

•

Remember, SAFETY is up to YOU. You can prevent serious injury or death.

Fig. 3-1 Wear Your Personal Safety Equipment 3-2

Operating Procedures

BI006828

Walk-Around Checks Walk-Around Checks 1.

Walk around machine and check for damage and faults including: • Leaks • Loose or missing fasteners • Damaged or missing parts • Wear on hoses, wires, etc.

2.

Tighten loose bolts, replace missing bolts. Refer to "Bolt Maintenance" and "Bolt Torque Specifications" in section 5.

3.

Review Daily Maintenance Check List.

4.

Review Maintenance Chart.

5.

Check for engine manual and operator's manual on machine.

Fig. 3-2 Daily Walk-Around Inspection

Operating Procedures

3-3

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Pre-Start Checklist WARNING:

ELECTRICAL SHOCK HAZARD. Unit Injector System 90 - 120 Volts.

On machines equipped with electronic engines, the Electronic Control Module (ECM) sends a high voltage signal to the injector solenoid.

DO NOT come in contact with the electronic unit injector terminals while engine is running.

WARNING:

NEVER open a pressurized vessel before pressure has been relieved and system has cooled down.

This includes: Radiator Compressor Receiver Tank Hydraulic Tank Detergent Tank Any hydraulic or pneumatic system fittings.

Fig. 3-3 Avoid Injury - DO NOT open radiator cap when coolant is hot - allow time for system to cool, then open cap S-L-O-W-L-Y. DO NOT open hot or pressurized vessels - allow time for system to cool down and de-pressurize.

3-4

Operating Procedures

BI006828

Pre-Start Checklist Engine and Gearcases 1.

Check crankcase oil level. Add oil if necessary. Do not mix types of oil.

2.

Check radiator coolant level. Coolant should be visible in the radiator filler neck. Add a 50/50 mixture of permanent antifreeze and water if necessary. Use caution when removing the radiator fill cap. Do not remove the radiator fill cap when the coolant is hot.

3.

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

4.

Check fuel separator bowl; drain if necessary.

5.

Check for adequate diesel fuel. To avoid priming and restarting problems, do not allow engine to run out of fuel.

6.

Check oil levels of gearbox. Add oil if necessary. Do not mix types of oil.

7.

Check oil level in feed motor gearcase assembly and planetary drive. Add oil if necessary; do not mix types of oil.

8.

Check fan belt tension.

For 3306 engine, belts should deflect .56" - .81" (14 - 20 mm) when pressed inward midway between the driving pulley and the driven pulley with a 25 lb. (11.4 kg) force.

For C10 engine, belts should deflect .35" - .59" (9 - 15mm) when pressed inward midway between the driving pulley and the driven pulley with a 25 lb. (11.4 kg) force.

9.

Be sure all engine air filter connections are tight. Check that vacuator valve is in place and operating correctly.

10. Check oil level in hydraulic reservoir. Add oil if necessary. Do Not Overfill. The SCH5000 is shipped with ISO 100 unless specified otherwise by the customer. See section 5 for lubricant specifications.

NOTE

The Hydraulic Filtering System used in the SCH5000 consists of 10 Micron Filters in the main pump charge loop and main return lines. During the warm up period (approximately 10 minutes), the cold hydraulic fluid may cause the indicators to function, giving a false "clogged filter" signal. By turning the indicator, the red color will reset. If the red color remains on, then a true clogged filter condition exists and the filter must be replaced immediately. Any time the indicator shows red during operation, turn it to see whether it will remain red before assuming the filter element is loaded. Occasional extraordinary pressure spikes will trip the indicator.

Pneumatic System 1.

Check sight tube on air receiver tank when system has cooled down. Add oil only if level is in the "Add Oil" range. Be sure system is cool and pressure relieved before removing cap on air receiver tank.

Do Not Overfill.

2.

Be sure all compressor air filter connections are tight. Check that vacuator valve is in place and operating correctly.

Operating Procedures

3-5

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Pre-Start Checklist

Fig. 3-4 Feed Table Pivot Pin 1. Retaining Bolts (6) - Torque to 282 ft. lbs. (384 Nm).

2. Retaining Cap, Feed Table Pin.

Fig. 3-5 Feed Table Pivot Pin 3. Grease Fittings (2)

Feed Table Pivot Pin WARNING:

BE SURE to check the feed table pivot pin for wear and any signs of damage. Pin failure could cause severe injury or death.

Weekly Checks:

3-6

1.

Be sure to check torque on the six pivot pin cap retaining bolts weekly. Torque to 282 ft. lbs. (384 Nm). Check for excessive play, cracking or other damage.

2.

Check for end play by inserting a feeler gauge between the retaining cap and positioner casting. If clearance is more than .005" (.13mm), report to maintenance personnel. Retaining cap will have to be removed and shims installed until the correct clearance is obtained. Procedure in service manual must be followed.

3.

Check for side play by raising the feed to a 45 degree angle. Have someone watch the pivot pin while you dump the feed back and forth. There should be no rocking of the pin. If so, report to maintenance personnel. Feed table will have to be removed and pin and bushing inspected and necessary repairs made.

Operating Procedures

BI006828

Pre-Start Checklist Boom, Feed and Drill 1.

Operator must be sure to check all pivot points for signs of wear or damage and grease daily.

2.

Check for loose drill hose retainers.

3.

Check feed chain for proper tension (see service manual).

4.

Chuck - Check for excessive shank side play indicating chuck wear. Grease chuck end cap after shank is inserted (use PG55 grease, part no. 312810 - 14 oz. tube).

5.

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

Drill Accumulators CAUTION:

DO NOT operate the hydraulic drill until accumulators have been charged.

Because of Federal regulations, the accumulators on the drill cannot be charged at the factory. Both the high and low pressure accumulators on the drill must be charged before the initial round is drilled and checked periodically thereafter. Refer to the Service and Maintenance sections of the manual for pressures and procedures.

Operating Procedures

3-7

BI006828

Daily Maintenance Daily Maintenance Checklist: 1.

Check fluid levels: Engine Radiator Coolant Engine Oil Fuel/Water Separator - Drain Water Fuel Compressor Oil Reservoir Hydraulic Oil Reservoir Pump Drive Gearbox Track Drive Gearcase Feed Drive Gearcase Automatic coupling grease pump reservoir. Recommended coupling grease is part no. 1416254 (5 gallon bucket).

2.

Lubrication at the beginning of each shift: Grease drill chuck end every 2 hours (5 strokes from a hand grease gun). We recommend using PG55 Grease (part no. 312810, 14oz. tube). See HPR5128 (HPR2) Drill Service Manual for other grease recommendations.

Grease centralizer pivot points.

Grease boom, feed and cylinder pivot points.

Grease feed sprockets Lubricate feed chain

3.

Check machine for loose fasteners, tighten if required.

See Bolt Torque Chart at the end of section 5.

4.

Check drill accumulator charge pressure. If hoses to drill backhead are vibrating excessively during drilling operation, this is an indication of low or no charge pressure.

5.

Check pressure on all pumps. Maximum output pressures of pumps to be set as follows (Selector valve at drilling mode): Drill / R.H. track pump - normal pressure 2,800 PSI (193.1 bar).

Air compressor / L.H. track pump - normal pressure 2,700 PSI (186 bar).

Drill rotation pump - normal pressure 2,500 PSI (172 bar).

6.

Check filter indicators.

7.

Check engine RPM: 3306 Engine Low idle - 1,400 RPM High idle - 1,900 RPM C10 & C11 Engine Low idle - 800 RPM Mid-Range - 1300 RPM High idle - 1800 RPM

3-8

Operating Procedures

BI006828

Mounting & Dismounting Machine Mounting & Dismounting Machine Always maintain 3-point contact with the machine when mounting or dismounting. Either two feet and one hand or two hands and one foot must be in contact with the machine. This practice will help prevent injury in case of a slip.

Fig3-6 Always keep 3 point contact with machine when mounting or dismounting.

Operating Procedures

3-9

BI006828

Start-Up Procedure Non-cab Machines

Cab Machines

Fig. 3-7 Tram Console (non-cab machine)

Fig. 3-9 Tram Console (cab machine)

Fig. 3-8 Instrument Panel (non-cab machine)

Fig. 3-10 Instrument Panel (cab machine)

3 - 10

Operating Procedures

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Start-Up Procedure WARNING:

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

After completing the pre-start checklist, use the following procedure to start the machine.

1.

Place the Drill/Tram selector switch to the "Neutral" (center) position (fig's. 3-7 or 3-9).

2.

Turn ignition switch to "Start" position (fig's 3-8 or 3-10) and hold the override switch (if equipped) up while cranking. Machines with electronic engines do not have an override switch. After engine starts and oil pressure is above 15 PSI (1bar), release the override switch.

NOTE 3.

If engine fails to start within 30 seconds, release start switch. Wait for two minutes and then turn start switch again.

After engine has started, allow ignition switch to return to "On" position.

CAUTION:

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

Cold Weather Starting WARNING:

DO NOT inject ether into the air compressor intake.

DO NOT use ether on engines equipped with an Air Inlet Heater (electrically or fuel ignited manifold heater).

1.

Do Not spray ether (starting fluid) into air intake on engines equipped with an air inlet heater or fuel system heater. If ether (starting fluid) is used, follow engine manufacturer's instructions. Use sparingly, as damage to pistons and piston rings can result from excessive ether use.

2.

If you are continually operating in a cold climate and your engine is not equipped with an air inlet heater, it would be wise to install an engine oil or coolant heater. This will help reduce white smoke, and engine misfire at start-up. You may also want to consider installing a fuel heater.

3.

Do not crank engine for more than 30 seconds. If engine does not start, wait two minutes before attempting to start again.

4.

After the engine has warmed up, (allow several minutes) switch the Drill/Tram selector switch to the "Drill" mode. Warm up the hydraulic system by actuating the rotation circuit.

5.

Check Hydraulic Pressure Gauges, located at the rear of the engine. Main hydraulic system pressure gauge indicates 2,800 psi (193 bar), compressor system pressure gauge should indicate 2,700 psi (186 bar) and drill rotation pressure gauge should indicate 2,500 psi (172 bar). If not, check and adjust hydraulic system.

Operating Procedures

3 - 11

Tramming-Preliminary Checks and Warnings

BI006828

WARNING:

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

ALWAYS wear an approved protective helmet, safety boots, and eye protection when on or near the machine.

BE SURE all personnel are clear of the machine before moving.

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

ALWAYS check operation of the brakes before tramming. (Brakes are automatically set while tram valve is in the neutral position. The brakes release when the tram valve is actuated either in forward or reverse position.)

SECURE the drill steels in the rod changer rack by actuating the rod lock device. Secure the drill steel in the feed by clamping the rod wrench on the lower position of the steel and close the centralizer before tramming over rough terrain.

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

DO NOT attempt to move the machine in a potentially unstable condition or when visibility is obstructed.

Tram carefully with steel in the steel rack.

Keep the tracks clear of rocks and other objects.

Fig. 3-11 Tram Control Panel in Cab 1. Left Track Control 4. Throttle Switch 2. Right Track Control 5. Right Track Oscillation Switch 3. Track Oscillation Control 6. Left Track Oscillation Switch 3 - 12

7. Tram Speed Switch 8. Tram Motor Speed 9. Tram/Drill Selector Switch Operating Procedures

BI006828

Tramming from Operator's Cab DANGER: DO NOT allow any part of the machine to contact or come near electrical power lines.

See high voltage clearance chart in section 1.

DO NOT raise the feed when the machine comes near electrical power lines.

WARNING:

BE SURE all personnel are clear of the machine before tramming.

CAUTION:

Retract the telescopic boom and lower feed to feed rest when tramming over rough ground and during long moves.

To Tram 1.

Place Drill/Tram switch (9) in TRAM position. On machines with C10 electronic engine, the RPM will automatically increase to 1300 RPM. Switching the throttle switch (4) to FAST will increase RPM to 1800. Use the higher RPM for high speed tramming. On machines with 3306 engines, pull the manual throttle out to increase RPM for high speed tramming.

2.

Raise feed high enough to clear ground obstacles, but low enough to clear overhead obstructions.

3.

Select the function switches to match tramming conditions: Tram Motor Speed (8) - LOW position provides higher torque and lower speed. HIGH position provides lower torque and higher speed.

Tram Speed (7) - Controls the sensitivity of the tram joysticks. In NORMAL position the joysticks function at 100%. In FINE position the joysticks function at 50% for precise maneuvering of the machine.

4.

Steering the carrier is accomplished with the tramming controls. A few moments should be spent becoming familiar with this operation and learning the "one-hand" technique of lever operation; you will find steering of this unit not only easy, but also precise.

5.

To make a very tight or "spin around" turn, make sure that one track is being operated in one direction and the other track in the opposite direction.

CAUTION:

For machines with 20 ft. feed, always keep the feed dump cylinder centered in the "cradle" on top of the boom when lowering the feed or damage to machine may result.

6.

When tramming over rough terrain or on a slope the feed must be in the horizontal position and rested on the mast rest to maintain the maximum tramming stability.

Operating Procedures

3 - 13

Tramming from Tram Station

Fig. 3-12 Tram Station 1. Track Oscillation 2. Feed Extend 3. Boom Extend 4. Feed Swing 5. Boom Swing 6. Feed Dump

3 - 14

BI006828

7. Boom Lift 8. Left Track 9. Right Track 10. Throttle (3306 engine only) 11. Track Oscillation Lock/Unlock 12. Drill/Tram Switch 13. Tram Motor Speed Switch

Operating Procedures

BI006828

Tramming from Tram Station DANGER: DO NOT allow any part of the machine to contact or come near electrical power lines.

See high voltage clearance chart in section 1.

DO NOT raise the feed when the machine comes near electrical power lines.

WARNING:

BE SURE all personnel are clear of the machine before tramming.

CAUTION:

Retract the telescopic boom and lower feed to feed rest when tramming over rough ground and during long moves.

To Tram 1.

Place Drill/Tram switch (12) in TRAM position. On machines with C10 electronic engine, the RPM will automatically increase to 1300 RPM. Switching the throttle switch (on the instrument panel) to FAST will increase RPM to 1800. Use the higher RPM for high speed tramming. On machines with 3306 engines, pull the manual throttle (10) out to increase RPM for high speed tramming.

2.

Raise feed high enough to clear ground obstacles, but low enough to clear overhead obstructions.

3.

Select the tram motor speed (13) to match tramming conditions: LOW position provides higher torque and lower speed.

HIGH position provides lower torque and higher speed.

4.

Steering the carrier is accomplished with the tramming controls. A few moments should be spent becoming familiar with this operation and learning the "one-hand" technique of lever operation; you will find steering of this unit not only easy, but also precise.

5.

To make a very tight or "spin around" turn, make sure that one track is being operated in one direction and the other track in the opposite direction.

CAUTION:

For machines with 20 ft. feed, always keep the feed dump cylinder centered in the "cradle" on top of the boom when lowering the feed or damage to machine may result.

6.

When tramming over rough terrain or on a slope the feed must be in the horizontal position and rested on the mast rest to maintain the maximum tramming stability.

Operating Procedures

3 - 15

Shutdown Procedure

BI006828

Fig. 3-13 Boom and Positioner for 20 ft. Feed 1. Feed Dump Cylinder 2. Feed Dump Cylinder "Cradle" 3. Proximity Sensor for Feed Dump Cylinder

Fig. 3-14 20 ft. Feed on Feed Rest 1. Feed Rest 2. Feed Rest Switch

3 - 16

Operating Procedures

BI006828

Shutdown Procedure To Shut Down the Machine 1.

Switch the dust collector switch to OFF, turn blowing air OFF.

2.

Secure steel in rod rack. (See Section 4).

CAUTION:

For machines with 20 ft. feed, always keep the feed dump cylinder centered in the "cradle" on top of the boom when lowering the feed or damage to machine may result.

3.

Set feed on ground or lower the feed to the feed rest.

NOTE

Special care must be taken for machines equipped with 20 ft. feeds.

A.

When lowering the 20 ft. feed be sure the feed dump cylinder is aligned with the feed dump cradle on top of the boom (fig. 3-13). If the feed dump cylinder is not centered and comes in contact with the proximity sensor (item 3, fig. 3-13) the feed dump UP and boom lift UP functions will be rendered inoperative. This is to prevent damage to the machine, as the feed dump cylinder can get in a bind if lowered too far and cannot lift the feed back up.

B.

As the feed approaches the feed rest (fig. 3-14), be sure the bracket on the feed is centered on the feed rest by adjusting boom swing and feed extend functions. When the feed is resting on the feed rest, the feed rest switch (item 2, fig. 3-14) will be activated.

C.

When the feed rest switch is activated, a red light on the control panel in the operator's cab (fig. 3-15) and at the tram station (fig. 3-16) will come ON. When the light is ON the feed dump UP and boom lift UP functions are rendered inoperative to prevent damage to the machine.

4.

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

5.

Place the drill / tram selector switch in NEUTRAL (center) position.

6.

Switch throttle switch to SLOW position or push manual throttle IN all the way. Allow engine to idle for approximately 3 minutes.

7.

Turn engine ignition switch to OFF.

Fig. 3-15 Cab Control Panel 1. Warning Light for Feed Dump Cylinder and Feed Rest Operating Procedures

Fig. 3-16 Tram Station 1. Warning Light for Feed Dump Cylinder and Feed Rest 3 - 17

Notes

3 - 18

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Operating Procedures

BI006828

Section 4

Drilling Procedures

Drilling Procedures

4-1

Loading Drill Steel

BI006828

Figure 4-1 Feed Position for Loading Drill Steel

4-2

Drilling Procedures

BI006828

Loading Drill Steel WARNING:

ALWAYS check for obstructions before moving mast or machine.

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

DO NOT wear loose clothing or jewelry.

KEEP AWAY from moving parts. Keep tools and rags away from moving parts.

Two people are required to load drill steel. One person must remain at the drilling controls at all times during the drill steel loading process.

CAUTION:

Apply adequate lubricant to all couplings and drill steel before loading.

Two people are required to load drill steel. One person must be at the drilling controls at all times! Visual, audible or verbal communication signals must be established and understood by both persons.

1.

Select "Drill" position with Drill / Tram selector switch.

2.

Apply coupling grease to threads and add coupling to each piece of drill steel to be loaded.

3.

Retract the upper and lower linear rod rack.

4.

Tilt the feed to a suitable angle which will allow insertion of a drill steel through dust collector pickup pot in alignment with the drill shank. (See Figure 4-1).

5.

Open the centralizer, position drill steel through dust collector pickup pot and hold in alignment with the shank.

6.

Rotate the drill shank counter-clockwise (forward rotation) to thread the shank into the coupling.

7.

Hoist the drill and drill steel up to allow closing the centralizer in order to support lower end of the drill steel. Continue to hoist the drill until the drill reaches the upper stop on the feed.

8.

Activate the rod wrench to clamp the drill steel, advance rod rack to insert the drill steel in the outermost socket.

9.

Repeat steps 2 thru 7 for the remaining drill steel.

10. Actuate the rod lock to secure all steel in the rod rack.

11.

Leave the last drill steel coupled to the drill and install the drill bit.

Drilling Procedures

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Drill Positioning Procedure

Fig. 4-2 Boom/Cab Proximity Switches 1. Cab Collision Switch 2. Cab Boom Collision Switch

Clearances from High Voltage Lines Voltage

Minimum Clearance

0 to 50 kv 50 to 200 kv

10 ft. (3 m) 15 ft. (4.6 m)

200 to 350 kv

20 ft. (6.1 m)

350 to 500 kv

25 ft. (7.6 m)

500 to 750 kv 750 to 1000 kv

35 ft. (5.2 m) 45 ft. (13.7 m)

Table 4-1 Minimum safe distances from high voltage lines.

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Drill Positioning Procedure WARNING:

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

See table 4-1 for minimum clearance from high voltage power lines.

CAUTION:

Extreme caution must be exercised when raising or positioning the feed to avoid striking any other components of the machine.

On machines equipped with a 20 ft. feed, the feed must o be raised a MINIMUM of 40 BEFORE swinging off centerline of boom.

1.

Before raising the feed, check for overhead electrical power lines or other obstructions. See section 1 for minimum clearances from high voltage power lines.

2.

Place track oscillation switches in LOCK position when machine is in position for drilling operation.

3.

Use caution when raising feed and positioning boom. On machines equipped with an operator's cab, watch for interference between cab and boom. The boom is equipped with proximity switches (fig. 4-2), to prevent the boom from damaging the cab. When the proximity switches come in contact with the cab or cab boom, a red light on the control panel (fig. 4-3) will come ON. When the light is ON the boom swing LEFT and cab swing RIGHT are rendered inoperative.

Fig. 4-3 Positioning Control Panel in Cab 1. Warning Light - Feed Dump Cylinder and Feed Rest (20 ft. Feed) 2. Warning Light - Cab/Boom Collision

Drilling Procedures

4-5

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Drill Positioning Procedure

Fig. 4-4 Vertical Indicator (optional) mounted in cab

Fig. 4-5 Feed Assembly 1. Pendulum 2. Stinger

To Position Feed for Vertical Drilling: 1.

There are two options available: A. If machine is equipped with a vertical indicator (fig. 4-4), follow the instructions for setting the feed plumb.

B.

2.

If machine is not equipped with a vertical indicator, position feed plumb by watching the pendulum (fig. 4-5). When pendulum is centered in the ring, feed is plumb.

When feed is plumb, plant the stinger firmly into ground using the feed extend lever. This will prevent the feed from "kicking out" when collaring the hole.

Vertical Indicator (optional)

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

Vertical Adjustment

4-6

1.

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

2.

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

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Drill Positioning Procedure To Position Feed for Angle Drilling

1.

2.

There are two options available: A.

The use of an electronic angle indicator is recommended if much angle drilling is to be done.

B.

If only a few angle holes are required, you can measure the feed angle with magnetic base adjustable protractor.

When feed is set at desired angle, plant the stinger firmly into ground using the feed extend lever.

This will prevent the feed from "kicking out" when collaring the hole.

Repositioning Feed or Lowering Feed to Horizontal Position CAUTION:

For machines with 20 ft. feed, always keep the feed dump cylinder centered in the "cradle" on top of the boom when lowering the feed or damage to machine may result.

NOTE A.

Special care must be taken for machines equipped with 20 ft. feeds.

When lowering the 20 ft. feed be sure the feed dump cylinder is aligned with the feed dump cradle on top of the boom (fig. 4-6). If the feed dump cylinder is not centered and comes in contact with the proximity sensor (item 3, fig. 4-6) the feed dump UP and boom lift UP functions will be rendered inoperative. This is to prevent damage to the machine, as the feed dump cylinder can get in a bind if lowered too far and cannot lift the feed back up.

Fig. 4-6 Boom and Positioner for 20 ft. Feed 1. Feed Dump Cylinder 2. Feed Dump Cylinder "Cradle" 3. Proximity Sensor for Feed Dump Cylinder

Drilling Procedures

4-7

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Drill Positioning Procedure

Fig. 4-7 20 ft. Feed on Feed Rest 1. Feed Rest 2. Feed Rest Switch

B.

As the feed approaches the feed rest (fig. 4-7), be sure the bracket on the feed is centered on the feed rest by adjusting boom swing and feed extend functions. When the feed is resting on the feed rest, the feed rest switch (item 2, fig. 4-7) will be activated.

C.

When the feed rest switch is activated, a red light on the control panel in the operator's cab (fig. 4-3) and at the tram station (fig. 4-8) will come ON. When the light is ON the feed dump UP and boom lift UP functions are rendered inoperative to prevent damage to the machine.

Fig. 4-3 Positioning Control Panel in Cab 1. Warning Light - Feed Dump Cylinder and Feed Rest (20 ft. Feed) 2. Warning Light - Cab/Boom Collision

4-8

Fig. 4-8 Tram Station 1. Warning Light for Feed Dump Cylinder and Feed Rest

Drilling Procedures

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Drill Positioning Procedure Final Checks

When machine is in position and feed is set at the desired angle for drilling you are ready to begin drilling the first hole. Refer to "Drilling Procedure" at the end of this section.

Check to be sure that: •

Track Oscillation Cylinders are Locked.

•

Drill/Tram Selector Switch is in DRILL position.

•

System gauges are in normal operating range.

•

Drill Steel is loaded and secured in rod rack.

•

Adequate supply of sharp drill bits.

•

Adequate supply of coupling grease is on hand for greasing drill steel, shank and coupling threads.

•

Grease gun and grease (we recommend Polytech PG55, part no. 312810) on hand to grease drill front end every two hours of drill operation.

•

Drill accumulator charge pressure has been checked.

Drilling Procedures

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Collaring The Hole

Fig. 4-9 Collaring the Hole Be sure feed is at proper angle.

Plant stinger firmly, so as to raise front of tracks about 2 - 3" off ground.

Start hole s-l-o-w-l-y with just a small amount of blowing air, feed, and hammer pressure.

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Drilling Procedure WARNING:

Keep all personnel away from hole while drilling is in progress.

DO NOT redrill a hole that has or may have contained explosives.

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

Fragmentation of the drill steel may result.

BE SURE the drill steel coupling does not unthread totally from both drill and shank; be alert to avoid coupling should it fall free.

CAUTION:

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

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

Dull drill bits cause severe stress level in drill components.

Apply adequate lubricant to all couplings and drill steel before loading.

DO NOT operate drill rotation and feed at full throttle until sure of rock conditions. Overfeeding and over-rotation can cause breakage of drill rotation parts and drill string.

Collaring The Hole 1.

Place the drill / tram selector switch in "Drill" position.

2.

Raise drill to top of mast. Couple the drill steel to the drill, then couple the drill bit to the section of drill steel. Always apply plenty of coupling grease to drill string threads. Close centralizer around drill steel.

3.

Turn the blowing air on just a small amount, and turn the dust collector switch to the "Drill" position.

4.

Slowly start forward (counterclockwise) drill rotation by placing drill rotation control about 1/2 way open.

5.

Slowly move drill feed lever forward to lower drill. Stop when bit contacts ground.

6.

Move hammer control lever to "On". Apply some feed pressure to collar the hole, gradually increase the air flow to full volume. This must be done carefully to assure a straight hole. Remember to start S-LO-W-L-Y until you get the feel of it. With some practice you'll be a good straight driller!

NOTE

Optional collaring circuit may be used to start (collar) the hole. Refer to "Collaring Circuit" on next page.

Drilling Procedures

4 - 11

Notes

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Drilling Procedures

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Drilling Procedure Collaring Circuit The SCH5000 is equipped with a collaring circuit. When the collaring switch (13) is activated, the pressure is reduced in the feed and hammer circuit. With the collaring switch "On", you place the hammer and feed levers in the " full on" position, but the hammer will only operate at 1500 PSI (103 bar) and the feed pressure will only be 1000 PSI (69 bar). After the hole is collared, you can turn the switch "Off" and full pressure will resume to the feed and hammer circuits. See Service Manual for circuit information.

Fig. 4-10 Drill Console in Cab

Normal Drilling After the hole is collared, the drilling cycle is for the most part automatic. Below are listed steps that need to be followed during the drilling cycle. On the following pages you will find helpful drilling practices to make drilling easier, more cost effective, and will result in less equipment downtime.

1.

After collaring hole approximately 3" (7.6 cm) deep, turn blowing air, hammer, feed, and rotation to full on position.

2.

Maintain proper feed pressure. If steel starts to bow, you are using too much feed pressure. If drill starts to bounce, or excessive heating in coupling is evident, you are not using enough.

3.

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

4.

When you get to the bottom of the hole (when drill is all the way down the feed, just above the centralizer), place the feed and hammer levers in neutral. Slow the rotation down and use reverse feed to raise drill. Keep blowing air on to clean hole. Turn off blowing air when bit is clear of hole. If you are adding another piece of drill steel, just raise drill up until upper coupling is within centralizer.

Clamp centralizer around coupling. Unthread drill shank from coupling using reverse rotation and reverse feed. Follow the "Adding and Removing Drill Steel" procedure to add another piece of drill steel.

NOTE

Remember to grease drill water swivel and rotation housing every two hours!

PG55 extreme pressure grease is recommended. See Drill Maintenance section.

Drilling Procedures

4 - 13

Drilling Practices

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Here are some tips for top drilling performance.

Collaring

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

Hole Deviation

The major cause of drill steel breakage is deviation of the drill hole. There is very little tolerance in the drill string for any deviation, due to the high energy output of the HPR2 rock drill.

Feed Pressure

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

Drill Pressures

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

Adjusting Drill Pressure and Monitoring the Machine

The operator should attempt to maintain a minimum amount of feed pressure, just enough to keep the drill steel couplings tight. The reason for this is to ensure smooth drilling and maximize penetration rate by: • Minimizing heat in the drill string • Eliminating "under and over feeding" • Minimizing rotation pressure Rotation flow should be increased in softer rock and decreased in harder rock as indicated by the penetration rate.

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

Plugged Bit and Stuck Drill Steel

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

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

Using the anti-jam option (if equipped) will help prevent stuck steel due to bad ground. The following pages describe the anti-jam system.

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Drilling Procedures

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Drilling Practices

Fig. 4-11 System Gauge Readings for Clay or Soft Ground.

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

Fig. 4-12 System Gauge Readings for Solid Rock.

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

Drilling Procedures

4 - 15

Drilling Procedure

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Anti-Jam System (optional)

Fig. 4-13 Anti-Jam Valve (ref. 1412020)

4 - 16

Drilling Procedures

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Drilling Procedure Anti-Jam System (optional) The optional anti-jam system may be used when drilling in incompetent ground. When the anti-jam switch (13a) is activated, the anti-jam system senses a change in rotation pressure; such as when the bit breaks into a void or seam in the rock. When this happens, the system will reverse the drill and then allow it to return to forward feeding. This cycle will repeat as necessary until the bit is clear in the hole, and then forward feeding will resume. When the anti-jam system is functioning, the operator should not touch the feed lever. If the operator deems it necessary to operate the feed lever; the anti-jam switch should be turned off first. The feed lever should then be returned to neutral for a few seconds to completely render the anti-jam system inoperative.

Operating Principle The variable factor utilized in the SCH5000 anti-jam system is rotation pressure. Rotation pressure will remain relatively constant with any given bit size, type, feed pressure, and type of rock. If the rotation pressure should increase, due to bad ground conditions, seams or cracks, a rise in pressure will be noted.

This rise in pressure is used to signal the feed system of the possibility of jamming the bit. Rotation pressure is sensed by an adjustable sequence valve (# 1). Fluid is allowed to pass to the pilot end of the spring biased directional valves (#3A & 3B). This pressure overcomes the spring and shifts the valves to reverse the flow to the feed cylinder. As the feed retracts the bit from the hole, rotation pressure decreases and the sequence valve spool shuttles closed and stops the flow of oil to the directional valves (#3A & 3B). The fluid trapped in the pilot circuit then drains to the reservoir through the reaction time orifice (needle valve #2). When the pressure drops sufficiently, the spring bias shifts the directional valves back to their normal position, the flow to the feed circuit resumes its normal path and the bit is moved forward into the hole. This sequence will repeat itself as many times as is required to clear the hole and normal drilling can continue.

The sensitivity of the system is determined by how close to the normal rotation pressure the sequence valve (#1) is adjusted. Backing the adjustment out will increase the sensitivity of the system.

Turning the screw in will decrease the sensitivity (require the rotation circuit to develop a higher working pressure before the sequence valve shifts to make the feed reverse).

The reaction time orifice (#2) determines how far the feed will retract before recycling. Turning the adjustment in will close the orifice and cause a longer cycle time. Backing out the adjustment will open the orifice and cycle time will become much faster.

NOTE The reaction time orifice (#2) must always be open at least 1 or 2 turns; otherwise, the directional valve will shift and remain shifted because leakage fluid will be trapped in the pilot line. It should also be noted that the reaction orifice is an extremely sensitive adjustment.

Setting the Anti-Jam With all other factors already determined (feed pressure, bit type and hole size) set up and drill.

When drilling, open the reaction time orifice (#2) 4 or 5 turns. Back the sequence valve (#1) adjustment out until anti-jam begins to function. Turn the reaction time adjustment in until the drifter backs up about 6 to 12 inches before recycling and moving forward again. Screw the sequence valve adjustment back in about 1-1/2 to 1-3/4 turns. Readjustment may be required to accommodate changes in rock conditions.

Drilling Procedures

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Drilling Procedure

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Reverse Percussion (optional)

Fig. 4-14 Reverse Percussion Operation

Fig. 4-15 Drill Console in Cab

4 - 18

Drilling Procedures

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Drilling Procedure Reverse Percussion (optional) Description

The reverse percussion is a true reverse percussion device, which uses a separate percussion piston to hammer against the drill shank. This independent unit is activated using a switch (13b) on the drill console, in the event of a stuck drill string. The reverse percussion will automatically transmit upward impact energy into the drill shank. The reverse percussion option is not intended to be used in place of good drilling practices, but rather for assistance in removing stuck drill strings due to adverse drilling conditions. If used continuously on every hole, a significant reduction in component life will result.

Operating Principle The reverse percussion (RP) piston is held upward against the anvil by supply pressure, in a stalled condition. When downward force exerted by the shank against the anvil exceeds upward force on the RP piston (indicating a stuck drill string), the RP piston is moved into its normal impacting position and it begins to impact on the anvil. The impact energy is transmitted through the anvil into the drill shank. The drill hammer has no function in the RP operation; whether it cycles or not is immaterial.

When the stuck drill string becomes free, the downward force exerted on the anvil by the drill shank will fall and the anvil will be pushed into its upward (idle) position by the RP piston. The RP piston is designed to stall in this position, which ceases the cycle. One advantage of this type of system is that it does not "rattle" the drill string during operation, so drill string component life is improved.

Maintenance The unit is designed for an operating pressure of 2000 PSI (138 bar). The unit is designed for intermittent usage in difficult drilling applications, where the hole has collapsed behind the bit or couplings. In most applications the unit will only need to be operated for a few seconds to a few minutes to free the drill string. Inspection frequency and wear item replacement will depend on the unit's operating cycle. The most critical components are the seals and the anvil. Refer to "Inspection" and "Adjustment" in the service manual.

Drilling Procedures

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Adding and Removing Drill Steel

WARNING:

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

DO NOT strike drill steel to dislodge it while the drill is operating. Fragmentation of the drill steel may result.

BE SURE the drill steel coupling does not unthread totally from both the drill steel and shank, be alert to avoid coupling should it fall free.

If bit becomes plugged, detach bit from steel to remove obstruction. NEVER hammer on bit or steel. Fragments can produce serious injury.

CAUTION:

Use sharp bits and periodically check for broken or loose carbides.

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

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

Adding Drill Steel After the first length of steel has been drilled to depth (coupling and shank even with centralizer jaws):

4 - 20

1.

With full blowing air turned on, run the drill up and down full length of hole to prevent stuck steel due to loose material above bit. Position to leave the bit at the bottom, or just above the bottom of the hole.

2.

Stop drill feed and rotate the air/dust collector switch to air off / dust collector off position.

3.

Place drill rotation and hammer controls in "Off" or "Neutral" position.

4.

Open and close Hammer Control in short bursts until steel is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the steel can be noted by change in sound in the drill string.

5.

Use Centralizer Control to close centralizer around the drill steel coupling.

6.

Use reverse rotation to unthread drill shank from coupling, while using the drill feed control to lift the drill.

7.

Actuate the automatic coupling grease by depressing the switch to grease drill shank thread.

8.

Raise drill to the top of mast.

Drilling Procedures

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Adding and Removing Drill Steel Adding Drill Steel (continued) 9.

Activate the Rod Index Locking lever to release the rod rack in locking position. Activate the rod change Carriage lever to advance rod racks to position first steel under drill shank, rod index locking pin will automatically locate the drill steel position.

10. Slowly start forward (Counterclockwise) rotation, using drill feed control to slowly lower drill shank into the coupling. Continue rotation and feed until coupling is tight and release the upper rod lock.

11. Actuate the Rod Wrench lever to position around the drill steel. (Keep Rod Wrench in "Guide" mode) 12. Raise the drill to clear the coupling from the upper rod rack.

13. Actuate the Rod Index Lock lever and retract the rod rack by actuating the carriage lever, actuating the upper rod lock to secure the next steel in position.

14. Lower the drill until the threads of the drill steel are in line with the coupling grease nozzle, depress the coupling grease switch to actuate the greaser.

15. Use drill feed control to slowly lower drill steel into coupling. Continue rotation and feed until all couplings are tight.

16. Open centralizer, adjust drilling control to same setting used when drilling with first length of steel.

When coupling clears the centralizer, close centralizer and retract the rod wrench.

17.

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

Removing Drill Steel When desired hole depth has been reached: 1.

With full blowing air turned on, run the drill up and down the full length of hole to prevent stuck steel due to loose material above bit. Position to leave the bit at the bottom, or just above the bottom of the hole.

2.

Stop drill feed.

3.

Place Drill Rotation and Hammer Controls in the "Off" or "Neutral" position.

4.

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

5.

Raise the drill until the coupling below the last drill steel is aligned with the centralizer jaws.

6.

If the steel is stuck, the feed override can be used to deliver extra hydraulic pressure to the Feed Control. If repeated attempts do not dislodge steel, turn hammer ON while feeding upward. Do not run drill in free oscillation mode (no feed pressure on hammer) for extended periods of time to prevent damage to the drill. If machine is equipped with reverse percussion option, use this feature to "hammer out of the hole" to remove stuck drill steel.

7.

Turn the dust collector switch to the off position; turn the blowing air off.

8.

Close the centralizer.

Drilling Procedures

4 - 21

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Adding and Removing Drill Steel Removing Drill Steel (continued) WARNING:

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

9.

Actuate rod wrench of rod changer to clamp the steel. Slowly start forward (counterclockwise) rotation to slightly tighten the coupling on the shank.

10. Loosen the rod wrench to guide mode. Slowly start reverse (clockwise) rotation at the same time utilizing the feed control to lift the drill until the coupling on the shank clears the upper rack level.

11. Actuate the rod index lock lever to release the rod rack in locking position and advance the rod rack by actuating carriage lever to position the last empty socket in the rod rack in line with the drill steel, lower the steel until the coupling is level with the upper rod rack.

12. Actuate the upper rod lock to lock on the coupling, slowly reverse the rotation and raise the drill to disengage the shank from the coupling.

13. Retract the rod wrench, and actuate the rod index lock lever and retract the rod rack.

14. Repeat the above steps until all of the drill steel has been removed from the hole.

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Drilling Procedures

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Drill Shank Replacement WARNING:

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

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

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

1.

With the feed vertical, remove the drill steel from the drill.

2.

Lower the drill to approximately four feet (1.22m) above the ground and shut down the engine.

3.

Loosen the two bolts, locknuts and belleville washers that secure the water swivel to the rotation housing. With one person holding the water swivel housing, remove the locknuts, belleville washers and bolts and remove water swivel and shank.

4.

Inspect drill front end parts for wear. See drill service manual for detailed instructions and wear tolerances. Inspect condition of thrust washer. Thrust washer should be replaced if wear on face exceeds .050" (1.27 mm).

5.

Apply grease to rear diameter of shank and shank splines (we recommend using PG55 grease, part no. 312810). Install shank into the drill chuck, being careful not to damage the seal in the bearing plate behind the chuck driver. Be sure to align the splines on the shank with those in the chuck.

6.

Grease both sides of thrust plate (we recommend using PG55 grease, part no. 312810) and install over shank and into rotation housing.

7.

With one person holding shank and thrust plate in position, slide water swivel over shank and up against rotation housing. Install bolts, belleville washers and locknuts.

8.

Tighten locknuts evenly and torque to 600 ft. lbs. (816 Nm).

9.

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

Fig. 4-16 HPR5128 (HPR2-C1) Shank Installation (ref. 304279b) Drilling Procedures

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Indexing the Swing Cylinder

Fig. 4-17 Position of feed and boom when indexing swing cylinder.

Note, upper end of feed is not yet secured to prevent the feed from pivoting when feed swing cylinder pin is removed.

3 1

2

Position 2 Position 1

Fig. 4-18 Feed Swing Cylinder 1. Retaining Ring and Thrust Washer 2. Bolt and Locknut 3. Pin 4 - 24

Drilling Procedures

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Indexing the Swing Cylinder WARNING:

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

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

BEFORE removing feed swing pin, be sure machine is on level ground and place feed in as near level position as possible with hydraulic rock drill centered over feed pivot.

SECURE the top end of the feed with a chain or lifting strap attached to a loader or backhoe bucket or similar equipment suitable to secure the feed.

If you have a special drilling application which requires repositioning of the feed, follow the procedure below to change the feed position.

NOTE

Position 1 is used for normal drilling. Position 2 is used for special applications.

1.

Remove drill steel and position the hydraulic rock drill so it is centered directly above the feed table pivot.

2.

Be sure machine is on level ground and place boom in horizontal position as shown in fig. 4-17.

Position the feed in as near horizontal position as possible. The feed must be raised high enough so the hose manifold will clear the boom when the feed is repositioned.

3.

Secure the top end of the feed so it can not move when the feed swing cylinder pin is removed (fig. 4-18). The use of a front end loader or backhoe is recommended to secure the feed with an adequate chain or lifting strap BEFORE removing the feed swing cylinder pin.

4.

Remove the retaining ring and thrust washer from the top end of the feed swing pin, then remove the locknut and bolt that secures the pin (fig. 4-18). Remove feed swing pin.

5.

Retract the feed swing cylinder to minimize feed movement. Carefully swing feed to line up with position 2 of positioner and install pin, bolt, locknut, thrust washer and retaining ring. Tighten locknut.

6.

Remove chain or lifting strap at top of feed.

Drilling Procedures

4 - 25

Notes

4 - 26

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Drilling Procedures

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Section 5

Preventive Maintenance

Preventive Maintenance

5-1

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Hydraulic Oils for Percussion Drills

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

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

OIL TYPE Mobil DTE 19M

ISO 100

Mobil DTE 18M

ISO 46

Mobil DTE 15M

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

EXTENDED RANGE o o 115 F (46.1 C) o

o

100 F (37.8 C) o

o

60 F (15.6 C)

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

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

OIL SELECTION

ISO EQUIVALENT

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

ISO 150/220 ISO 100 ISO 46

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

NOTE

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

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

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

o

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

5-2

Preventive Maintenance

BI006828

Lubrication and Inspection WARNING:

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

NOTE

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

To avoid unnecessary machine repairs, keep the following in mind when handling fuel and lubricants: •

Clean grease fittings with a clean cloth before greasing.

•

Keep all fuels and lubricants stored in clean and tightly sealed containers.

•

Keep filler caps clean of dust and oil.

•

Replace filters inside a shop or when no dust is in the air.

•

Never reuse paper filters.

•

Wash metal parts of filters with clean oil. Do not wipe the parts with a cloth.

•

Keep dirt and dust from entering any fluid system.

•

Keep the fuel storage containers and system filled.

•

Watch for metal filings on any magnetic drain plugs. Filings are a sign of internal component wear or misadjustment. If the source can be determined and repaired as a part of scheduled maintenance, costly down time can be avoided later.

•

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

Engine Oil •

The following is a list of preferred and acceptable oils for use in Caterpillar diesel engines.

Caterpillar Diesel Engine Oil (DEO) (perferred oil)

•

EMA LRG-1 multigrade oil (preferred oil)

•

API CH-4 multigrade oil (preferred oil)

•

API CG-4 multigrade oil (preferred oil)

•

API CF-4 multigrade oil (acceptable oil)

EMA - Engine Manufacturers Association

API - American Petroleum Institute

Engine Oil Viscosities For Ambient (outside) Temperatures Oil Viscosity SAE 0W-20 SAE 0W-30 SAE 0W-40 SAE 5W-30 SAE 5W-40 SAE 10W-30 SAE 15W-40 Preventive Maintenance

Min -40 -40 -40 -30 -30 -20 -15

o

C

Max. 10 30 40 30 40 40 50

Min. -40 -40 -40 -22 -22 -4 5

o

F

Max. 50 86 104 86 104 104 122 5-3

BI006828

Bolt Maintenance Bolt Maintenance WARNING:

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

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

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

5-4

Preventive Maintenance

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

Note: K = .15 for plated or lubricated fasteners.

Nominal Diameter

UNC

UNF

UN

SAE Grade 5 ASTM A-449 Tightening Torque Ft. Lbs. (Nm) Newton meter

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

6 (8.2) 13 (17.7) 23 (31.3) 35 (47.6) 57 (77.5) 82 (111.5) 113 (153.7) 200 (272) 322 (437.9) 483 (656.9) 596 (810.6) 840 (1142.4) 1102 (1498.7) 1462 (1988.3) 1714 (2331) 2576 (3503.4) 3768 (5124.5) 5155 (7010.8) 6996 (9514.6) 9231 (12554.2) 7 (9.5) 14 (19) 26 (35.4) 40 (54.4) 64 (87) 91 (123.8) 127 (172.7) 223 (303.3) 355 (482.8) 528 (718.1) 668 (908.5) 930 (1264.8) 1254 (1705.4) 1645 (2237.2)

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

1879 (2555.4) 2857 (3885.5) 4127 (5612.7) 5726 (7787.4) 7693 (10462.5) 10064 (13687)

Preventive Maintenance

SAE Grade 8 Tightening Torque Ft. Lbs. (Nm) Newton meter 9 (12.2) 18 (24.5) 33 (44.9) 55 (74.8) 80 (108.8) 115 (156.4) 159 (216.2) 282 (383.5) 455 (618.8) 681 (926.2) 966 (1313.8) 1363 (1853.7) 1786 (2429) 2371 (3224.6)

10 (13.6) 20 (27.2) 37 (50.3) 60 (81.6) 90 (122.4) 128 (174.1) 180 (244.8) 315 (428.4) 502 (682.7) 746 (1014.6) 1083 (1472.9) 1509 (2052.2) 2034 (2766.2) 2668 (3628.5)

5-5

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Preventive Maintenance Chart SERVICE POINTS

SERVICE OR MAINTENANCE EVERY 10 HOURS or DAILY

LUBRICANT/CAPACITY

Engine Oil (Cat C11) Engine Oil (Cat C10)

Check level - Refill as required.

Check level - Refill as required.

1 / 42 Qts. (40 L) 1 / 36 Qts. (34 L)

Engine Oil (Cat 3306) Engine Coolant (C11)

Check level - Refill as required.

Check level - Refill as required.

1 / 29 Qts. (27.5 L) 5 / 11.1 Gal. (42 L)

Engine Coolant (3306 or C10 engine) Fuel / Water Separator - Engine

Check level - Refill as required.

Check. Drain if required.

5 / 10 Gal. (38 L)

Fuel Tank Hydraulic Oil

Check. Fill Check level - Refill as required.

110 Gal. / (417 L) 8 / 80 Gal. (303 L)

Air Compressor Oil Pump Drive Gear Case Oil (Funk)*

Check level - Refill as required.

Check level - Refill as required.

2 / 7 Gal. (26.5 L) 4 / 7.5 Qts. (7.1 L)

Engine Air Filter Air Compressor Air Filter

Check. Clean as required.

Check. Clean as required.

Hydraulic Oil Filters Air Compressor Oil Filter

Check. Replace if required.

Check. Replace if required.

Radiator / Oil Cooler Cylinder / Boom Pivots

Check level. Clean as required.

Lubricate and Inspect.

Feed Chain Sprockets Feed Chain Drill Steel Centralizer Drill

7 Lubricate and Inspect.

6 Lubricate, Inspect, adjust as required. 3 Lubricate and Inspect.

7 Inspect, Lubricate every 2 hours.

9 EVERY 50 SERVICE HOURS or WEEKLY (whichever occurs first)

Batteries

Check Level - Refill as Required

Track Chain Tension Drill Slide Wear Pads

Check and Adjust Check and Adjust

Feed Table Wear Pads Feed Table Pivot Pin

Check and Adjust Check End Play (.005" max.)

Dust Collector Filters Detergent System Strainer

Check. Clean or replace if required.

Check. Clean if required.

Compressor Oil Reservoir Track Drive Gearcase Oil

Check level - Refill as required.

Check level - Refill as required

7

Torque Retaining Cap Bolts to 282 ft. lbs. (384 Nm)

2 / 7 Gal. (26.5 L) 4 / 4.8 Qts. (4.5 L)

* Funk Model 594 Gearbox (late model machines, 5/98 and later) - Oil Capacity is 7.5 Qts. (7.1 L).

Terrell Model KJ3 Gearbox (early model machines, up to 5/98) - Oil Capacity is 7.75 Qts. (7.3 L).

KEY TO LUBRICANTS 1.

5-6

Cat DEO (Diesel Engine Oil)S, or API CH-4 preferred. API CG-4, or API CF-4 acceptable. Normal factory fill is 15W-40.

2.

ATF - Dexron III.

3.

SAE 30 Engine Oil.

4.

EP 90W Gear Oil.

5.

50/50 mix, water and anti-freeze, plus 2 qts. (1.9 L) coolant conditioner (#1405131).

6.

Grease, lead base - heat resistant.

7.

Grease, NLGI No. 1, medium grade above 10o F (-12.2o C), light grade below 10o F (-12.2o C).

8.

Hydraulic Oil, ISO 100 (standard factory fill). Refer to "Selection of Hydraulic Oil" in this section.

9.

Grease, Polytech PG55 (#312810 - 14 oz. tube).

10.

Special Purpose Grease (SPG) Available in a NLGI No. 2 grade with a polyurea thickener.

Preventive Maintenance

BI006828

Preventive Maintenance Chart SERVICE POINTS

SERVICE OR MAINTENANCE

LUBRICANT/CAPACITY

EVERY 250 SERVICE HOURS or 6 MONTHS (whichever occurs first) Drain and Replace SEE DAILY Replace

Engine Oil Engine Oil Filter Engine Fuel Filter Engine Belts, A/C Belts

Replace Check and Adjust

Engine Fan Drive Bearing Drain Water from Fuel Tank

Lubricate Drain

10

Engine Coolant Conditioner Feed Gearcase Oil

Check for concentration Check level - Refill as required

P/N 1405131/2 qts (1.9 L) 4 / 3.5 Qts. (3.3 L)

Track Drive Gearcase Oil Compressor Air Receiver Pressure

Initial Change, then every 1500 hours.

Check and Adjust

4 / 4.8 Qts. (4.5 L)

Dust Collector Air Filters Canopy Hinges

Replace, P/N 419090 (6) Lubricate

3

EVERY 500 SERVICE HOURS or 6 MONTHS (whichever occurs first) Replace

Engine Air Filter Hydraulic Oil Filters Compressor Air Filter

Replace Replace

Compressor Oil Filter Compressor Oil

Replace Drain and Replace

Detergent System Strainer Feed Table Bushing

Replace Check and Replace

Pump Drive Gear Case Oil (Funk)*

Initial Change, then every 1200 hours.

Fuel / Water Separator Fan Hub

2 / 7 Gal. (26.5 L)

4 / 7.5 Qts. (7.1 L)

EVERY 1200 SERVICE HOURS or YEARLY (whichever occurs first) Drain and Replace Inspect

Pump Drive Gear Case Oil (Funk)* Drain and Replace 4 / 7.5 Qts. (7.1 L) EVERY 1500 SERVICE HOURS or 2 YEARS (whichever occurs first) Track Drive Gear Case Oil Drain and Replace 4 / 4.8 Qts. (4.5 L) EVERY 2400 SERVICE HOURS or 2 YEARS (whichever occurs first) Hydraulic Tank Suction Screens (not used with Rexroth pumps) Hydraulic Oil

Clean and replace if required

Compressor Oil Separator Element Engine Coolant

Replace Drain, Flush and Replace

Feed Gear Case Oil

Drain and Replace

NOTE

Drain and Replace

8 / 80 Gal. (303 L) SEE DAILY 4 / 3.5 Qts. (3.3 L)

When filling gearcases, always fill to proper level, if gearcase is fitted with an oil level plug. Be sure plug is positioned according to instructions for specific gearcase.

Operate gearcase for a few minutes. Reposition gearcase so plug is in proper position according to instructions. Shutdown machine and check level again.

Preventive Maintenance

5-7

SCH5000 Grease Points

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Fig. 5-1 SCH5000 - Left Side with 12 ft. feed and extendable boom.

Fig. 5-2 SCH5000 - Right Side with 20 ft. feed and fixed boom.

5-8

Preventive Maintenance

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SCH5000 Grease Points The general area's for greasing are shown in fig's. 5-1 and 5-2. Detailed drawings are provided to illustrate specific grease points. For example: When greasing the hose reel rollers, fig. 5-1 shows the location of the hose reel. Then go to the hose reel drawing (fig. 5-11) to see the specific grease points.

Establish a pattern for greasing the machine and stick with it. That way, you won't miss any grease points by skipping around. The following table starts out with greasing the drill, then all the feed points, then the feed table, positioner and boom points. Next, grease the cab positioning points (if machine is not equipped with a cab, then grease the drill console boom pivot points). Finally, grease the track oscillation cylinders and track pivot points. Don't forget to grease the pin on the feed rest on machines with 20 ft. feed.

SERVICE LOCATION

LUBE POINTS

FREQUENCY

NOTES

HPR2 Rock Drill Front End - fig. 5-3 Centralizer - fig. 5-4 Lower Feed Chain Sprocket - fig. 5-5 Feed Drive Sprocket - fig. 5-6 Lower Rod Rack - fig. 5-7

4 4 1 1 7

Every 2 hours Daily Daily Daily Daily

Polytech PG55 grease recommended

Rod Wrench - fig. 5-8 Rod Rack Driveline, Midpoint - fig. 5-9 Upper Rod Rack - fig. 5-10

4 2 8

Daily Daily Weekly

Hose Reel - fig. 5-11 Upper Feed Chain Sprocket - fig. 5-5 Feed Table - fig's. 5-12 & 13

9 1 4

Daily Weekly Daily

Positioner - fig's. 5-14 & 15 Feed Dump Cylinder (12 ft. feed) - fig. 5-14 Feed Dump Cylinder (20 ft. feed) - fig. 5-15 Boom Extend Cylinders (12 ft. feed) - fig. 5-16 Boom Lift Cylinder - fig. 5-16 Boom Swing Cylinder - fig. 5-16 Boom Pivot - fig. 5-16

4 3 4 4 2 3 4

Daily Daily Daily Daily Daily Daily Daily

Drill Console Boom - fig. 5-17

8

Daily

Cab Swing Arm - fig. 5-18

4

Daily

Cab Swing Cylinder Pins - fig. 5-18 Cab Tilt Cylinder Pins - fig. 5-18 Cab Pivot Pin - fig. 5-18 Track Oscillation Cylinders (2) - fig. 5-19 Track Frame Pivot Points - fig. 5-20

2 2 2 4 4

Daily Daily Daily Daily Daily

Feed Head Rest Switch - fig. 5-21 Fan Drive Bearing (C-10 engine) - fig. 5-22

2 1

Preventive Maintenance

4 rollers, 2 driveline bearings, 1 rod lock pin 1 coupling, 1 bearing 4 rollers, 2 driveline bearings, 1 rod lock pin, 1 driveline to motor coupling 9 rollers 2 feed swing cylinder, 2 feed extend cylinder 2 at trunnion, 1 at rod end 2 each end 1 each end 1 each end 1 rod end, 2 base end & clevis top & bottom of pivot pin, and 1 each side of boom clevis 2 at pivot pin, 1 each end of boom, 1 each end of boom swing cylinder 1 each end of boom lift cylinder 3 places on center pivot pin and 1 at cab end pin 1 each end 1 each end

1 each end Grease fittings are located on hydraulic tank. Lube lines go to track pivot points.

Daily Grease plunger pin - 2 places 6 months or 250 hours - use Special Purpose Grease

5-9

Drill & Centralizer Grease Points

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Fig. 5-3 HPR2 Drill - 4 Grease Points

Fig. 5-4 Centralizer - 4 Grease Points

5 - 10

Preventive Maintenance

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Feed & Feed Drive Grease Points

Fig. 5-5 Feed Chain Sprockets - 2 Grease Points

Fig. 5-6 Feed Drive Sprocket - 1 Grease Point

Preventive Maintenance

5 - 11

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Lower Rod Rack & Rod Wrench Grease Points

Fig. 5-7 Lower Rod Rack - 7 Grease Points

Fig. 5-8 Rod Wrench - 4 Grease Points 5 - 12

Preventive Maintenance

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Rod Rack Driveline Grease Points

Fig. 5-9 Rod Rack Driveline - 7 Grease Points See Upper and Lower Rod Rack for bearing lube points

Preventive Maintenance

5 - 13

Upper Rod Rack & Hose Reel Grease Points

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Fig. 5-10 Upper Rod Rack - 8 Grease Points

Fig. 5-11 Hose Reel - 9 Grease Points 5 - 14

Preventive Maintenance

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Feed Table Grease Points

Fig. 5-12 Feed Table for 12 Ft. Feed - 4 Grease Points

Fig. 5-13 Feed Table for 20 Ft. Feed - 4 Grease Points Preventive Maintenance

5 - 15

Positioner (12 Ft. Feed) Grease Points

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Fig. 5-14 Positioner & Feed Dump Cylinder for 12 Ft. Feed - 7 Grease Points

5 - 16

Preventive Maintenance

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Positioner (20 Ft. Feed) Grease Points

Fig. 5-15 Positioner & Feed Dump Cylinder for 20 Ft. Feed - 8 Grease Points

Preventive Maintenance

5 - 17

Boom Assembly Grease Points

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Fig. 5-16 Boom Assembly (extendable shown) - 11 Grease Points (Fixed Boom does not use boom extend cylinders, so there are only 7 grease points).

5 - 18

Preventive Maintenance

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Drill Console Boom (non-cab) Grease Points

Fig. 5-17 Drill Console Boom Assembly (non-cab machines) - 8 Grease Points

Preventive Maintenance

5 - 19

Cab Mounting Grease Points

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Fig. 5-18 Cab Swing/Tilt Arm - 10 Grease Points

5 - 20

Preventive Maintenance

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Track Assembly Grease Points

Fig. 5-19 Track Oscillation Cylinders - 4 Grease Points

Fig. 5-20 Track Frame Pivot - 4 Grease Points (grease fittings located on hydraulic tank) Preventive Maintenance

5 - 21

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20 Ft. Feed Headrest Grease Points

Fig. 5-21 20 Ft. Feed Headrest Switch - 2 Grease Points

C10 & C11 Engine Fan Drive Grease Point

Fig. 5-22 Cat C10/11 Engine Fan Bearing - 1 Grease Point Grease every 250 hours of operation or 6 months, whichever occurs first.

5 - 22

Preventive Maintenance

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Maintenance Record

DATE

HOUR METER

Preventive Maintenance

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

5 - 23

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Maintenance Record

DATE

5 - 24

HOUR METER

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

Preventive Maintenance

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Maintenance Record

DATE

HOUR METER

Preventive Maintenance

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

5 - 25

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Maintenance Record

DATE

5 - 26

HOUR METER

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

Preventive Maintenance

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Maintenance Record

DATE

HOUR METER

Preventive Maintenance

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

5 - 27

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Maintenance Record

DATE

5 - 28

HOUR METER

MAINTENANCE PERFORMED

WORK PERFORMED BY

WORK AUTHORIZED BY

Preventive Maintenance

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Section 6

Drill Maintenance

Drill Maintenance

6-1

BI006828

Charging the Accumulators

1 2

Fig. 6-1 Accumulator Charging Set-up 1. Low Pressure Accumulators (top of drill).

2. High Pressure Accumulators (one on each side of drill).

Requirements 1.

Nitrogen filled tank.

2.

Pressure regulator with proper fittings to hook to nitrogen tank and receive charging hose.

3.

Charging hose, with proper fittings, to connect to charging and checking gauges. Hose should be long enough to reach drill and tank (approximately 6-8 feet).

4.

One 300 PSI (20.7 bar) gauge assembly with proper fittings to connect to low pressure accumulator valve and to the charging hose.

5.

One 2000 PSI (138 bar) gauge assembly with proper fittings to connect to high pressure accumulator valve and to the charging hose.

NOTE

6-2

The fittings, gauges and hose are supplied with the Drill Charge Kit shown on page 6-6.

Drill Maintenance

BI006828

Charging the Accumulators Procedure

NOTE BE SURE to charge both high pressure and both low pressure accumulators.

To begin with, charge the high pressure accumulators to 1000 psi (69 bar), charge the low pressure accumulators to 50 psi (3.5 bar). Then, drill a few holes to warm up the machine and check to be sure the high pressure accumulators are charged to 30% of the supply pressure and the low pressure accumulators are charged to 30% of the return pressure. Measure the pressures during actual drilling conditions with drill hammer and rotation on, feed on and compressor and dust collector on.

1.

Connect pressure regulator to nitrogen tank and tighten.

2.

Connect the 2000 PSI (138 bar) checking and charging gauge assembly to the high pressure accumulator. (The high pressure accumulators are located on the sides of the drill).

3.

Connect charging hose to pressure regulator and tighten. If the regulator is not being used for any other service, it is advisable to leave this connection intact permanently.

4.

Connect the charging hose to the high pressure gauge assembly.

5.

Check and make sure the valve on the pressure regulator is in the OFF position. The regulator valve should be backed out.

6.

Turn the handle on the nitrogen tank counterclockwise until the tank pressure is shown on the pressure regulator gauge.

7.

Open the accumulator valve on the high pressure accumulator, counterclockwise all the way until it stops.

8.

Turn the valve handle on the pressure regulator slowly clockwise until the 2,000 PSI (138 bar) gauge on the checking and charging gauge assembly reads 30% of the hydraulic pressure at the inlet port of the drill (the high pressure port is on the right side as viewed from the rear).

9.

Close (clockwise) the accumulator valve on the high pressure accumulator until it is snug (10 ft. lbs.).

10. Close off the nitrogen tank by turning the handle clockwise until it is tight. Back out the regulator valve (counterclockwise).

11. Disconnect the charging hose and gauge assembly from the accumulator valve.

12. Charge the low pressure accumulators (located on the top of the drill), in the same manner, using the 300 PSI (20.7 bar) charging and checking gauge assembly. The gauge should read 30% of the hydraulic pressure at the return port of the drill. See note below: NOTE

Check return pressure during actual drilling conditions, i.e. drill hammer and rotation on, feed on, compressor and dust collector on. Gauge should read in the range of 50 - 150 psi (3.5 - 10.3 bar). Some HPR2 drills have an orificed fitting on the return port to boost return pressure. When reading the return pressure on HPR2 drills with and orificed fitting, you will have to ADD 100 P.S.I. (6.9 bar) to the gauge reading. Low pressure charge will be 30% of the sum of the two pressures. If the SCH5000 track drill is equipped with a backpressure valve (mounted between boom and cab pivots), the HPR2 (HPR5128) will not have an orifice in the return (left) side, so charge to 30% of gauge reading.

Drill Maintenance

6-3

Checking the Accumulator Charge Pressure

BI006828

WARNING:

DO NOT remove accumulator covers from hydraulic drills before completely bleeding off the gas charge in the accumulators.

The high and low pressure accumulators must be properly charged during machine setup and prior to drilling the initial round. Check accumulator pressures only if excessive hose vibration or loss in penetration rate is noted.

The procedure for checking the high and low pressure accumulators is the same. However, use the 2,000 PSI (138 bar) checking and charging gauge for the high pressure accumulator. The high pressure accumulators are located on the sides of the drill. Use the 300 PSI (20.7 bar) gauge for the low pressure accumulator. The low pressure accumulators are located on top of the drill.

NOTE

Some charge pressure is lost to the gauge during the checking process. To check for a gas leak, brush soapy water on charge valves and accumulator covers.

To Check Charge Pressure 1.

Connect the appropriate checking and charging gauge to the accumulator; use 2,000 PSI (138 bar) gauge for the high pressure accumulator, use 300 PSI (20.7 bar) gauge for low pressure accumulator.

2.

Open the valve on the accumulator counterclockwise all the way until it stops.

3.

Read accumulator charge pressure. Correct accumulator charge pressure is 30% of the hydraulic pressure at the inlet port to the drill. The correct low pressure accumulator charge is 30% of the hydraulic pressure at the return port of the drill. Refer to graphs on next page for quick reference. See note below.

NOTE

6-4

Check return pressure during actual drilling conditions, i.e. drill hammer and rotation on, feed on, compressor and dust collector on. Gauge should read in the range of 50 - 150 psi (3.5 - 10.3 bar). Some HPR2 drills have an orificed fitting on the return port to boost return pressure. When reading the return pressure on HPR2 drills with and orificed fitting, you will have to ADD 100 P.S.I. (6.9 bar) to the gauge reading. Low pressure charge will be 30% of the sum of the two pressures. If the SCH5000 track drill is equipped with a backpressure valve (mounted between boom and cab pivots), the HPR2 (HPR5128) will not have an orifice in the return (left) side, so charge to 30% of gauge reading

4.

Close the accumulator valve clockwise all the way until it stops. Tighten snugly (10 ft. lbs. max.).

5.

Remove the test gauges and replace the accumulator valve safety caps.

Drill Maintenance

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Checking the Accumulator Charge Pressure SUPPLY (HIGH PRESSURE) ACCUMULATOR

DRILL OPERATING PRESSURE - PSI (BAR)

3000 (206.9) 2500 (172.4) 2000 (138) 1500 (103.4) 1000 (69)

•

500 (34.5)

•

•

•

•

• The graphs shown here are based on the following calculation: Accumulator charge pressure = .30 X operating pressure.

RETURN (LOW PRESSURE) ACCUMULATOR

280 (19.3) 260 (17.9) 240 (16.6) 220 (15.2) Actual Gauge Reading - PSI (bar)

DRILL RETURN LINE PRESSURE - PSI (BAR) DOWNSTREAM FROM ORIFICE FITTING (if used) IN DRILL To determine total backpressure on drill, add 100 psi (6.9 bar) to gauge reading if orifice is used.

150 300 450 600 750 900 (10.3) (20.7) (31) (41.4) (51.7) (62) HPR5128 SUPPLY (HIGH) ACCUMULATOR CHARGE PRESSURE - PSI (BAR)

200 (13.8) 180 (12.4) 160 (11) 140 (9.7) 120 (8.3) 100 (6.9) 80 (5.5) 60 (4.1) 40 (2.8) 20 (1.4) 0

• 6 (0.4)

• 12 (0.8)

• 18 (1.2)

•

24 (1.7)

•

•

30 36 (2.1) (2.5)

•

42 (2.9)

•

48 (3.3)

•

•

•

•

54 60 66 72 (3.7) (4.1) (4.6) (5)

PSI BAR

HPR5128 RETURN (LOW) ACCUMULATOR CHARGE PRESSURE Drill Maintenance

6-5

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Accumulator Charge Kit

Fig. 6-2 Charging and Checking Gauge Setup (ref. 316120 Rev. B)

1HPR781X CHARGE KIT ITEM QTY.

U/M PART NO.

N/S N/S N/S 4 5

1.00 1.00 1.00 1.00 3.00

EA. EA. EA. EA. EA.

1053152 1053069 1053068 1052134 1052121

6 7 8 9 N/S 11 12 13

2.00 2.00 2.00 2.00 1.00 1.00 1.00 1.00

EA. EA. EA. EA. EA. EA. EA. EA.

1052120 1052059 1052049 353906 1051606 1051605 1051604 1051169

DESCRIPTION

FILLER, FOAM CASE, KIT INSTRUCTION SHEET ASSEMBLY, HOSE CONNECTOR, SWIVEL (one per gauge, one on hose) VALVE, BLEEDER VALVE ASSEMBLY, TANK ADAPTER, SPECIAL NIPPLE, PIPE BOTTLE, NITROGEN GAUGE, PRESSURE, 0-300 PSI GAUGE, PRESSURE, 0-2000 PSI REGULATOR, PRESSURE

N/S - NOT SHOWN

6-6

Drill Maintenance

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Lubrication Grease Lubrication with a Hand Grease Gun Every drill has a primary and one or more secondary lubrication points. The primary lubrication point is the one lubricating the thrust plate and the shank splines. Secondary lubrication points are for pinion bearings and swivel bearings. For best performance and reliability, use only high pressure, high temperature grease such as: PG55 - Part No. 312810 (14 oz. tube) Petro Canada Supreme EP2 BP/Sohio Super Bearing Guard EP2 Primrose 327 Armor Plate with Moly-D For normal operation grease twice per shift. For severe applications such as large bit sizes, deep holes, hard rock, difficult hole cleaning conditions, broken ground, etc., where rapid shank or chuck wear is experienced, an increase in the frequency of lubrication is recommended from 4 hours to every 2 hours. Generally, it is better to lubricate every 2 hours with 5 "shots" out of a hand grease gun than 10 "shots" every 4 hours.

Depending on the problems encountered in specific applications, the grease specification of different manufacturers should be compared.

Drop Point ASTM D2265; Preferably 500o F (260o C) or higher.

Load Carrying Ability Timken test ASTM D2509; Preferably 50 LBS (22.7 Kg) or higher.

4-Ball EP Test ASTM D2596; Preferably 440 LBS (200 Kg) or higher.

Water Washout ASTM D1264; Preferably 1% or lower.

Automatic Lubrication The SCH5000 can be equipped with an automatic drill lubrication system. The grease pump is operated by a timer and is factory set to apply grease for 10 minutes every 2 hours. The pump will supply lubricant up to NLGI #2 grease. Heavier grease, such as listed for hand grease gun lubrication should not be used in this system. See following page for operation and maintenance.

Fig. 6-3 Electric Grease Pump Mounted in engine compartment on right side of machine.

Drill Maintenance

6-7

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Automatic Grease Lubricator (optional) To Fill Reservoir

Fill the reservoir through the grease fitting located at the base of the reservoir, using a hand operated grease pump. Refill reservoir when grease reaches MIN mark on reservoir. Fill to the MAX mark.

To Prime System

Pump and Supply Line: After reservoir has been filled with grease, loosen the supply line fitting. Operate the pump until grease flows from outlet, then tighten fitting.

Feed Lines: Pre-fill each feed line with grease before connecting to outlet of divider valve and drill.

Fig. 6-4 Electric Grease Pump 1. Reservoir 18. Black Power Cord 22. Sealing Plug 25. Filler Grease Fitting 33. Optional Manual Lube Cord 35. Pump Element Assembly 37. Pressure Relief Valve Assembly

6-8

Fig. 6-5 Timer Setup

1.

The LED marked BATTERY lights when power is applied to the PC board.

2.

The LED marked MOTOR lights when pumping lubricant.

3.

Depressing button for 2 seconds will initiate a manual lube event.

4.

OFF time rotary switch. Can be adjusted to 15 values (see chart).

5.

ON time rotary switch. Can be adjusted to 15 values (see chart).

Drill Maintenance

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Automatic Grease Lubricator (optional) Timer Operation:

The OFF timer begins accumulating time when the ignition switch closes. When the OFF timer reaches the preset value, the pump will turn on. The pump remains activated for the period of time that is preset on the ON timer.

When the ignition switch opens, the OFF timer will retain its accumulated time for a period of five days. When the ignition switch closes during the five day period, the OFF timer will resume timing from the accumulated time it reached prior to the ignition switch opening. If ignition switch is not closed before the end of five day period, timer will begin with an ON period.

To Set Timer:

Remove sealing plug (item 22, fig. 6-3) to access manual lube switch, timer adjustments or to view the system LED's.

IMPORTANT: DO NOT use the zero position located on the OFF time and ON time switches.

OFF Time Rotary Switch Setting

Interval Between Lube Cycles

ON Time Rotary Switch Setting

Pump will run for:

0

Will not run

0

Will not run

1

1 Hour

1

2 Minutes

2

2 Hours

2

4 Minutes

3

3 Hours

3

6 Minutes

4

4 Hours

4

8 Minutes

5

5 Hours

5

10 Minutes

6

6 Hours

6

12 Minutes

7

7 Hours

7

14 Minutes

8

8 Hours

8

16 Minutes

9

9 Hours

9

18 Minutes

A

10 Hours

A

20 Minutes

B

11 Hours

B

22 Minutes

C

12 Hours

C

24 Minutes

D

13 Hours

D

26 Minutes

E

14 Hours

E

28 Minutes

F

15 Hours

F

30 Minutes

Drill Maintenance

6-9

Notes

6 - 10

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Drill Maintenance

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Section 7

WARNING:

HEALTH HAZARD Always use dust collector or water suppression to control dust when drilling.

Avoid breathing airborne dust particles.

Prolonged inhalation of silica dust can cause silicosis, a serious and sometimes fatal disease.

Dust Control

Dust Control

7-1

Dust Collector Assembly

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Fig. 7-1 Dust Collector Assembly (HDE 1200)

7-2

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Dust Collector Assembly Function of Dust Collector The function of the dust collector is to convey the dust and rock chips from the hole collar to the filter housing and separate the solid particles from the clean air.

Detailed Function of Components Pick Up Pot: The pot is of special design, sized to the collector's performance. The pot must be mounted to the drill feed in such a manner that it provides unrestricted entry of make-up air (approximately 2" above the hole collar). The offset suction hose outlet and the accelerator ring inside the lower section of the pot blend to create a vortex air flow in the pot. Two wear resistant flexible seals, mounted on the top plate, form an effective seal between the drill steel and the pot, to prevent the cuttings escaping into the atmosphere.

Primary Separation: This function takes place in the hopper which is the lower section of the collector. The separator deflects the heavier particles downward into the hopper, so they do not come into contact with the filters. The hopper stores the separated material for final discharge through the dump flap, attached to the lower section of the hopper. The dump flap is held closed by the internal vacuum and releases the separated material when the fan is turned off. When drilling is in progress, should the volume or weight of the separated material overcome the vacuum effort, the dump flap will automatically discharge. This feature permits uninterrupted drilling to continue indefinitely.

Final Separation: The main body of the collector is divided into separate chambers. The lower, dirty air chamber, contains the filters and the top section (the clean air chamber) houses the pulse air manifold and the impulse valves. The pleated filters are attached to the bulkhead, forming a barrier so that only clean air can pass. The dust laden air is drawn upwards from the hopper where it passes through the filters which remove the remaining microfine dust particles, allowing only clean air to enter the top chamber. The trapped dust builds up in layers on the filters, forming a dust cake, which if left undisturbed, would block the passage of air through the filters. To prevent the dust cake from building up, it is removed from the filters by reverse flushing. The electronic timer controls the impulse valves by cycling the firing order of the valves, delivering a measured quantity of compressed air to the inside of the filters. This charge of compressed air is transformed into a high velocity flow that dislodges the built up dust cake from the filters and causes it to settle in hopper. This repeated cleaning cycle enables continuous drilling, while providing sufficient air flow to prevent blockage of the filters and the suction hose.

Fan: The fan generates the required vacuum and air flows which convey the material through the system. The taperlock coupling secures the fan wheel to the motor shaft while providing adjustment for setting the wheel clearance.

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7-3

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Dust Collector Setup Initial Start-up and Tuning WARNING:

NEVER look directly into the fan outlet. Loose particles in the fan housing may exit at high velocity and cause personal injury.

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

Normally, the initial start up service is carried out by the drill manufacturer or by the distributor's field personnel. It is, however, advantageous to understand this procedure as the same principles apply when tuning the collector, to maintain optimum performance.

4

5

1

3 7

6

Fig. 7-2 Dust Collector Control Valve (ref. 421600) Late Model Machines 1. Relief Valve - 2000 PSI (138 bar) 2. Check Valve 3. Differential Sensing Valve 4. Gauge Port 5. Flow Control (fan speed) Adjustment 6. "M1" Port 7. "M2" Port 8. Solenoid Valve

7-4

2

Fig. 7-2a Dust Collector Control Valve (ref. 1419284) Early Machines 1. Solenoid Cartridge, 24 VDC - 2000 PSI (138 bar) 2. Cartridge Check Valve 3. Cartridge Valve (2 mm shim under cap) 4. Gauge Port 5. Flow Control (fan speed) Adjustment 6. "M1" Port 7. "M2" Port

Dust Control

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Dust Collector Setup CAUTION:

The SCH5000 machines use a separate hydraulic pump to power the dust collector. Set dust collector control relief valve at minimum setting (screwed all the way out) and block the "M1" port. Make sure the solenoid valve is wired to the dust collector switch. Failure to do this will result in pump damage and/or personal injury.

Fig. 7-3 Dust Collector Switch

Fig. 7-4 Manual Throttle Low Idle Position

Fig. 7-4a Manual Throttle High Idle Position

Dust Collector Valve - Adjustment (non-electronic engine) This valve is located inside the canopy at the right rear of the machine, adjacent to the dust collector. The dust collector control valve is a manifold valve which consists of a solenoid valve with an integral pressure relief valve, a bypass type flow regulator and compensator, and an anti-cavitation check valve.

Fig. 7-2 shows the late model valve, fig. 7-2a shows the earlier style valve.

1.

2.

Remove the hose from the inlet connection at the dust collector fan motor. This is the hose that connects to the "M1" port of the dust collector control valve. Install a #8 plug in the hose end and install a #8 cap on the adapter of the motor inlet.

Install a 5000 psi (345 bar) gauge in the gauge port (4) of the dust collector valve.

3.

Loosen the locknut and back the pressure relief adjustment screw (item 1, fig's 7-2 & 7-2a) all the way out (counter-clockwise) to avoid pump damage and possible personal injury.

4.

Turn dust collector switch to OFF position. Start machine and place tram/drill switch in DRILL position, leave throttle in low idle position. Reading on pressure gauge installed in dust collector control valve should be very low or zero.

5.

Turn dust collector switch to DRILL position and turn blow air valve ON; this will increase engine rpm to full governed RPM.

6.

Turn adjustment screw (1) until gauge installed in "G" port reads 2000 PSI (138 bar). Tighten locknut.

7.

Turn dust collector switch off and turn blowing air off. Shut down machine, remove gauge and connect hose to dust collector motor.

Dust Control

7-5

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Dust Collector Setup CAUTION:

The SCH5000 machines use a separate hydraulic pump to power the dust collector. Set dust collector control relief valve at minimum setting (screwed all the way out) and block the "M1" port. Make sure the solenoid valve is wired to the dust collector switch. Failure to do this will result in pump damage and/or personal injury.

Fig. 7-2 Dust Collector Control Valve (ref. 421600) Late Model Machines 1. Relief Valve - 2000 PSI (138 bar) 2. Check Valve 3. Differential Sensing Valve 4. Gauge Port 5. Flow Control (fan speed) Adjustment 6. "M1" Port 7. "M2" Port 8. Solenoid Valve

Dust Collector Valve - Adjustment (electronic engine) This valve is located inside the canopy at the right rear of the machine, adjacent to the dust collector. The dust collector control valve is a manifold valve which consists of a solenoid valve with an integral pressure relief valve, a bypass type flow regulator and compensator, and an anti-cavitation check valve.

1.

2.

7-6

Remove the hose from the inlet connection at the dust collector fan motor. This is the hose that connects to the "M1" port of the dust collector control valve. Install a #8 plug in the hose end and install a #8 cap on the adapter of the motor inlet.

Install a 5000 psi (345 bar) gauge in the gauge port (4) of the dust collector valve.

3.

Loosen the locknut and back the pressure relief adjustment screw (item 1, fig. 7-2) all the way out (counter-clockwise) to avoid pump damage and possible personal injury.

4.

Turn dust collector switch to OFF position. Start machine and place tram/drill switch in DRILL position, leave throttle in low idle position. Reading on pressure gauge installed in dust collector control valve should be very low or zero.

5.

Turn dust collector switch to DRILL position and turn blow air valve ON; this will increase engine rpm to full governed RPM.

6.

Turn adjustment screw (1) until gauge installed in "G" port reads 2000 PSI (138 bar). Tighten locknut.

7.

Turn dust collector switch off and turn blowing air off. Shut down machine, remove gauge and connect hose to dust collector motor.

Dust Control

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Dust Collector Setup

Fig. 7-3a Dust Collector Switch

Fig. 7-4b Engine Throttle Switch

Air Pressure Regulator - Adjustment The dust collector air pressure regulator is located to the right of the rotation pump at the left rear of the machine, just below the gauge panel.

1.

Start machine and place tram/drill switch in DRILL position, keep manual throttle in low idle position.

2.

Turn dust collector switch to PULSE position and turn blowing air valve on.

3.

Adjust pressure regulator to 80 PSI (5.5 bar). Lift up on the cap (fig. 7-5) and turn cap to adjust pressure. When pressure is set, push cap down.

Fig. 7-5 Air Pressure Regulator 1. Adjustment (lift and turn)

Dust Control

7-7

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Dust Collector Setup

Fig. 7-6 Timer Panel

Timer - Adjustment 1.

Start machine and place tram/drill switch in DRILL position, turn dust collector switch to PULSE position, turn blowing air valve on.

2.

Open small door on upper side of dust collector to expose timer panel (fig. 7-6). The green pilot light should be illuminated, indicating power is reaching the panel. The red indicator lights will flash in rotation.

3.

Turn the step control knob to adjust the time delay between each flash of the red pulse indicator lights, so the time between each flash is about 4 seconds.

4.

Turn the pulse control knob to adjust the duration of each flash to two tenths of a second (200 milliseconds).

5.

These adjustment will result in the pulse air valves (fig. 7-1) pulsing in sequence for a short duration every 4 seconds.

Fan Speed Adjustment

7-8

1.

Be sure dust collector relief valve is set at 2000 PSI (138 bar) as described previously.

2.

Be sure pickup pot is at least 6 in. (15.2 cm) clear of the ground.

Dust Control

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Dust Collector Setup

3

1 5

1

4

2 3

2

5

6 4

Fig. 7-6a Timer Panel 1. Green Pilot Light 2. Red Indicator Lights (6) 3. Step Control (time interval between pulses) 4. Pulse Control (duration of pulse) 5. Fuse

Fig. 7-7 Dust Collector 1. Fan Exhaust 2. Upper Test Port 3. Jump Tube 4. Lower Test Port 5. Water Drain 6. Timer Compartment Door

WARNING:

ALWAYS wear eye protection when working on or operating machinery.

NEVER look directly into the fan outlet. Loose particles in the fan housing may exit at high velocity and cause personal injury.

3.

Start machine and place tram/drill switch in DRILL position, switch dust collector switch to DRILL position. Turn blowing air valve on momentarily to activate dust collector fan and then turn off. As fan slows down, observe direction of rotation through exhaust opening (fig. 7-1). Fan should turn clockwise when viewed from the top. If fan rotation is correct, turn blowing air back on, if not, the hydraulic hoses are installed incorrectly. Port "M1" from the dust collector valve is the pressure port to the motor, port "M2" is the return port from the motor. The motor ports are marked "P" and "T", pressure goes to "P" , return connects to "T".

Do not use the upper return port (#6) on the motor, because the load adapter will not receive lubrication. Use the lower return port (#4-#6) connection.

Air pressure regulator should be set at 80 PSI (5.5 bar) as described previously.

NOTE 4.

5.

Remove "jump" tube from lower test port (fig. 7-7). Connect one end of manometer to the lower test port (see pages 7-10 & 11 for manometer setup instructions), leave other end of manometer open to atmosphere.

6.

Loosen the locknut and adjust the flow control on the dust collector valve (fig. 7-2) so fan speed will pull 17-18 inches (43.2-45.7 cm) W.G. (Water Gauge) on manometer. When correct reading is obtained, tighten locknut. Fan speed must not exceed 3400 RPM.

Dust Control

7-9

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Dust Collector Setup

1 5

2 3 6 4

Fig. 7-7 Dust Collector 1. Fan Exhaust 2. Upper Test Port 3. Jump Tube 4. Lower Test Port 5. Water Drain 6. Timer Compartment Door

Filter Elements 1.

Remove jump tube and connect manometer to upper and lower test ports.

2.

Start machine and place tram/drill switch in DRILL position, switch dust collector switch to DRILL position and turn blowing air valve on.

3.

Manometer should read 1-2 inches (2.5-5 cm) W.G. (Water Gauge) for new filter elements. This pressure reading represents the pressure drop across the filters. If manometer reads over 4 inches (10.2 cm) W.G. filters are contaminated to the point that are flow is restricted.

4.

Remove manometer and install jump hose between upper and lower ports to seal out dirt and other contaminants.

Dust Collector Efficiency

Following the dust collector setup procedures outlined previously will result in the dust collector running at about 75% capacity. This is sufficient to handle most drilling conditions.

In lighter duty applications, such as, smaller diameter holes in rock of light specific gravity; energy may be saved by decreasing the purging air pressure and increasing the time interval between pulses.

In heavier duty applications, the purging air pressure may be increased and the time interval between pulses may be decreased.

7-10

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Dust Collector Setup Operational Variables

Variables: Are a combination of factors that influence what is commonly known as "Drilling Conditions". These include: The hardness of the formation, the moisture content, the specific gravity of the material, the ratio of microfine dust particles to larger sized chips in the drill cuttings, the size and type of drill bit used and the drill penetration rate.

Suction Air Velocities: It is generally accepted that when using a smooth bore suction hose, air velocities of 3000 F.P.M. (915 m/min.) are required the convey light, fine, particles, while velocities in the range of 4000 F.P.M. (1220 m/min.) are needed for heavier, larger, cuttings. Should the drilling conditions include material with a high specific gravity, such as iron ore, or contain a high moisture content such as sticky clays that tend to impinge on surfaces, air velocities greater than 4500 F.P.M. (1372.5 m/min.) could be required to prevent the suction hose from blocking.

Degree of Difficulty: Any combination of the fixed and variable factors will dictate the degree of difficulty under which the dust collector will operate. The governing factors controlling the dust collector's performance, are the air velocity in the suction hose and the pressure drop across the filters. The first can be governed by adjustment of the fan speed and the second by maintaining clean filters with suitable purge air pulses.

Fine Tuning ate.

As outlined previously drilling conditions dictate the degree of difficulty the collector has to oper-

Assuming the electronic timer and fan speed settings are in accordance with the "Initial Start Up and Tuning" instructions and drilling is in progress, the initial setting can be assessed and adjusted to comply with the degree of difficulty. If the settings are too low, suction hose blocking problems will result.

If the suction hose is free from blockage, the setting is either correct or too high. If the setting is too high, an "overkill" condition exists, which if allowed to continue, will result in unnecessary wear of the suction hose, the inlet tube and the separator. The filter life will also be reduced.

Suction Hose Blocking: Remove the suction hose blockage. Connect manometer to upper and lower test ports and start drilling. The manometer is now reading the pressure drop across the filters. If the reading is over 4 inch (10.2 cm) W.G. the filters are contaminated to the extent that air flow is being restricted. To correct this, shorten the interval between valve firing by gently adjusting the step control knob. In doing so, the W.G. (Water Gauge) reading should decrease, which in turn permits more air to pass through the system preventing blockage. If the reading is below 2 1/2 inch (6.4 cm) W.G., the filters are not restricting the air flow. Gradually increase the fan speed until the hose stays free from blockage.

Overkill Situation: This condition is reached when the dust collector performance far exceeds the degree of difficulty being encountered in drilling the hole. Ideally, the level of performance is set just above the level required to create a dust free environment at the hole collar, with sufficient air flow to prevent the suction hose from blocking.

Reducing the fan speed to the "just above" level will prolong the life of the wear components.

Dust Control

7-11

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Dust Collector Setup Manometer Setup Instructions

X

Y

12 11 10 9 8 7 6 5 4 3 2 1

0

1 2 3 4 5 6 7 8 9 10 11 12

X

Y

12 11 10 9 8 7 6 5 4 3 2 1

0

Distance "A"

1 2 3 4 5 6 7 8 9 10 11 12

Fig. 7-8 Illustration of Slack Tube Manometer

7-12

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Dust Collector Setup Manometer Setup Instructions Introduction:

A manometer is a simple device used to measure static pressure, vacuum or differential pressure.

The unit can be purchased from Dwyer Instruments Inc. or a simple manometer can be made using a length of clear plastic tubing and a 24" (70 cm) ruler.

Filling: 1.

Use distilled water and add 3/4 oz. bottle of Dwyer A-126 Fluorescein green color concentrate or equal to color water. Remove a tubing connector from manometer and add water to mid-point level. Tap tubing to remove air bubbles.

Installation: 1.

Make sure both ends of tubing are open to atmosphere. Connect one end of manometer ("X") to lower test port (fig. 7-42) on dust collector, leave other end ("Y") free for reading fan speed.

Connect both ends of manometer to upper and lower test ports to read pressure drop across filters.

2.

Mount manometer to dust collector as shown in fig. 7-8.

3.

Slide scale so zero mark of scale is in line with water level (fig. 7-8).

Reading: 1.

With manometer installed per instructions and dust collector running with dust collector hose connected to precleaner and pickup pot (pickup pot must be at least 6" above the ground) you are observing the vacuum produced by the air flow in inches of water.

2.

One column will travel up and the other column will go down a like amount.

3.

To measure the vacuum in inches, measure the distance "A" between column "X" and column "Y" (fig. 7-8).

4.

After reading is taken, close the connectors, which seals the tube and no fluid will lost.

5.

Connect jumper tube to test ports on dust collector to seal out dirt.

Upper Test Port Lower Test Port

Fig. 7-9 Dust Collector Test Ports.

Dust Control

7-13

Dust Collector Setup

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Timer Installation

Fig. 7-10 Timer Installation Diagram

Either 12 V-DC or 24 V-DC solenoid coils are supplied to match the crawler drill's nominal electrical system. Wiring from timer junctions 1 2 3 4 is to solenoid coils 1 2 3 4 Wiring from solenoid coils 1 2 3 4 bunched at connector, from connector to C on timer junction.

From timer junction + to connector to air pressure switch to manual switch to + pos. battery terminal.

From timer junction - to connector to - neg. battery terminal To Set Timer: Start machine, switch tram/drill switch to DRILL position, turn blowing air valve on, turn dust collector switch to PULSE position. The green light in top right hand corner indicates power on. Gently turn pulse control to set duration of pulse to about two tenths of a second duration (indicated by red lights flashing). Gently turn step control to set the time between pulses between 3 to 5 seconds (indicated by red lights flashing).

7-14

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Dust Collector Setup Control Circuit

Fig. 7-11 Hydraulic, Electrical, and Air Circuits

Hydraulic Circuit 1

Hydraulic Pump

2

Electric Solenoid Control Valve With Pressure Regulator

3

Manual Flow Control Valve

4

Hydraulic Motor

Electrical Circuit 5 6 7 8

Manual Switch (console mounted) Air Pressure Switch - normally open, 20 PSI (1.4 bar) Timer Circuit Switch (console mounted) Electronic Timer

Air Circuit 9

Blowing Air To Drill Valve (console mounted)

10

Drill

11

Manual Air Valve To Impulse Valves (console mounted)

12

Air Strainer/Regulator

Dust Control

7-15

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Dust Collector Assembly Fan Removal and Installation

Fig. 7-12 Dust Collector Fan Assembly.

WARNING:

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

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

NEVER look directly into the fan outlet. Loose particles in the fan housing may exit at high velocity causing personal injury.

•

Removal:

Tag and remove any hoses if complete housing is to be removed from machine.

•

Remove the capscrews that hold the fan housing cover to the fan housing and remove cover along with fan and motor.

•

Remove the 3 capscrews holding the taperlock bushing.

•

Use a wheel puller to remove the bushing.

•

•

Installation:

DO NOT hard hammer the bushing onto the shaft. Hammering can damage the bearings and shorten the life of the motor. Use a soft mallet or other cushioned device to tap the bushing on the shaft. The correct location of the bushing is when the end of the shaft protrudes approximately .15" (3.8 mm) from the bushing.

The preferred way to install the fan, is to remove the fan housing from the dust collector; this enables you to check the actual clearance as shown in fig. 7-12.

The correct clearance of the fan from the inlet ring is .12-.18 in. (3 mm-4.6 mm).

Excess clearance will reduce the efficiency of the fan wheel.

Clean old silicone from all mating surfaces and seal with new silicone sealant before assembling parts.

NOTE • • 7-16

Install any hoses that were removed.

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Dust Collector Troubleshooting Troubleshooting Hints Impulse Valves Not Pulsing (fig. 7-10): First check that the compressed air is turned on to the impulse manifold (gauge on filter regulator). If air supply is over 100 PSI (6.9 bar), reset to 80-95 psi (5.5-6.6 bar). If air supply is okay, check that the green pilot light is on in timer; if not illuminated, fault is in the electric current supply. Check switch, battery condition, corroded terminals, any fuses that may be in circuit, electric wiring, connectors and ground. Ensure that step and pulse control knobs are not turned off by gently turning both knobs. If no faults are found, finally check test the + and - terminals at timer junction block, with test lamp. If power is reaching block, replace timer and return it to distributor for service.

Impulse Valves Misfiring (fig. 7-10): If the red indicator lights are flashing on and off in the programmed order and the misfire is regular (one valve misfiring), the problem is either that the electric current is not reaching the coil or that the coil is faulty. The misfiring valve can be identified quickly by noting the terminal number of the valve that fails to fire when the red indicator light flashes above it.

Inspect the coil wiring for damage and make sure that all connections are tight. If the wiring is not at fault, check the coil by removing the DIN fitting and supply power directly to the coil. If faulty, replace the coil.

If misfiring is of an irregular nature and the green power 'on' light flickers, the fault is that intermittent current is reaching the timer. Check wiring circuit to timer. If the green light is steady, the fault may be loose terminals. If the irregular firing persists, change out timer and return it to distributor for service.

NOTE

The dust collectors have 3 to 6 filters and the red indicator lights will operate in sequence; for instance, if the unit has 4 filters, 4 lights will function.

Solenoid Valves: In the event that air is passing through the solenoid valve when the timer is off, check that there is no contamination under the valve seat and that the diaphragm is not damaged.

Remove contamination or replace diaphragm to correct. If the seat of the valve is damaged, replace the valve. A broken diaphragm return spring also prevents the valve from seating; replace broken spring.

Suction Hose Blocking: First check that suction hose is not damaged or flattened and has no sharp bends. As the dust collector is higher than the pick up pot, the cuttings must be moved upwards, the suction hose should be kept as short as possible, rising steeply from the pot then leveling out to the collector. If the material is of a very damp sticky clay nature it may be necessary to remove the suction hose from the pot and to discharge the cuttings from the pot outlet; when drilling conditions return to normal, reconnect hose to the pickup pot. This procedure should also be followed if high inflows of water are encountered in the hole.

Dust is emitted from exhaust of dust collector: A. Check that filters are not loose. Do not over tighten filter retaining bolt as this could cause the filter to split, collapse or suffer other mechanical damage.

B.

Dust Control

Inspect filters for damage, holes, splitting and correct sealing. Replace damaged filter or seal. Dust passing the fan will cause rapid wheel erosion and failure.

7-17

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Dust Collector Troubleshooting Troubleshooting Hints (continued) Fan: The fan has ample capacity to produce the required air flow and suction. The governing factors affecting the volume of air moved through the fan are: A. The clearance between the fan wheel and the housing ring B. NOTE

The fan wheel rotation speed.

To set the fan wheel clearance see instructions on page 7-16. To set fan speed see instructions on page 7-8 & 7-9.

WARNING:

NEVER look directly into the fan outlet. Loose particles in the fan housing may exit at high velocity causing personal injury.

Ensure that the direction of fan rotation is correct, clockwise when viewed from the top. Ensure that fan wheel speed does not exceed 3400 RPM, over speeding can cause the fan to go into cavitation, resulting in loss of efficiency.

If the fan wheel speed fails to respond to increased pressure or flow adjustments, check hydraulic oil level in supply tank. Check filters in the hydraulic system, that they are not restricting oil flow.

Finally, check the condition of the hydraulic pump and motor and replace or repair as needed.

Although suction is increased to 20-25 (50.8-63.5 cm) WG, the collector is not operating efficiently: A. High suction pressures will not allow the purging air to repel the dust cake from the filters.

B. Reduce the suction air pressure to 18"-20" (45.7-50.8 cm) WG (Water Gauge) and make sure the fan is not running during rod change or tramming. Absence of suction makes purging much more efficient.

Dust and cuttings around the hole collar are not being sucked into the collector: A. Make sure the hoses are clear.

B. Suction in the top test port is between 12-20 in. (30.5-50.8 cm) WG (Water Gauge).

C. Pickup pot is 2" (5 cm) above ground during drilling.

D. Make sure fan is off during rod changing and tramming and purging air pulse is operating.

Dust and cuttings blow through the seals of the pickup pot: A. Reduce the volume of blowing air.

B. There should be two seals installed in every pickup pot. If trouble persists, more seals may be added as necessary.

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Detergent System Description The detergent system consists of a pressurized 80 gallon (303 L) water tank mounted at the rear of the machine. An air line from the compressor circuit is used to pressurize the tank. The tank has a 200 PSI (14 bar) relief valve mounted on top of the tank. There is an ON/OFF water valve and metering valve to control flow mounted in the operator's cab or on the drill console on the swing arm for non-cab units.

Operation Normally the dry dust collector is used when drilling, however when collaring the hole in loose rock or dirt, it will be necessary to build up a mud collar to keep the hole from collapsing around the bit. To do this, turn the dust collector "off", and turn the water valve "on". Adjust the water flow at the bit, using the metering valve. When the hole is collared, turn the water "off", and turn the dust collector "on".

Fig. 7-14 Cab Controls

Fig. 7-13 80 Gallon (303 L) Detergent Tank Dust Control

Fig. 7-15 Drill Console (non-cab machine) 7-19

Detergent System (optional)

7-20

Fig.7-16 Upper Detergent Tank 1. Pressure Bleed Valve 2. Pressure Relief Valve (200 PSI)

3. Filler Cap 4. Air Cut-off Valve

Fig.7-17 Lower Detergent Tank 5. Water Cut-off Valve 6. Y Strainer

7. Air Line IN 8. Water Line OUT

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Detergent System (optional) WARNING:

RELIEVE air pressure from detergent tank before opening filler cap or any other fittings.

Filling The Tank 1.

Always relieve air pressure from the tank before removing filler cap. Close air cut-off valve (4) to stop air flow to tank.

2.

Open air bleed valve (1) until you can no longer hear air escaping. Close valve.

3.

Close water cut-off valve (5).

4.

Unscrew filler cap (3) and fill with water. If freezing temperatures are expected, add a couple gallons of non-toxic anti-freeze to the tank. Screw filler cap back on and tighten. Open air cut-off valve (4) and water cut-off valve (5).

Servicing the "Y" Strainer The detergent system water line strainer mounted in the "Y" connection (6) in the water line should be inspected every 50 hours and cleaned or replaced every 600 hours or whenever clogged.

To replace: 1.

Shut down machine and relieve pressure from detergent tank, by opening the pressure bleed valve (1).

2.

After pressure is relieved from tank, close the water cut-off valve (5) and unscrew the strainer fitting from the reducer in the "Y" Strainer (6) and remove strainer.

3.

Clean the old strainer or install a new one. Screw in fitting and tighten. Open the water cutoff valve (5).

Detergent System Freeze Protection Detergent system should not be used when temperatures below freezing are expected. To protect the detergent system from freezing, the following steps should be carried out.

1.

Shut down machine and relieve air pressure by opening the bleed valve (2) and allowing air to bleed off.

2.

When you can no longer hear air escaping from bleed valve, open tank filler cap (3), then close cutoff valve (5) and remove fitting and screen from "Y" strainer (6). Open cutoff valve to drain tank.

3.

After tank is drained, install screen (clean, or replace if necessary) and fitting in "Y" strainer. Open cutoff valve and add 2 gallons of Recreational Vehicle water line antifreeze or equivalent non-toxic anti-freeze to detergent tank. Replace detergent tank filler cap and tighten.

4.

Start machine and switch to drill mode. Open blowing air valve at drill console and turn on detergent valve (detergent metering valve must also be open). When anti-freeze solution comes out of drill shank or drill bit, shut off air and detergent system. Lines are now full of anti-freeze solution.

Shut down machine in normal manner.

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7-21

7-22

Detergent System Piping (ref. 1415371-T1) 1. Relief Valve, 200 PSI 3. Cutoff Valve 2. Check Valve 4. Y Strainer

Fig. 7-18

5. Needle Valve 6. Atomizer

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Section 8

Glossary

Glossary

8-1

Glossary of Terms

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

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

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

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

Boom ............................ Horizontal structure that supports and positions the feed. One end attaches to a pivot at the boom bulkhead at the front of the machine, the other end attaches to the positioner. Some booms are extendable, others are fixed (non-extendable).

Centralizer .................... A device used to keep the drill steel centered with respect to the centerline of the feed. An end centralizer is located at the bottom end of the feed. It has jaws that open and close around the drill steel, but allow the drill steel to pass through and rotate freely. The jaws are also used to clamp around the drill steel coupling and hold it tight for threading and unthreading of drill steel.

A mid-point or travelling centralizer is used on long feeds to support the midpoint of the drill steel.

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

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

Drill Rod ........................ Another name for “drill steel”.

Drill Steel ...................... A specially made length of steel with threads on both ends to allow coupling together and to the drill shank and drill bit. The drill steel transfers energy from the drill to the bit and is also used to convey air or water for hole cleaning.

Drill Steel Coupling ......... A devise used to join two pieces of drill steel together and to join the drill steel to the drill shank, by means of internal female threads or sometimes male and female threads.

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

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

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

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

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Glossary

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

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

Hammer(ing).................. A term used to describe the action of the drill hammer or piston striking the drill shank, thus transferring the blow energy through the drill steel to the bit.

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

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

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

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

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

Retract ......................... To move object IN or TOWARDS the machine in the horizontal plane, or to move object AWAY from the ground in the vertical plane.

Rock Drill ....................... The device that provides the percussive and rotation forces for drilling.

Sometimes referred to as the “hammer” or “drifter”.

Shank............................ A specially made short length of steel with splines at one end and threads at the other end. The splined end is inserted into the rock drill and engages the splines of the chuck end of the drill. The drill steel attaches to the other end by means of a coupling.

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

Also called "belleville washer".

Sting ............................. To apply pressure to the ground by extending the feed to prevent the feed from moving while drilling.

Stinger .......................... A device attached to the end of the feed which contacts the ground to stabilize the feed while drilling.

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

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

Glossary

8-3

Notes

8-4

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Glossary

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