CAT Rotary Track Drills 59HR Blast Hole Drill Maintenance And Operation Manual - PDF DOWNLOAD

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

August 2006

Manual No. 10424

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Manual No. 10424

August 2006

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

59HR Electric Blast Hole Drill Maintenance and Operation Manual Manual No. 10424 sn: 141171 Lot 14 –Table of Contents– This manual is divided into major sections covering the various serviceable components and systems of the 59R Electric Blast Hole Drill. These sections and their contents are organized as shown below.

Section 1 - INTRODUCTION Section 2 - OPERATION Section 3 - LUBRICATION Section 4 - PREVENTIVE MAINTENANCE Section 5 - SERVICE PROCEDURES Section 6 - BRAKES AND COUPLINGS Section 7 - COMPRESSED AIR SYSTEM Section 8 - AIR FILTRATION Section 9 - ENGINEERING DATA

IMPORTANT NOTE This document is protected under applicable copyright laws to the extent available. Any unauthorized and unlawful reproduction, distribution or other use shall be subject to liability.

© 2006 August 2006

Bucyrus International, Inc. All Rights Reserved.

Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

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

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

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

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

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

August 2006

Manual No. 10424

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Manual No. 10424

August 2006

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

1

Introduction Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL INFORMATION ............................................................................................................ 3 SAFETY .................................................................................................................................. 4 SAFETY PRECAUTIONS ........................................................................................................ 5 FIRE PREVENTION CONSIDERATIONS ..................................................................................... 8 STANDARD CRANE HAND SIGNALS .......................................................................................... 9 MACHINE PLACARDS ................................................................................................................ 12 MACHINE OVERVIEW ................................................................................................................ 14 Deck Plan .................................................................................................................................. 15

MACHINE SPECIFICATIONS ................................................................................................ 16 Machine Dimensions .................................................................................................................. 17

COMPONENT SYSTEMS ........................................................................................................... 20 COMPONENT WEIGHTS ........................................................................................................... 21 DECK PLAN - Color ...................................................................................................... ( foldout )

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Section

1

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

RIGHT and LEFT refer to machine locations as viewed by the operator with the mast as the rear of the machine and the engine on the left side.

THIS MANUAL IS NOT THE PARTS BOOK and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, the machine’s specific design and original equipment is accessed quickly by the Bucyrus International parts representative.

Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or: Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin 53172-0500, USA Telephone (414)-768-4000 Fax: (414) 768-4210 It is Bucyrus International’s policy to improve its products whenever possible and practical to do so.

The company reserves the right to make changes or add improvements to it’s machines at any time. This will be without incurred obligation to install such changes on machines sold previously.

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

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

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

If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory.

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

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION:

This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

DANGER:

This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER:

This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

CAUTION:

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

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

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SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

• Check limit switches for proper operation.

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

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

• Use proper interior and exterior lighting.

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

• Perform functional tests of all safety circuits.

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

• Use extreme caution when working around drilled holes.

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

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

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

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

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

Deactivate or isolate the entire system prior to performing maintenance.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

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

DO NOT smoke while handling flammables or when near batteries.

Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 of this manual for the Scheduled Maintenance recommendations and the Walk Around Inspection procedure.

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

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

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

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

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

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

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

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

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

hscran_1

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

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

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

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

(Hand signals continued on following page.)

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

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

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

TRAVEL With arm extended forward, hand open and raised at wrist, make a pushing motion in the desired direction of movement. hscran_3

DOG EVERYTHING Clasp hands together in front of body.

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

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

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

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

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

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

TRAVEL (Single Track) Use a raised fist on the side that remains locked and make a vertical circular motion in front of chest for the direction and side of desired movement. hscran_5

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

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

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

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

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MACHINE PLACARDS Shown below are samples of various safety decals found on the 59HR Blast Hole Drill. These decals are for the protection of all personnel who have contact with the machine. If the decals on the machine become unreadable, defaced or missing, they should be replaced immediately.

Duplicates are available from Bucyrus International, Inc. Parts Sales Department. When ordering the decals use the part numbers indicated.

TO PREVENT BO DILY INJU RY

sgna_59r

Part No. 61349524 7 x 10 Inches ~Red and Black on White.

Located inside the operator’s cab, on the wall behind the operator’s console.

sgnb_59r

Part No. 61349574 7 x 10 Inches ~Red and Black on White.

Located on the doors of the electrical cabinet in the machinery house.

TO PREVENT IN JURY

sgnc_59r

Part No. B004124-01 7 x 10 Inches ~Red and Black on White.

Located on the right side of the machinery house on the doors to the high voltage transformer enclosure, and on the left side of the house, above the main junction box.

Manual No. 10424

sgnd_59r

Part No. C105719-01 10 x 14 Inches ~Red and Black on White.

Located on the right side of the machine near the boarding stairs, and at the left-front corner of the machine.

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PLATFORM W HEN DRILLIN G sgne_59r

sgnf_59r

Part No. 61350003 10 x 14 Inches ~Red and Black on White.

Located outside the operator’s cab door to the drilling platform.

Part No. B003376-01 2 x 3 Inches ~Red and Black on White.

Located in the machinery house, on the main compressor radiator fan motor, and at the hydraulic oil cooler.

sgng_59r

Part No. 61349528 3-1/4 x 4-3/4 Inches ~Black on Yellow.

Located inside the operator’s cab on the the operator’s console.

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sgnh_59r

Part No. 61350006 10 x 14 Inches ~Black on Yellow.

Located on the inside of the machinery house entrance door.

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MACHINE OVERVIEW The 59HR Blast Hole Drill is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and will provide trouble free operation if properly maintained.

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MACHINE SPECIFICATIONS

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

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

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

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

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Machine Dimensions

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

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

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

(5,433 kg) PIPE RACKS: SINGLE RACK 1 PIPE RACK 2 PIPE RACKS 4 PIPE RACKS

STANDARD 10.75” TO 17.5” 10.75” TO 17.5” to 10.75”

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

ROTARY DRIVE: CONTINUOUS OUTPUT MAXIMUM BIT SPEED

205 hp (153kw) 120 rpm

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

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

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LUBRICATION: Automatic Centralized System

Standard

CRAWLER MOUNTING: DUAL AXLES OVERALL LENGTH OVERALL TREAD WIDTH (standard) CRAWLER BELT WIDTHS STANDARD OPTIONAL WIDE LINKS

Fixed Rear/Pivoting Front 25’-5” (7.75M) 21’-11” 36” 42”

(914mm) (1.06M)

PROPEL: Chainless hydraulic drive with counter-rotation capability Crawler mounted disc brakes with brake release for towing Propel Speed up to 0.9 mph (11.45kph) Operating Propel Grade 25% (3) ELECTRICAL: EQUIPMENT Static DC – Variable Output POWER REQUIREMENTS 3 phase, 60 Hz, 4,160V (4) AIR COMPRESSOR/AC INDUCTION MOTOR Dual Shaft, 800 – 1,000 hp (597-746 kw) @ 460V ROTARY DRIVE DC Motor (205 continuous hp output) 195 hp MAIN HYDRAULIC OIL PUMPS Driven by main air compressor motor 250 hp nominal COMPRESSOR RADIATOR FAN AC-TEFC Motor 20 hp (15kw) @ 460V MACHINERY HOUSE PRESSURIZATION 25,000 CFM (708m3/min) 25 hp (19 kw) @ 460V OPERATOR’S CAB PRESSURIZATION W/HEATER and AIR CONDITIONER Self contained unit manufactured by SIGMA LIGHTING and CONTROL 120V NOTES: (1) (2)

(3) (4)

With optional angle hole drilling equipment.

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

Can be stability limited.

For alternate power sources consult Bucyrus International.

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COMPONENT SYSTEMS PROPEL MACHINERY: The propel system of the 59HR is a chainless hydraulic drive system which will allow the separate tracks to counter-rotate. This capability provides the machine with the capacity to turn completely around within it’s own length. Each track is driven by a hydraulic motor and a planetary gearbox equipped with a hydraulically released, spring activated brake. The machine is capable of 2 different propel speed ranges. The lower speed range is used for maneuvering in close spaces while the high speed range is used for tramming in open areas, over long distances.

MAIN FRAME AND DECKS: The 59HR main frame is of welded box type construction with integrally placed mast supports and jack towers.

MAST: The 59HR drill mast is a fabricated structure of steel tubes and formed plates. The major structure is composed of vertical tubes welded together with back bracing. The mast functions to provide the mounting and guide for the equipment required to operate the drilling function of the machine. The mast is capable of being positioned at any 5o increment within it’s operating range from 65 degrees through 90 degrees (vertical). The mast can be raised and lowered by 2 (two) 8.00 inch (203mm) hydraulic cylinders.

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

HYDRAULIC SYSTEM: Hydraulic pressure for operation of the 59HR is provided by four separate pumps. These pumps are driven by the electric motor located in main machinery house, forward of the hydraulic filters and reservoir. The machine has 2 separate, though not completely independent hydraulic systems, the OPEN and CLOSED circuits. Both draw fluid from a common reservoir.

OPERATOR’S CAB: The sound insulated operator’s cab of the 59HR provides a sealed, comfortable enclosure from which the operator can perform the tasks involved with the operation of the machine.

The location and design of this compartment have been structured to provide the optimum viewing angles with immediate accessibility. The swivel mounted chair provides easy access to all required controls. The auxiliary control console is within reach to provide access to additional functions of the machine. The cab is provided with dual doorways to the main deck.

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COMPONENT WEIGHTS Qty.

Weight Ea. (Lbs.)

Lower Works Frame, R.H. Crawler ......................................................... 1 ..................... 11,050 Frame, L.H. Crawler .......................................................... 1 ..................... 11,050 Axle, Crawler Front Equalizer ............................................ 1 ....................... 4,000 Axle, Crawler Rear ............................................................. 1 ....................... 9,700 Tumbler, Crawler Drive ...................................................... 2 ....................... 1,200 Tumbler, Take-Up ............................................................... 2 ....................... 1,300 Gearbox, Planetary Drive ................................................... 2 ....................... 2,800 Link, Crawler ..................................................................... 86 ......................... 300 Pin, Link ..................................................................... 172 .......................... 10 Motor, Propel Drive ............................................................ 2 .......................... 200 Roller, Upper / Lower ........................................................ 20 ......................... 350 Shaft, Take-Up Tumbler ..................................................... 2 .......................... 300 Shaft, Lower Roller ........................................................... 18 ......................... 100 Shaft, Lower Roller-Front ................................................... 2 .......................... 110 Support, Take-Up Tumbler ................................................. 4 .......................... 140 Bearing Block, Rear Axle ................................................... 2 .......................... 800 Guard, Lube, Center .......................................................... 8 ............................ 40 A-Frame Leg, Front A-Frame ............................................................

Leg, Rear A-Frame ............................................................

Cylinder, Mast Latch ..........................................................

Pin, A-Frame Lock .............................................................

Pin, Mast Pivot ...................................................................

2 ....................... 1,000 1 ....................... 2,950 1 ............................ 25 2 ............................ 25 6 ............................ 50

Main Frame Main Frame Structure ........................................................ 1 ..................... 55,000 Casing Assembly, Left Rear Jack ................................ 1 ....................... 2,300 Casing Assembly, Right Rear Jack .............................. 1 ....................... 5,800 Cylinder Assembly, Leveling Jack ................................ 4 .......................... 810 Cylinder, Jack ............................................................... 4 .......................... 850 Spud, Jack ................................................................... 4 .......................... 660 Shoe, Spud .................................................................. 2 .......................... 530 Pump Drive Assembly ...........................................................................................

Gearcase, Pump Drive ................................................ 1 .......................... 180 Pump, Tandem ............................................................ 1 ............................ 50 Pump, Propel ............................................................... 2 .......................... 150 Coupling, Gearbox ....................................................... 1 ............................ 70 Guard, Coupling ........................................................... 2 ............................ 20 Pump, Gear ................................................................. 1 ............................ 40

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Qty. Air Compressor Assembly .................................................

Valve, Butterfly .............................................................

Coupling .......................................................................

Receiver ......................................................................

Cooler, Oil ....................................................................

Motor, Air Compressor .................................................

Reservoir, Hydraulic ...........................................................

Cover, Plain ..................................................................

Cover, Header ..............................................................

Filter, Return ................................................................

Header, Suction ...........................................................

Valve, Butterfly .............................................................

Manifold, Return Piping ................................................

Reservior, Lube ..................................................................

MCC, Low Voltage #1 ........................................................

MCC, Low Voltage #2 ........................................................

MCC, Main Compressor ....................................................

Cabinet, Hoist/Pulldown .....................................................

Panel, Static DC Drive Control .....................................

Cabinet, Rotary ..................................................................

Cabinet, PLC .....................................................................

Transformer, Main Power ...................................................

Transformer, Lighting .........................................................

Air Conditioner ...................................................................

Tank Assembly, Water .......................................................

Tank, Water ..................................................................

Pump, Water Injection ..................................................

Pump, Water ............................................................

Valve Assembly, 3-Station ..................................................

Valve Assembly, 10-Station ................................................

Jack Valve Stand Assembly ...............................................

Valve, Direct, 4-Spool .........................................................

Valve Assembly, 5-Station ..................................................

Valve Assembly, 7-Station ..................................................

Valve, Spool, 3-Section ......................................................

Valve Assembly, 6-Station ..................................................

Jaw, Breakout Wrench ......................................................

Arm, Tong, Breakout Wrench ......................................

Cylinder, Clamping .......................................................

Cylinder Assembly, Positioning ....................................

Cylinder Assembly, Breaking .......................................

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Weight Ea. (Lbs.)

1 ..................... 20,500 1 ............................ 90 1 .......................... 160 1 .......................... 300 1 .......................... 450 1 ....................... 4,300 1 .......................... 800 1 ............................ 50 1 ............................ 50 2 ............................ 20 1 ............................ 40 1 ............................ 20 1 ............................ 30 1 .......................... 600 1 ....................... 1,000 1 .......................... 550 1 ....................... 1,050 1 .......................... 600 1 .......................... 210 1 .......................... 600 1 .......................... 800 1 ....................... 4,000 1 .......................... 280 1 .......................... 880 1 ....................... 5,610 1 ....................... 5,500 1 .......................... 230 1 ............................ 70 1 ............................ 60 1 ............................ 40 1 .......................... 500 1 .......................... 190 1 ............................ 60 1 ............................ 80 1 ............................ 60 1 ............................ 50 1 .......................... 770 1 ....................... 1,010 1 .......................... 120 1 .......................... 400 1 .......................... 360

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Qty.

Weight Ea. (Lbs.)

Wrench, Bit ........................................................................

Box, Pipe Handling .............................................................

Box, Bit Handling ................................................................

Extender, Drill Pipe ............................................................

Cylinder, Tool Wrench ........................................................

Dust Curtain ......................................................................

Dust Seal ...........................................................................

Cone, Chip Deflector .........................................................

Stairway, Boarding .............................................................

Cable Reel Assembly ........................................................

Reducer, Right Angle ...................................................

Arm, Upper Support .....................................................

Collector Rings, Cable Reel ........................................

1 .......................... 110 1 .......................... 150 1 ............................ 60 1 ....................... 1,700 2 .......................... 470 9 ............................ 10 1 ............................ 20 1 .......................... 110 1 .......................... 270 1 ....................... 6,600 1 ............................ 50 2 ............................ 50 1 .......................... 190

Machinery House Wall, Machinery House R.H. ..............................................

Wall, Machinery House Front .............................................

Extension, Left ...................................................................

Cove, Hydraulic ..................................................................

Panel, Center Roof ............................................................

Panel, Rear Roof ...............................................................

Wall, Machinery House Left ...............................................

Door, Service, Machy House, 30” ......................................

Door, Service, Machy House, 34” ......................................

Door & Frame Assy, L.H. ...................................................

Hatch, Pressurization Unit Roof ........................................

Enclosure, Dynavane Bleed Fan .......................................

Duct, Pressurization Unit Transition ..................................

Duct, Upper Bleed Fan Discharge .....................................

Duct, Lower Bleed Fan Discharge.....................................

Shroud, Pressurization Unit Rain ......................................

Filter, Air/Bleed Air Duct .....................................................

Fan, Vane Axial...................................................................

Blower & Motor ..................................................................

Operator Cab Structure .....................................................

Hatch, Bit View...................................................................

1 ....................... 3,000 1 ....................... 1,000 1 ..................... 10,000 1 ....................... 1,800 1 .......................... 710 1 .......................... 670 1 ....................... 1,700 2 .......................... 170 2 .......................... 300 1 .......................... 250 1 .......................... 350 1 .......................... 380 1 .......................... 280 1 ............................ 90 1 .......................... 100 1 .......................... 120 1 ....................... 1,000 1 .......................... 830 1 .......................... 250 1 ....................... 5,000 1 .......................... 180

Mast Braces Brace, Mast .......................................................................

Sleeve, Mast Brace ............................................................

Support, Front Brace .........................................................

Eyebolt ...............................................................................

Pin, Lock ............................................................................

Cylinder, Brace Lock ..........................................................

Pin, Pivot ............................................................................

Cylinder, Mast Hoist Hydraulic ...........................................

2 ....................... 2,810 2 .......................... 810 2 ....................... 1,210 2 ............................ 50 2 ............................ 30 2 ............................ 30 2 ............................ 20 2 ....................... 1,470

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Qty.

Weight Ea. (Lbs.)

Mast Assembly Mast Structure.................................................................... 1 ..................... 35,000 Mast Rack ................................................................... 38 ......................... 110 Frame, Auxiliary Winch ...................................................... 1 .......................... 820 Rope, Auxiliary Winch ........................................................ 1 .......................... 180 Sheave, Auxiliary Winch..................................................... 2 ............................ 40 Winch, Auxiliary .................................................................. 1 .......................... 420 Support Arm, Up LH Safety Sling ....................................... 1 .......................... 230 Support Arm, RH Safety Sling ............................................ 2 .......................... 120 Support Arm, Lower LH ..................................................... 1 .......................... 190 Brace, Pipe, Safety Sling ................................................... 1 ............................ 20 Hose, Lower Air .................................................................. 1 .......................... 300 Hose, Upper Air .................................................................. 1 .......................... 470 Hose, Cable Retaining ....................................................... 1 .......................... 340 Pipe Rack, Single .............................................................. 2 ....................... 3,650 Cylinder, Rack .............................................................. 2 .......................... 100 Cylinder, Rack Gate ..................................................... 2 ............................ 10 Cylinder, Rack Lock ..................................................... 2 ............................ 10 Gearcase & Cover, Pulldown ............................................. 1 ....................... 2,200 Support, Gearcase ............................................................ 1 ....................... 1,300 Shaft, Intermediate ............................................................. 1 .......................... 200 Gear, Intermediate ............................................................. 1 ....................... 2,010 Shaft, Shipper .................................................................... 1 ....................... 1,200 Gear, Output ...................................................................... 1 ....................... 1,050 Shaft, Input ......................................................................... 1 .......................... 100 Coupling ............................................................................. 1 ............................ 40 Brake, Pulldown ................................................................. 1 .......................... 160 Motor, Pulldown .................................................................. 1 ....................... 2,650 Gearcase, Rotary .............................................................. 1 ....................... 5,200 Cover, Inspection ............................................................... 1 ............................ 40 Pinion, Rotary Motor .......................................................... 1 ............................ 80 Gear, Intermediate ............................................................. 1 .......................... 180 Shaft, Intermediate ............................................................. 1 .......................... 110 Cover, Lower Bearing ........................................................ 1 ............................ 20 Gear, Drive ......................................................................... 1 .......................... 700 Bearing, Drive Shaft, Main ................................................. 1 .......................... 160 Shaft, Rotary Drive ............................................................ 1 .......................... 570 Housing, Seal, Upper ......................................................... 1 ............................ 30 Carrier, Drive Shaft Bearing ............................................... 1 .......................... 400

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Qty.

Weight Ea. (Lbs.)

Motor, Rotary ..................................................................... 1 ....................... 2,780 Guide Frame ...................................................................... 2 ....................... 2,010 Spreader, Guide Frame ................................................ 2 ............................ 70 Guard, Gearcase ......................................................... 1 .......................... 100 Housing, Bearing - Right .............................................. 1 .......................... 690 Guide Rollers, Lower ................................................... 2 ............................ 50 Guide Rollers, Upper.................................................... 2 .......................... 150 Roller Assembly ....................................................... 4 ............................ 40 Roller, Track ............................................................ 12 ........................... 10 Shaft, Guide Roller Shipper ......................................... 1 ....................... 1,200 Mast Machinery Gearcase & Cover, Pulldown .............................................

Support, Gearcase ......................................................

Shaft, Intermediate .......................................................

Gear, Intermediate .......................................................

Shaft, Shipper ..............................................................

Gear, Output ................................................................

Shaft, Input ...................................................................

Coupling .......................................................................

Brake, Pulldown ...........................................................

Motor, Pulldown ............................................................

Gearcase, Rotary ..............................................................

Cover, Inspection .........................................................

Pinion, Rotary Motor.....................................................

Gear, Intermediate .......................................................

Shaft, Intermediate .......................................................

Cover, Lower Bearing ..................................................

Gear, Drive ...................................................................

Bearing, Drive Shaft, Main ...........................................

Shaft, Rotary Drive ......................................................

Bearing Housing, Upper ...............................................

Carrier, Drive Shaft Bearing .........................................

Motor, Rotary ................................................................

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1 ....................... 2,200 1 ....................... 1,500 1 .......................... 200 1 ....................... 2,010 1 ....................... 1,200 1 ....................... 1,050 1 .......................... 100 1 ............................ 40 1 .......................... 160 1 ....................... 2,650 1 ....................... 5,200 1 ............................ 40 1 ............................ 80 1 .......................... 180 1 .......................... 110 1 ............................ 15 1 .......................... 700 1 .......................... 160 1 .......................... 570 1 ............................ 50 1 .......................... 400 1 ....................... 2,780

August 2006

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Tank, Water

High Voltage Disconnect

Cooler, Hydraulic

Auxiliary Transformer

Programmable Controller Main Transformer

Cooler, Compressor Hoist/Pulldown Cabinet

Leveling Jack, Left-Rear Casing Tong

Pipe Rack

Lighting Load Center

Cold Weather Damper

Hydraulic Valves Leveling Jack, Left-Front

C L Machine and Deck Bushing

Tool Wrench Junction Boxes

Hydraulic Reservoir

Air Compressor Low MCC Voltage MCC

Air Compressor Remote Control Air Panel Compressor

Isolator

Bit Viewing Hatch

Mast Raising Cylinder

Auto-Lube System

Mast Propel Control Panels

Main

Operator’s Cab

Leveling Jack, Right-Front

Panelview

Hydraulic Gearcase and Pumps

Leveling

Buddy Seat

Rotary Drive Cabinet

Operator’s Seat

Leveling Jack, Right-Rear

Main Drive Motor

Walkway, Right

Main Air Butterfly Valve Front of Machine Boarding Stairs

C L Deck Bushing

BUCYRUS R

59HR Deck Plan

LOT 14, SN: 141171 141171_D.cdr

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

2

Operation Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents SAFETY ........................................................................................................................................ 5 SAFETY PRECAUTIONS ........................................................................................................ 6 FIRE PREVENTION CONSIDERATIONS ..................................................................................... 9 OPERATION NEAR ELECTRICAL TRANSMISSION LINES ................................................. 10 PRESTART CHECKS ................................................................................................................. 11 EXTERNAL INSPECTION ..................................................................................................... 11 Daily Inspection Items ................................................................................................................ 12

ONBOARD INSPECTION ..................................................................................................... 14 Onboard Inspection Items .......................................................................................................... 14

PRESTART LUBRICATION ................................................................................................... 16 MAINTENANCE DURING OPERATION ...................................................................................... 17 PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK ............................................ 18 CONTROLS - LOCATION AND FUNCTION ............................................................................... 19 OPERATOR’S CONTROL CONSOLE ................................................................................. 20 Operator’s Control Console - Overall View .................................................................................. 20

MAIN CONTROL PANEL ....................................................................................................... 21 Main Control Panel ..................................................................................................................... 21

HOIST/PULLDOWN RHEOSTAT .................................................................................... 22 ROTARY RHEOSTAT ..................................................................................................... 22 DRILL/PROPEL CONTROLS ON AND OFF PUSHBUTTON ......................................... 22 HOIST/PULLDOWN SPEED SELECTOR SWITCH ...................................................... 23 ROTARY SPEED SELECTOR SWITCH ........................................................................ 23 HOIST BRAKE SWITCH ................................................................................................. 24 PIPE RACK SELECTOR SWITCH ................................................................................. 24 PIPE RACK JOYSTICK (LEFT CRAWLER PROPEL) ................................................... 24 WINCH/MAST SELECTOR SWITCH .............................................................................. 25 MAST/WINCH JOYSTICK (RIGHT CRAWLER PROPEL) .............................................. 25 TOOL WRENCH SWITCH .............................................................................................. 26 DUST CURTAIN SWITCH ............................................................................................... 26 BIT VIEW HATCH SWITCH ............................................................................................. 26

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PROPEL CONTROL PANEL ................................................................................................ 27 Propel Control Panel .................................................................................................................. 27

EMERGENCY STOP PUSHBUTTON ............................................................................. 27 PROPEL SPEED SELECTOR SWITCH ........................................................................ 27 COMPRESSOR STOP PUSHBUTTON ......................................................................... 28 COMPRESSOR VENT/DRILL SWITCH ......................................................................... 28 HEATER/VENT/AIR CONDITIONER CONTROLS .......................................................... 28 OPERATING MODE SELECTOR SWITCH .................................................................... 28 PROPEL JOYSTICKS ..................................................................................................... 28 SELECTOR SWITCH PANEL ............................................................................................... 29 Selector Switch Panel ................................................................................................................ 29

BREAKOUT WRENCH SWITCH .................................................................................... 30 PIPE POSITIONER SWITCH .......................................................................................... 30 DUST SEAL SWITCH ..................................................................................................... 30 A-FRAME LOCK SWITCH .............................................................................................. 30 MAST BRACE LOCK SWITCH ....................................................................................... 30 MAST LOCK SWITCH .................................................................................................... 31 BOARDING STAIRS SWITCH ......................................................................................... 31 PEDESTAL HEATER SWITCH ....................................................................................... 31 FIRE SUPPRESSION SYSTEM INDICATORS ............................................................... 31 RADIO ............................................................................................................................. 31 LEVELING CONTROL PANEL .............................................................................................. 32 Leveling Control Panel ................................................................................................................ 32

MANUAL LEVELING JOYSTICKS .................................................................................... 33 AUTOMATIC LEVELING SWITCH ................................................................................... 33 WATER INJECTION ON/OFF SWITCH .......................................................................... 33 WATER INJECTION FLOW CONTROL ......................................................................... 33 HORN PUSHBUTTON .................................................................................................... 34 DEPTH INDICATOR RESET PUSHBUTTON ................................................................. 34 PROGRAMMED DRILL CONTROL SWITCH ................................................................. 34 EMERGENCY STOP PUSHBUTTON ............................................................................. 34 OPERATOR’S DISPLAY TERMINAL ..................................................................................... 35 Operator’s Display Panel ............................................................................................................ 35

MACHINERY HOUSE CONTROLS ...................................................................................... 36 LIGHTING LOAD CENTER .............................................................................................. 36 CONTROLS ON THE LOW VOLTAGE START CABINET .............................................. 36 CONTROLS ON THE LOW VOLTAGE CABINET .......................................................... 37 Low Voltage Cabinet (Typical) .................................................................................................... 37

CONTROL ON THE PROGRAMMABLE CONTROLLER CABINET ............................... 37 Programmable Control Cabinet .................................................................................................. 37

HOIST/PULLDOWN AND ROTARY DRIVE CONTROL CABINETS ............................... 38

Hoist Pulldown and Rotary Drive Cabinets .................................................................................. 38

CONTROLS ON OR NEAR THE AIR COMPRESSOR .................................................. 39 Air Compressor Mounted Controls .............................................................................................. 39

MISCELLANEOUS CONTROLS ..................................................................................... 40

Portable Remote Propel Station (Optional) ................................................................................. 40 Hydraulic Reservoir Remote Fill Control Panel ............................................................................ 40 Lube Control Panel .................................................................................................................... 41

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MACHINE START-UP .................................................................................................................. 42 MACHINERY CHECK ...................................................................................................... 43 BREAK-IN OF NEW COMPONENTS ............................................................................. 43 ROTARY DRIVE UNIT BREAK-IN ............................................................................. 43 HOIST/PULLDOWN GEARCASE BREAK-IN ........................................................... 43 ELECTRIC MOTOR BREAK-IN ................................................................................ 43 MACHINE OPERATION ............................................................................................................... 44 PROPELLING ....................................................................................................................... 44 PROPEL PROCEDURE ................................................................................................. 45 Operator Controls - Propel .......................................................................................................... 46 Propel - Forward or Reverse ....................................................................................................... 47 Propel - Gradual Right Hand Turn ...............................................................................................47 Propel - Gradual Left Hand Turn ................................................................................................. 48 Propel - Counter-Rotation Left Hand Turn ................................................................................... 48 Gradual Turns - 15° Increments .................................................................................................. 49

TOWING PROCEDURE ................................................................................................. 50 CABLE REEL OPERATION .................................................................................................. 51 LEVELING ............................................................................................................................. 52 Machine Orientation ................................................................................................................... 52 Controls for Leveling the Machine ............................................................................................... 54

MAST RAISING AND LOWERING ......................................................................................... 54 MAST RAISING ................................................................................................................ 54 Controls for Raising or Lowering the Mast ................................................................................... 55

MAST LOWERING .......................................................................................................... 56 Controls for Angle Drilling ........................................................................................................... 57

PULLDOWN MACHINERY OPERATION .............................................................................. 58 Controls for Hoist / Pulldown ...................................................................................................... 58

AUXILIARY WINCH OPERATION .......................................................................................... 59 Controls for Operating the Winch ...............................................................................................59

PIPE RACK OPERATION ............................................................................................... 60 Controls for Operating the Pipe Racks ....................................................................................... 61

TOOL HANDLING .................................................................................................................. 64 PIPE LOADING AND UNLOADING .................................................................................. 64 DRILL TOOL STRING ASSEMBLY .................................................................................. 66 Stabilizer Installation ................................................................................................................. 67 Controls for Drill Pipe Installation ............................................................................................... 67 Installing Drill Pipe ..................................................................................................................... 68 Stabilizer Installation ................................................................................................................. 70 Bit Installation ............................................................................................................................ 71

BREAKOUT WRENCH OPERATION ................................................................................... 72 DRILL TOOL STRING DISASSEMBLY .................................................................................. 73 ADDING ADDITIONAL DRILL PIPE .................................................................................. 75 REMOVAL OF MULTIPLE SECTION DRILL PIPE ........................................................... 76 ANGLE DRILLING ................................................................................................................. 77 Jib Crane ................................................................................................................................... 78

DUST SUPPRESSION SYSTEM OPERATION .................................................................... 78

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VERTICAL DRILLING ............................................................................................................ 79 Controls for Normal Drilling ......................................................................................................... 80

STARTING THE HOLE (COLLARING) ............................................................................ 80 NORMAL DRILLING ......................................................................................................... 81 ENDING THE HOLE ........................................................................................................ 83 ENDING THE HOLE (MULTIPLE PIPE SECTIONS) ....................................................... 84 DRILLING DIFFICULT FORMATIONS ............................................................................. 84 UNCONSOLIDATED MATERIALS ................................................................................... 85 WET OR STICKY FORMATIONS ................................................................................... 87 ANGLE DRILLING ................................................................................................................. 88 PROGRAMMED DRILL CONTROL DRILLING ..................................................................... 89 Controls for Programmed Drill Control ........................................................................................ 89

PREPARING TO MOVE ........................................................................................................ 90 MACHINE SHUTDOWN .............................................................................................................. 92 SHUTDOWN PROCEDURE ................................................................................................ 92 SHORT TERM STORAGE .................................................................................................... 93 LONG TERM STORAGE ...................................................................................................... 94 ATTENDED LONG TERM STORAGE .................................................................................. 95 UNATTENDED LONG TERM STORAGE ............................................................................. 95 TOOL RECOVERY ............................................................................................................... 96 PIPE SIZE LIMITATIONS .............................................................................................................. 98 Drill Stability Chart ..................................................................................................................... 99

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

2

Operation

SAFETY The importance of overall safety in the maintenance of mining equipment should always be emphasized. Many critical components are subject to wear and other deterioration that limits their useful life and makes them expendable. When new, all such parts have a built-in reserve strength against these factors and reasonable loss of durability from gradual wear. If, however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the machine also constitutes a safety problem. Study this manual carefully and follow all recommended procedures to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators and maintenance personnel should continuously follow safe practices.

The safety alert symbols displayed here, and throughout this manual, are used to call your attention to instructions concerning your personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER, and CAUTION graphics mounted on various areas of the machine.

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

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

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

NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken.

CAUTION:

This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to.

CAUTION:

This signal word denotes an imminently dangerous hazard which will result in death, grievous bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

DANGER:

This signal word denotes an imminently dangerous electrical hazard which will result in death, grievous bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions.

Safety must always be paramount!

Consult your supervisor when safety is in doubt.

SAFETY PRECAUTIONS Safe operation of a rotary blast hole drill promotes personal safety and minimizes delays and costly damage to equipment. Carefully study and follow all recommended procedures in this manual.

Safety guidelines are intended to help prevent accidents from occurring and are provided in the interest of all mine personnel. Overall safety depends upon a good sense of judgment and alertness on the part of the entire mining crew.

The following is a list of some important safety rules relating to prestart and operation of the 59HR drill. The safety instructions given in this manual cover normal daily operations of the machine.

Additional precautions may be necessary to cover unusual circumstances. Be constantly alert for any potentially dangerous conditions and take action as necessary to correct the conditions immediately.

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

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

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

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

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

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

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

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

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

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

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

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

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

• Check limit switches for proper operation.

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

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

• Use proper interior and exterior lighting.

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

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

• Use extreme caution when working around drilled holes.

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

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

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

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

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

Deactivate or isolate the entire system prior to performing maintenance.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

FIRE PREVENTION CONSIDERATIONS • Always have a “charged” fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate.

• All personnel should be familiar with the location, usage, and operation of all on-board First-Aid kits, fire extinguishers, and other safety/emergency equipment.

• DO NOT smoke while handling flammables or when near batteries.

• Inspect all lines, tubes, and hoses carefully. Tighten all connections to their recommended torque specification. See Section 4 of this manual for the Scheduled Maintenance recommendations and the Walk Around Inspection procedure.

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

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

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

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

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

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

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

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

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

CAUTION:

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

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

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

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

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

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

2.

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

3.

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

4.

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

5.

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

6.

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

7.

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

CAUTION:

Manual No. 10424

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

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

EXTERNAL INSPECTION 1.

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

2.

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

3.

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

4.

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

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Daily Inspection Items

5.

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

6.

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

CAUTION:

Manual No. 10424

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

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7.

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

8.

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

9.

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

CAUTION:

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

10.

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

11.

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

12.

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

13.

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

14.

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

15.

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

16.

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

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ONBOARD INSPECTION 1.

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

2.

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

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

3.

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

4.

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

5.

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

Onboard Inspection Items

6.

7.

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

Close and lock all electrical cabinet doors.

CAUTION:

8.

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

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

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9.

Check the operator’s display terminal for any faults.

10.

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

NOTE: Do not use compressed air to clean the machinery house. Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the machine.

Failure to clean the inside of the machinery house will cause damage to many of the components located there.

11.

Inspect the auxiliary winch and auxiliary winch line.

12.

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

13.

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

14.

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

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

15.

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

CAUTION:

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

16.

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

17.

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

18.

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

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19.

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

20.

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

21.

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

22.

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

23.

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

24.

Check the hoist brake for proper operation.

25.

Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation. The deflector should seal around the drill pipe securely.

26.

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

PRESTART LUBRICATION Lubrication of the 59HR blasthole drill is an extremely important job. Most drills come equipped with automatic lubrication systems that lubricate most of the necessary points at regular intervals.

These systems, although automatic, are not foolproof. Broken lines, dirty lubricant, faulty feeders, and a whole range of other problems can cause wearing parts to loose lubrication. For this reason, it is important that all lubrication points be inspected every shift to verify that they are receiving lubrication. Also, there are several points for lubrication that either need lubrication very infrequently, or are not possible to pipe into the automatic system. These points will need lubrication applied manually.

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

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

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

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

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

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

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

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

DANGER:

August 2006

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

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

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

Secure the rotary drive unit and tool string.

Set all brakes.

De-energize and tag control functions.

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

DANGER:

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

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

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

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

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

DANGER:

Many of the components of the 59HR drill are heavy, bulky items.

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

CAUTION:

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

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

Since this manual covers all possible controls that could be used on the 59HR Electric Blasthole drill, he should familiarize himself with both this manual and the particular machine being operated.

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

Operator’s Console Controls.

2.

Machinery House Controls.

3.

Miscellaneous Controls.

CAUTION:

August 2006

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

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

Operator’s Control Console - Overall View

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

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MAIN CONTROL PANEL

Main Control Panel

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

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

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

Maximum speed is available at full counterclockwise position.

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

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

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

Maximum rotary speed is achieved at full clockwise position.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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PROPEL CONTROL PANEL

Propel Control Panel

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

The pushbutton is tied to the power source ground check circuit.

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

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

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

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

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

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

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

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

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SELECTOR SWITCH PANEL

Selector Switch Panel

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

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

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

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

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

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

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

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

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

RADIO The radio (10) is standard equipment.

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LEVELING CONTROL PANEL

Leveling Control Panel

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

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MANUAL LEVELING JOYSTICKS The four two-directional joysticks (1, 2, 3, & 4) are used to manually raise or lower the leveling jacks. Moving a joystick forward will extend the corresponding jack cylinder and raise that corner of the machine. Pulling the joystick toward the operator will retract the corresponding leveling jack cylinder and lower that corner of the machine. These joysticks are not functional if the automatic leveling switch is being used.

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

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

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

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

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

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

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

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

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

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

The pushbutton is tied to the power source ground check circuit.

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OPERATOR’S DISPLAY TERMINAL

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

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

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

Operator’s Display Panel

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MACHINERY HOUSE CONTROLS NOTE:

The controls shown on the following illustrations are typical of the controls on a machine. Because of the variations of controls that can be supplied for customers needs, be sure to become acquainted with the controls on the cabinets of your machine. All controls will be identified with nameplates.

LIGHTING LOAD CENTER

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

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

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

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

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

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

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

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

Low Voltage Cabinet (Typical)

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

Programmable Control Cabinet

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

Hoist Pulldown and Rotary Drive Cabinets

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

Air Compressor Mounted Controls

NOTE:

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

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

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

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

Portable Remote Propel Station (Optional)

The hydraulic reservoir remote fill control panel is used to monitor the reservoir as it is being filled.

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

Hydraulic Reservoir Remote Fill Control Panel

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

Lube Control Panel

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

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

1.

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

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

2.

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

3.

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

4.

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

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

5.

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

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

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

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

1.

Check the main air system for leaks.

2.

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

3.

Check for leaks in the hydraulic system.

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

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

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

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

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

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

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MACHINE OPERATION Operation of the 59HR Blasthole Drill is, in principle, the same as the operation of any other blasthole drill. But just because the machines operate using the same in principles does not mean they operate the same in all respects. For this reason it is important that the operator become familiar with the particular machine that is being operated.

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

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

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

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

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

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

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

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

CAUTION:

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

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

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

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

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

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

All of the stability values shown are based on a fully loaded machine (i.e. full water tank, cable on cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by the Customer and shipped by Bucyrus International, Inc. The 59HR is propelled using the controls on the operator’s console in the operator’s cab or radio controlled from the remote propel station outside the machine.

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Operator Controls - Propel

1.

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

2.

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

3.

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

4.

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

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

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

5.

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

Propel - Forward or Reverse

6.

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

Propel - Gradual Right Hand Turn

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Propel - Gradual Left Hand Turn

7.

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

8.

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

Propel - Counter-Rotation Left Hand Turn

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9.

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

Gradual Turns - 15° Increments

CAUTION:

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

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

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

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

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TOWING PROCEDURE CAUTION:

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

1.

Secure the machine by blocking crawlers.

2.

Secure the tow bar to the towing vehicle.

3.

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

4.

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

Ensure that the propel pump controls are in neutral position

b.

Loosen shifter lever lock screw

c.

Pull out shifter lever to disengage clutch

d.

Tighten shifter lever lock screw

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5.

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

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

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

6.

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

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

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

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

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

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

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2.

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

3.

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

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

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

Maximum angle for jack pad is 17°.

2.

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

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

Machine Orientation

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3.

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

4.

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

5.

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

CAUTION:

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

6.

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

7.

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

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Controls for Leveling the Machine

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

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

2.

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

3.

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

MAST RAISING CAUTION:

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

CAUTION:

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

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CAUTION:

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

1.

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

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

2.

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

CAUTION:

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

Controls for Raising or Lowering the Mast

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

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3.

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

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

NOTE:

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

4.

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

5.

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

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

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

2.

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

3.

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

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Controls for Angle Drilling

4.

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

5.

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

6.

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

CAUTION:

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

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

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

7.

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

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

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

Controls for Hoist / Pulldown

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

Move the operating mode selector switch to the DRILL position.

2.

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

For this procedure, turn the switch to the PULLDOWN position. For a review of each switch position, refer to HOIST/PULLDOWN SPEED SELECTOR SWITCH. 3.

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

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display terminal operator’s display screen.

4.

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

5.

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

6.

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

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

7.

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

CAUTION:

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

AUXILIARY WINCH OPERATION

Controls for Operating the Winch

To operate the auxiliary winch proceed as follows: 1.

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

2.

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

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3.

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

4.

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

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

•

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

•

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

•

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

The third pipe rack is a swing out rack that will be in #4 position.

•

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

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Controls for Operating the Pipe Racks

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

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

2.

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

3.

Select the desired pipe rack.

4.

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

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

1.

One pipe rack configuration. a.

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

b.

Operate the rack as described under general procedure.

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2.

Two pipe rack configuration. a.

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

b.

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

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

3.

Three pipe rack configuration. a.

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

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

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

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

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

NOTE:

4.

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

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

Four pipe rack configuration. a.

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

b.

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

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

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

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

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

CAUTION:

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

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

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

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

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

2.

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

CAUTION:

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

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3.

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

CAUTION:

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

4.

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

5.

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

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

6.

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

CAUTION:

Block the pipe securely to prevent it from moving unexpectedly.

7.

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

8.

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

9.

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

10.

Repeat the procedure for additional lengths of pipe.

11.

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

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

To install the stabilizer proceed as follows: 1.

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

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

2.

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

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

3.

Install the stabilizer and drill bushing in the hole in the drill deck. Make sure the drill bushing is seated properly. Lower the stabilizer until the slots in the stabilizer are aligned with the tool wrenches. Extend the tool wrenches to hold the stabilizer in place.

4.

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

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

Stabilizer Installation

Controls for Drill Pipe Installation

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

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

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Installing Drill Pipe

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

2.

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

3.

Verify that the main compressor/hydraulic pump motor is running, the hoist/pulldown speed selector switch is in PIPE RACK/JOINTS position, the operating mode selector switch is in DRILL position, and on the operator’s display terminal that the head is clear of pipe rack.

Place the pipe rack selector switch in #1 position. The pipe rack joystick will now control only the #l pipe rack.

4.

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

5.

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

6.

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

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

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7.

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

CAUTION:

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

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

CAUTION:

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

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

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

8.

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

9.

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

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

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

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10.

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

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

CAUTION:

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

Stabilizer Installation

11.

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

12.

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

13.

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

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

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To install the bit, proceed as follows: 1.

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

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

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

Bit Installation

2.

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

3.

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

As soon as the threads start to catch, set the hoist brake and let the stabilizer screw itself onto the bit.

4.

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

5.

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

6.

Lower the completed tool string so that the guide bushing is seated in the hole in the drill deck. Set the hoist brake and depress the drill/propel control OFF pushbutton. The tool string is now complete for single pass drilling or for the first pass of multiple pass drilling.

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BREAKOUT WRENCH OPERATION CAUTION:

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

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

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

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

CAUTION:

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

2.

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

3.

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

4.

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

5.

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

CAUTION:

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

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6.

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

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

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

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

3.

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

4.

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

5.

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

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

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

2.

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

3.

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

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4.

After selecting the pipe rack to be used by turning the pipe rack selector switch to #l or #4, swing the pipe rack over the hole. Then return the joystick to the NEUTRAL position.

5.

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

6.

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

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

7.

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

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

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

8.

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

9.

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

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

10.

Swing the pipe rack into the stored position.

To remove the stabilizer, proceed as follows; 1.

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

2.

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

3.

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

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

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

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

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

2.

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

3.

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

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

4.

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

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

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

5.

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

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6.

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

7.

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

8.

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

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

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

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

9.

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

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

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

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

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

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

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

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

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

NOTE:

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

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

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

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

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

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

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

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Jib Crane

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

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

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

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

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

NOTE:

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

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

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

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

Starting the hole (collaring).

2.

Drilling the hole.

3.

Cleaning or reaming the hole.

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

For the purpose of this section of the Operator’s Manual it is assumed that the hole will be drilled in a consolidated rock formation. This is probably the simplest formation to drill in. Special circumstances will be taken into account in the Drilling In Difficult Formations section of this manual.

It is also assumed that the operator is familiar with the location and operation of all of the controls on the machine and that the machine is in good repair.

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Controls for Normal Drilling

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

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

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

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

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

2.

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

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the lugs on the drill deck. Reset the hoist brake.

3.

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

4.

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

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

5.

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

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

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

6.

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

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

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

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

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

To begin normal drilling proceed as follows: 1.

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

Turning the control in the pulldown direction will increase the pressure on the bit by calling for a desired pulldown speed.

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

2.

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

3.

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

NOTE:

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

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

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4.

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

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

5.

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

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

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

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

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

2.

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

3.

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

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

This filling of the hole may reduce the actual depth of the hole significantly, so it is necessary

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to remove these cuttings from the hole. To do this, release the hoist brake and turn the hoist/ pulldown rheostat slowly in the pulldown mode.

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

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

4.

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

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

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

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

The main cause of difficult drilling are unconsolidated material or wet sticky material. Unconsolidated material causes vibration far greater than experienced in consolidated formation, and if severe enough, may also decrease the bailing velocity of the main air stream. Wet, sticky material causes problems with cleaning the hole since the material may coat the hole and the drill pipe, increasing the air pressure above the working range. Wet material may also plug the bit orifices, freeze the bit

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cones, or compact into balls that refuse to be bailed out of the hole. The general procedure for drilling in difficult formations is the same as the procedure for drilling in good formations. The hole is collared, drilled, reamed, and cleaned using the standard operating procedures. Monitoring of the machine is, however, critical while drilling in difficult formations.

NOTE:

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

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

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

This is the last procedure that should be tried since if the pulldown speed is left high and the rotary speed diminished, the vibration will be just as severe, only at a different frequency.

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

If unconsolidated material is causing the loss of bailing air volume or caving of the hole it is necessary to continually clean the hole as the recycled cuttings or the caved material will plug the hole. Closely monitor both the bailing air pressure and the flow of cuttings from the hole. If the air is being lost the air pressure will remain constant but the flow of cuttings will stop or drastically decrease while penetration does not decrease. Continue drilling for a few feet to try and get past the leak. If the bailing air pressure starts to rise, the hole is plugging. Immediately hoist the tool string until the pressure drops and allow the drill string to rotate for a few moments to clear itself. Then lower the

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tool string to the bottom of the hole and clean it out. It may be necessary to regrind the cuttings to make them small enough to seal the leak and be bailed out of the hole by reduced air volume. Once the hole is clean, repeat the hoisting and lowering procedure every 2 to 3 feet (0.3 to 0.6 m) to keep it so.

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

If the caved material is large it will be necessary to pull the tool string out of the hole and then redrill the caved material.

NOTE:

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

Experience will dictate what procedure to follow when encountering material which tends to cave in. When the formation is unfamiliar always be cautious. Caution may result in lower production, but it could save a great amount of work and a complete tool string should the tool string become stuck. Always clean the hole often and monitor the air pressure constantly. If the air pressure starts to climb, hoist the tool string immediately — do not wait to see if the pressure will level off or not. By the time it is determined what the air pressure will be, the hole is plugged. Cleaning the hole often accomplishes two things.

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

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

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

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

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minutes and restart it. Continue this procedure until the tool string is free.

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

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

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

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

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

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

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

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

Drilling in wet formations follows the same practices as drilling any other formation. Drilling wet

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formations, however, requires that particular attention be paid to the bailing air pressure and penetration rates. Wet formations are more susceptible to plugging the hole, but recovering the tool string from the plugged hole is easier than with unconsolidated material.

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

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

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

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

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

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

When drilling an angle hole, monitoring of the system indicators such as the drilling air pressure, the rotary load and the machine vibration, becomes more critical than when drilling a vertical hole.

The reason these monitors become more important is the fact that an angle hole will tend to wander downward as the hole is being drilled. This wandering is due to the drill steel assuming a

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natural camber as it is being extended past the guide bushing. This camber is unavoidable and becomes worse as the angle of the hole approaches 30 degrees.

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

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

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

Controls for Programmed Drill Control

1.

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

2.

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

3.

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

4.

Place the operating mode selector switch in the DRILL position.

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5.

Press the drill/propel control ON pushbutton.

6.

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

7.

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

8.

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

9.

Place hoist brake control in the RELEASE position.

10.

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

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

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

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

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

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

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

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

2.

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

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CAUTION:

3.

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

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

NOTE:

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

4.

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

5.

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

CAUTION:

6.

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

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

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

7.

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

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

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

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

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

2.

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

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

3.

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

4.

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

5.

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

6.

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

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7.

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

8.

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

9.

Close all doors and windows tightly.

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

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

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

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

2.

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

3.

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

4.

Manually cycle the lube system and verify that all points on the mast are receiving lubricant.

If the auto lube system is not functioning properly, repair or replace components as necessary.

5.

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

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6.

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

7.

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

8.

Close and lock all electrical cabinet doors.

9.

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

10.

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

11.

Lube all manual lube points.

12.

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

13.

Close and lock all windows and doors.

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

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

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

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

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

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

Complete all short term storage procedures.

2.

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

3.

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

4.

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

5.

Remove the auxiliary winch line.

6.

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

7.

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

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8.

Close and completely seal all electrical cabinets.

9.

Close and completely seal the operator’s cab.

10.

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

11.

Completely drain the compressor coolant system.

12.

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

13.

Block the leveling jacks in the full retracted position.

14.

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

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

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

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

If the tools have uncoupled and the upper end of the tool string is below the guide bushing but still above ground level, re-couple the tool string as would normally be done to tool joint make-up, except use caution when making the joint. Caution is necessary when making the joint as the tools in the hole will now be at an angle with respect to the tools on the drill. Cross threading of the joint is possible in this situation and should be avoided since it will not only damage the threads but result in an unreliable joint. One method to realign the tools would be to attach a suitable pulling device to the tools in the hole and center the tools with blocking (make sure it doesn’t fall down the hole). This would allow normal joint make-up without abandoning the hole. If this is not possible, the leveling jacks may be adjusted to align the tools. Be sure that the stability limits of the machine are Manual No. 10424

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not exceeded. It will be necessary to abandon the hole since the drill cannot be repositioned in the exact same orientation as before losing the tools. When the tools are recovered, clean the pipe and bit as detailed in the first procedure of this section and return to drilling.

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

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

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

CAUTION:

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

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

CAUTION:

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

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

CAUTION:

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

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Drill Stability Chart

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Section

3

Lubrication Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents LUBRICATION GUIDELINES ......................................................................................................... 3 LUBRICANT CLEANLINESS ......................................................................................................... 4 LUBRICATION BENCHMARKS ..................................................................................................... 5 ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT .................................................. 5 MPO - MULTIPURPOSE OIL................................................................................................... 6 RWRL - RUNNING WIRE ROPE LUBRICANT ....................................................................... 7 HYDO – HYDRAULIC OIL ....................................................................................................... 9 PAO SYNTHETIC HYDRAULIC FLUID ............................................................................ 10 Recommended Viscosity vs. OAT Chart .................................................................................... 10

PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID .................................................. 10

Recommended Viscosity vs. OAT Chart .................................................................................... 11

LUBRICATION POINTS ............................................................................................................... 13 Capacities - Gearcases and Reservoirs ...................................................................................... 14 Lubrication - Lower Works ......................................................................................................... 15 Lubrication - Main Frame ........................................................................................................... 16 Lubrication - Mast, View 1 .......................................................................................................... 17 Lubrication - Mast, View 2 .......................................................................................................... 18 Lubrication - Mast, View 3 .......................................................................................................... 19

LINCOLN AUTOMATIC SYSTEM................................................................................................. 20 TROUBLESHOOTING SYSTEMS ........................................................................................ 20 AIR LOCKS ..................................................................................................................... 20 DIRTY SUPPLY LINES .................................................................................................... 20 ALL INJECTORS DO NOT FUNCTION PROPERLY ...................................................... 21 INDICATOR STEMS DO NOT RETURN TO NORMAL ................................................... 21 FAILURE OF THE PUMP TO BUILD UP PRESSURE .................................................... 22 SLOW PRESSURE RISE ............................................................................................... 22 PUMP OPERATION ........................................................................................................ 22 Schematic - Hydraulic Lube Pump System ................................................................................ 23

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PUMP DISASSEMBLY AND REASSEMBLY .......................................................................... 24 Hydraulic Pump Assembly ......................................................................................................... 25

LINCOLN TYPE SL-1 LUBRICANT INJECTORS .................................................................. 26 LUBRICANT INJECTOR OPERATION ............................................................................ 27 INJECTOR ADVANTAGES .............................................................................................. 28

ADDITIONAL LUBRICATION BENCHMARKS: MPG - MULTIPURPOSE GREASE ................................................................................... (insert) EGL - ENCLOSED GEAR LUBRICANT ............................................................................ (insert) OGL - OPEN GEAR LUBRICANT ..................................................................................... (insert) CERTIFIED LISTING FOR LUBRICANTS ......................................................................... (insert)

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Section

3

Lubrication

LUBRICATION GUIDELINES Lubrication may well be the most important portion of a preventative maintenance program. Do not allow anything to interfere with the lubrication of the machine. It may require some study to adjust the amount of lubricant to use at each servicing, however; the extra effort will result in a smooth running machine with less wear and breakdowns.

NOTE: On diesel powered machines, refer to the engine literature for engine lubrication instructions.

There is no way to predict how much lubricant should be applied to a particular bearing. It is dependant upon on how hard the machine is being worked, how much the bearing has previously worn, and the grade of lubricant being used. Watch all the bearings closely until you are sure the lubricant added at one servicing is enough to last until the next servicing.

Most wearing parts require that lubricant be applied regularly in small quantities, instead of large amounts applied occasionally. Make regular inspections of the machine and watch for signs of improper lubrication such as accumulation of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line or lubricant pipe. Usually, it is a waste to pump more lubricant into a plain bearing after the lubricant starts to come out. However, certain bearings, in locations which may collect dirt (such as the lower works) should have extra lubricant added to purge all of the old lubricant which may have collected abrasive dirt.

New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant.

Old bushings may overheat because they are so worn that lubricant will not stay in until the next time of servicing. In the case of the new bearing, it may be necessary to give it more frequent lubrication until it is worked in. It may be necessary to do the same for the old bearing, until it can be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a point which needs it rather than trying to run it to the end of the shift.

The most common cause of overheating of an anti-friction bearing is churning of the lubricant. This happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing, it is almost a sure sign that too much lubricant was added to the bearing. Continue to lubricate it as often as before, but use less lubricant.

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LUBRICANT CLEANLINESS Even the best lubricant is a useless wear preventative if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt gets into the lubricant.

Follow these points of good lubrication practice: •

Keep all oil and other lubricants in tightly covered containers.

•

Wipe off covers before opening containers.

•

Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off before using them.

•

Wipe off each fitting before attaching the lubricant gun.

•

Wipe off oil filler caps or covers and the surrounding area before removing them.

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LUBRICATION BENCHMARKS

ACSL - AIR COMPRESSOR (SCREW-TYPE) LUBRICANT SCOPE:

Lubrication performance requirements and recommendations for Air Compressor (Screw-type) Lubricants.

IMPORTANT NOTE

These lubricant performance requirements for screw-type air compressors are only good for A-C Compressor Corporation screw compressors. If the machine is equipped with air compressors manufactured by other than A-C you must refer to the vendor’s maintenance information provided with the machine and Section 7 of this manual.

LUBRICANT RECOMMENDATIONS: The following lubricants are recommended: 1.

If the ambient temperature is expected to always be above -26°C (-15°F), use either: Automatic Transmission Fluid (ATF) - General Motors Dexron III or Ford Type F. or Synthesized Hydrocarbon Fluid - Mobil Rarus SHC 924.

2.

If the ambient temperature is expected to drop to -40°C (-40°F), use Mobil Rarus SHC 1024 or Phillips Philesco ISO32 or equivalent.

NOTE: If the ambient temperature drops below -26°C (-15°F), it may cause the lubricant to thicken in the oil cooler and could result in unit shutdown after a short run. If this happens often and the compressor is being lubricated with ATF, it is recommended that a synthesized hydrocarbon lubricant be used, instead.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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MPO - MULTIPURPOSE OIL SCOPE:

Lubricant performance requirements for Multi-Purpose Oil.

APPLICATION:

The addition of a lubricant to the compressed air system (not for screw-type air compressor systems - see ACSL), hand oil cans, etc.

GENERAL REQUIREMENTS: 1.

Must be fluid at temperature applied.

2.

Should contain rust in

3.

Motor oil - API service classification “MS”.

VISCOSITY RECOMMENDATIONS: 1.

Air Line Lubricant AMBIENT TEMPERATURE

2.

SAE NUMBER

Below 10°F

5W

Above 10°F

10W

Hand Oil Can - Viscosity suitable for application and temperature.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

RWRL - RUNNING WIRE ROPE LUBRICANT SCOPE:

Lubrication performance requirements for hoist rope lubricant.

APPLICATION:

Primarily for hoist ropes or any other running ropes where fatigue and not wear is of prime concern.

GENERAL REQUIREMENTS: 1.

Penetrate between adjacent wires in order to lubricate and protect them against wear and to keep the rope core from drying out and deteriorating.

2.

Provide a lubricant between sheaves and wire rope.

3.

Resist being washed off.

4.

Protect against rusting or corrosion.

5.

Form a non-sticky film so that dust and dirt will not build up on the wires.

6.

Remain pliable and resist stripping at the lowest temperatures to which the rope will be exposed.

7.

Preferably, it should form a light colored transparent film so that wear, corrosion or broken wires can be readily detected by inspection.

8.

Be capable of easy application, both manually and by devices without being heated.

COMPOUNDING: Suitable for penetrating between the adjacent wires of a rope in order to lubricate them and also to replenish the lubricant in the core.

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SPECIAL REQUIREMENTS: 1.

Must pass United States Steel Retention Test Using a Timken Tester

2.

Shell Four Ball E.P. - (ASTM D-2596) Load wear index, kg., min.:

40

Load weld kg., min.: 3.

250

Shell Four Ball Wear - (ASTM D-2266) Wear scar diameter, mm., max.:

4.

Timken O.K. Load lbs., min - (ASTM D-2782)

5.

Copper Strip Corrosion - (ASTM D-130)

6.

Suggested Application Temperature Ranges

0.60 45 pass

There should be a lubricant for each of the following temperature ranges: 110°F to 30°F 40°F to 9°F 10°F to -50°F NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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HYDO – HYDRAULIC OIL Bucyrus recommends hydraulic oil suitable for year-round use, rather than summer or winter only, which can create a mixing of viscosities if a complete draining of oil is not accomplished. This can compromise the intended oil viscosity.

The oil viscosity benchmark for the 59HR drill is 3,000 centistokes (CST) maximum on the coldest day for start-up, and 10 centistokes absolute minimum on the hottest day during machine operation.

Optimum oil viscosity at normal operating temperatures is 30 to 60 centistokes.

For climates that rarely see ambient temperatures drop much below freezing (25°F to 32°F), a paraffinic-based petroleum hydraulic oil with little or no viscosity improver (VI) can be acceptable.

For climates where ambient temperatures drop as low as -40°F on their coldest day and are as high as 104°F on their hottest day, a higher VI fluid is required. Paraffinic-based fluids should NOT be used where ambient temperatures reach freezing or slightly below freezing. At freezing or slightly below freezing temperatures, the paraffin wax starts to solidify causing the fluid to have a thicker viscosity than the temperature-viscosity curve actually implies. In addition, the VI additive in petroleumbased oils has the ability to be mechanically sheared, causing the viscosity to drop. This can result in a fluid that can be totally incorrect for use after it has been in service for some time.

For all the above reasons, plus concerns of the oxidation-rate and water-ingestion that leads to sludging, Bucyrus recommends draining intervals of 2,000 hours when using petroleum-based paraffinic or naphthenic-type hydraulic oils.

The preferred hydraulic oil for the 59HR drill is a PAO (poly-alpha-olefin) synthetic fluid with a naturally high VI. Examples being: 198 for Shell® Oil Tellus T 722, a range of 135 to 145 for Mobil® Oil SHC 500 series, 134 for Esso/Exxon® Terrestic SHP 22 Hydraulic Fluid, or 135 for Conoco® SYNCON AW Oil. The 3 to 4 times multiplier in the cost of synthetic fluids, as compared with paraffinic-based petroleum oils, is offset by the fact that the synthetic oil can be left in the system 4 times longer (i.e. 8,000 hours) before a drain interval requirement. The savings with synthetic fluid use results because the frequency of draining intervals is decreased by a factor of 4. This reduces the maintenance time dedicated to changing the system oil and the cost of system oil disposal to 1/4 of what they would otherwise be.

With all of the above in mind, using a SHC-type oil from Shell®, Mobil®, Esso/Exxon® or Conoco® can result in considerable cost savings, whether the mine is located in a cold or warm climate.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

PAO SYNTHETIC HYDRAULIC FLUID The following bar graph shows recommended viscosity grades for SHC hydraulic oil for various ambient temperatures. For temperatures outside of these ranges, contact the Bucyrus Service Department for recommended oil.

Recommended Viscosity vs. OAT Chart

PARAFFINIC BASE PETROLEUM HYDRAULIC FLUID Approved oils will typically have Denison HF-O specification certification. In general, the oils will meet the following minimum requirements: 1.

Maximum Viscosity = 14,000 SUS (3,000 CST) at the minimum expected ambient temperature (for start-up).

CAUTION:

Starting with viscosities greater than 3,000 CST could void warranty.

2.

Minimum Viscosity = 65 SUS at the maximum operating temperature of the hydraulic system.

3.

Ideal Viscosity = 100 SUS at normal operating temperature of the hydraulic system.

4.

Minimum Viscosity Index = 90

5.

Neutralization Number = 10 or less for new oil.

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6.

Oxidation Hours to 2.0 Neutralization Number per D-943 = 1,500 hours minimum.

7.

Demulsibility (easy separation from water) per D-1401 = 30 ±15 minutes to 3 ml. max. of emulsion.

Recommended Viscosity vs. OAT Chart

CAUTION:

8.

In general, water will not separate from motor oils or automatic transmission fluids, therefore these fluids are NEVER recommended as hydraulic system fluids.

Hydrolytic Stability per D-2619 = Copper wt. loss not to be more than 0.50 mg/cm2

The oil should contain rust and oxidation (R+O) inhibitors and foam depressants.

CAUTION:

August 2006

The use of water or glycol base or any other fire resistant fluid is prohibited since serious damage to the hydraulic system will occur which will void the warranty on the machine hydraulic system.

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Obtain oil from a reputable supplier. Contact the Bucyrus Service Department for specific oil recommendations or approval.

The lower figure on the previous page illustrates the acceptable temperature range for various viscosity grades (VG) of oil assuming a viscosity index of 125.

1.

The left side of the bars show the absolute minimum ambient temperature for cold startup.

2.

The right side of bars show the absolute maximum oil temperature.

3.

Ideal maximum operating oil temperature is a viscosity of 100 SUS.

NOTE: When determining an oil for the hydraulic system, Bucyrus designed the system for an all-year oil and for use without heaters. The hydraulic system is tailored to the ambient temperature at the customer’s mine and the correct type of hydraulic fluid is selected.

For extremely cold temperatures, a very light fluid is used with oversize oil coolers to accommodate higher summer temperatures. With this procedure, viscosity limits as little as 30° above ambient can be met.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

NOTE: These performance requirements are bench marks and not a specification. Therefore, meeting these limits as described above does not relieve the supplier of the responsibility associated with brand name products.

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LUBRICATION POINTS The lubrication charts in this section show the principal points to be lubricated. Automatic lube systems should be checked daily to see that they are operating properly and that each lube point is receiving the correct amount of lubricant. The types of lubricants are explained under Lubricant Benchmarks in the Appendix.

The frequency of lubrication given in each chart is intended as a guide. Under unusual operating conditions, some points may require more frequent lubrication or other special attention. Use good judgement in lubricating the machine. If a bearing is showing sign of trouble, such as overheating or unusual noise, give it immediate attention. Make sure the lubricant was not dirty or of the wrong grade. Then the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is so that no lubrication point will be missed, and none will be overlubricated. It is usually best to do this at the beginning of each shift.

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Capacities - Gearcases and Reservoirs

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* Pack Cavities at the Crawler Frame and Bearing Block. Check Annually.

NOTE: The above frequencies are for manual lubrication. When the machine is equipped with automatic lube systems, the frequencies are set at the lube control station. At initial start-up of a new machine with an automatic lube system, the injectors should be set at full opening then readjusted as required.

Lubrication - Lower Works

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NOTE: The above frequencies are for manual lubrication. When the machine is equipped with automatic lube systems, the frequencies are set at the lube control station. At initial start-up of a new machine with an automatic lube system, the injectors should be set at full opening then readjusted as required.

Lubrication - Main Frame

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NOTE: The above frequencies are for manual lubrication. When the machine is equipped with automatic lube systems, the frequencies are set at the lube control station. At initial start-up of a new machine with an automatic lube system, the injectors should be set at full opening then readjusted as required.

Lubrication - Mast, View 1

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NOTE: The above frequencies are for manual lubrication. When the machine is equipped with automatic lube systems, the frequencies are set at the lube control station. At initial start-up of a new machine with an automatic lube system, the injectors should be set at full opening then readjusted as required.

Lubrication - Mast, View 2

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NOTE: The above frequencies are for manual lubrication. When the machine is equipped with automatic lube systems, the frequencies are set at the lube control station. At initial start-up of a new machine with an automatic lube system, the injectors should be set at full opening then readjusted as required.

Lubrication - Mast, View 3

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

LINCOLN AUTOMATIC SYSTEM TROUBLESHOOTING SYSTEMS The following are normal conditions encountered when setting a new system in operation.

AIR LOCKS When the system is not primed properly, air is often trapped in the pump, supply line, injectors, or feed lines. Since the air pockets, with their great compressibility, provide a cushion against the normal rapid rise in supply line pressure, they serve to make the cycling of the system sluggish and erratic. In some extreme cases, particularly when the pump is air locked, they may make the system inoperable.

NOTE: If cycling time of a new installation greatly exceeds the cycling time determined from the system planning, it is an indication of an air lock in the system.

Correction: When the pump fails to prime and pump due to air locks, the vent plug located on or near the pump outlet on all Lincoln models should be opened while the pump is in operation and all of the air allowed to escape. The use of oil as an aid to priming is recommended. Air in the supply lines is expelled by loosening pipe plugs at the end of each line (main supply lines, etc.) and allowing generous quantities of lubricant to escape carrying with it the entrapped air. Air locks in the injectors are corrected, in the case of the SL-1 injectors, by opening the lube fitting and allowing the lubricant and air to escape. Air locks in the feed line can be corrected by loosening the feed line connection at the bearing inlet and allowing lubricant and air to escape as the system is cycled repeatedly. Do not loosen any connections which are under pressure.

DIRTY SUPPLY LINES This is a preventive maintenance problem and should be thoroughly checked before the system is installed. However, a malfunction of the injectors or the vent valve can usually be traced, by the disassembly of the unit and examination, to foreign material from the supply line inner surfaces preventing proper operation.

Correction: After the trouble has been encountered, only the disassembly and complete cleaning of the affected units will restore the system to its original state. Preventively, the supply lines should be thoroughly cleaned and blown out before installation.

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ALL INJECTORS DO NOT FUNCTION PROPERLY On a newly installed system, the difficulty usually exhibits itself by the fact that the indicator stems on one or more injectors will not move to their discharge positions (“IN” on the SL-1). As a result, some of the bearings are not receiving their measured shot of lubricant.

Correction: Those units equipped with a pressure switch must be adjusted to allow a higher developed pressure, at which level all of the injectors will discharge.

3500 PSI maximum for high pressure systems.

1000 PSI maximum for low pressure systems.

(For long life, keep pressure to a minimum permissible for proper injector operation.)

INDICATOR STEMS DO NOT RETURN TO NORMAL After venting, the indicator stems on the injectors do not return to their normal position. This condition could be due to the sluggish operation of all new assemblies and after a few operations this stiffness may disappear.

However, it could be an indication that the residual supply line pressure after venting is too high to allow the injectors to operate normally. This is due to a restriction in the supply line which hampers the rapid venting pressure. This condition may be the result of many things: notably, lubricants, low temperatures at which lubricants stiffen, or coupled with the above, an extremely short lubrication cycle. This condition is usually encountered when the lubrication cycle is relatively short. In the automatic system, where the cycle can be as low as 3-3/4 minutes, it can be a big problem.

Correction: In this case, several paths to a solution of the problem are open: 1.

The lubricant should be checked. The use of the centralized system eliminates the need (in most cases) for the heavy soap additive which only lengthens the effective line of the individual lubricant application.

2.

The lubricant can be made more resistant to physical change by the use of low temperature additives.

3.

The output of lubricant per cycle can be increased and the lubrication interval lengthened.

4.

Be sure lubricant used meets requirements of system.

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Quite often, when hand operated systems are being tested after installation, repeated operations of the system are made and sometimes the interval between cycles is short, resulting in the subject difficulty. It should be remembered that under normal conditions, the cycling of a hand operated system will usually be infrequent (once an hour at the most), allowing plenty of time for proper venting.

FAILURE OF THE PUMP TO BUILD UP PRESSURE This difficulty is in evidence when repeated operation of the pumping unit fails to produce line pressures sufficient to cause the system to cycle.

Correction: First check to see that there is a supply of lubricant in the drum or reservoir. The majority of these cases is traceable to the air locks in the pump and the familiar corrective measures are effective.

However, the trouble may be caused by the failure of the pump outlet checks to hold the pressure developed on each plunger stroke in the supply line while the plunger moves backward preparatory to the next stroke. Usually the malfunction of the check seats is caused by the presence of foreign material which prevents the ball or check from seating securely. The disassembly and thorough cleaning of the check seat should correct the difficulty.

SLOW PRESSURE RISE Particularly on extensive systems, a slow pressure rise, while at times due to improper operation of the pump, may also be due to loose supply line connections. Under these circumstances, the connections throughout the entire system must be carefully checked for evidence of lubricant leakage.

PUMP OPERATION With the pump and controller systems in a rest state, a preset time interval occurs as determined by the bearings lubrication requirements.

A 24 VDC signal is sent to solenoid valve SV1 from the controller which opens SV1. As solenoid valve SVI opens, resulting hydraulic fluid pressure closes the vent valve and flows through the pressure reducing valve. The pressure reducing valve lowers hydraulic fluid pressure to the operating range of the hydraulic pump.

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Schematic - Hydraulic Lube Pump System

After the system pressure has been reduced, it passes on to solenoid valve SV2 which controls the direction of the hydraulic cylinder that operates the grease pump. The controller generates a pulsing signal to solenoid valve SV2, operating the pump at 30 cycles per minute and delivery 15 cubic inches of grease per minute.

With the vent valve closed, the pump continued to cycle until maximum pressure is achieved and the injectors have metered grease to the bearings. When the maximum system pressure is reached, the pressure switch opens. The open pressure switch signals the controller to stop the pumping cycle.

The controller terminates the signal to solenoid valve SV2 which de-energizes SV2 and stops pump cycling.

The controller also terminates the signal to solenoid valve SV1 which de-energizes SVI stopping the flow of hydraulic fluid to the pressure reducing valve and the vent valve. With the hydraulic fluid stopped to the vent valve, the vent valve opens and allows the grease pressure to drop to zero so the injectors can recharge for the next output cycle.

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PUMP DISASSEMBLY AND REASSEMBLY CAUTION:

Bleed all pressure from hydraulic and grease lines before disassembling pump.

1.

Disconnect hose assemblies (1) and (2) from upper portion of pump.

2.

Remove cylinder adapters (3) and gaskets (4).

3.

Remove bolts (5) and washers (6) securing cover to pump.

4.

Remove cover (7) and valve assembly (8).

5.

Using two wrenches, unscrew coupling nut (9) from piston end (10).

6.

Remove four upper bolts (11) and lock washers (12) securing mounting plate (13) to the tie rods (14).

7.

Remove hydraulic cylinder (15) and mounting plate (13).

8.

The hydraulic cylinder can be disassembled from the mounting plate by removing four bolts (16) and lock washers (12).

9.

Tie rods (14) can now be removed from pump outlet body (17) by removing four lower bolts (11) and lock washers (12).

10.

Unscrew pump tube from outlet body (12).

11.

Extend pump piston rod (18) out of the bottom of outlet body (17). Place wrenches on piston end (10) and flats of piston rod (18) and unscrew piston rod. Thread the piston rod through the gland packing to allow removal of the pump tube.

12.

Unscrew gland packing nut (19) from outlet body and remove all gland parts.

13.

Remove the priming tube (20) from the bushing extension (21).

14.

Extend plunger rod (22) out of bushing extension and unscrew priming plunger (23) to allow removal of priming check parts and plunger rod (22).

15.

Remove bushing extension (21) and unscrew plunger and bushing assembly (24) from pump tube. Unscrew coupling nut (25) from plunger adapter (26) to allow removal of plunger and bushing assembly intact, reducing the chance of losing ball stop (27) and check ball (28).

16.

Clean and inspect all parts. Repair or replace all worn or damaged parts. Reassemble in reverse of disassembly.

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Hydraulic Pump Assembly

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LINCOLN TYPE SL-1 LUBRICANT INJECTORS These pressure-operating, spring-reset, series-installed injectors are supplied in banks mounted on manifolds or individually. Each injector expels a maximum of 0.08 cu. inch of lubricant from its outlet port each cycle. Dual outlet ports on each injector permit the injectors to be piped in series for increased lube supply to a common point. The quantity of lube to each point on this machine has been carefully designed by our engineers for proper coverage. Each injector output can be adjusted; however Bucyrus recommends that injectors initially be set and used at their maximum setting.

NOTE:: MAXIMUM Operating Pressure: RECOMMENDED Operating Pressure: MINIMUM Operating Pressure: MAXIMUM Recharge Pressure:

3,500 2,500 1,850 600

PSI PSI PSI PSI

To set an injector for maximum output: 1.

2.

3.

4.

Loosen locknut.

Turn adjusting nut until there is a small gap at the top of the stem.

Orient the adjusting nut so that the opening is toward the front of the injector.

Tighten the locknut.

To reduce an injector’s output: 1.

2.

3.

Loosen locknut.

Turn adjusting nut clockwise (CW) until desired discharge rate is obtained. This forces the stem into the body, retarding the stem’s movement.

Set the locknut.

CAUTION: Do not turn adjusting nut down (clockwise) more than 5 full turns from the maximum discharge setting. Check output flow from injector at this time to ensure it is still operating. If not, back off adjusting nut until injector does consistently operate. Inspect the adjusted injector for operation over 3 or 4 cycles after returning machine to work to make sure it is functioning.

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LUBRICANT INJECTOR OPERATION STAGE 1:

The injector piston is in its normal or reset position. The discharge chamber is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant, the slide valve is about to open the passage leading to the piston.

STAGE 2:

STAGE 3:

When the slide valve uncovers the passage, lubricant is admitted to the top of the piston, forcing the piston down. The piston forces lubricant from the discharge chamber through the outlet port to the bearing.

As the piston completes its stroke, it pushes the slide valve past the passage, cutting off further admission of lubricant to the passage. The piston and slide valve remain in this position until lubricant pressure in the supply line is vented (relieved) at the pump.

STAGE 4:

After the pressure is relieved, the compressed spring moves the slide valve to the closed position. This opens the port from the measuring chamber and permits the lubricant to be transferred from the top of the piston to the discharge chamber.

NOTE: The injectors may be mounted individually, or grouped in a manifold at one location.

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INJECTOR ADVANTAGES

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Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) SCOPE: 1. This specification covers “Multi-Purpose Grease”.

2. Materials furnished under this specification are primarily intended to lubricate heavy duty ball, roller, and plain bearings.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors or metering blocks.

4. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS: 1. Heat Resistance - Shall be thermally stable, should not flow or harden in service.

2. Retention - Shall not exhibit high leakage.

3. Stability - Shall work continuously with a minimum change in consistency.

4. Water Resistance - Shall withstand water washout or leaching.

5. Reversibility - Shall be stable with repeated heating and cooling.

6. Pressure Separation - Shall resist oil-soap separation.

7. Extreme Pressure - Shall withstand heavy shock loading.

8. Compatibility – a. Low temperature greases shall be compatible with mineral oil base greases. b. Grease must be compatible with oil seal lip materials (Nitriles, Viton), and all centralized lubrication system components (i.e. gaskets, o-rings, vent valves, etc.). Reference ASTM D 4289-03.

9. Compounding – a. Suitable for producing the extreme pressure characteristics (without inert fillers) required for heavy duty ball, roller, and plain bearing lubrication.

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Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) b. Base fluid is to be mineral or synthetics which are compatible with mineral base. c. Thickener types are to be of the following varieties: Aluminum, Lithium, or Calcium.

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Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY Ambient Temperature (See Note #1) NLGI Consistency # Dropping Point °C(°F) Minimum Timken O.K. load-lbs(kgf) Minimum Shell Four Ball EP Load wear index (LWI) kg Minimum Load Weld kg Minimum Shell Four Ball Wear Wear Scar mm Maximum 40KG for 1 hour @ 75°C @ 1200 RPM Copper Strip Corrosion 24 Hrs @ 100°C (212°F) Rust Test Viscosity of Base Fluid Minimum Motormatic Grease Worker Mechanical Stability 10,000 strokes, Maximum change Roll Stability Test Maximum change in 2 hours Wheel Bearing Test 6 hours @ 104°C(220°F) Maximum loss Water Washout Test Loss @ 38°C(100°F), Maximum Loss @ 80°C(175°F), Maximum

REFERENCE

REQUIREMENT -1°C to +43°C -18°C to +27°C Less than -12°C (+30°F to +110°F) (0°F to +80°F) (Less than +10°F) ASTM D-217 2 1 1, 0, 00 (See Note #2) ASTM D-2265 177(350) 177(350) 177(350) ASTM D-2509

50(23)

50(23)

50(23)

ASTM D-2596

65

65

65

ASTM D-2596

400

400

400

ASTM D-2266

0.6

0.6

0.6

2e

2e

Pass 220cSt @ 40°C

Pass 130cSt @ 40°C

ASTM D-4048

2e

ASTM D-1743 Pass ASTM D-445 460cSt @ 40°C

ASTM D-217A

10%

10%

10%

ASTM D-1831

15%

15%

15%

ASTM D-1263

10%

10%

10% (NLGI #1 Only)

ASTM D-1264

5%

5%

5% (NLGI #1 Only)

15%

15%

15% (NLGI #1 Only)

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Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) PROPERTY REFERENCE REQUIREMENT Pressure Oil Separation The Lubrication Engineers U.S. Steel test method - Cake Manual (United States Steel). penetration not less than 25% of grease penetration.

Grease Mobility The Lubrication Engineers U.S. Steel method - not less than 0.10 Manual (United States Steel). grams flow per second at the lowest anticipated ambient temperature.

(Testing temperature not less than -34°C/-30°F).

Pumpability, The Lubrication Engineers To vent from 1800 psi (127 kgf/cm^2) Lincoln Ventmeter Manual (United States Steel). to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Lubricating Solids (Molybdenum Disulfide, Less than or equal to 5% Graphite, Etc.) % by Weight Lubricating Solids (Molybdenum Disulfide, 10 Microns Graphite, Etc.) Particle Size, (Microns, max.)

NOTES: 1. Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

2. Low Temperature Grease - For extended use in low temperature (-12°C to -46°C / +10°F to -50°F) areas, this product should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing.

This product should meet the Mobility and Pump-ability criteria for the lowest anticipated ambient temperature. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

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BI616958

Bucyrus International, Inc. SPECIFICATION FOR

MPG – MULTI-PURPOSE GREASE

SD4711 (August 18, 2005) CERTIFIED LUBRICANTS: Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Multi-Purpose Grease” (see the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000 SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

Page 5 of 5

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

SCOPE: This specification covers the requirements for “Enclosed Gearcase Lubricant” used on models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

The materials furnished under this specification are intended to lubricate spur and helical gears as well as anti-friction bearings at the interior of enclosed planetary and non-planetary type gearcases (Propel, Rotary, Pull Down and Pump Drive).

This specification covers “Enclosed Gearcase Lubricants” that may be applied in service at temperatures ranging from –50ºC (-58ºF) to the highest ambient temperature conditions.

GUIDELINES FOR SELECTING AN APPROVED LUBRICANT: Step #1 Using Table 1, determine the recommended oil type (Mineral or Synthetic) based upon the anticipated ambient temperature range.

AMBIENT TEMPERATURE RANGE: Ambient Temperature: The ambient temperature is defined as the air temperature in the immediate vicinity of the gearcase. a. Use atmospheric temperature for gearcases located outside of the machinery house (Rotary, Pull Down and Propel Gearcases). b. Use machinery house temperature for gearcases located inside of the machinery house (Pump Drive Gearcase) for some machines are equipped with machinery house heaters. c. For cold weather applications, the pour point of the lubricant must be at least 5°C (9°F) below the minimum ambient starting temperature. If the ambient starting temperature approaches the lubricant pour point, oil sump heaters may be required to facilitate starting and ensure proper lubrication. Use oil temperature for gearcases having oil sump heaters.

Page 1 of 4

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 1 Ambient Temperature Range 14°F to 100°F (-10°C to 37°C) Less than 14°F to 120°F (Less than -10°C to 50°C)

ISO Viscosity Grade / Oil Type ISO VG 220 / Mineral or Synthetic (poly-α-olefin) Oil ISO VG 220 / Synthetic (poly-α-olefin) Oil

Step #2 Select an approved lubricant for the Propel, Rotary, Pull Down and Pump Drive Gearcases from the Approved Lubricant Tables 2 & 3.

The pour point and flash point of individual brand name gear oils must be observed.

Refer to the oil manufacturers technical data sheets for these properties.

APPROVED LUBRICANTS: Lubricants that have been approved for use by the Gearcase manufacturers are listed in the Approved Lubricant Tables 2 & 3. The use of non-approved lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/regulatory requirements.

Page 2 of 4

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 2 Approved Mineral Oil Lubricants (ISO VG 220) Manufacturer BEL-RAY BP

CASTROL

CHEVRON ESSO FUCHS LE (Lubrication Engineers) MOBIL PETRO CANADA SHELL TEXACO W HITMORE

Product Description Bel-Ray 100 Gear Oil 90 Energol PM 220 Energol GR-XP 220 Energol GR-XF 220 Alpha SP 220 Alpha MAX 220 Optigear BM 220 Tribol 1100/220 Chevron Ultra Gear Lube 220 Gear Compound EP 220 Spartan EP 220 (Only Product Originating from Europe) Renolin CLP 220 Plus Almasol 607 Mobilgear XMP 220 Ultima EP 220 Omala F 220 Auriga EP 220 Meropa 220 Meropa W M 220 Paragon 220

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BI616958

Bucyrus International, Inc. SPECIFICATION FOR

ENCLOSED GEARCASE LUBRICANT SD4722 (June 26, 2006) Applicable to Models 33HR, 35HR, 37HR, 39HR, 49HR and 59HR Rotary Blasthole Drills.

Table 3 Approved Synthetic (Poly-α-olefin) Oil Lubricants (ISO VG 220) Manufacturer BEL-RAY BP

CASTROL

CHEVRON FUCHS MOBIL PETRO CANADA SHELL TEXACO WHITMORE

Product Description Synth. Gear Oil 6690 Enersyn EP-XF 220 Enersyn HTX 220 Optigear Synth. A 220 Optigear Synth. X 220 Alphasyn EP 220 Alphasyn T 220 Tribol 1510/220 Tribol 1710/220 Tegra Synth. Gear Lube 220 Renolin Unisyn CLP 220 Mobil SHC 630 Mobilgear SHC 220 Mobilgear SHC XMP 220 Ultima Synth. EP 220 Omala HD 220 Pinnacle EP 220 Decathlon F 220

SPECIFICATION REVISIONS: This specification is subject to change without notice. Please refer to the Bucyrus International, Inc. web site www.bucyrus.com for the latest specification.

Page 4 of 4

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) SCOPE: 1. This specification covers “Open Gear Lubricant”.

2. Materials furnished under this specification are primarily intended to lubricate open gears, but may also be used to lubricate racks, bushings, rails, rollers, dipper handles and propel mechanism components.

3. The material furnished under this specification must be dispensable through the distribution lines of a centralized lubrication system to the most remote application point, at the lowest anticipated operating temperature. It must not plate or plug components of the centralized lubrication system such as injectors, metering blocks, or spray nozzles.

4. This specification covers open gear lubricants that may be applied in service at temperatures ranging from -50°C (-58°F) to the highest ambient temperature conditions. The particular grade or consistency selected must perform within the specific temperature range in which it is utilized.

PHYSICAL CHARACTERISTICS: 1. Materials furnished under this specification may be asphaltic (bitumen) compounds, or blends of a thickener and mineral oils and/or synthetic fluids. They may be in the form of viscous fluids, semi-fluid greases or pastes.

2. Materials furnished under this specification are produced with highly fortified blends of viscous fluids combined with additives to form stable, long lasting, high load carrying, wear resistant films that lubricate under mixed film and boundary conditions.

3. Open gear lubricants supplied under this specification must have excellent adhesive and cohesive qualities, must not chip or throw off, and must provide sufficient film thickness and scuffing resistance to prevent metal to metal contact between applications under all operating conditions.

4. Various grades or consistencies of open gear lubricants may be required to provide proper lubrication and application properties over a wide range of ambient temperatures. The consistency of the lubricant as applied must be appropriate for the method of application, and the in-service consistency shall be appropriate for the lubricant to meet or exceed the minimum performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

Page 1 of 4

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) 5. Viscosity, a fluid's resistance to flow, is the principal physical characteristic of a fluid in terms of its ability to produce a lubricating film between two interfacing surfaces.

All lubricating fluids possess a natural viscosity that may be altered (enhanced) by additives such as resins or polymers. Some "viscosity enhancers" are shear sensitive, which could result in insufficient protection of the lubricated components under high load, elevated temperatures and/or high shear conditions. The viscosity of the fluids utilized in the open gear lubricants shall be sufficient under operating conditions for the product to meet or exceed the performance requirements listed in the "MINIMUM PERFORMANCE REQUIREMENTS" section.

6. Open gear lubricants supplied under this specification must be specifically formulated to protect surfaces, reduce wear, and provide satisfactory service life under all anticipated operating conditions.

7. Open gear lubricants supplied under this specification must have excellent water tolerance and rust preventive qualities, as well as minimal dripping qualities for operation over wide temperature ranges.

8. Should the material furnished under this specification contain a diluent to improve dispensability, special care must be exercised to ensure its compatibility with all centralized lubrication system components, i.e., gaskets, o-rings, vent valves, etc., and oil seal lip materials (Nitriles, Viton). Reference ASTM D 4289-03.

9. For extended use in low temperature areas, open gear lubricants supplied under this specification should be capable of slumping in containers and should be pumpable through lube lines without the aid of heat tracing. In order to minimize compatibility problems, it is desirable that the thickener and additive system be compatible with the additional grades that are suitable for the other ambient temperatures.

Page 2 of 4

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) MINIMUM PERFORMANCE REQUIREMENTS: PROPERTY REFERENCE REQUIREMENT Flash point of product as applied, minimum (base product with diluent) ASTM D92 / ISO 2592 Ambient Temperature (See Note #1) -50°C(-58°F) to +10°C(50°F) 61°C (142°F) Above +10°C(50°F) 80°C (176°F) Flash point of base fluid(s), minimum ASTM D92 / ISO 2592 140°C (284°F) Rust protection ASTM D 1743 Pass Copper strip corrosion maximum rating ASTM D 4048 2e 24hr. @ 100°C (212°F) Four ball EP test weld point, minimum kgf ASTM D 2596 800 (base product without diluent) Load wear index (LWI), minimum ASTM D 2596 120 (base product without diluent) Four ball wear test 60 minutes @ 40 kgf.

ASTM D 2266 0.7 Maximum scar, mm (base product without diluent) Adhesive properties Must adhere to surfaces at the lowest anticipated ambient temperature.

Pumpability, Lincoln Ventmeter To vent from 1800 psi (127 kgf/cm^2) to less than or equal to 600 psi (42 kgf/cm^2) within 30 seconds at the lowest anticipated ambient temperature (Testing temperature not less than -25°C/-13°F).

Minimum Base Fluid Viscosity Ambient Temperature ASTM D 445 (See Note #1) °C (°F) -50 to +10 (-58 to +50) 680 cSt at 40°C -20 to +40 (-4 to +104) 1860 cSt at 40°C +10 to +50 (+50 to +122) 3600 cSt at 40°C Lubricating Solids (Molybdenum Disulfide, Graphite, Etc.) 15 Microns Particle Size, (Microns, max.)

NOTE: 1. Ambient Temperature - The ambient temperature shall be the temperature at the point of lubricant application.

Page 3 of 4

BI616958

Bucyrus International, Inc. SPECIFICATION FOR

OGL – OPEN GEAR LUBRICANT

SD4713 (August 18, 2005) CERTIFIED LUBRICANTS: Lubricants certified by their manufacturers as complying with this specification will be listed on the “Certified Lubricants Listing for Open Gear Lubricant” (see the Bucyrus International, Inc. web site www.bucyrus.com for the latest listing). The use of non-certified lubricants may invalidate the Bucyrus International, Inc. product warranty obligation.

Specific product selection is the responsibility of the equipment operator/owner and is dependent on climate, application, performance and regional/local regulatory requirements.

Lubricant manufacturers seeking to certify their products should contact the following for direction: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000 SPECIFICATION REVISIONS: This specification is subject to change without notice. Please contact the following for the latest specification: Bucyrus International, Inc. Engineering Services & Technical Support 1100 Milwaukee Avenue South Milwaukee, Wisconsin 53172 Phone (414) 768-4000

Page 4 of 4

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

4

Preventive Maintenance Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents ABOUT THIS SECTION ................................................................................................................ 3 DESCRIPTION .............................................................................................................................. 3 ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM .................................................... 6 SCHEDULED PREVENTIVE MAINTENANCE PROGRAM ........................................................... 6 GENERAL SAFETY CONSIDERATIONS ...................................................................................... 7 FREQUENCY OF INSPECTION AND MAINTENANCE ............................................................... 10 DAILY INSPECTION CHECKLIST ............................................................................................... 11 EXTERNAL INSPECTION ..................................................................................................... 11 ONBOARD INSPECTION ..................................................................................................... 14 AFTER START-UP INSPECTION ......................................................................................... 18 WEEKLY INSPECTION CHECKLIST ......................................................................................... 19 ON-BOARD INSPECTION .................................................................................................... 22 MONTHLY INSPECTION CHECKLIST ........................................................................................ 25 SEMI-ANNNUAL INSPECTION CHECKLIST ............................................................................... 27

August 2006

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Manual No. 10424

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Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

4

Preventive Maintenance ABOUT THIS SECTION This section of the manual describes those aspects of preventive maintenance such as inspection, adjustment and routine repetitive tasks of the Blast Hole Drill. Information related to lubrication techniques, frequency, and service points is also partially included. Further detailed information can be found in Sections 3 and 5 of this manual.

At the end of this section you will find reproducible maintenance schedules that may assist in your record keeping and maintenance scheduling.

DESCRIPTION Preventive Maintenance Programs may be defined as a systematic series of operations performed periodically on equipment to prevent breakdowns.

Any breakdown WILL reduce productivity and increase overhead expense. Machinery is only new at one point in time. From that moment, the machinery begins to deteriorate through use and aging.

A well organized maintenance program will avoid unexpected high-cost breakdowns and will increase component life.

A systematic approach to the program should be followed, and detailed records of all findings kept, to detect potential problem areas. Valuable time and effort can be saved if defects are corrected before they lead to a major breakdown. The records should be reviewed often and kept on file for future reference.

Personnel involved in the program should go through an established training program, to know WHAT to check and HOW to rectify any potential problem area. When personnel are able to do routine maintenance and normal repairs efficiently, downtime is reduced and machine productivity increased. Also, to keep the machine in good running condition, the necessary parts, tools and current information should be kept on hand.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Equipment maintenance is a science and its practice an art. This art can be divided into 6 types of operations - they are: Inspection is probably the most important operation. Careful observation is required of all parts of the equipment. Slight abnormalities may not interfere with the equipment performance BUT those that are a deviation from the normal should be discovered early. When inspecting, notice placement, state of cleanliness, color, etc. of part(s). Example: discoloration indicates overheating; all guards, bolts in place and good housekeeping.

Cleaning, and keeping clean, is essential for good operation. Periodic cleaning should be more frequent on exposed parts than those which are contained within cabinets. Parts, connections and joints should be free of dust, corrosion and other foreign matter.

A Feeling operation is used more often to check guarded rotating machinery for vibration due to worn parts, lack of lubrication, overheating, etc. Feeling operation on electrical items should be performed as soon as possible AFTER power has been removed and the circuit grounded. Feeling of excessive heat may indicate an overloaded condition and should be corrected.

A Tightening operation should be done on all connections that have worked loose due to vibration, etc. Loose parts are a definite hazard because they may fall out of place and damage nearby components. The importance of firm mounting and tight connections cannot be overemphasized.

Always replace missing or broken bolts with proper size and use the correct tools.

Adjusting should be done when inspection indicates that it is required to maintain normal operating conditions. Specific adjustment is contained in the “Mechanical Adjustment Section” of this manual, the electrical manual or the component manufacturer’s manual.

Lubrication refers primarily to the application of CORRECT LUBRICANT in the CORRECT AMOUNT to bearings and other rotating parts. It also means the application of a light oil to door hinges or other sliding surfaces. Use only clean and proper lubricant.

Planned maintenance, common sense and good judgment is less costly and more effective than panic maintenance. Action taken on recommendations made on the following suggested inspection Check List, or Lists by your maintenance department, should reduce repair, maintenance cost, and increase production.

Replacing worn components with genuine Bucyrus parts on a scheduled basis will avoid costly downtimes and emergency repairs. The cost of parts is small when compared to unscheduled breakdowns that result in excessive overtime man-hours and lost machine production.

Whenever a problem is indicated, the inspector should briefly explain it on the maintenance report (a suggested form is at the end of this section) along with his signature. Then, an authorized person should briefly explain a solution to the problem. Finally, CORRECT THE PROBLEM.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

ELEMENTS OF AN EFFECTIVE MAINTENANCE PROGRAM •

Preventive Maintenance Program.

•

Well Trained and Motivated Work Force.

•

Effective Communications.

•

Proper Equipment Selection and Procurement.

•

Meaningful Documentation.

•

Cooperation with the Operations / Maintenance Department.

•

Warehouse Support.

•

Good Shop Facilities.

SCHEDULED PREVENTIVE MAINTENANCE PROGRAM Economically maintaining the productivity and performance of a Bucyrus Blast Hole Drill requires maintenance and inspection activities in a scheduled manner. Manpower requirements and performance of needed maintenance during scheduled downtime dictates a system which recognizes the recommended inspection interval. For example, crawler assemblies are exposed to severe service and should be inspected every maintenance period, while other components can be reasonably expected to operate twice this interval before inspection. By staggering the inspection or servicing of these items, labor time and work-force size is balanced.

Maintenance and component inspection should be performed simultaneously during scheduled downtime. History of drill maintenance practices has shown that parts replacement and component rebuild in advance of destructive failure yields the lowest operating costs. Keeping good records is vital to support any preventive maintenance program. Early “change-out” reduces unscheduled downtime and prevents secondary damage. Record keeping should be an “easy to use” format and contain enough detail to isolate the function. For instance, drill bit wear will often directly relate to the number of holes drilled, rather than machine operating hours. However, power transmission shafting and bearings wear rates correspond closer to operating hours. Since basic machine life extends over thousands of operating hours, maintenance records can be utilized to forecast budgets for maintenance expenditures. This makes records a very valuable planning tool for mine management.

Use the Bucyrus maintenance program that is outlined here to formulate a schedule suited to your work-force and mining environment. Over a period of time, additional inspection or planned work may supplement the activities described in this manual.

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Manual No. 10424

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

GENERAL SAFETY CONSIDERATIONS The importance of overall safety in the maintenance of a mobile drill should always be emphasized; drilling operations may involve a variety of hazardous conditions. Many critical drill components are subject to wear and other deterioration which limits their useful life; thus making them expendable.

When new, all such parts have a built in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If however; inspection and adjustment are neglected, these parts eventually reach a condition where they become a potential problem. Similarly, failure to replace various mechanisms to ensure proper performance of the machine could constitute a problem. Study this manual carefully to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisors, operators, and maintenance men should continuously follow safe practices.

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

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the shovel is running. Obviously, there are some maintenance procedures, such as gear tooth inspections and replacement which require machine shut down. However; many support duties can be effectively handled at shift change when the shovel is still activated.

Automatic lubrication systems function throughout the operational cycles of the machine. These systems release pre-measured lubricant which extends the wear life of the machinery units. Other parts of the machine may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible, the machine must be shut down during the required lubrication.

CAUTION:

Manual No. 10424

A repair or maintenance job on DRILL equipment is not complete until all guards, plates and other safety devices have been replaced before the equipment is restored to operation.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

PRECAUTIONS BEFORE AND DURING MAINTENANCE The operator must be sure that the drill equipment is in a safe position before repairs or adjustments are made. The machine should not be endangered by falling rock or a possibly yielding support surface. Before beginning repair or adjustment, the operator shall: 1.

Lower the Pulldown/Rotary gearbox to it’s lower stops.

2.

Set all brakes.

3.

De-energize control functions.

4.

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

DANGER:

If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when repair work is being done.

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the OFF position and tagged. The lock and tag should be removed only by the maintenance people who installed them, or other authorized personnel. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.

Approved protective equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled.

DANGER:

Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches.

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

DANGER:

August 2006

Many of the components comprising the 59HR ELECTRIC BLAST HOLE DRILL are heavy, bulky items. Extreme caution should be used when lifting these items. Personnel should be certain of the weights of components before attempting to lift them, either manually or with a lifting device. All applicable safety rules should be followed when using a crane or other lifting device. Be aware of the load rating, lifting height and swing radius of the lifting device before lifting a load. Failure to follow all applicable safety rules when performing maintenance could result in serious injury, or death.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

LUBRICATION GUIDELINES Lubrication may well be the most important portion of a preventative maintenance program. Do not allow anything to interfere with the lubrication of the machine. It will require some study to adjust the amount of lubricant to use at each servicing, however; the extra effort will result in a smooth running machine with less wear and breakdowns.

There is no way to predict how much lubricant should be applied to a particular bearing. It is dependant upon on how hard the machine is being worked, how much the bearing has previously worn, and the grade of lubricant being used. Watch all the bearings closely until you are sure the lubricant added at one servicing is enough to last until the next.

Most wearing parts require that lubricant be applied regularly in small quantities as accomplished by the automatic lubrication system instead of large amounts applied occasionally. Make regular inspections of the machine and watch for signs of improper lubrication such as accumulation of excess lubricant or discolored lubricant. Ensure that the lubricant has not come from a broken or disconnected line or lubricant pipe. Usually, it is a waste to pump more lubricant into a plain bearing after the lubricant starts to come out. However, certain bearings, in locations which may collect dirt (such as the lower works and dipper padlocks) should have extra lubricant added to purge all of the old lubricant which may have collected abrasive dirt.

New bushings sometimes overheat because they are too tight to allow normal distribution of lubricant.

Old bushings may overheat because they are so worn that lubricant will not stay in until the next time of servicing. In the case of the new bushing, it may be necessary to give it more frequent lubrication until it is worked in. It may be necessary to do the same for the old bushing, until it can be replaced. It is much better to lose a little time on a shift to give some extra lubricant to a point which needs it rather than trying to run it to the end of the shift.

The most common cause of overheating of an anti-friction bearing is churning of the lubricant. This happens when the bearing is packed excessively full. If lubricant leaks out of an anti-friction bearing, it is almost a sure sign that too much lubricant was added to the bearing. Continue to lubricate it as often as before, but use less lubricant.

Section 3 of this publication will provide more detailed, and specific information on lubricants and their usage.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

LUBRICANT CLEANLINESS Even the best lubricant is a useless wear preventative if it has become contaminated by careless handling and storage. The lubricant manufacturer packs the lubricant in a tight container to keep it clean. It is the responsibility of the person performing the machine lubrication to be sure that no dirt gets into the lubricant.

Follow these points of good lubrication practice: •

Keep all oil and other lubricants in tightly covered containers.

•

Wipe off covers before opening containers.

•

Keep funnels, oil cans, grease guns, etc., in a clean place and wipe them off with a clean lint-free cloth before using.

•

Wipe off each fitting before attaching the lubricant gun.

•

Wipe off oil filler caps or covers and the surrounding area before removing them.

LUBRICATION POINTS AND SERVICE AREAS The next portion of this manual describes and illustrates the principal points or areas which require lubrication and maintenance. Refer to the topic “Lubricant Benchmarks” in Section 3 of this manual for an explanation of each type of lubricant required for servicing this machine.

The frequency of lubrication given in each chart is intended as a guide only. Under unusual operating conditions, some points may require more frequent lubrication or other special attention. Use good judgment in lubricating the machine. If a bearing is showing signs of trouble, such as overheating or unusual noise, give it immediate attention. Make sure the lubricant was not dirty or of improper viscosity. When the machine is operated for more than one shift each day, all crews must cooperate on checking lubrication. This is to ensure that no lubrication point will be missed, or over-lubricated.

It is usually best to do this at the beginning of each shift. Reproducible service schedules are provided for recording service information.

NOTE:

Lubrication instructions provided by any vendor for a vendor supplied item have priority over Bucyrus lubrication intervals and procedures.

CAUTION:

August 2006

Do not climb on the machine to perform maintenance procedures.

Use a “cherry picker” or “man basket” when inspecting or servicing elevated areas. A slip or fall can result in severe personal injury or death.

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FREQUENCY OF INSPECTION AND MAINTENANCE The suggested maintenance schedule is developed on a planned usage of 5,000 operating hours per year. This is a planned reference only. The actual conditions within your mine site, operator’s abilities and habits, along with the quality of components and consumables will ultimately drive the inspection schedule used on your machine.

Care should be take to properly evaluate your maintenance approach during the initial period after machine commissioning.

MAINTENANCE CHECKLISTS On the following pages can be found reproducible maintenance schedules that will help provide the maintenance personnel with a consistent, easy to follow inspection cycle.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

DAILY INSPECTION CHECKLIST

59HR

EXTERNAL INSPECTION 1.

Check areas around and under the machine for signs of water or lubricant leaks. If single droplets of water or lubricant are noticed, leakage is minimal.

Determine the source of the leak and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine the source and take remedial action immediately.

2.

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

3.

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

Check the lubricant level in the drive tumbler gearcase.

4.

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

5.

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

CAUTION:

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ITEM #

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

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

August 2006

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6.

Inspect the trail cable for proper placement out of the line of travel of the drill. Inspect the insulation for cuts or abrasion. Make sure the cable is kept out of water and away from sharp rocks.

Have an electrician inspect the strain relief device and the condition of the cable where it enters the machine.

7.

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

8.

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

9.

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

Check all hoses and cylinders for leaking.

CAUTION:

10.

Blast Hole Drill pmc_59hr

ITEM #

NOTED DISCREPANCY

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

Inspect the mast hinge pins for loose or missing keepers or bolts. Replace missing or damaged parts immediately.

Check the pins for sufficient lubrication and lubricate if necessary.

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59HR R

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

11.

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

12.

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

13.

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

14.

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

15.

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

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pmc_59hr

ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

August 2006

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

59HR

ONBOARD INSPECTION 1.

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

2.

Check the condition of the air compressor intake filter. Replace the filter cartridge if the red flag is visible in the service indicator. Empty the dust hopper and clean the pre-cleaner element. Inspect the housing and ducting for damage or leaks. Repair or replace leaking components.

3.

Check the oil level in the hydraulic tank.

Fill the tank to the proper level as described on the instruction plate on the tank.

4.

Check hydraulic system for leaks.

Correct all leaks immediately and clean up all oil spills immediately.

5.

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

6.

Inspect the automatic lubrication central pumping stations for proper operation.

Check the supply of lubricant and change or refill drums as necessary.

7.

Close and lock all electrical cabinet doors.

CAUTION:

Manual No. 10424

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

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ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

8.

Inspect the compressor radiator and fan. Check for signs of deterioration or damage to hoses, valves, fittings, etc.

Check for leaks at all joints. Check the radiator core for blockage by dust, dirt, leaves, paper, etc. and clean as necessary

9.

Check the operator’s display terminal for any faults.

10.

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

NOTE:

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ITEM #

NOTED DISCREPANCY

Do not use compressed air to clean the machinery house.

Compressed air will only move the dirt around. Use a vacuum cleaner to remove the dirt from the machine. Failure to clean the inside of the machinery house will cause damage to many of the components located there.

11.

Inspect the auxiliary winch and auxiliary winch line.

12.

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

13.

Check all controls for free operation.

Return all controls to the OFF or SET position.

Date: Shift: Inspected By: Supervisor:

August 2006

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

14.

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

NOTE:

15.

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ITEM #

NOTED DISCREPANCY

Do not use compressed air to clean the operator’s cab.

Compressed air will only move the dirt around. Use a VACUUM CLEANER TO REMOVE DIRT FROM THE OPERATOR’S CAB

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

CAUTION: Before working near or under the rotary drive/ pulldown unit, make sure all of the operator’s controls are off and tagged and the hoist brake set to prevent movement of the unit.

Serious personal injury or death could result should the rotary drive/ pulldown unit fall when personnel are working near or under it.

16.

17.

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

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

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Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

18.

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

19.

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

20.

Inspect the rotary gear case for lubricant leaks, damaged lines, dirt accumulation and other damaged or missing parts.

Check the lubricant level in the gearbox.

Fill to the recommended level with an approved gear lubricant. Check the rotary motor ventilation inlets for leaves, paper, rags, etc. blocking the flow of air.

21.

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

22.

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

Inspect the guide rollers for proper adjustment and excessive wear.

23.

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

August 2006

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pmc_59hr

ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

24.

59HR

Check the hoist brake for proper operation.

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pmc_59hr

25.

Check the dust or chip deflector for loose or missing parts, excessive wear or dirt accumulation. The deflector should seal around the drill pipe securely.

26.

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

ITEM #

NOTED DISCREPANCY

AFTER START-UP INSPECTION 27.

Check all brakes for proper setting and releasing.

28.

Listen for unusual noises in the gearcase.

29.

Check all bearings for unusual noises and excessive heat.

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

59HR

WEEKLY INSPECTION CHECKLIST 1.

Check for missing or worn crawler link pins and retaining pins.

2.

Check for cracked or worn crawler links.

3.

Check the tumblers and rollers for cracking, wear and lubrication.

4.

Check for cracking of the crawler frames.

5.

Check for excessive dirt accumulation.

6.

Check for proper belt adjustment (1-3 inch sag between end of upper slide and drive or take-up tumbler).

7.

Check drive tumbler for cracking and wear.

8.

Check the oil level in the propel planetary gearboxes.

CAUTION:

9.

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ITEM #

NOTED DISCREPANCY

BE CAREFUL WHEN REMOVING THE PLUGS, ESPECIALLY IF THE UNIT IS HOT. PRESSURE BUILDS IN THE GEARCASE AND AS THE LAST THREAD OF THE PLUG IS REMOVED, THE PLUG MAY FLYOFF WITH SOME FORCE. Date:

Check the propel gearbox. Hydraulic motor and hydraulic lines for leaks.

Shift: Inspected By:

10.

Check that rear axle bearing block bolts are tight.

August 2006

Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

11.

Check front equalizer axle for wear and cracking.

12.

Check equalizer axle pins for wear and lubrication.

13.

Check dust curtains for wear or damage.

Check that the curtains are not frozen to the ground.

14.

Check the curtain raising levers for wear, damage, lubrication.

15.

Check the curtain raising cylinders for wear, damage or leaking.

16.

Check the dust deflector for wear or damage.

17.

Visually Check the condition of the trail cable.

18.

Check the cable reel for damage, wear and lubrication. Manually lubricate the drum shaft bearings - 2 points.

19.

Check the cable reel controls for ease of operation and hydraulic leaks.

20.

Check the cable reel drive chains for wear, damage, lubrication and adjustment.

21.

Check the leveling jack frames for cracking.

22.

Check the leveling jack shoes for cracking. Clean off any dirt or rocks.

23.

Check for missing or worn shoe pins and retaining pins.

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ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

24.

Check the leveling jack spuds for proper lubrication.

25.

Check the leveling jacks for oil leaks.

26.

Check the mainframe for cracking.

27.

Check the retractable stairway for proper operation.

28.

Check the outside of the machinery house and cab for damage or cracking.

29.

Check that all blowers for ventilating and radiators are not obstructed.

30.

Check dry-type dust collection unit duct and hoses for leaks.

31.

Lube drive shaft bearings on dry-type dust collection unit.

32.

Check that water tank is full.

33.

Check the condition of the mast braces and brace pins.

34.

Check the mast brace lock cylinders and hydraulic lines for leaks.

35.

Check that the mast hoist cylinder pins and retaining pins are in place.

36.

Check the mast structure for wear, damage or cracking.

37.

Check the mast’s racking for wear, damage and lubrication.

38.

59HR pmc_59hr

ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By:

Check the mast ladder, safety guards and platforms for cracking and missing bolts.

August 2006

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

39.

Check the condition of the auxiliary winch line.

40.

Check the condition of the mast head sheaves.

41.

Check the condition of the upper portion of the tool racks.

42.

Check the condition of the mast air pipe, bull hose and lube lines. Visually check the condition of the electrical lines.

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ITEM #

NOTED DISCREPANCY

ON-BOARD INSPECTION 43.

Check oil level in the pump drive gearbox.

Add oil if required.

44.

Check the mast hoist cylinder anchor pin and retaining pins.

45.

On the drilling deck, check the guide bushing for wear.

46.

Check the tool wrenches for wear, lubrication and oil leaks.

47.

Check the lower portion of the tool racks for wear or damage.

48.

Check the pawls in the rack pockets that they work freely.

49.

Check that the rack levers work freely.

50.

Lubricate the rack lower arms. Check the cylinders.

Date: Shift: Inspected By: Supervisor:

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51.

Check the rotary coupling for cushion wear and tightness of bolts.

52.

Check the oil level in the rotary gearcase.

Add oil if required.

53.

Check the gearcase and frame for cracking and oil leaks.

54.

Check the guide rollers for proper adjustment.

55.

Check the pulldown gearcase for cracking and oil leaks.

56.

Check the oil level in the pulldown gearcase. Add oil if required.

57.

Check the hoist brake on the pulldown gearcase for proper operation.

58.

In the machinery house, check the oil level in the hydraulic reservoir. Add oil if required.

59.

Check all oil filters. Change if required.

60.

Check all belt drives for proper belt tension.

61.

Check the oil level in the screw compressor separator. Add oil if required.

62.

Check all hydraulic, air, lube piping for leaks.

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ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

August 2006

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

59HR

MONTHLY INSPECTION CHECKLIST 1.

Check the crawler belt adjustment and adjust belts if required.

2.

Position the machine so that crawler rollers and take-up tumblers can be checked for excessive movement which indicates bushing wear.

3.

Take sample of propel gearcase oil for testing.

CAUTION:

pmc_59hr

ITEM #

Remove rotary gearcase inspection cover and inspect gearing.

5.

Take sample of rotary gearcase oil for testing.

6.

Check the rotary gearcase drive shaft bearing adjustment and adjust if required.

7.

Remove pulldown gearcase inspection cover and inspect gearing.

8.

Take sample from the pulldown gearcase oil for testing.

9.

Check the rotary air seal and replace it if required.

Date: Shift: Inspected By:

Take sample of hydraulic oil from reservoir for testing.

August 2006

NOTED DISCREPANCY

Be careful when removing the plugs, especially if the unit is hot. Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly-off with some force.

4.

10.

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11.

Check and clean or replace all air filters.

12.

Check and clean or replace all oil filters.

13.

Take a close look at all structural units, including crawler frame, axles, mainframe and mast. Check for cracking, stress marks or buckling.

14.

Take care of any deficiencies found during prior inspections which did not require immediate action.

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ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

59HR

SEMI-ANNUAL INSPECTION CHECKLIST

Blast Hole Drill

R

1.

2.

Position the machine so that one takeup tumbler and lower roller can be removed for inspection of the bushings.

ITEM #

NOTED DISCREPANCY

Drain the propel gearcase and fill with new oil.

CAUTION:

BE CAREFUL WHEN REMOVING THE PLUGS, ESPECIALLY IF THE UNIT IS HOT. PRESSURE BUILDS IN THE GEARCASE AND AS THE LAST THREAD OF THE PLUG IS REMOVED, THE PLUG MAY FLY-OFF WITH SOME FORCE.

3.

While the gearcase is drained, inspect the gears, pinions, bearings and seals.

4.

Drain the pump drive gearbox and fill with new oil.

5.

Drain the rotary gearcase and fill with new oil.

6.

While the gearcase is drained, remove the motor and inspect the gears, pinions, bearings and seals.

7.

Drain the pulldown gearcase and fill with new oil.

8.

While the gearcase is drained, inspect the gears, pinions, bearings and seals.

9.

pmc_59hr

Date: Shift: Inspected By: Supervisor:

Re-pack the bearings in the masthead winch sheaves.

August 2006

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

10.

59HR

Drain the auxiliary winch and fill with new oil.

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11.

Drain the hydraulic reservoir and fill with new oil.

12.

Change all hydraulic oil filters.

13.

Correct any deficiencies found during prior inspections which did not require immediate action.

14.

Clean up around the machine and touchup paint any parts of the machine where paint is missing and rusting could occur.

ITEM #

NOTED DISCREPANCY

Date: Shift: Inspected By: Supervisor:

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

5

Service Procedures Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents MAINTENANCE SCHEDULES AND REPORTS ........................................................................... 5 SAFETY ........................................................................................................................................ 7 IN-OPERATION MAINTENANCE ............................................................................................. 7 PRECAUTIONS BEFORE AND DURING MAINTENANCE WORK ........................................ 8 LOWER WORKS ......................................................................................................................... 9 Lower Works Exploded View ....................................................................................................... 9

CRAWLER BELTS .................................................................................................................. 9 ADJUSTMENT ....................................................................................................................... 10 LINK REPLACEMENT ........................................................................................................... 11 BELT REPLACEMENT .......................................................................................................... 12 Crawler Belt Replacement .......................................................................................................... 12

LOWER ROLLERS .............................................................................................................. 14 Crawler Frame Lower Load Rollers .............................................................................................. 14

UPPER ROLLERS ................................................................................................................ 16 Crawler Frame Upper Load Rollers ............................................................................................. 16

TAKE-UP TUMBLERS ........................................................................................................... 18 DRIVE TUMBLER ................................................................................................................. 20 Drive Tumbler and Planetary Gearbox - Two Versions ................................................................ 20

PLANETARY GEARBOX ............................................................................................................. 21 Planetary Gearbox - Exploded View ............................................................................................ 23

CRAWLER FRAMES ............................................................................................................ 26 Crawler Frame Removal ............................................................................................................. 26

AXLES ................................................................................................................................... 28

Front Equalizer Axle ................................................................................................................... 28 Rear Pivot Axle .......................................................................................................................... 29

MAINFRAME ................................................................................................................................ 31 BIT VIEWING HATCH ............................................................................................................ 32 MAST A-FRAME .................................................................................................................... 33 LEVELING JACKS ................................................................................................................. 34 MACHINERY HOUSE .................................................................................................................. 38 Compressor Radiator Compartment ........................................................................................... 39

HOUSE VENTILATION FAN AND FILTER ............................................................................. 40 WALKWAYS AND LADDERS ................................................................................................ 40 OPERATOR’S CAB .................................................................................................................... 41

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OPERATOR’S SEAT ............................................................................................................. 41 OPERATORS CONTROLS .................................................................................................. 41 VENTILATION UNIT ............................................................................................................... 42 HYDRAULIC PUMP DRIVE ............................................................................................. 42 Hydraulic Pump Drive Assembly ................................................................................................ 42 Pump Drive Gearbox - Exploded ................................................................................................. 43

CABLE REEL .............................................................................................................................. 45 LEVEL WIND DRIVE ADJUSTMENT ..................................................................................... 46 HYDRAULIC ADJUSTMENTS ............................................................................................... 46 Cable Reel Hydraulic Equipment ................................................................................................ 47

LUBRICATION ....................................................................................................................... 48 HYDRAULIC MAINTENANCE ................................................................................................ 49 Cable Reel - Level Wind ............................................................................................................. 49 Cable Reel Collector Rings ........................................................................................................ 50 Cable Reel Electrical Schematic ................................................................................................51

MAST STRUCTURE ................................................................................................................... 52 MAST SAFETY SLING ........................................................................................................... 53 ROTARY GEARCASE ........................................................................................................... 53 DRIVE SHAFT ADJUSTMENT ......................................................................................... 54 Rotary Machinery Drive Shaft Assembly ..................................................................................... 57

ROTARY MOTOR ................................................................................................................. 61 ROTARY COUPLING ............................................................................................................ 62 ROTARY SHOCK SUB ......................................................................................................... 63 Rotary Shock Hub ..................................................................................................................... 64

ROTARY/PULLDOWN GUIDE FRAME ................................................................................. 65 Rack Pinion and Upper Guide Roller .......................................................................................... 66

GUIDE ROLLER ADJUSTMENT ..................................................................................... 66

Lower Guide Rollers ................................................................................................................... 67

PULLDOWN GEARCASE ..................................................................................................... 71

Pulldown Machinery Gearcase and Base .................................................................................... 72 Pulldown Machinery Shipper Shaft .............................................................................................. 73 Pulldown Machinery Intermediate Shaft ...................................................................................... 74 Pulldown Machinery Input Shaft .................................................................................................. 75

HOIST BRAKE ...................................................................................................................... 77 BRAKE WEAR ADJUSTMENT ........................................................................................ 77 REPLACEMENT OF FRICTION DISCS .......................................................................... 78 DISASSEMBLY OF MAGNET BODY AND ARMATURE .................................................. 79 Hoist Brake Assembly ............................................................................................................... 79

REASSEMBLY OF MAGNET BODY AND ARMATURE ................................................... 79 PIPE RACKS............................................................................................................................... 80 TOOL WRENCHES .................................................................................................................... 81 Tool Wrench ............................................................................................................................... 82 Auxiliary Winch Rope and Sheaves ............................................................................................ 83

AUXILIARY WINCH ...................................................................................................................... 84

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MAST BRACES ........................................................................................................................... 84 ADJUSTMENT ....................................................................................................................... 84 Mast Brace Assembly ................................................................................................................ 85

DUST CONTROL ....................................................................................................................... 86 GENERAL MAINTENANCE ................................................................................................... 86 DRILLING PLATFORMS AND DUST CURTAINS .................................................................. 86 Dust Deflector ............................................................................................................................ 86

SEMI-ANNUAL MAINTENANCE CHECKS ....................................................................... 87 WATER INJECTION SYSTEM .............................................................................................. 87 Water Injection System Schematic ............................................................................................ 87

WATER INJECTION DRAIN VALVES CHECK ...................................................................... 87 WATER INJECTION PUMP FUNCTION CHECK .................................................................. 88 WATER INJECTION WASHDOWN CHECK ........................................................................ 90 FILLING THE WATER TANK ................................................................................................. 90 DECK WASHDOWN SYSTEM ............................................................................................. 91 HYDRAULIC SYSTEM................................................................................................................. 92 SYSTEM OPERATION .......................................................................................................... 92 CYLINDER CIRCUIT HYDRAULIC SYSTEM ........................................................................ 92 PROPEL CIRCUIT HYDRAULIC SYSTEM ............................................................................ 93 HYDRAULIC SYSTEM CLEANLINESS ................................................................................. 93 OIL REQUIREMENTS ........................................................................................................... 94 OIL AND FILTER CHANGES ................................................................................................. 94 FILTER MAINTENANCE ........................................................................................................ 95 WEEKLY MAINTENANCE CHECKS ..................................................................................... 96 OIL RESERVOIR REPAIRS .................................................................................................. 96 LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING ........................... 96 REAR JACKS .................................................................................................................. 97 FRONT JACK .................................................................................................................. 97 PRESTART INSPECTION .................................................................................................... 98 HYDRAULIC SYSTEMS TESTS ........................................................................................... 99 PROPEL PUMP CHARGE PRESSURE CHECK ........................................................... 99 CONTROL PRESSURE CHECK .................................................................................. 100 Pump Adjustments (Sundstrand Pumps) ................................................................................. 100

PROPEL ENABLE VALVE AND LOW SPEED SELECT CHECK ................................. 101 JACK CYLINDER CHECK IN MANUAL MODE .............................................................. 101 FLOW CONTROL CHECK ........................................................................................... 103 JACK CYLINDER DRIFT TEST .................................................................................... 103 BRAKE RELEASE PRESSURE CHECK ..................................................................... 104 PROPEL BRAKE EMERGENCY RELEASE CHECK ................................................... 104 PROPEL PUMP MAIN RELIEF PRESSURE CHECK ................................................... 105 CRAWLER FUNCTION CHECK ................................................................................... 106 BIT VIEWING HATCH CHECK ...................................................................................... 106 BOARDING STAIR CHECK ........................................................................................... 106 MAIN FLOW VALVE CHECK ......................................................................................... 106

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BREAKOUT WRENCH AND TOOL WRENCH CHECK ............................................... 107 DUST CURTAIN CYLINDERS ....................................................................................... 107 DUST SEAL SLIDER ..................................................................................................... 107 MAST LOCK .................................................................................................................. 107 MAST BRACE LOCK CYLINDERS ............................................................................... 108 A-FRAME LOCK CYLINDERS ...................................................................................... 108 MAST LOCK CONSTANT PRESSURE CHECK .......................................................... 109 MAST BRACE CONSTANT PRESSURE CHECK ........................................................ 109 A-FRAME LOCK CONSTANT PRESSURE CHECK .................................................... 109 MAST RAISE/LOWER .................................................................................................. 110 AUXILIARY WINCH ........................................................................................................ 111 HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK ........................................ 112 WINDOW GUARD FUNCTION CHECK ....................................................................... 113 CHECK JACKS IN AUTO LEVEL MODE ....................................................................... 113 PIPE RACK POSITION CHECK ................................................................................... 114 PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING .......................... 114 Test Point Locations, Chart #1 ................................................................................................. 115 Test Point Locations, Chart #2 ................................................................................................. 116 Test Point Locations, Chart #3 ................................................................................................. 117 Location Descriptions ............................................................................................................... 117

HYDRAULIC SCHEMATICS ........................................................................................... (insert)

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Section

5

Service Procedures This section of the manual describes those aspects of preventive maintenance such as scheduled reports and safety precautions as they pertain to the 59HR drill.

MAINTENANCE SCHEDULES AND REPORTS Ideally, all maintenance should be approached from the preventive standpoint and on a regularly scheduled basis. Obviously, this approach keeps downtime to a minimum and results in reduced maintenance costs. To establish a preventive upkeep program, scheduled inspections and an operator’s daily report are the most useful tools available. Scheduled inspections should be conducted by the Mine Mechanical and Electrical Maintenance Departments since they are the most qualified. Either department should generate a certain amount of paperwork such as inspection records that become a part of the mine’s permanent file on the machine. The inspection records should be explicit, complete, and cover every part of the machine. Each machine operator should complete a daily record of the machine’s performance. This record should include time worked, time down, reasons for all delays, and observations on any unusual conditions encountered during operation. From these records, items that can potentially cause machine downtime can be corrected or prevented immediately, or scheduled for a future date when the machine availability can be coordinated with the other mine activities.

Each problem should be thoroughly reviewed and evaluated before scheduling any maintenance or repair. The following points should be considered during the evaluation.

1.

Is the problem one of normal wear?

2.

Is the problem caused by machine application?

3.

Is the problem a result of operator error?

4.

Is the problem a result of unavoidable circumstances?

5.

Is the problem of a repetitive nature?

6.

By leaving the repairs to a later date, will any other component be affected?

7.

Can repairs be accomplished immediately?

8.

Will the cost of repairs immediately rather than later be worthwhile?

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9.

How long will the machine be down?

Once maintenance or repair has been scheduled, take the following points into consideration to minimize downtime and expense: 1.

Are all tools and equipment needed to accomplish maintenance or repair available on the job, and are they in good repair?

2.

Are all replacement parts on hand and readily available?

3.

Is replacement of auxiliary parts, such as seals and bearings, necessary to accomplish repair, and have they been ordered?

4.

Is all disassembly and re-assembly data available?

5.

Have repair crews been scheduled?

6.

Will there be adequate supervision on hand for the repair crews?

7.

Has the manufacturer been consulted for Service or Engineering assistance?

8.

How long will the machine be down?

Once repair has been accomplished, the problem should again be reviewed with the following things in mind: 1.

Was the cause of the problem permanently corrected or just patched?

2.

What guarantee is there the same problem will not occur again?

3.

Is consultation with the manufacturer for design improvement necessary?

4.

What costs were incurred in downtime, parts, tools and labor?

5.

Could the problem have been prevented by prior action?

CAUTION:

Manual No. 10424

Many of the components of the 59HR drill are heavy, bulky items.

Extreme caution should he used when lifting. Personnel should be certain of the weights of components before attempting to lift them, either manually or with some lifting device. Follow all applicable safety rules when using cranes or other lifting equipment. Be sure of the load, lifting height and radius, and capacity of the lifting device before lifting. FAILURE TO FOLLOW ALL APPLICABLE SAFETY RULES WHEN LIFTING CAN CAUSE SERIOUS OR FATAL INJURY TO PERSONNEL.

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CAUTION:

USE EXTREME CAUTION WHEN STRIKING METAL PARTS WITH A SLEDGE HAMMER AS CHIPS MAY FLY OFF WITH GREAT FORCE AND POSSIBLY CAUSE SERIOUS INJURY. Wear adequate protective clothing including a face shield. Alternate methods of removal might involve using a soft metal hammer or a hydraulic jack with applicable fixtures.

SAFETY The importance of overall safety in the maintenance of mining equipment should always be emphasized; excavating operations should always be emphasized; excavating operations may involve a variety of hazardous conditions. Many critical components are subject to wear and other deterioration which limits their useful life; thus they are expendable. When new, all such parts have a built-in reserve strength against unknown factors and reasonable loss of durability from gradual wear. If, however, inspection and adjustment are neglected, these parts eventually reach a condition where they become a safety problem. Similarly, failure to replace various mechanisms to insure proper performance of the machine also constitutes a safety problem. Study this manual carefully and follow all recommended procedures to avoid unsafe conditions. Review the manual periodically to refresh your knowledge of these procedures. Supervisor, operators and maintenance men should continuously follow safe practices.

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

From an economic standpoint, it is advisable to perform as much of the upkeep as can be safely accomplished while the machine is running. Obviously, there are some maintenance procedures, such as gear tooth inspection and replacement, which require machine shut down. However, many support duties can be safely and effectively handled at shift change when the machine is still activated.

Automatic lubrication systems function throughout the operation cycles of the machine. These systems release premeasured lubricant which lengthen the wear life of the machinery units. Other parts of the machinery may be manually lubricated in a safe manner through extended grease or oil fittings designed to keep the operator’s hands at a safe distance. Where this is not possible the machine must be shut down during the required lubrication.

A repair or maintenance job on equipment is not complete until guards, plates and other safety devices have been replaced before the equipment is restored to operation.

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

Secure the rotary drive unit and tool string.

•

Set all brakes.

•

De-energize control functions and tag.

•

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

NOTE: If power is essential to the repair, it should only be energized when all personnel are clear of electrical and mechanical hazards. The power should only be energized during the required period and not when repair work is being done.

Prior to undertaking any work, maintenance personnel should notify the operator about the nature and location of the job. If work is to be done on or near moving parts, the starting controls should be locked in the “OFF” position and tagged. The lock and tag should be removed only by the maintenance people who installed them. During all phases of maintenance, use extreme caution when working near electrical equipment. Never work near exposed, energized high voltage connections.

Approved protection equipment such as gloves and insulated hooks or tongs should always be used when high voltage electrical cables are handled. Only qualified electricians are permitted to directly maintain electrical equipment such as motors, transformers, and switches. While performing maintenance, the awkward positions assumed often increase injuries due to handling heavy parts.

As a precautionary measure, use mechanical handling equipment whenever possible. The mining foreman can facilitate safer and easier maintenance work by providing blocking materials. Service crews should have a fundamental knowledge of lifting practices so their knees and legs are used rather than their backs.

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LOWER WORKS

Lower Works Exploded View

CRAWLER BELTS The crawler belts should be inspected frequently to prevent an unexpected breakdown.

Check the links for cracks, worn lugs, elongated link pin bores and other damage. Minor cracks in the link do not constitute a major problem. However, cracked links should be repaired by welding or replaced at a convenient time. Links with broken or worn drive lugs should be replaced at the earliest convenient time as they can cause the belt to ride off the rollers or take-up tumblers. Links with elongated pin bores should be checked carefully for cracks at the pin lugs and replaced if badly worn or cracked. Bent, broken, or badly worn link pins should be replaced.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

ADJUSTMENT To determine if the crawler belts should be adjusted, raise the machine so that the crawler belts are hanging free and not contacting the ground. At the center of the crawler frame measure the clearance between the bottom of the crawler frame and the roller surface of crawler link. Do not operate the machine with belt slack in excess of 14 inches.

Adjustment of the crawler belts is accomplished at the take-up tumbler of the belts. The take-up tumblers are mounted on shafts which are mounted in supports which in turn ride in slots in the crawler frames.

Shims placed ahead of, or behind the supports position the tumbler to provide the desired belt tension.

To adjust belt tension: 1.

Using the leveling jacks, raise the machine until the crawlers and belts are suspended above the ground. Block the machine in this position.

2.

Remove the tumbler shim guards from the inside and outside of the crawler frame.

3.

Position suitable hydraulic jacks (25 ton), supplied with the machine, behind each of the supports.

4.

Remove several shims from behind the supports.

5.

Actuate the hydraulic jacks to push the supports rearward to provide the desired belt tension. Make sure the supports slide straight in the crawler frame and do not become cocked.

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6.

Insert sufficient shims in front of the supports to maintain the adjustment.

Several different thicknesses of shims are provided. Be sure that the shims are the same thickness behind each support.

7.

Remove the hydraulic jacks.

8.

Reinstall the shim guards on the crawler frame.

9.

Repeat the procedure for the other crawler belt if necessary.

10.

Remove blocking and lower machine.

LINK REPLACEMENT To replace a link in the crawler belts: 1.

Propel the machine to position the defective link in an accessible position near one end of the crawler.

2.

Remove the tension from the belt by removing all of the tensioning shims from behind the take-up tumbler supports. Refer to the CRAWLER BELT ADJUSTMENT for details of this procedure.

3.

Secure the belt against unwanted movement.

4.

Attach a suitable lifting device to the defective link. Part the belt at the defective link by removing the two link pins securing the link to one end of the belt.

5.

With the lifting device, lower the end of the crawler belt with the defective link to the ground.

6.

Remove the defective link from the belt.

7.

Install the replacement link on the end of the belt resting on the ground.

8.

Using the lifting device, lift the end of the belt into position to insert the remaining link pins.

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9.

Insert the link pins and secure with cotter pins.

10.

Remove any equipment, securing the belt against movement.

11.

Readjust belt tension as described in the CRAWLER BELT ADJUSTMENT topic of this manual.

BELT REPLACEMENT Although belt replacement is required infrequently, there are times when it is necessary. To replace a belt: 1.

Propel the machine to firm, flat, level ground. Remove tension from the belt by removing the shims from behind the take-up tumbler supports as described in the topic CRAWLER BELT ADJUSTMENT.

2.

Part the belt at the midway point between the upper rollers by removing the link pins.

Crawler Belt Replacement

3.

Attach a suitable lifting device to the ends of the belt and drag and lift each end of the belt off the crawler frame and lay it on the ground.

4.

Using the machine leveling jacks, raise the machine sufficiently to allow the old belt to be dragged from underneath of the crawler frame. Securely block the machine in this position.

5.

Using a suitable vehicle and rigging, drag the old belt from underneath of the crawler frame.

6.

Assemble the new belt and lay it flat on the ground near the crawler frame.

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7.

Using a suitable vehicle and rigging, drag the new belt underneath of the crawler frame so that the roller path in the center of the belt is aligned with the lower rollers, drive tumbler and take-up tumbler.

8.

Remove the blocking and slowly lower the machine until the crawler rollers and tumblers are resting on the belt.

9.

Using a suitable lifting device, lift the ends of the belt into a position to insert the link pins.

10.

Insert the link pins and cotter pins to complete the belt.

11.

Readjust the belt tension as described in the topic CRAWLER BELT ADJUSTMENT.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

LOWER ROLLERS Inspect the lower rollers for cracks and damage that can impair normal tracking of the crawler.

Once a month raise the machine with the leveling jacks to allow inspection of the rollers. Block the machine in a raised position. Using a suitable lever, check the clearance of the roller bushing by lifting and then lowering the roller. Replace the bushing if the clearance is excessive.

Crawler Frame Lower Load Rollers

The most common problem encountered with lower rollers is bushing wear. However, over a period of time, the rollers will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Contact Bucyrus International for a repair procedure or replacement parts.

If bushing replacement is necessary, the roller must be removed from the machine. To remove a roller: 1.

Relieve the crawler belt tension as described in the topic CRAWLER BELT REPLACEMENT.

2.

Using the machine leveling jacks, raise the machine sufficiently to allow removal of the roller.

Block the machine in the raised position. It may be necessary to jack the crawler belt away from the crawler frame and block in position to remove the extreme front or rear rollers.

3.

Remove lubrication guards and lube lines of so equipped to gain access to the roller shaft.

4.

Remove the bolt and retainer securing the lower roller shaft to the crawler frame.

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5.

Support the lower roller with suitable blocking.

6.

Remove the roller shaft.

7.

Remove the blocking and lower the roller out of the crawler frame.

8.

Inspect the roller bushing. Remove and replace the bushing if necessary.

9.

Inspect the lower roller shaft. Replace if worn.

10.

Inspect the crawler frame in the area of the lower roller. Repair shaft bore or thrust surfaces if necessary.

11.

Lubricate the roller bushing and shaft.

12.

Install roller in crawler frame and block in line with the shaft bore.

13.

Insert roller shaft.

14.

Install the retainer and bolt to secure roller shaft to crawler frame. Remove the roller blocking.

15.

Install lubrication guards and lube lines if so equipped.

16.

Adjust belt tension as described in the topic CRAWLER BELT ADJUSTMENT.

17.

Remove blocking and lower machine. Propel the machine to distribute the lubricant evenly in the roller and check roller operation.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

UPPER ROLLERS Inspect the upper rollers for cracks and damage that can impair normal tracking of the crawler belt Once a month use a jack to lift the crawler belt off the upper rollers. With a suitable lever, check the clearance of the roller bushings by lifting and then lowering the rollers. Replace the bushings if the clearance is excessive.

Crawler Frame Upper Load Rollers

The most common problem encountered with upper rollers is bushing wear. However, over a period of time, the roller will wear and possibly develop cracks. The cracks may be repaired by gouging and welding. Contact Bucyrus International for an appropriate repair procedure or required parts.

If bushing replacement is necessary, the roller must be removed from the machine. To remove a roller:

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1.

Relieve the crawler belt tension as described in the topic: CRAWLER BELT ADJUSTMENT.

2.

Using a jack, raise the crawler belt high enough so that the upper roller can be removed.

Block the belt in this position.

3.

Remove the bolt and retainer securing the roller shaft to the crawler frame.

4.

Support the roller with suitable blocking and remove the roller shaft.

5.

Remove the roller and blocking from the crawler frame.

6.

Inspect the roller bushing. Remove and replace the bushing if necessary.

7.

Inspect the roller shaft. Replace if worn.

8.

Inspect the crawler frame in the area of the upper roller. Repair shaft bore or thrust surfaces if necessary.

9.

Lubricate the roller bushings and shaft.

10.

Install roller into the crawler frame and block in line with the shaft bore.

11.

Install the roller shaft and secure the shaft with the retainer and bolt. Remove the roller blocking.

12.

Remove the crawler belt blocking.

13.

Adjust belt tension as described in the topic CRAWLER BELT ADJUSTMENT.

14.

Lubricate the roller. Propel the machine to distribute the lubricant evenly and check roller operation.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

TAKE-UP TUMBLERS Inspect the take-up tumbler for cracks and damage that can impair normal tracking of the crawler belts.

Every six months raise the machine with the leveling jacks to allow inspection of the tumblers.

Block the machine in a raised position. Using a suitable lever, check the clearance of the tumbler bushing by lifting and then lowering the tumbler. Replace the bushing if the clearance is excessive.

The take-up tumblers do not require replacement or repair very often. The most common problem encountered is bushing wear. However, it is possible for the tumbler to develop cracks. When cracks do occur, they can be repaired by gouging out metal on both sides of the crack, and welding the crack. Contact Bucyrus International for a specific repair procedure.

If bushing replacement is needed, the tumbler must be removed from the machine. To remove the tumbler: 1.

Position the machine so that the take-up tumbler to be removed is over a slight depression (about 6" deep). This depth will be enough to relieve the weight of the machine from the tumbler.

2.

Relieve crawler belt tension and separate the crawler belt as described in the topic CRAWLER BELT REPLACEMENT. Separation of the belt should take place at a point near the take-up tumbler, and the links laid back out of the way.

3.

Remove the shim guards and lube lines if so equipped.

4.

Using a suitable lifting device to support the take-up tumbler, remove the shaft from the tumbler.

Lift the tumbler from the crawler frame.

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5.

Remove the supports and shims from the crawler frame.

6.

Inspect the tumbler bushings. Remove and replace the bushings if necessary.

7.

Inspect the tumbler shaft and replace if necessary.

8.

Inspect and clean the shaft supports. Replace if worn.

9.

Inspect the crawler frame in the areas where the supports slide. Rebuild and grind if worn.

10.

Lubricate the tumbler bore and shaft. Install the supports in the crawler frame. Using a suitable lifting device, position the tumbler in the crawler frame.

11.

Install the bearing tumbler shaft and secure with the shaft retainer pin.

12.

Re-assemble the crawler belt.

13.

Adjust the crawler belt tension as per topic CRAWLER BELT ADJUSTMENT.

14.

Replace the shim guards and lube lines if so equipped.

15.

Propel the machine to distribute the lubricant evenly in the tumbler bushing and check operation of tumbler.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

DRIVE TUMBLER Inspect the drive tumbler for cracked and broken lugs and other defects that can impair normal tumbler function and belt tracking. Check the tumbler retainer bolts for tightness.

Repair of the drive tumbler is limited to repair welding of the lugs or roller area or replacement of the entire unit. Refer to the welding instructions for exact weld repair procedures.

Drive Tumbler and Planetary Gearbox - Two Versions

To replace the drive tumbler:

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1.

Relieve the crawler belt tension and separate the crawler belt as detailed in the CRAWLER BELT REPLACEMENT topic of this manual. Separation of the crawler belt should take place near the drive tumbler and the links laid back out of the way.

2.

Using the machine leveling jacks, raise the machine sufficiently to allow the drive tumbler to clear the lugs on the crawler belt. Block the machine in the raised position.

3.

Remove the tumbler retainer bolts and remove the tumbler from the planetary gearbox.

NOTE: The tumbler retainer bolts are metric bolts.

4.

Inspect the drive tumbler. Repair or replace if the lugs or rolling surface are worn or damaged.

5.

Install the drive tumbler on the planetary gearbox. Torque the bolts to 2,600 Ft-Lbs. (lubed) and 1,100 Ft-Lbs. (lubed) respectively.

6.

Remove blocking and lower machine. Verify that all of the rollers and the drive tumbler are resting on the roller path of the belt.

7.

Assemble and adjust the tension of the crawler belts as described in CRAWLER BELT ADJUSTMENT.

8.

Propel the machine to check the operation of the drive tumbler.

PLANETARY GEARBOX The planetary gearbox should be checked daily for oil leaks. The oil level should be checked weekly by removing the oil level plug. The gearbox uses approximately 7.9 gallons of lubricant. The oil should be changed after the first 150 hours of operation and then every 1,500 hours of operations.

Additionally, after 12 months of operation, the gearbox should be drained and flushed completely prior to refilling with new oil.

CAUTION:

Be careful when removing the plugs, especially if the unit is hot.

Pressure builds in the gearcase and as the last thread of the plug is removed, the plug may fly off with some force.

Monthly, the external bolts of the gearbox should be randomly inspected for tightness. Bolt torques are shown on figure.

To remove the gearbox from the crawler frame proceed as follows:

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1.

Remove the drive tumbler as described under the topic DRIVE TUMBLERS.

2.

Unbolt and remove the hydraulic motor from the gearbox. If necessary, disconnect the hydraulic lines from the motor. Tag and plug the lines. Plug the motor ports. The motor coupling sleeve will be removed with the motor.

CAUTION:

Failure to thoroughly clean dirt from joints before opening hydraulic lines could lead to component failure if dirt gets into the system.

3.

Remove the hydraulic line from the gearbox brake port. Tag and plug the line. Plug the brake port.

4.

The gearbox is mounted in the crawler frame so that the hydraulic motor mounting is 15o above horizontal. Before removing gearbox match mark the gearbox and crawler frame so that at re-assembly the gearbox will be at the desired angle.

5.

Secure a crane to the gearbox and remove the mounting bolts. Remove the gearbox from the crawler frame.

NOTE: The gearbox mounting bolts are metric bolts.

6.

Clean and inspect the gearbox. Repair or replace the gearbox as required and reinstall in reverse of removal. Refer to the figure for bolt torquing values.

To disassemble the planetary gearbox completely, proceed as follows: 1.

If the lubricant was not drained from the gearbox prior to removal from the crawler frame, drain the gearbox now.

CAUTION:

The planetary gearbox weighs approximately 2,860 lbs. When disassembling the unit, a hoist will be required to handle the larger parts.

NOTE: All the bolts in this unit are metric.

2.

Remove the 4 socket head bolts that secure the motor mount to the housing. Remove the motor mount. As the motor mount is removed., watch that the shift ring does not fall as it slides from the input shaft.

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Planetary Gearbox - Exploded View

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3.

To disassemble the brake assembly and shift fork from the motor mount, proceed as follows: a.

Remove the socket head bolt that holds the shift fork to the shift shaft.

b.

Remove the hex head bolt that secures the shift shaft in the motor mount and slide the shift shaft from the mount and shift fork.

c.

Remove the shift fork. Remove the shift shaft o-ring and seal from the motor mount.

d.

Remove the brake disc stay ring snap ring from the motor mount. Slide the stay ring and disc assembly from the mount. There are 9 inner and 10 outer discs in the assembly.

e.

Install a clamp to secure the piston to the back-up plate to prevent the springs in the piston from flying out when the back-up plate snap ring is removed. Remove the snap ring and the clamped piston and back-up plate. Remove the piston seal and back-up rings from the motor mount.

f.

Slowly release the clamp to allow the spring compression to fully release. Remove the plate, springs, seal and seal back-up rings from the piston.

4.

Remove the motor mount o-ring from the housing.

5.

Remove the input shaft bearing snap ring and remove the shaft with bearings from the housing.

Separate the bearings from the shaft. The bearing cage of the inner bearing will remain in the housing.

6.

Remove the 1 inner socket head bolt and 15 outer hex head bolts that hold the housing to the twin ring gear.

7.

Remove the spur gear assembly, ball bearing and sun shaft from the housing. Also remove the input shaft inner bearing cage. If required, separate the spur gear from the coupler by removing the 12 socket head bolts.

8.

Slide the first stage planetary gear assembly from the twin ring gear.

9.

Separate the first stage planetary gear assembly as follows: a.

Remove the gear snap ring and slide the gear assemblies from the carrier shafts.

b.

Remove the bearings, stay rings and snap rings from the gears.

c.

Remove the sun shaft snap ring and remove the sun shaft from the carrier.

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10.

Remove the 24 hex head bolts that secure the twin ring gear to the back-up plate and remove the twin ring gear. The second stage planetary gear assembly front bearing cage will remain in the twin ring gear. Remove it, if required.

11.

Remove the 8 hex head bolts that secure the tumbler sprocket hub retainer to the second stage planetary gear assembly. Separate the retainer, hub, face seal and backup plate from the second stage planetary gear assembly. Remove the o-rings from the retainer and planetary gear assembly.

12.

Separate the second stage planetary gear assembly as follows:

13.

a.

Remove the front bearing inner race if required.

b.

Remove the gear pin snap ring and remove the pins. Remove the gear assemblies from the carrier.

c.

Use a puller to remove the rear spherical bearing from the carrier.

d.

Separate the bearings, snap rings, spacer ring and locating rings from the gears.

Clean and inspect all parts. Replace all damaged or worn parts. Reassemble in reverse of disassembly noting the following: a.

Replace all o-rings, wipers, seals and back-up rings.

b.

Use Loctite on housing inner socket head bolt and spur gear coupler socket head bolts. Be sure to follow manufacturer’s instructions when using Loctite.

c.

Lightly oil all items during assembly.

d.

There should be a 1-2 mm clearance between the spur gear ball bearing and the housing.

e.

Tighten all bolts as follows: Shift fork bolt Shift shaft bolt Motor mount bolt Retainer bolt Twin ring gear bolt Housing bolt Spur Gear Bolt

August 2006

63 Ft-Lbs. (8.6 da N-m) 36 Ft-Lbs. (4.8 da N-m) 36 Ft-Lbs. (4.8 da N-m) 737 Ft-Lbs. (100 da N-m) 302 Ft-Lbs. (41 da N-m) 64 Ft-Lbs. (8.6 da N-m) 218 Ft-Lbs. (29.5 da N-m)

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CRAWLER FRAMES Inspect the crawler frames for cracks or damage. Pay particular attention to the axle attachment points and the bottom flange plate. Any cracks, wear or damage should be repaired immediately.

Repair of the crawler frames may be accomplished while the crawler frames are attached to the drill or the crawler frames may be removed to facilitate repair.

To remove the crawler frames from the machine proceed as follows: 1.

Disconnect all hydraulic and lubrication lines connected to the crawler frame. Be sure all joints are clean and all lines and ports are plugged.

Crawler Frame Removal

2.

Using the machine leveling jacks, raise the machine sufficiently to allow blocking to be placed under the crawler belts and extending 6 to 8 feet from the crawler frame. Blocking material should be selected to facilitate the sliding of the crawler frame away from the machine.

3.

Slowly lower the machine until there is no weight on the rear axle or equalizer axle. Securely block the machine in this position.

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4.

From this point either one or both crawler frames may be removed from the machine.

NOTE: Steps 5 through 14 describe the procedure for removing and reinstalling one crawler frame. If both frames are to be removed, repeat steps 5 through 14 for the other crawler frame.

5.

Remove rear axle retainer bolts and remove the retainer. Remove the retaining collar.

6.

Remove the equalizer axle pin retaining pin cotter pins, retaining pins and pin.

7.

Using suitable rigging and suitable vehicle(s), pull the crawler frame straight away from the machine. Pull the crawler frame to a position to be repaired or handled with lifting equipment.

8.

Repair the crawler frame and components as necessary.

9.

To replace the crawler frame, first position the crawler in-line with the rear equalizer axle.

10.

Lubricate the rear axle, axle bore, equalizer axle pin and bores.

11.

Using suitable rigging and vehicle(s), pull the crawler frame toward the machine. Proceed slowly when attaching the crawler to the rear axle. Make sure the crawler is straight as it is being pulled onto the axle.

12.

When the crawler is in position, insert the equalizer axle pin and retaining pins. Insert the retainer pin cotter pins.

13.

Install the rear axle retaining collar, retainer, retainer bolts and lockwire.

14.

Connect the hydraulic and lubrication lines.

15.

Raise the machine with the leveling jacks just enough to remove the blocking, then lower the machine.

16.

Propel the machine to check the operation of the crawler components.

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AXLES The crawler frames are attached to the machine by two axles. The front axle (equalizer axle) allows the front of the crawlers to pivot, equalizing the load of the machine between the two crawlers.

Each end of the axle is pinned to the crawler frames while the middle of the axle is pinned to the bottom of the drill mainframe.

Front Equalizer Axle

The rear axle is the pivot axle in that as the front of the crawlers move up and down to equalize the loads when propelling over rough terrain, the rear of the crawler pivots about the rear axle. This axle is solidly attached to both sides of the mainframe and does not move during operation.

Inspect the axles and the attachment points frequently for loose bolts or hardware. Inspect the axles for cracks or damage. Repair or replace the axles if worn or damaged. Inspect the pivot pins and retainers for wear or damage and replace as necessary. Normally the axles will not need repair during the life of the machine. Accidents or abnormal wear situations do occur, however, that may make repair of the axles necessary.

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Rear Pivot Axle

Due to the inaccessibility of the axles, removal of the axles from the machine will most probably be necessary. To remove the axles from the machine: 1.

Following the procedure listed under CRAWLER FRAME REPAIR, remove one crawler from the machine. Position the crawler to allow removal of the axles from the machine. Be sure the machine and the opposite crawler are solidly blocked.

2.

To remove the equalizer axle, first remove the remaining equalizer axle pin, then securely block the axle to allow removal of the pivot pin.

3.

Remove the axle pivot pin. The pivot bearing block may be removed to facilitate removal of the pin.

4.

Remove the axle from beneath the drill and repair or replace as necessary.

5.

Reinstall the axle by first positioning the axle to allow installation of the pivot bearing block and/or pivot pin. Install the bearing block and/or pivot pin.

6.

Install the equalizer axle pin and retaining pins. Install the crawler frame if only the equalizer is to be repaired.

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7.

To remove the rear axle, remove the remaining axle retainer and retaining collar.

8.

Securely block the axle to allow it so slide out of the crawler frame.

9.

Remove the bearing block bolts attaching the axle to the mainframe.

10.

Slide the axle from the crawler frame and remove from beneath the drill.

11.

Repair or replace the axle as necessary.

12.

Position the axle to allow it to slide into the crawler frame.

13.

Lubricate the axle bearing bores in the crawler frame.

14.

Slide the axle into the crawler frame.

15.

Align the axle with the mainframe.

16.

Install the bearing block and bolts to attach the axle to the mainframe.

17.

Install the crawler frame per topic CRAWLER FRAME REPAIR.

18.

Raise the machine slightly with the leveling jacks and remove the remaining blocking. Lower the machine to the ground.

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MAINFRAME The 59HR drill mainframe consists basically of two I-beams tied together with bracing and covered on the top surface with deck plates. Inspect the drill mainframe for wear, damage or cracks. Pay particular attention to the following critical areas.

•

Cross bracing which ties the bottom flanges of the I.-beams together.

•

Cross bracing and deck plates which tie the top flanges of the I-beams together.

•

Mast lock pin attachment areas.

•

Leveling jack attachment areas.

•

Areas where the mast A-Frame is pinned to the mainframe.

•

Mast hoist cylinder attachment lugs and the immediate area surrounding these lugs on the mainframe.

Cracking, wear or damage to the critical areas listed above require immediate repair. The urgency of repair to other areas of the mainframe plates is dictated by the area in which the repair must be done and the severity of the damage. Minor damage may not require immediate attention but all damage to the mainframe should be repaired at the first available opportunity. Repair to the mainframe is limited to repair welding. If damage is severe or unusual circumstances arise, contact the Bucyrus International Service Department for specific recommendations.

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BIT VIEWING HATCH The bit viewing hatch is mounted in the mainframe aligned with the drill pipe and the operator’s station. When the hatch cover is lowered, the operator can view the bit as, a new hole is started.

The structure should be checked monthly for weld cracks. The cylinder and hydraulic lines should be checked daily for leaks. Any cracking should be repaired.

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MAST A-FRAME The mast A-Frame is a welded structure that is pinned to the mast and the mainframe and helps support the mast at it’s lower end. The rear leg lock pins are hydraulically operated. The structure should be checked monthly for weld cracks, structural bending and wear. The cylinders and hydraulic lines should be checked daily. Any cracking, wear, or damage to the A-Frame must be repaired immediately. Repair to the A-Frame and rear leg is limited to repair welding.

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LEVELING JACKS Inspect the leveling jacks for structural damage, proper lubricant coating and proper operation. Verify that all bolts are tight and all pins are in place. Check the jack pads for cracks or damage. Clean excess material from the jack pads. Check the jack spuds for wear or damage. Verify that the spuds are coated with lubricant.

Proper operation of the jack dictates that the jacks do not settle either while the machine weight is resting on the jacks or when the jacks are in the stored position. To check the jacks, raise the machine on the leveling jacks until the machine is completely off of the ground.

Scribe a line on the jack spuds I foot below the jack housing. Allow the machine to remain idle for 1 hour. Measure the distance between the scribe lines and the jack housings. If the distance is less than 11.75 inches, the jack(s) and/or other hydraulic components are leaking and must be repaired.

Repair of the leveling jacks is limited to repair welding of selected components and cleanout of others. Repair welding of structural damage is allowable on the jack casing and jack pad. Repair welding of the jack spud is not recommended if the damage has caused the spud to be bent or become out-of-round.

The spud should be replaced if it is bent or no longer round.

Repair of the hydraulic cylinder is limited in this manual to clean-out of the cylinder. Repair of the cylinder itself follows the basic procedures for repair of any hydraulic cylinder.

Repair of the jack casing is limited in this manual to repair of minor cracks or damages.

Should any serious damage occur, consult the Bucyrus International Service Department for repair details.

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Note that bolts securing the rear jack casing to the mainframe are torqued to 390 Ft-Lbs. (snug tight) then turned an additional 1/2 turn. Refer to turn-of-the-nut torquing method found at the end of this section under TORQUE APPLICATION. There should be hardened washers under bolt heads and nuts.

To remove and replace a hydraulic cylinder and jack spud proceed as follows: 1.

If the rear jack is to be worked on, lower that jack until the pad is 1 or 2 inches from the ground. Raise the other three jacks not being worked on, to the full retracted position. If a front jack is to be worked on, both front jacks should be lowered to 1 or 2 inches from the ground Raise the rear jacks to the full retracted position.

2.

Stop the hydraulic pump and relieve any pressure in the system by loosening the reservoir breather. When trapped air in the reservoir is relieved, immediately replace the breather.

3.

Carefully disconnect the main hydraulic lines attached to the counterbalance valve at the jack cylinder.

NOTE: Do not disturb the lines going from the counterbalance valve to the electric junction box.

4.

With appropriate plugs, seal open holes in the main hoses that were removed in step 3.

WARNING:

If working on a rear jack, refer to steps 5 through 8 and 15 through 31. If working on the front jacks, refer to steps 9 through 31.

5.

For rear jack repair, with an open-end wrench, remove the female half of the quick disconnect from the male half that is attached to port PR of the counterbalance valve. Leave the 1/4" hose attached to the female half of the quick disconnect.

6.

When step 5 has been completed, disconnect the 1/4" hose at the electric junction box.

CAUTION:

Always maintain a firm grip on the hose while the oil is flowing from it.

DO NOT ALLOW THE STREAM OF OIL TO CONTACT YOUR SKIN AS INJURY CAN OCCUR.

7.

Point the open end of the 1/4" hose into an empty 5 gallon pail and reattach the female half of the quick-disconnect to the male half that is still attached to port PR. When the quick disconnect opens, a stream of oil from the rod side of the cylinder will exhaust from the 1/4" hose into the pail. This will allow the jack pad to lower by gravity to the ground at which time the oil will stop flowing.

8.

Again remove the female quick disconnect half with 1/4" hose as in step 5 and reconnect the 1/4" hose onto port of electric junction box.

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9.

For front jack repair, uncouple the quick disconnect at both front jacks, using a 1 1/ 4" openend wrench. The male half of the quick-disconnect will remain attached to the valve.

10.

At one front jack only, remove the other end of the quick-disconnect hose from the electrical junction box on the jack.

11.

Place the hose end, removed from the electrical junction box, into a clean five gallon container.

(Two additional 5 gallons will be required to handle the oil from both front jacks.)

CAUTION:

Always maintain a firm grip on the hose while the oil is flowing from it.

DO NOT ALLOW THE STREAM OF OIL TO CONTACT YOUR SKIN AS INJURY CAN OCCUR.

12.

Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose-end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

13.

To remove the oil from the other front jack, a helper will be required. Have the helper continue to hold the disconnected hose into a empty 5-gallon container while you re-couple the quickdisconnect on the other front jack. The oil from this jack will now flow from the hose being held by the helper.

14.

When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be re-connected to the electrical junction box.

15.

Remove male half of quick-disconnect from port PR and thread it loosely into female half.

Cover open end with protection cap.

16.

Remove 3/8" hose at counterbalance valve and plug open end of hose.

17.

Insert SAE-6 steel o-ring boss plug into ports PR and PH.

18.

Remove the casing cover bolts.

NOTE: If one of the front jacks is to be repaired, the mast brace support must be removed and an eyebolt installed in the cover for removal purposes.

19.

Remove the bolt securing the shoe retainer to the spud. Separate the shoe from the spud and remove the retainer and split retainer from the shoe.

20.

Attach a suitable lifting device to the lifting lug or eyebolt on the casing cover and carefully lift the spud and cylinder from the casing.

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21.

To remove the cylinder from the spud, remove the pipe plugs securing the spud foot pin and remove the pin.

22.

Slide the cylinder from the spud. Remove the casing cover from the cylinder.

23.

Repair or replace components as necessary.

24.

Install the casing cover on the cylinder.

NOTE: The cylinder rod should be retracted fully into the cylinder body. If not, using hydraulic pressure, retract the hydraulic cylinder to the fully retracted position. Note that hydraulic pressure must be used and pressure be exerted at port VR before the counterbalance valves will allow the cylinder to move. Use oil similar to what is used in the hydraulic system.

25.

Using a suitable lifting device, slide the cylinder, cylinder body end first, into the spud.

26.

Align the foot pin holes and insert the foot pin. Secure with the square head pipe plugs.

27.

Using a suitable lifting device, lower the spud and cylinder assembly into the jack casing.

28.

Attach the casing cover to the casing. Note that the rear jack casing cover bolts must be torqued to 480 Ft-Lbs. There should be no plating or lubrication on the bolts.

29.

Install the fittings into the hydraulic cylinder and attach the hydraulic hoses.

30.

Position the pad under the jack and slowly lower the spud end into the pad. Attach the jack pad to the spud using the split retainer and solid retainer. Torque the retainer bolts to 280 FtLbs. (dry threads).

31.

Cycle the jack 2-3 times to check the operation of the unit and to remove any air pockets created during the repair procedures. The jack should be extended and retracted to the maximum without lifting the machine.

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MACHINERY HOUSE Frequently inspect all house panels and structural members for cracking. Include a close examination of all roof structures and bracing. Always restore defective structural members to their original state by repair welding. Periodically inspect the hinges and latches on all doors and windows to insure they will remain closed during machine operation. Verify the sealing of all doors and windows to prevent the entrance of dust. Search thoroughly for all loose or missing bolts. The absence of these fasteners can result in excessive vibration and wear of house components. Inspect the condition of the paint on both the interior and exterior surfaces of the house. Prepare any paint any areas where the paint has been damaged or any areas where repairs have been made.

Repair of the machinery house is usually limited to repair of individual structures within the house.

Any repair procedure should be undertaken with the object being to prevent the entrance of dust, dirt, or moisture into the house. All joints in the house structure should be adequately sealed and openings in the machinery house should be kept to a minimum.

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Compressor Radiator Compartment

The machinery house roof is removable, as well as the cross members over the main air compressor.

Verify that the cross members are securely fastened. Verify that the roof is sealed properly and that the clamps are secured.

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HOUSE VENTILATION FAN AND FILTER The machinery house is equipped with a ventilation fan and inertial filter which provides clean ventilation air to the main air compressor and machinery house. The machinery house is pressurized slightly above the atmospheric pressure by the fan. This serves to keep dust and moisture from entering the machinery house. The ventilation fan should be operating any time the machine is being operated. Keep all machinery house doors closed at all times to prevent the entrance of dust.

Inspection of the ventilation fan itself is not required except as necessary to repair some malfunction. The inertial filter cleans the air entering the machinery house. This filter is selfcleaning and does not require routing service typical of other filters. Proper operation of the filter, however, is dependent upon proper air flow.

Restriction of the intake by leaves, rags and paper will lessen the effectiveness of the filter and ventilation fan. A light coating of dust on the blades of the filter is normal and will not impair the efficiency of the filter. To remove material which has accumulated on the blade surfaces, it is necessary to remove the filter cell and steam clean the blades.

WALKWAYS AND LADDERS Inspect all handrails, walkways, platforms, stairs and ladders on the machine daily. Verify that all structural members are in good repair and that all fasteners and welds are intact.

Repair or replace components immediately to insure the integrity of the structures and ensure compliance with safety regulations. Keep all walkways, stairways and ladders clear of materials which could present slipping or tripping hazards. Keep walkways clear of tools, supplies or other obstructions. Clean up all grease or oil spills immediately.

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OPERATOR’S CAB

Inspect the operator’s cab daily for cracks or structural damage to all side, roof and floor panels. Check the doors and windows for proper operation and correct sealing. Keep the cab clear of all oil, grease or water spills to help prevent slipping.

OPERATOR’S SEAT The individual operator may adjust the operator’s seat as desired with respect to height, tilt and travel. Periodically lubricate all bearings and pivot points to maintain smooth movement.

OPERATORS CONTROLS Inspect all of the operator’s controls daily for wear or damage. Verify the correct operation of all controls daily.

Repair or replace malfunctioning controls immediately. Clean all nameplates and markers and maintain all markers and signs in a legible condition including warning signs.

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VENTILATION UNIT

Inspect the ventilation unit on the operator’s cab roof for proper operation, structural integrity and sealing. All permanent side panels should be in place and adequately sealed and secured.

Monitor the filter clogged indicator and replace the filter cartridge when the indicator comes on.

HYDRAULIC PUMP DRIVE The hydraulic system pumps are driven by the main air compressor motor through a gearbox. The gearbox is mounted to the compressor base. The oil level in the gearbox should be checked weekly and oil added if required. Daily check the gearbox for oil leaks and repair as required. To remove and disassemble the gearbox, proceed as follows:

Hydraulic Pump Drive Assembly

1.

Place the machine in a secure area to perform the repair. Shut off and tag the controls.

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2.

Drain the oil from the gearbox. There is approximately 7.75 quarts of oil in the gearbox.

3.

Remove the pump mounting bolts and remove the pumps and gaskets.

4.

Separate the gearbox drive coupling. Remove the gearbox mounting bolts. Remove the gearbox from the mounting pads. Note the thickness of shims.

Pump Drive Gearbox - Exploded

5.

On a clean surface, position the gearbox so that the hydraulic pump adapter plates are facing up. Remove the plate mounting bolts and lift the adapter plates from the gearbox.

6.

Lift the driven gears and their bearings from the gearbox. This can be done by hand since the bearings are slip fit to the gearbox and adapter pad bores. The bearings are press fit to the gear hubs. It may be necessary to tip the gear slightly to clear the drive gear bearing pocket.

7.

After the driven gears have been removed, turn the gearbox over so that the drive shaft and gear can be removed.

8.

Remove the shaft adapter mounting bolts and remove the adapter assembly and gasket from the gearbox.

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9.

10.

Separate the drive shaft adapter assembly as follows: a.

Remove the large snap ring from the bore of the adapter.

b.

Remove the small snap ring from the drive shaft and pull the shaft from the adapter.

Take care not to damage the oil seal.

c.

Remove the bearing from the adapter. Remove the oil seal from the adapter.

Clean and inspect all parts. Repair or replace all damaged or worn parts and reassemble in reverse of disassembly, noting the following: a.

When reassembling the gearbox, use new seals, gaskets and bolts.

b.

Use Loctite on all bolts and torque all bolts to 200 Ft-Lbs.

When installing gearbox coupling, proceed as follows: 1.

Verify that the motor shaft is centered.

2.

Mount the coupling hubs on the motor and gearbox.

3.

Mount the gearbox so that a 0.51" gap exists between the ends of the shafts.

4.

Check the coupling for angular and offset misalignment. Maximum misalignment should not exceed 0.010". Use shims under the gearbox feet to correct misalignment.

5.

Tighten the coupling bolts (dry threads) to 30 Ft-Lbs.

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CABLE REEL CAUTION:

The cable reel handles the trail cable during propelling. THE TRAIL CABLE CARRIES A HIGH VOLTAGE WHICH CAN CAUSE SERIOUS OR FATAL INJURY. WHENEVER WORK IS TO BE DONE ON THE CABLE REEL THE TRAIL CABLE MUST BE DISCONNECTED FROM ITS POWER SOURCE.

NOTE: The cable reel described in the following paragraphs is an INDUSTRIAL WELDER & MACHINISTS, EVC. cable reel. If your cable reel is of a different manufacturer, do not use the following information but refer to the manuals of that manufacturer.

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The cable reel should be checked daily to assure that it is working properly and that the trail cable is being spooled on and off the reel correctly. Check that the level wind mechanism works freely.

Check that all drive chains are properly tensioned and well lubricated. Check the hydraulic tank for the proper level. Add fluid if required. Check the hydraulic lines for leaking. Check all structural components for cracking.

LEVEL WIND DRIVE ADJUSTMENT

The level wind drive is chain-driven from the reel drum. Trolley travel is adjusted by changing sprockets on the output shaft of the rightangle reducer. Before winding trail cable on the reel, remove the chain between the reducer and level wind drive shaft and install the correct sprocket on the reducer. Refer to the LEVEL WIND SPROCKET TABLE for the correct sprocket.

When determining the correct sprocket, allow approximately 1/8" clearance between wraps for cable variables. Start winding trail cable on reel drum opposite the collector ring end of the reel.

After several wraps have been installed, position the trolley on the centerline of the cable and install the chain on the right-angle reducer. Continue winding cable on reel slowly while checking trolley travel. If not correct, adjust the trolley position and/or sprocket ratio.

HYDRAULIC ADJUSTMENTS When properly adjusted, the cable reel will pick up cable when the drill moves toward its power source. The reel will stall when the drill is stationary and the reel drive will be overpowered when the drill moves away from the power source, allowing the cable to be unwound from the reel.

WARNING:

The cable reel should not be used to pull the trail cable onto the reel. Wind the cable onto the reel only as the drill moves toward the cable. ATTEMPTING TO PULL 50 FEET OR MORE CABLE, LAID IN A STRAIGHT LINE ONTO THE REEL WITHOUT MOVING THE MACHINE TOWARD THE CABLE, WILL DAMAGE OR POSSIBLY BREAK THE CABLE.

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

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

Adjust the line pull and line speed as follows: 1.

Verify that the hydraulic tank is full with the correct hydraulic fluid.

2.

Place the control valve in the neutral (center) position.

Cable Reel Hydraulic Equipment

3.

Open the flow valve fully.

NOTE: This valve is used for setting operating pressure and system diagnostics only. All system flow adjustments are made on the hydraulic pump.

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4.

Adjust the pump for maximum flow. The hydraulic pump is normally run at maximum flow.

5.

Jog the electric motor and check pump rotation. If pump rotation does not correspond with arrow on the pump, change motor wiring.

6.

Start hydraulic system and let oil circulate for 5 minutes.

7.

Check all hydraulic connections for leaks.

8.

Close valve slowly while watching hydraulic pressure. If pressure exceeds 750 PSI, adjust pump, to lower pressure.

9.

Close flow valve completely. Adjust pump pressure to 950 PSI.

10.

Loosen lock nut on relief valve adjusting screw. Set relief valve to 900 PSI. Lock adjusting screw.

11.

Adjust pump pressure to 800 PSI. The hydraulic pump is normally set at 100 PSI below relief pressure setting.

12.

Open flow valve fully. This valve is normally left in the full open position.

13.

Place control valve in the wind position and check operation of cable reel.

14.

If cable tension is too great or not enough, repeat steps 9 through 13 increasing or decreasing pump pressure and relief valve settings in 100 PSI increments until cable tension is satisfactory.

If line speed is too fast, adjust pump flow to a lower setting.

LUBRICATION Lubricate the cable reel bearings, trolley wheels and guide rollers monthly using MPG lubricant.

The chains should be lubricated every two months using a good chain lube. Diamond Chain Company’s CHAIN LUBE, which is a foam type aerosol lube, is recommended. The level wind reducer uses 1-1/2 pints of gear oil.

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HYDRAULIC MAINTENANCE After the first 48 hours of operation, change the return line filter and hydraulic fluid. From this time on change hydraulic fluid and line filter every 2000 hours. Clean the tank sump filter yearly. Repairs of cable reel will consist mainly of replacing worn or damaged parts. Refer to the following figures.

Cable Reel - Level Wind

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Cable Reel Collector Rings

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Cable Reel Electrical Schematic

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MAST STRUCTURE The 59HR drill mast is a fabricated structure made of steel tubes and formed plates. The structure is formed by four vertical tubes tied together on three sides with tubular lacing. The fourth side is open to allow the rotary drive unit to be raised and lowered the length of the mast.

Inspect the structure daily for wear or damage.

Inspect all mast ladders and platforms for loose hardware and structural integrity. Inspect the racking on the outside of the rear mast tubes for proper lubrication and any wear or damage. Inspect the mast hinge pins and the structure surrounding the pins for wear or damage. Verify that the hinge pin keepers are in place and tight. Inspect the mast hoist cylinder attachments for wear or damage.

Lubricate the pins weekly with the appropriate lubricant. Inspect the mast lock pins for wear and damage. Verify that the lock pin hydraulic cylinders and hydraulic line are not leaking.

Every 80 operating shifts lower the mast and inspect all welds thoroughly for cracks or damage. Clean the racking on the outside of the two rear mast tubes and check the welds securing the racking to the tubes.

Repair of the mast structure is limited to repair welding of cracked or broken welds or components or replacement of severely damaged structures. Contact Bucyrus International for specific procedures involved in repair welding of the mast. When repairing mast structures by welding it is important to keep in mind that the repair should return the structure to its original condition. All welds should be smooth and any notches or undercuts should be welded and ground. Do not add reinforcing material or change the geometry of the structure. Replace any damaged components with material of the same strength and cross section.

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MAST SAFETY SLING

The mast safety sling is used to help prevent drill pipe coming loose from the rotary unit and falling off the machine or onto the operator’s cab. The sling should be checked weekly to verify that all braces are properly adjusted and all yoke pins are secured in place. Repair of the safety sling consists mainly of replacing worn or damaged components. Repair welding may be used to repair cracks.

ROTARY GEARCASE

Inspect the rotary gearcase every shift for loose or missing hardware. Check the gearcase for lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper lubricant to the required level. If water has accumulated in the gearcase remove the drain plug and completely drain the case. Refill the gearcase to the required level with an approved lubricant. Check the air swivel for leaks and repair as necessary.

Every 80 operating shifts partially drain the gearcase and remove the inspection cover.

Inspect the gear teeth for wear or damage. Check the rotary drive shaft bearing pre-load. If any clearance exists in the drive shaft bearings it will be necessary to adjust the pre-load by removing shims from the lower retainer.

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DRIVE SHAFT ADJUSTMENT The drive shaft must be adjusted to give 0.001"- 0.003" pre-load on the bearings. To adjust the bearing pre-load proceed as follows:

1.

Remove the bolts which secure the lower bearing retainer to the gearcase. Remove the retainer shims.

NOTE: Cut shims in half for ease of removal and installation.

2.

With the shims removed, reinstall the bolts and torque to 40 Ft-Lbs. to ensure proper bearing seating.

3.

Remove every other bolt leaving 8 equally spaced bolts. Re-torque the remaining eight bolts

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to 40 Ft-Lbs., in 10 Ft-Lbs. increments so that the retainer remains square to the case. Turn the shaft and recheck the bolt torque. Allow torque to stabilize.

4.

Measure the gap between the retainer and gearcase at all eight bolts. Obtain the average gap by dividing the sum of the measurements by 8.

5.

The average gap plus 0.003" to 0.005" is the total shim pack thickness required to provide 0.001"- 0.003" pre-load on the bearings.

6.

Remove the eight remaining bolts and install the required shim pack and all the bolts. Torque the bolts to 200 Ft-Lbs.

There are three areas on the rotary gearcase where repair is possible. This topic deals only with the repair of the internal components of the unit. Repairs of the rotary motor and the rotary coupling are covered under separate topics. Repair of the rotary gearcase is limited to replacement of worn or damaged components. The unit may be repaired in place on the machine or may be removed from the machine and repaired elsewhere. Refer to the ROTARY/PULLDOWN GUIDE FRAME topic for the procedure necessary to remove the assembly from the machine. To repair the gearcase either on or off of the machine use the following procedure: 1.

Securely block the gearcase in the upright position. Remove the rotary motor from the gearcase. Refer to the topic ROTARY MOTOR. Drain the oil from the gearcase. Remove the motor seal ring. Remove the motor o-ring from the gearcase.

NOTE: If the drive unit is left in the machine, lower it to the bottom of the mast and rest it on the lower stops. Shut off and tag the controls.

2.

Remove the air pipe and gasket from the swivel housing.

3.

Remove the gearcase front cover and gasket.

4.

Remove the intermediate shaft upper bearing cover and cover o-ring. Remove the upper bearing retainer.

5.

Screw an eyebolt into one of the tapped holes in the top of the intermediate shaft. Support the shaft with rigging and a crane.

6.

Support the intermediate gear with blocking so that when the shaft is removed the gear will not fall.

7.

Remove the bolts securing the lower bearing retainer to the gearcase. Remove the bearing retainer. Remove the o-ring from the retainer.

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8.

Slowly lower the intermediate shaft out of the gearcase. Remove the lower bearing, retainer, and spacer from the shaft. The lower bearing has an interference fit of 0.0005" - 0.0025" to the shaft.

NOTE: The inner race of the upper bearing has an interference fit of 0.0004" 0.0018" to’ the shaft and may require a slight force to separate it from the shaft.

9.

Position the intermediate gear to be removed through the front opening of the gearcase. Remove the gear and upper bearing inner race and seal sleeve.

10.

Remove the upper bearing cage and oil seal from the upper bore in the gearcase.

11.

Support the drive shaft with blocking under the rotary coupling.

12.

Remove the lockwire and bolts securing the swivel housing to the gearcase.

Remove the housing.

13.

Remove the seals, spacers and wave spring from the housing.

14.

Remove the locknut, lockwasher and spacer at the top of the drive shaft.

NOTE: The locknut has left hand threads.

15.

Remove the bolts attaching the lower bearing retainer to the gearcase.

16.

Slowly lift the gearcase until the vertical shaft gear is resting on the bottom of the gearcase. If the weight of the vertical shaft will not free itself from the upper bearing inner race, additional force will have to be placed on the top of the shaft to force the race off the shaft as the gearcase is raised. The race has an interference fit of 0.0006”- 0.0026" to the shaft.

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Rotary Machinery Drive Shaft Assembly

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17.

When the upper race is removed from the shaft, continue raising the gearcase until it clears the shaft. Remove the shaft and lower the gearcase back onto its blocking.

18.

Remove the upper bearing inner race, seal sleeve, gear spacer and gear from the gearcase through the front opening.

19.

Remove the upper bearing cage and oil seal from the gearcase.

20.

Unbolt and remove the drive shaft clamp collars.

21.

Unbolt and remove the rotary coupling or shock sub from the shaft lower section.

CAUTION:

In the following step a torch is used to heat the lower shaft section hub. When using the torch be sure to take all safety precautions. Also use suitable protective equipment when handling the heated item.

22.

Use a torch to heat the hub of the lower section and separate the two sections of the drive shaft. Remove the o-ring from the shaft upper section.

23.

Slide the lower bearing retainer assembly from the shaft upper section and disassemble as follows:

24.

a.

Remove the o-ring and shims.

b.

Remove the seal retainer bolts and retainer.

c.

Remove the seals and spacer.

d.

Remove the lower bearing cup from the retainer. The cup has an interference fit of 0.0010" - 0.0050" to the retainer.

With a bearing puller, remove the lower bearing cage and the thrust bearing from the shaft.

NOTE: The lower bearing cage has an interference fit of 0.0050" - 0.0070" to the shaft. The thrust lower bearing has an interference fit of 0.0030" - 0.0050" to the shaft.

25.

Inspect all components. Repair of replace all components as necessary.

CAUTION:

26.

There are a number of steps in the following procedure which require heating of certain items prior to assembly. Use suitable protective equipment when handling the heated items.

To reassemble the gearcase first clean all components thoroughly. Inspect all bores and shaft surfaces, and remove any nicks or burrs. Lightly oil all parts. Apply Loctite #271 to all clean threads at assembly. Be sure to follow manufacturer’s instructions when using Loctite.

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27.

Install the thrust bearing and lower bearing cage on the drive shaft upper section. The cage and thrust bearing are interference fit and will require heating in an oil bath to 250oF prior to assembly. Be sure the cage and bearing are tight against the shoulders of the shaft. Install the gear spacer on the shaft.

28.

Assemble the lower bearing retainer assembly as follows: a.

Install the lower bearing cup in the retainer. This cup is interference fit and will have to be pressed in. Be sure the cup is tight against the shoulder of the retainer.

b.

Install the oil seals and spacer in the retainer. Be sure the lips of the seals face toward the bearing cup.

c.

Install the seal retainer and bolts. Tighten and lockwire the bolts.

d.

Install the o-ring on the retainer.

29.

Install the retainer assembly on the drive shaft upper section. Do not install the shims on the retainer.

30.

Install the o-ring in the bottom of the shaft upper section.

31.

Heat drive shaft lower section in an oven or oil bath to 250o - 300oF maximum. Install the rotary drive collar on the shaft lower section. Insert lower section on upper section and install clamp collars and bolts. Allow shaft to cool to ambient temperature.

32.

Remove the clamp collars and install the rotary coupling upper cushion seal strip. Reinstall the shaft clamp collars, tighten bolts and lockwire. The splits in the collars should be offset 90o from each other.

33.

Re-install remaining parts of rotary coupling per topic, ROTARY COUPLING.

34.

Install the drive gear in the gearcase. Make sure the gear is aligned to the shaft bore. Slowly raise the gearcase so that the shaft can be positioned for installation.

35.

Securely block the drive shaft in an upright position. Slowly lower the gearcase down onto the shaft being careful not to damage the shaft threads. It may be necessary to rotate the gear slightly to align the splines of the gear and shaft.

36.

Insert and snug up the lower bearing retainer bolts.

37.

Install the seal sleeve with larger bore end toward gear. Install upper bearing oil seal. Be sure the lip of the seal faces upward. Heat the upper bearing inner race in an oil bath to 250oF maximum and install on the shaft tight against the sleeve. Install the bearing spacer, lockwasher and locknut. The locknut has left hand threads. Tighten the locknut firmly. Allow the race to cool to ambient temperature.

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38.

When the race has cooled remove the locknut and lockwasher, and install the upper bearing cage. Re-install and tighten the lockwasher and locknut.

39.

Pre-load the lower bearings as follows: a.

Torque the lower bearing retainer bolts to 40 Ft-Lbs. to insure proper bearing seating.

b.

Remove every other bolt, leaving eight equally spaced bolts. Re-torque the remaining eight bolts to 40 Ft-Lbs., in 10 Ft-Lbs. increments, so that the retainer remains square to the gearcase. Turn the shaft and re-check the bolt torque. Allow torque to stabilize.

c.

Measure the gap between the retainer and gearcase at all eight bolts. Obtain the average gap by dividing the sum of the measurements by 8.

d.

The average gap plus 0.003" to 0.005" is the total shim pack thickness required to provide 0.001" to 0.003" pre-load on the lower bearings

e.

Remove the eight remaining bolts and install the required shim pack and all the bolts.

Torque the bolts to 200 Ft-Lbs. and lockwire.

NOTE: If the shims are complete circles, cut in half for ease of installation.

40.

Install the seals and spacers in the swivel housing as shown. Be sure the seal lips are facing upward. Install the o-ring in the gearcase.

41.

Install the swivel housing and secure with the bolts. Tighten and lockwire the bolts.

42.

Install the intermediate gear and block in place. Set the seal sleeve on top of the gear. Align the bore of the gear with the bore of the shaft.

43.

Heat the lower bearing in an oil bath to 250oF maximum and install the bearing on the shaft.

Secure the bearing with the retainer and lockwire the bolts.

44.

Install the o-ring in the lower cover. Insert the shaft assembly into the gearcase. Install the lower cover and secure it with the cover bolts. Tighten and lockwire the bolts.

45.

Install the upper oil seal. Heat the inner race of the upper bearing in an oil bath to 250oF maximum and install on the shaft. Be sure the race is tight against the spacer, then secure the race with the bearing retainer. Tighten and lockwire the retainer bolts. Allow the race to cool to ambient temperature.

46.

Install the upper bearing cage in the gearcase. Install the o-ring on the upper cover and install the cover on the gearcase. Tighten and lockwire the cover bolts.

47.

Install the motor per topic, ROTARY MOTOR and fill the gearcase with an approved lubricant.

48.

Lubricate all lube points with an approved lubricant.

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ROTARY MOTOR Inspection, lubrication and maintenance instructions for the rotary motor are described in the manufacturer’s Motor Manual. To remove the rotary motor proceed as follows: 1.

Lower the rotary drive unit to the bottom of the mast and rest it on the lower stops.

DANGER: HIGH VOLTAGE. OPEN AND TAG THE AUXILIARY POWER AND CONTROL BREAKERS IN THE MACHINERY HOUSE BEFORE ATTEMPTING TO DISCONNECT THE MOTOR LEADS. Failure to comply may result in serious injury or death.

2.

Have an electrician identify and disconnect the electrical leads to the rotary motor.

Remove the cable from the junction box on the motor.

3.

Remove the motor attachment stud nuts and washers.

4.

Using a suitable crane and rigging, lift the motor from the rotary gearcase.

5.

Repair or replace the motor as necessary.

6.

The motor pinion is press fit to the motor shaft. Refer to the topic MOTOR COUPLINGS for instructions regarding replacement or installation of the motor pinon.

7.

Prior to installation of the motor clean the mounting surfaces on both the gearcase and the motor

8.

Install the rotary motor in reverse order of removal. Torque the attachment stud nuts using turn-of-the-nut method. Tighten nuts snug, and then an additional 1/3 turn.

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ROTARY COUPLING The rotary coupling connects the rotary drive shaft to the tool string. The coupling incorporates rubber cushions to reduce shock loading and an o-ring to seal the main air passage. Inspect the rotary coupling every shift for loose or missing bolts or other wear or damage. Check the coupling frequently for air leaks and worn cushions. Check the coupling teeth for wear and damage.

Repair of the rotary coupling is limited to replacement of the lower coupling half, rubber cushions, and o-ring. Replacement of the upper coupling clamp collar or drive shaft is detailed in the ROTARY GEARCASE - REPAIR topic.

To replace the cushions, lower coupling half or oring in the rotary coupling, proceed as follows: 1.

Lower the rotary drive unit until it is approximately 6 inches from the stops.

2.

Securely block under the lower half of the rotary coupling. Lower the rotary drive unit so as to rest the coupling on the blocking.

Set the hoist brake and tag all controls to prevent unauthorized operation.

3.

Remove the coupling bolts from the assembly.

4.

Raise the rotary drive unit to allow access to the lower coupling half. Set the hoist brake and tag all controls.

5.

Remove the lower cushion, seal strip, and o-ring from the coupling half.

6.

Lift the upper coupling clamp collar to allow access to the upper cushion and seal strip.

If the cushion is original equipment on the drill, it will be necessary to cut the cushion to allow removal.

7.

Replace the upper cushion with a “split” type cushion and a new seal strip.

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8.

Lightly lubricate the o-ring and groove. Install the o-ring on the lower coupling half.

9.

Install the lower cushion and a new seal strip on the lower coupling half.

10.

Slowly lower the rotary drive unit to bring the coupling halves together. Be careful to align the two halves before lowering the drive unit completely.

11.

Install the coupling bolts. Install lockwire as required.

NOTE:

When installing coupling bolts use a dial indicator to check levelne

ss of lower half of coupling. An out-of-level condition indicates bolts are not tightened equally.

12.

Remove all blocking and test the coupling for proper operation.

ROTARY SHOCK SUB The rotary shock sub is an optional assembly that replaces the standard lower rotary coupling half.

The shock sub is used to reduce the shock loading transmitted to the rotary drive unit.

NOTE: The procedures detailed in this topic are for a Bucyrus International shock sub. Since shock subs manufactured by companies other than Bucyrus may be furnished with the machine, be sure to verify that the shock sub being repaired is one manufactured by Bucyrus International before using the procedure listed below.

Inspect the shock sub daily for loose or missing lock nuts or other wear or damage. Inspect the coupling frequently for air leaks. When the cushions have worn to a point that the main bailing air stream begins to leak between the cushions, or the cushioning effect of the assembly is reduced, the cushions must be replaced. Repair of the shock sub is limited to replacement of worn or damaged components. Replacement of any of the components will require disassembly of the unit.

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To disassemble the shock sub proceed as follows: 1.

Place secure blocking under the shock sub and lower the shock sub onto the blocking. Shut off and tag the controls.

2.

Remove the cotter pins and slotted nuts from the shock sub bolts. Remove the bolts.

3.

Be sure the shock sub is securely blocked then slowly raise the rotary machinery until the drive shaft lower section clears the shock sub. Shut off and tag the controls.

4.

Separate the upper cushion, lower cushion, cushion retainer, and o-ring from the coupling section of the shock sub.

5.

If the drive shaft lower section is to be removed, use the procedure as outlined in steps 20 and 22 of the topic ROTARY GEAR CASE - REPAIR.

6.

Clean and inspect all components of the assembly. Replace worn or damaged components as necessary.

7.

If removed, reinstall the drive shaft lower section per steps 30 and 31 under the topic ROTARY GEARCASE - REPAIR.

8.

Assemble the upper cushion, lower cushion, cushion retainer and o-rings to the coupling section.

9.

Securely block the assembly in line with the drive shaft lower section. Lower the rotary unit slowly until the shaft is seated in the coupling. Do not compress the cushions.

Rotary Shock Hub

10.

Install the shock sub bolts and hand tighten the slotted nuts to establish a free height of 13.75 inches nominal.

11.

Progressively tighten the locknuts no more than 1/2 turn at a time until the free height is reduced by 0.375 inches then install cotter pins.

12.

Lubricate the o-rings through the lubrication fitting in the side of the shock sub. Remove the blocking.

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ROTARY/PULLDOWN GUIDE FRAME The rotary guide frame consists of the two frames that support the rotary machinery and the pulldown machinery. The guide frames also include the guide rollers which are used to align and secure the unit to the mast.

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Inspect the entire guide frame daily for loose or missing hardware. Inspect the bumper blocks for wear or damage and replace if necessary. Inspect the rack pinions for wear or damage. Check the adjustment of the guide rollers and adjust if necessary. Inspect the alignment of the guide frame in the mast. Check the main air pipe connections for leaks. Verify that the chock bars securing the rotary gearcase are in place and that the welds on the chocks are intact. Check the lubrication of the rack pinion.

Rack Pinion and Upper Guide Roller

GUIDE ROLLER ADJUSTMENT The guide rollers on the rotary/pulldown guide frame keep the assembly aligned to the mast and the rack pinions in contact with the mast rack. As the guide rollers wear, it is necessary to periodically adjust the clearance between the rollers and the mast rack mounting tee. When the thickness of the roller tread has decreased to 1/4", the roller should be replaced. To adjust the guide rollers proceed as follows: 1.

Position the rotary/pulldown unit so that the upper guide rollers and rack pinions are accessible.

Shutdown and tag the controls.

2.

Using a suitable jack or pulling device, pull or push the rack pinion keeper plate snug against the mast column plate on both sides of the mast. This assures that the backlash of the pinions is correct.

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3.

Measure the distance from the face of the mast column plate to the center of the bearing housing mounting bolts. Compare this distance to the theoretical distance of 19.050". Note the difference between the two measurements, as the difference will be used in adjusting the lower rollers.

Lower Guide Rollers

4.

Remove the bolt, nut and washer from the lower rear guide roller eccentric pin handle. Move the handle until the distance from the face of the mast column plate to the center of the rotary gearcase mounting bolt is equal to the theoretical distance of 17.737,” plus the difference noted in step 3. Secure the handle with the bolt, washer and nut.

CAUTION:

In the following steps when using a torch to break a welded wedge or when re-welding the wedge, be sure to follow all safety precautions. Also, use suitable protection equipment when handling the heated items.

5.

Break the weld on the chord wedges on the upper and lower front guide roller frames. Loosen the frame bolts and slide the frames toward the mast until the rollers contact the face of the mast column. DO NOT pre-load the rollers against the column. Re-tighten the bolts and reweld the wedges.

6.

Center the head assembly in the mast and parallel to the inside face of the mast racks.

Remove the side guide roller bolts and remove enough shims so that the roller contacts the inside of the mast column. The rollers should NOT be pre-loaded against the column. Reinstall and tighten the roller mounting bolts.

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Repair of the rotary/pulldown guide frame is limited to replacement of worn or damaged components.

Repair welding of any of the components is not recommended. Since only limited repairs to the guide frame are possible with the unit installed on the machine, it is assumed for the purposes of this manual that the entire rotary/ pulldown unit will be removed from the machine prior to repairs.

Replacement of the rack pinions and guide rollers is possible without removal of the entire guide frame from the machine. The repair procedures for these components are included in the following procedures. To remove the guide frame assembly complete with the rotary gearcase and pulldown machinery form the machine, proceed as follows: 1.

Lower the rotary drive unit to its lowest position and rest it on the lower mast stops. Open the auxiliary power and control breakers and tag all controls to prevent unauthorized operation.

2.

Remove the upper air pipe from the swivel housing and from the guide angle. Discard the gasket. Use new gaskets at re-assembly.

3.

Have an electrician disconnect the electrical leads to the rotary motor and remove the cable from the drive unit.

4.

Disconnect and remove the lubrication hoses leading to rotary drive unit, if so equipped.

5.

Using a suitable crane and rigging, support the entire rotary/pulldown unit.

6.

Remove the upper and lower front guide roller chocks, wedges and anchor bolts. Remove the guide rollers. If necessary, remove the upper and lower side guide rollers.

7.

With the crane and rigging installed in Step 5, lift the rotary/pulldown unit from the mast and place it on secure blocking.

8.

If required, completely disassemble the front upper, lower and side guide rollers removed in Step 6.

9.

Remove the shipper shaft pinion retainers and remove the pinions.

10.

Remove the rear lower guide roller retainer bolts and remove the retainers, shims, rollers spacers from the pin. Remove the bearings from the rollers. The bearings have an interference fit of 0.0010” - 0.0030” to the roller and will require a puller for removal.

11.

Using the eccentric pin handles, pull the rear lower guide roller eccentric pins from the frame.

Separate the handle from the eccentric pins.

12.

Separate the pulldown motor coupling. Remove the motor hold-down bolts, chocks and shims.

With a crane and suitable rigging remove the motor.

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13.

Remove the two spreaders at the top of the guide frame. Remove the pulldown unit guard.

14.

Remove the bolts that secure the shipper shaft end bearing housings to the guide frames.

Slide the housing toward the pulldown gearcase.

NOTE: The shipper shaft end bearing outer labyrinth seal is press fit to the bearing housing and will require a certain amount of force to separate it from the bearing housing.

Remove the outer labyrinth seals.

15.

Remove the pulldown gearcase hold-down bolts, chocks and shims. With a crane and suitable rigging maneuver the gearcase out of the guide frame and place it on secure blocking.

16.

Unbolt and remove the pulldown unit base.

17.

Verify that the rotary gearcase is securely blocked and supported.

18.

Using a suitable crane and rigging, support one side of the guide frame.

19.

Remove the bolts securing the guide frame to the rotary gearcase and remove the guide frame form the shipper shaft.

NOTE: It may be necessary to remove the upper chock bar from the guide frame in order to remove the guide frame from the rotary gearcase.

20.

Repeat Steps 14 and 15 for the opposite guide frame.

21.

Clean and inspect all components and replace as necessary.

22.

Reassemble the guide frames and install on the machine in reverse order of disassembly noting the following. a.

Locate and assemble the shipper shaft bearing housings to the guide frames. Bolt and chock complete.

b.

Assemble the rear lower guide rollers and handles to the guide frames.

c.

Install the R.H. and L.H. guide frames loosely to the rotary gearcase so that the guide frames tip outward to allow the pulldown base to be installed.

d.

Install the pulldown base with dowels and clearance bolts. Install dowels and clearance bolts in rotary gearcase and tighten all bolts.

NOTE: All dowels are to be removed after chock bars are in place and replaced with bolts.

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e.

Install pulldown gearcase and align to center of shipper shaft bearing housings. Shim case as required to center shaft to housings. Insure that inboard retainers are loose on shipper shaft when installing case.

f.

Install bearings to shipper shaft bearing housings and install all retainers and rack pinions. Chock gearcase in place.

g.

Install pulldown motor. Align motor and coupling as follows: 1.

Verify that the motor armature is centered and then position the motor so that there is a gap of 0.19" between shafts (approx. 1.56" between coupling hub faces).

2.

The coupling should be aligned within the following maximum limits as measured on the coupling hub O.D. MAXIMUM OFFSET ...................... 0.002" MAXIMUM ANGULAR OFFSET .... 0.002"

3.

CAUTION:

25.

Use shims under motor mounting feet to achieve proper alignment.

In the following steps when welding chocks, be sure to follow all safety precautions. Also use suitable protection equipment when handling heated items.

4.

When properly aligned tighten motor hold-down bolts and weld chocks to motor base.

5.

Pack coupling with lubricant.

h.

Lay rotary/pulldown unit down and install all lower chocks.

i.

Install rotary/pulldown unit in mast. Install front upper and lower guide rollers and adjust per topic GUIDE ROLLER ADJUSTMENT.

j.

Install air pipe and lube line; have an electrician reconnect motors.

Lubricate all points and verify correct operation of the rotary/pulldown unit.

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PULLDOWN GEARCASE Inspect the pulldown gearcase every shift for loose or missing hardware.

Check the gearcase for lubricant leaks and repair as necessary. Verify the operation of the automatic lube system or manually lubricate all points as necessary. Check the lubricant level in the gearcase and add the proper lubricant to the required level. If water has accumulated in the gearcase, remove the drain plug and completely drain the case. Refill the gearcase to the required level with an approved lubricant.

Repair of the pulldown gearcase is limited to replacement of worn or damaged components. The unit may be repaired in place on the machine or may be removed from the machine and repaired elsewhere. Refer to the topic ROTARY/PULLDOWN GUIDE FRAME for the procedure necessary to remove the assembly from the machine. To repair the pulldown gearcase proceed as follows: NOTE: For this procedure we will consider the pulldown gearcase has been removed from the machine per Steps 15 and 16 of the topic ROTARY PULLDOWN GUIDE FRAME REPAIR. CAUTION:

Be sure the rotary pulldown guide frame is secured to the mast by cable or other means, since the rack pinions and upper guide rollers have been removed.

1.

Remove the bearing spacer from the ends of the shipper shaft. Use a puller to remove the end bearing from the shaft. The bearings have an interference fit of 0.0018 - 0.0038” to the shaft.

2.

Slide the bearing housing from the shaft and separate the inner labyrinth seal from the housing.

3.

If not previously done, drain the gearcase.

4.

Remove the bearing cover from the gear end of the intermediate shaft. Remove the o-ring from the cover.

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5.

Remove the encoder housing from the opposite end of the intermediate shaft. Remove the housing gasket.

Pulldown Machinery Gearcase and Base

6.

Remove the encoder coupling spring pins, then unbolt and remove the encoder and coupling.

Remove the retainer/encoder support from the gearcase. Remove the o-ring and oil seal from the retainer.

7.

Remove the bearing retainer from each end of the shipper shaft. Separate the o-ring, oil seal and labyrinth seal from the retainer.

8.

Remove the rod bolts, tapered pins and bolts securing the gearcase cover to the gearcase.

With a crane lift the cover from the gearcase.

9.

Lift the shipper shaft from the gearcase. Remove the bearing spacer from the short end of the shipper shaft.

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Pulldown Machinery Shipper Shaft

10.

Remove the bearing retaining nut and lockwasher, along with the bearing and spacers from each end of the shaft,

11.

Slide the shipper shaft gear from the shaft.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Pulldown Machinery Intermediate Shaft

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12.

Lift the intermediate shaft from the gearcase. Remove the gear end bearing retainer and bearing. The bearing has an interference fit of 0.0012 - 0.0032” to the shaft and will require a puller for removal.

13.

Remove the encoder end bearing retainer and bearing. The bearing has an interference of 0.0012 - 0.0032” to the shaft and will require a puller for removal.

14.

Remove the gear spacer. The gear is interference fit to the shaft and will require puller for removal. Remove the gear key.

Pulldown Machinery Input Shaft

15.

Remove the cover from the hoist brake. Remove the bolts securing the brake cage to the gearcase. Slide the brake off the brake hub. Remove the brake hub, hub retainer, retainer bolt and oil slinger.

16.

At the coupling end of the shaft remove the bearing carrier bolts. Slide the shaft assembly from the gearcase. The brake end bearing inner race will be removed with the shaft assembly.

Remove the carrier gasket.

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17.

Remove slinger spacer, bearing retainer, retainer o-ring, oil seals, bearing cage, bearing spacer and oil deflector from the brake side of the gearcase.

18.

Use a puller to remove the half coupling from the end of the shaft. Remove the coupling key.

19.

Remove the seal retainer from the bearing carrier. Remove the o-ring, oil seals and seal spacer from the retainer.

20.

Remove the bearing spacers. The bearing has an interference fit of 0.0005 - 0.0022” to the shaft and will require a slight force for removal. Remove the carrier and bearing as an assembly, then separate them.

21.

If required, with a puller remove the bearing inner race from the brake end of the shaft. The race has an interference fit of 0.0005 to 0.0022”.

22.

Disassemble the brake as covered under the topic, HOIST BRAKE.

23.

Clean and inspect all parts and repair or replace all damaged or worn parts. Reassemble in reverse of disassembly noting the following: CAUTION:

During re-assembly of the pulldown gearcase certain items must be heated or cooled for assembly purpose. When heating or cooling the items take all necessary precautions and use suitable protective equipment when handling the heating or cooled items.

a.

On the input shaft the bearings, bearing spacer and the coupling half are interference fit to the shaft and will require heating to install.

b.

Use thread locking compound on the brake hub retainer bolt and the coupling end bearing oil seal retainer bolts.

c.

Fill the cavity between seals with lubricant at assembly.

d.

On the intermediate shaft, the bearing and gear are interference fit to the shaft and will require heating to install.

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HOIST BRAKE The hoist brake is an electromagnetic brake. Periodically inspect the brake for wear by measuring air gap through slots in cage. When air gap reaches 0.075", the gap should be adjusted. Normal operating gap is 0.060". When the friction disc pack is worn to 1/2 its thickness the disc pack should be replaced.

BRAKE WEAR ADJUSTMENT 1.

Remove the housing screws and housing.

2.

Insert brass feeler gages (0.060 supplied with brake) into air gap at 3 slots and release brake electrically or with manual release bolts.

3.

Remove locking screws from slots in cage.

4.

Insert adjusting rod into hole in wear adjusting ring and rotate CCW to end of slot. Repeat until resistance is felt.

5.

Remove gages and turn adjusting rod to nearest end of slot. Remove rod and reinstall locking screws. Set brake and re-install the housing.

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REPLACEMENT OF FRICTION DISCS 1.

Energize magnet and clamp armature to magnet body with four manual release bolts. Deenergize magnet and remove leads.

2.

Remove cage mounting bolts and magnet body and armature assembly. Back off wear adjusting ring slightly to allow space for new friction disc.

3.

Friction discs may now be slid from hub and replaced.

4.

Replace magnet body and armature assembly. (Arrows metal stamped on each part must be in line).

5.

Reconnect lead wires, energize brake and remove four manual release bolts.

6.

Set gap to 0.060" per BRAKE WEAR ADJUSTMENT.

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DISASSEMBLY OF MAGNET BODY AND ARMATURE 1.

Place assembly in press with spacer.

2.

Press armature against magnet body and remove manual release bolts from armature. (10,400 lbs press force required).

3.

Slowly release pressure from press until spring pressure is relieved. Remove armature.

Pressure spring assemblies may now be removed.

Hoist Brake Assembly

REASSEMBLY OF MAGNET BODY AND ARMATURE 1.

Place magnet body with flange side up on spacer on press base. Insert pressure spring assemblies and set armature in place being sure to align arrows on armature and magnet body.

2.

Insert temporary pins into release bolt holes for aligning.

3.

Press armature against magnet body (10,400 lbs press force), remove temporary pins and install four manual release bolts. Tighten bolt to hold armature against magnet body. Remove assembly from press.

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PIPE RACKS

The pipe racks of the 59HR are used to store drill pipe in a position ready for drilling. The pipe rack is operated by a hydraulic cylinder which swings the rack into position to accept or deliver drill pipe.

Inspect the pipe rack daily for loose or missing hardware or any wear or damage. Inspect the rack each shift for proper operation. Verify that the pipe is held securely by the upper gate. Check the operating cylinder for proper operation and any oil leaks. Check the bushings on the pipe rack for wear and replace as necessary. Check the pawls in the pocket on the lower end of the pipe rack for proper operation. Remove any dirt, ice or other debris from the pipe pocket and verify the operation of the gate operating system if no pipe is stored in the rack. Lubricate all points with the required lubricant.

There are no wear items on the pipe rack. With the exception of the bushings, all major components of the pipe rack should last through the lifetime of the machine. Repair of the pipe rack is limited to this discussion to replacement of bushings. To replace the bushings, proceed as follows: 1.

Raise the rotary drive unit to its highest position and set the hoist brake.

2.

Disconnect, plug and tag all hydraulic lines to the pipe rack.

3.

Secure the pipe rack against unwanted movement. Remove the bolts attaching the upper pivot bracket to the bracket support.

Remove the bracket and then remove the bushings from the bracket.

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4.

Remove the bolts attaching the middle pivot bracket to the bracket support. Remove the cover from the pivot bracket and remove the bushing halves.

5.

Secure a suitable crane and rigging to the pipe rack. Separate and remove the rack positioning cylinder. With the crane lift the pipe rack from the mast bottom plate.

Remove the bushing from the mast bottom plate.

6.

Clean and inspect all components.

Replace worn or damaged components as necessary.

7.

Reinstall in reverse of disassembly, lubricate all lubrication points and check for proper operation.

TOOL WRENCHES The tool wrenches are used to clamp the drill pipe in order to break a pipe joint. The tool wrenches are two specially built hydraulic cylinders operating inside a square casing. A spring loaded pawl engages a pocket in the drill pipe to prevent rotation of the pipe.

Inspect the tool wrenches daily for loose or missing hardware, or any wear or damage. Inspect the wrenches each shift for proper operation. Check each wrench and associated hydraulic lines for oil leaks and repair any leaks found immediately. Verify that the pawls are fully extended and secured with dowel rod. Verify that the wrenches can pivot about the Year pin. Clean any accumulation of cuttings from beneath the wrenches. Verify that the top blocks are in place and intact. Verify that the rear pin bearing blocks are secured firmly to the drill deck and that the piston rod anchor bolts are secure. Lubricate the assembly with an approved lubricant at the recommended intervals.

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Repair of the tool wrenches is essentially limited to replacement of the pawl insert. Replacement of the entire tool wrench is accomplished by removing the two hydraulic lines from the piston rod and then removing the four bolts securing the bearing blocks. Repair of the tool wrench itself follows standard procedures for repair of hydraulic cylinders. To replace the pawl insert, proceed as follows:

Tool Wrench

1.

Remove the defective tool wrench from the drill deck by removing the hydraulic lines leading to the piston rod and removing the 4 bolts securing the bearing blocks to the drill deck.

2.

Using suitable equipment compress the pawl springs slightly to remove pressure from the pawl retaining pin.

3.

Using suitable equipment remove the pawl retaining pin.

CAUTION:

4.

The pawl is spring loaded. Be sure to adequately restrain the pawl before removing the retaining pin. Failure to restrain the pawl will result in it being forcibly ejected from the cylinder body, possibly causing death or serious injury to personnel in the area.

Completely relax the tension on the pawl springs. When tension is completely removed, remove the pawl and pawl springs from the cylinder body.

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5.

Inspect the springs and pawl and replace as required.

6.

Lubricate the springs and pawl with an approved lubricant and reassemble the components in reverse order of disassembly.

Auxiliary Winch Rope and Sheaves

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AUXILIARY WINCH The auxiliary winch is used to lift tools on and off the drilling deck. The winch consists of a hydraulically driven reel mounted at the bottom of the mast, a cable with hook, and cable guide sheaves at the top of the mast.

The oil level in the winch should be checked monthly. The sheaves at the top of the mast should be checked monthly for wear or damage. Once a year the sheave bearings should be re-packed with lubricant. For repair of the hydraulic winch refer to the HYDRAULIC SYSTEM section of this manual.

MAST BRACES The mast braces on the 59HR are used to support the mast while angle drilling.

Inspect the mast braces daily for loose or missing hardware or any wear or damage. Replace any missing hardware and repair any damage immediately. Inspect the upper anchor pins, washers, retainer pins daily, making sure that the retainer pins are in place. Inspect the mast brace structure for cracks and any other damage. Inspect the telescoping lock pins for wear. The telescoping lock pin cylinders and hydraulic lines should be checked daily for leaks. Verify that the adjustment bolt lock nuts are tight and that the mast braces are adjusted properly.

Inspect the mast braces sleeves and supports for wear, damage or loose or missing hardware.

Lubricate all pins with an approved lubricant at the recommended intervals. Lubricate the adjustment bolt with a rust inhibiting oil as required. The mast braces are not normally considered wear items; therefore any repairs required will have to be handled on an individual basis.

CAUTION:

The mast braces are critical components especially on angle drilling machines. Consult the Bucyrus International Service Department before attempting major repair or modifications.

ADJUSTMENT Normally the mast braces are adjusted during the machine erection and further adjustment is not necessary. Special circumstances may require the re-adjustment of the mast braces to original condition. To readjust the mast braces proceed as follows: 1.

Remove the telescoping lock pins from the mast braces.

2.

Accurately level the machine. Be certain that all four corners of the machine are at the same elevation and that the mast is positioned vertically.

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3.

Loosen the adjustment bolt lock nut.

4.

Turn the adjustment bolts until the telescoping lock pins can be freely inserted (approx. 14.25" +/- 2.50" from centerline of adjustment bolt pin to end of brace).

5.

Lock the adjustment bolt in place with the lock nut.

Mast Brace Assembly

WARNING:

Once the mast braces are adjusted, it is not necessary to alter the adjustment unless the mast brace is replaced. Difficulty in pinning the mast braces usually results from the machine not being level or the mast not being vertical. Arbitrary adjustment of the mast braces without accurately leveling the machine may cause serious damage to the mast and should be avoided.

NOTE: Proper adjustment of the mast braces is made with machine leveled and supported on jacks. Difficulty will later be encountered in removal or re-assembly of the telescoping lock pin if the machine is resting on the crawlers.

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DUST CONTROL GENERAL MAINTENANCE The dust control system on the 59HR drill consists of the drilling platform and dust curtains which trap the cuttings and dust in an area under the machine. Two methods of controlling the trapped dust are available: water injection - which dampens the dust before it leaves the drilling hole, and a dry-type system which draws the dust laden air through filter elements which separates the dust from the air.

DRILLING PLATFORMS AND DUST CURTAINS Inspect daily the dust curtains for tears and other damage. Replace worn or damaged curtains.

Check the curtain raising ropes for broken or frayed ropes. Replace broken or damaged ropes.

Check the dust deflector seal which fits around the drill pipe for damage. Replace if damaged.

Check the curtain raising lever mechanism for proper operation. Lubricate all pins once a week.

Dust Deflector

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SEMI-ANNUAL MAINTENANCE CHECKS Inspect the impulse and solenoid valves. Inspect the suction hose leading to the housing for dust buildup and clean if necessary. Inspect the blower to be sure there is no dust buildup or abrasive wear on the blades or housing.

WATER INJECTION SYSTEM The maintenance of the water injection system consists mainly of keeping the water tank full of clean water, checking weekly that the pump and valves are operating correctly, and that all hoses and fittings are not leaking.

Water Injection System Schematic

WATER INJECTION DRAIN VALVES CHECK (Station 1 of 5-Station Manifold Assembly) 1.

With a 0-1500 PSI gauge at test port 74, with pumps running and Water Injection Switch (WIS) turned OFF, adjust reducing valve at station 1 of 5-station manifold to see 175 PSI.

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NOTE: Water Injection Control Valve (WICV) will be energized anytime pumps are running regardless of whether Water Injection Switch (WIS) is turned ON or OFF. When Water Injection Switch (WIS) is turned OFF, pump speed control is disabled. When switch (WIS) is turned ON, pump speed control is enabled.

2.

Check function of valves described in valve note.

WATER INJECTION PUMP FUNCTION CHECK NOTE: Needed for this test is 10-15 inches of clear water inside the main portion (above the sump) of the water tank, a clean 5-gallon pail and a stopwatch to check water flow rate.

Check water height by opening top cover.

NOTE: Before starting test, insure that 23 fluid ounces of SAE 30 non-detergent oil has been poured into water pump crankcase.

1.

With a 0-7,500 PSI gauge at test port 23 and with a 0-1,500 PSI gauge at test ports 72 and 73 (located at stations 1 and 2 of 7-station manifold) and with Water Injection Switch (WIS) turned OFF, start pumps and energize Main Flow Increase Valve (MFV) via hydraulic test function on operator’s display terminal screen.

2.

Pressure at test port 73 should be at or near 0 PSI and pressure at 23 should be at or near 3,000 PSI.

3.

Adjust reducing valve at station 2, as required, so pressure at port 72 is exactly 200 PSI greater than observed at port 73. Record pressure.

4.

De-energize Main Flow Increase Valve (MFV) and turn off pumps. Remove 0-1,500 PSI gauge from test port 73 and install at test port 23.

5.

With pumps running, use shop test function to energize (HPRV) at station 1 (top sandwich valve).

6.

Five seconds after step 5 is accomplished and while (HPRV) is still energized, energize (MFV) via shop test function.

7.

With steps 5 & 6 still in effect, adjust sequence valve at top sandwich valve of station 1, so that pressure at test port 23 is 300 PSI greater than observed at test port 72. Record pressures.

8.

De-energize (MFV) first and then de-energize (HPRV).

CAUTION:

9.

Failure to accomplish step 8 in the proper manner described will destroy gauge at port 23.

With suction and discharge hoses of water pumps in place and with water level in tank at

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the proper height, energize water system shop test function and start hydraulic pumps.

With water speed control (WIR) at full CCW position, rotate (WIS) Water Injection Switch to ON. 10.

With a 0-1,500 PSI gauge at test port 73 and with a 0-7,500 PSI gauge at test ports 23 and 72, use shop test function to energize (HPRV) and then energize (WPSCV) Water Pump Speed Control Valve gradually to check function through full speed range. Maximum shaft speed should be 1,750 RPM.

11.

As drive speed increases, pressure at test port 72 should always be 200 PSI greater than the pressure at port 73. Pressure at port 23 should always be 300 PSI greater than pressure at port 72.

12.

If drive speed cannot be observed, then measure the time in seconds to pump 5 gallons of water into a 5-gallon pail. With a pump flow of 8 GPM, a 5-gallon container should fill in 37.5 seconds. Record fill time and volume of container.

NOTE: (HPRV) will normally ONLY be energized when the compressor is loaded and water injection is turned ON. If compressor is unloaded and water pump is running, (HPRV) will be de-energized and (MFV) ONLY will be energized.

NOTE: Volume may be calculated as follows: •

Measure I.D. and height in inches.

•

(I.D.)2 x 0.7854 x height of water level divided by 231 equals volume in gallons.

•

Measured volume in gallons x 60 divided by fill time in seconds should equal 8 gal. per minute.

EXAMPLE: •

If I.D. of 5-gallon pail is 11.25" then (11.25)2 x 0.7854 ÷ 231 = 2.32" of height per gallon; so 5 gallons will total 11.6" of height.

•

For reasonable accuracy, the fill time should be at least 30 seconds.

NOTE: If washdown feature is on the machine, leave water drum filled with water to check washdown function.

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WATER INJECTION WASHDOWN CHECK 1.

With a 0-1500 PSI gauge at test port 76, and with pumps running, use hydraulic test function on operator’s display terminal screen to energize Main Flow Increase Valve (MFV) solenoid.

2.

Adjust pressure reducing valve located immediately beneath test port 76, to see 175 PSI on gauge.

3.

De-energize Main Flow Increase Valve (MFV).

4.

With an empty 5-gallon container available, locate washdown switch and hose.

NOTE: Switch is in operator’s cab on water injection console. A coiled hose with a quarter-turn shutoff valve is secured on hooks outside of the railing to the rear of the left rear jack tower. When the switch is energized, the Washdown Valve (WV) will energize causing a quarter-turn water valve to block flow to the main air line and also causing the water pump to run at maximum speed.

5.

Remove sufficient hose length from the hooks so the manually operated quarter-turn valve can be positioned close to the 5-gallon container. With quarter-turn valve CLOSED, energize washdown switch. Open quarter-turn valve to check function.

6.

Close quarter-turn valve and de-energize switch. Open quarter-turn valve with switch deenergized to relieve water pressure from the hose.

7.

Recoil hose on hooks.

FILLING THE WATER TANK The fill line of the water tank includes a ball valve-type shutoff and a basket-type strainer.

When filling the water tank, connect the water supply hose to the ball valve. Open the ball valve and fill the tank. When the tank is full, shutoff the ball valve and disconnect the water supply hose.

Reopen the ball valve and allow the water in the fill line and tank standpipe to drain out. While the water is draining out it will backflush the strainer.

NOTE: Care must be taken in extreme cold weather that the strainer does not freeze as the water is draining out of the fill line and backflushing the strainer.

If the strainer must be removed for cleaning, proceed as follows:

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1.

Loosen the two handscrews on the strainer cover.

2.

Move the cover to the side. The strainer basket will drop out of the housing.

3.

Clean the strainer basket and reassemble into the housing.

4.

Close the cover and tighten the cover handscrews.

DECK WASHDOWN SYSTEM When the machine is equipped with a deck washdown system, switch WIS (on the operator’s console) will have an additional position designated WASHDOWN. With the switch in the WASHDOWN position, solenoid valve WV on the 4-station manifold will energize and activate the washdown hydraulically operated ball valve to close off water to the mast air pipe and direct the water to the deck washdown hose.

CAUTION

August 2006

Ball valves with hydraulic actuator are hydraulically controlled with a spring return. The spring in the actuator is extremely strong. The screws that secure the spring and cover are not long enough to relieve the spring tension. Before attempting to remove the cover screws, the cover MUST be restrained (ie: in a vise). Then open the vise SLOWLY until the spring tension is relieved.

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HYDRAULIC SYSTEM SYSTEM OPERATION The following description is intended to help understand the 59HR blast hole drill hydraulic systems and their operation. The explanation consists of an overview of the systems and the relationship of the schematics to the actual components on the machine.

The 59HR has two separate though not independent major hydraulic systems: Propel circuit and Cylinder circuit. Both systems draw their oil from a common 143 gal. capacity reservoir. The pumps for the circuits are driven through a gear drive box by the main compressor motor. The gear drive box will increase, decrease or maintain the same speed ratio between the motor speed and the pump speed. The main compressor motor determines the gear ratio of the gear box.

The propel circuit consists of two hydraulic pump/motor drives, one for each crawler. Piggybacked to the left propel pump is a single gear pump which supplies oil under pressure to leveling jacks and mast raising cylinders and actuators. Piggybacked to the right propel pump is a two-section gear pump. The cover end pump supplies control pressure for the propel pumps as well as pilot pressure for the mast hoist, auxiliary winch and pipe rack valves. This pump also supplies oil to actuate the bit viewing hatch cylinder, boarding stair cylinder, and the lube system.

The propel circuit includes brake controls for each crawler. For towing purposes, the system is equipped with a hand pump for manual release of the crawler brakes. The shaft end pump of the two-section gear pump supplies oil under pressure to the remaining hydraulic cylinders and actuators of the machine. If the machine is equipped with a cable reel, the complete hydraulic system, including reservoir, pump and motor are part of the cable reel unit. The systems are totally sealed and filtered so as to keep the oil as clean as possible.

The gear box with pumps is mounted to the rear drive shaft of the main air compressor motor. The reservoir, oil cooler and main frame manifold valves are located at the rear of the machinery house and the various cylinders are mounted at various points around the machine.

CYLINDER CIRCUIT HYDRAULIC SYSTEM Fluid for this system is supplied from the common reservoir. The single gear pump and two-section gear pump supply oil to the actuators at the following rates: 2704 RPM @ 60 HZ Single Pump 65 GPM Shaft end Pump

17 GPM

Cover End Pump

18 GPM

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2253 RPM @ 50 HZ Single Pump 54 GPM Shaft end Pump

14 GPM

Cover End Pump

15 GPM

The multiple station manifold valve assemblies contain control valves for the various actuators.

Usually the control valves will be assembled in stacks – one stack for each actuator. A typical valve stack could include a relief valve, a flow control valve, a check valve, a quick disconnect valve for pressure testing and a solenoid valve.

Most hydraulic lines run from the manifold valve to bulkheads, then from the bulkheads to the actuators. All oil returning to the reservoir passes through 10 micron filters before entering the reservoir.

PROPEL CIRCUIT HYDRAULIC SYSTEM Fluid for the propel system is also supplied from the 143 gallon reservoir. Most hydraulic control valves of the propel circuit are modules bolted directly to the pumps. The pilot pressure valve and brake valves are separate from the pumps. The oil for each pump control circuit is directed through a 10 micron filter equipped with a 25 PSID by-pass valve.

The pilot pressure is controlled to 600 PSI by the sum of the 450 PSI relief valve and the 150 PSI supercharge relief. The pumps are equipped with two main relief/pressure override assemblies referred to as a combination valve; one for the forward propel side, and the other for the reverse propel side.

The pressure override portion of the assembly is set at 5365 PSI. The main relief portion is set 500 PSI above the pressure override as a fixed non-adjustable level. The pressure override valve prevents continuous dumping of excessive flow, at load pressure, through the main relief valves. This eliminates unnecessary heating of the oil and protects the pump and motor from damage.

HYDRAULIC SYSTEM CLEANLINESS It is extremely important to use the correct oil in the system. It is equally important to keep the oil clean. Whenever a repair procedure requires a connection to be broken or a part to be replaced, first clean the immediate area around the joint and/or part to be replaced. This step is required to assure no contaminates enter the system through the hydraulic lines or replacement parts.

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While performing the repair keep everything clean and also keep openings covered or plugged until they are re-connected. Contamination is the most common cause of trouble in a hydraulic system.

It causes excessive wear of parts, interferes with the close clearances, and hinders normal operation.

WARNING:

Never add oil to the system by removing the reservoir breather and pouring it in through the funnel. Even new drum oil is dirty and can cause sticking valves.

When hydraulic oil is added to the system, it should always be pumped into the system. The pump discharge line should be attached to the quick-disconnect coupling at the top of the tank. This connection insures that the new oil will pass through the tank return filters before entering the system.

If the pump used to add the oil is equipped with a filter buggy and the pump has been used for other fluids, the pump system and filter buggy must be purged of the other fluid prior to connecting the pump unit to the quick-disconnect coupling. This purging can be accomplished by flushing the pump unit and filter buggy with at least one gallon of the specified hydraulic oil.

OIL REQUIREMENTS For hydraulic oil benchmarks refer to Appendix A4 Lubrication Benchmarks - Hydo Hydraulic Oil.

OIL AND FILTER CHANGES During normal operation change the element when indicated by the filter condition indicator with the oil at normal operating temperature and whenever oil is changed.

WARNING:

Before changing the element, open the circuit breaker for the hydraulic pump motor. Be sure there is no pressure on the system to prevent possible oil leakage.

The change frequency for hydraulic oil depends on the type of oil used in your machine. This cycle can range from 2,000 hrs. for standard grade petroleum base type oil as determined by the lube bench marks in the Appendix, to 8,000 hrs. for certain synthesized hydrocarbon hydraulic oils as noted in the lube bench marks in the Appendix. These change frequencies can be shortened or lengthened depending on the condition of the oils. To determine the condition of the oils, samples should be taken periodically (i.e. 200 hrs.) and analyzed by a reputable manufacturer. When taking oil samples, never take the sample from the tank drain system. If possible, the sample should be taken from a point near the return manifold just before the return filters.

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CAUTION:

To minimize fire hazard, no open flames or other ignition sources are allowed when changing oil.

Water should be drained from the bottom of the hydraulic oil reservoir once a day, after a period of shutdown and when the oil is cold. The hydraulic oil reservoir holds 143 gallons of oil.

FILTER MAINTENANCE The mast / winch pipe rack 3-spool valve to tank line filter is a cleanable filter which must be cleaned every 90 days by backflushing. To remove and clean the filter, proceed as follows: 1.

With the hydraulic system shut down, remove the tank breather to release the pressure in the tank. Reinstall the breather on the tank.

2.

Have a container available to catch the hydraulic fluid in the line from the 3-spool valve to the filter.

CAUTION:

The line will have a pressure of 5 PSI, therefore care should be taken when breaking the fittings to remove the line from the filter.

3.

When removing the line, drain the hydraulic fluid into the container (approx. 1 quart).

4.

Remove the filter completely from the machine and backflush with a suitable fluid and blowout with dry air. Do not attempt to remove the filter screen as it is not replaceable.

CAUTION:

5.

When using air to blow out the filter be sure to wear safety glasses.

When re-installing the filter, be sure the filter o-ring is in place and all fitting are tight.

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WEEKLY MAINTENANCE CHECKS Check for correct operation of all components of the system. Valves, cylinders, and motors and pumps should operate smoothly, with no jerking or binding. Check the oil level in the reservoir. The reservoir should be almost full (143 gal.) when the mast is horizontal and all other cylinders are retracted. With the mast vertical and all other cylinders retracted, the reservoir should be slightly below 7/8 full.

CAUTION:

Before topping off the fluid in the hydraulic tank, verify that the mast cylinders are extended and all other cylinders are retracted. Failure to comply with the above (i.e. jack cylinders extended) will overfill the tank when the jack cylinders are retracted and will cause the tank to rupture.

WARNING:

Do not operate with low oil level. Operating with low oil level can cause cavitation and air pockets. This will cause faulty operation and can also cause damage to the system components.

Inspect all components and lines to be sure they are in good operating condition. Check for obstructed or distorted cylinders. Inspect the system for leaks. If a leak is found, tighten the screws or fittings around the leaking area before beginning major repairs. If that does not stop the leak, it may then be necessary to repair or replace the leaking part. If an o-ring is damaged or missing from the hydraulic plumbing, check o-ring kit 68120749 for replacement o-rings.

OIL RESERVOIR REPAIRS The hydraulic oil reservoir is epoxy coated on the inside to prevent scale and oxidation.

WARNING:

DO NOT WELD on the reservoir; it will damage the coating.

LEVELING JACK COUNTERBALANCE VALVE PRESSURE RELIEVING If it becomes necessary to work on the leveling jack counterbalance valve for any reason, relieve pressure in the cylinder using the following procedure: 1.

Position the machine with crawlers on the ground and jacks retracted so that the jack pads are approximately one inch off the ground.

2.

Turn off the hydraulic pump and relieve any pressure in the system by loosening the reservoir breather. When trapped air in the reservoir is relieved, immediately replace the breather.

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REAR JACKS 1.

Uncouple the quick disconnect using a 1 1/4" open end wrench. The male half of the quick disconnect will remain attached to the valve.

2.

Remove the other end of the quick disconnect hose from the electrical junction box on the jack.

3.

Place the hose end, removed from the electrical junction box, into a clean five gallon container.

4.

Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

CAUTION:

Always maintain a firm grip on the hose while the oil is flowing from it.

Do not allow the stream of oil to contact your skin as injury can occur.

5.

When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

6.

With the pressure relieved, the counterbalance valve or jack cylinder can now be safely worked on.

FRONT JACK 1.

Uncouple the quick disconnect at both front jacks, using a 1 1/4" open end wrench. The male half of the quick disconnect will remain attached to the valve.

2.

At one front jack only, remove the other end of the quick disconnect hose from the electrical junction box on the jack.

3.

Place the hose end, removed from the electrical junction box, into a clean five gallon container.

(Two additional 5 gallons will be required to handle the oil from both front jacks.)

CAUTION:

4.

Always maintain a firm grip on the hose while the oil is flowing from it.

Do not allow the stream of oil to contact your skin as injury can occur.

Re-couple the quick disconnect. As the connection nears completion, oil will run out of the hose end in the container and the jack pad will drop to the ground! This will relieve all pressure on the piston rod and create a vacuum on the housing end of the cylinder.

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5.

To remove the oil from the other front jack, a helper will be required. Have the helper continue to hold the disconnected hose into a empty 5 gallon container while you re-couple the quick disconnect on the other front jack. The oil from this jack will now flow from the hose being held by the helper.

6.

When the oil flow has stopped and the jack pad is on the ground, the loose end of the hose can be reconnected to the electrical junction box.

7.

With the pressure relieved, the counterbalance valve or jack cylinder can now be safely worked on.

PRESTART INSPECTION If the machine hydraulic systems have had a major overhaul, the following prestart inspection should be completed before start-up of the machine.

CAUTION:

Before starting pumps, establish a safe walking perimeter around machine to reduce possible injury to ground personnel due to automatic operation of boarding stair, dust curtain, or cable reel.

NOTE: Read all instructions before starting any individual test. Initial each step after its completion or record the requested information.

1.

Check all lines and fittings for tightness and plumbing accuracy.

2.

Visually check that no open port exists on any valve.

3.

If the crawlers or mast have been removed from the machine, be sure that all ports have been plugged or capped and all loose lines terminated in a quick disconnect or plugged with a steel fitting.

NOTE: Make note of the oil manufacturer and type of oil being used in this hydraulic system (e.g. Conoco Syncom AW22).

4.

Verify that the hydraulic reservoir is filled to the correct level with the required hydraulic oil.

5.

Check the suction plumbing and the reservoir for external leaks.

6.

From the test kit install 0-1500 PSI gauges to test ports 14 and 15 at the left and right propel pump charge filter outlet, respectively.

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NOTE: All pressure gauges must be calibrated before using.

7.

Verify that pump drive gear box is filled with 7.75 quarts of S.A.E. 80 - 90W oil.

8.

Check the pump drive motor for correct rotation by jogging the main compressor start/stop pushbuttons or PTO clutch, if diesel driven. Pump drive gearbox input shaft rotation is opposite pump shaft rotation.

9.

When item 8 is complete, continue to jog electric motor until pressure on gauges at test ports 14 and 15 is 100 PSI.

10.

When pressure rise is verified, turn on the hydraulic pumps and visually check all plumbing for leaks.

HYDRAULIC SYSTEMS TESTS The hydraulic systems are equipped with quick disconnect test ports for checking the operation of the systems. These tests are designed to assure that the specified units are operating correctly and, if they are adjustable, they are adjusted to the correct pressure setting. The results of each of the following tests should be noted in a log book so that on future checks and in case of system failure, pressure readings can be compared to help locate the failure.

NOTE: For location of test points on the machine see table at end of this section of this manual.

CAUTION:

Before attaching or disconnecting pressure gauges to test ports be sure that the hydraulic pumps are turned OFF.

PROPEL PUMP CHARGE PRESSURE CHECK NOTE: Charge pump relief adjustment is on right side of pump.

1.

With pump controls at NEUTRAL and pumps running, check pressure at test port 14 on a 1500 PSI gauge. Set charge pump relief pressure of left propel pump as required to obtain 350 PSI ±10 PSI (use 1-1/16" hex wrench and screwdriver).

2.

With pump controls in neutral and pumps running, check pressure at test port 15 on a 1500 PSI gauge. Set charge pump relief pressure of right propel pump as required to obtain 350 PSI ±10 PSI (use 1-1/16" hex wrench and screwdriver).

3.

Turn off the pumps.

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CONTROL PRESSURE CHECK 1.

With Pilot Pressure Valve (PPV) disconnected electrically at station 6 of 6 station manifold located immediately above and to the rear of the jack valve stand, and with a 1500 PSI gauge at test ports 7 and 17, turn pumps on. Record pressure at test ports 7 and 17 (approx. 150 PSI).

Pressure at test port 17 should be greater than port 7.

NOTE: Before performing step 2, warm-up hydraulic system so that oil cooler motor has cycled ON at least once.

Pump Adjustments (Sundstrand Pumps)

2.

With solenoid wires re-connected to pilot pressure valve (PPV), start pumps and after 10 seconds, with PPV energized, observe pressure at test port 17. Adjust relief valve at station 6 as required to see: 1000 ±10 PSI if GRACO central lube pump is used or 600 PSI ±10 PSI if LINCOLN central lube pump is used. Adjustment is facing wall, opposite the electrical solenoid.

3.

Record pressure at test port 7 (approx. 150 PSI).

4.

Note whether GRACO or LINCOLN central lube pump is on machine.

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PROPEL ENABLE VALVE AND LOW SPEED SELECT CHECK 1.

With drill/propel select switch in PROPEL NORMAL, in on-board propel, with a 1500 PSI gauge at test ports 8 and 18, start the pumps and depress the drill/propel ON pushbutton.

Record the pressure at test ports 8 and 18. Test port 18 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK. Test port 8 reading should be zero (0)

2.

With pump still running, first lift one propel joystick out of the DETENT position and then release it. Do the same with the other joystick.

NOTE: There is no need to move joysticks out of NEUTRAL. Just lift the joystick clutch straight up to engage solenoid Propel Active Valve (PAV). Accomplishing step 2 will cause PAV to energize which should cause pressure at test port 18 to go from 600 PSI to 0 and test port 8 should go from 0 to 600 PSI. 3.

With a 1500 PSI gauge at test port 9 and the pumps running, rotate Propel Selector Switch to SLOW speed and record pressure.

4.

Pressure in step 3 should be within 50 PSI of control pressure check step 2.

5.

With Propel Selector in NORMAL, record pressure at test port 9. (Should read zero.)

JACK CYLINDER CHECK IN MANUAL MODE NOTE: Under no circumstances must either 3-spool valve or relief valve adjustments be allowed to bottom-out. The spool valve is located on the back wall of the machinery house to the left of the hydraulic oil tank and slightly below the top of the tank. The main relief is near the inlet port.

1.

With a 7,500 PSI gauge at test port 16 and pumps running, energize auto level in RETRACT mode. With all cylinders fully retracted, adjust 3-spool valve relief to show exactly 3,300 PSI on the gauge.

2.

Check all jacks for operation versus manual lever movement (i.e. moving the right front jack control to EXTEND, extends the right front jack. Check both directions with all 4 jacks).

NOTE: Re-check hydraulic oil level and add oil as required.

WARNING:

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3.

Back-out adjustment of relief valve 1/8th of a turn and then tighten the jam nut.

4.

Install a 0-1,500 PSI gauge at test port 70, located at inlet to back pressure valve underneath and slightly to the left (rear) of the 3-spool valve.

5.

With the right front jack manually extending from full RETRACT position, adjust back pressure relief as necessary to see 400 PSI.

6.

With step 5 complete, install a 7,500 PSI gauge at test port 16 and with right front jack extending from full RETRACT towards the ground, adjust relief valve located at inlet of jack spool valve on jack stand. Adjust to see 3,200 PSI.

NOTE: Do not bottom any relief valve adjustments.

7.

Re-check all jacks for operation versus manual lever movement.

8.

Install all four jack pads.

* Rear-Most flow control is Position 1. Front-Most flow control is position 8. ** Flows are for 60HZ pump drive input speeds and also for 50HZ with pump drive input speeds of 3,000 RPM.

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FLOW CONTROL CHECK 1.

Remove hose nearest wall from 3rd flow control (counting from left to right) on jack valve stand and install a -10 ORS steel plug into the open hose.

2.

Install a 20 GPM Hedland flow meter #700-020 (inlet side) into the open port of flow control.

3.

Disconnect hose coming from the spool valve to the 7th flow control. Install a steel -10 ORS cap onto the flow control’s open port.

4.

Connect the outlet side of the flow meter to the hose just removed from the 7th flow control.

5.

With pumps running and with the aid of a helper, energize left rear jack, in either UP or DOWN mode, to show flow in the meter. Adjust flow regulator, as required, to see EXACTLY the flow as shown on the following chart.

NOTE: If all 4 jack cylinders are the same size (i.e. all are 8" bore diameter or all are 9" bore diameter), then do not use flow setting chart. Instead, set all 8 flow controls to 15 GPM for 60 Hz machines as well as for 50 Hz machines running at 3,000 RPM input speed.

All other 50 Hz machines are to be set at 12.5 GPM. 6.

After first flow regulator is tested, substitute the remaining untested regulators into the 3rd position until all eight flow regulators have been checked. All flow regulators MUST end up in their proper position when test is complete.

NOTE: During calibration of flow controls, as well as anytime jacks are being operated in MANUAL or AUTO-LEVEL mode, the flow controls should not exhibit any chattering or screaming noise.

7.

With step 6 complete, re-assemble hoses to proper ports.

8.

Now complete Jack Cylinder Check In Manual Mode starting with step 3.

JACK CYLINDER DRIFT TEST NOTE: Read items 1 through 5 of this test before continuing.

1.

Lower all jacks to ground such that the jack pads are firmly on the ground but are not lifting the machine.

NOTE: If in steps 2 and 3 the crawlers are not mounted and the machine is resting on blocks, only lift the machine a few inches.

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2.

Manually extend left and right front jacks simultaneously to lift the front of the machine.

3.

Manually extend left and right rear jacks simultaneously to lift the rear of the machine.

4.

Continue to lift the machine by alternating front to rear until the crawler tracks have cleared the ground by 3 or more inches. If crawlers are not mounted, lift the machine approx. 6 inches off the blocks.

5.

With machine approximately level, position all manual jack controls to NEUTRAL and check for jack cylinder drift. Drift should not exceed 1/8" in 30 minutes.

BRAKE RELEASE PRESSURE CHECK NOTE: Crawlers must be mounted to mainframe for this test.

1.

With 0-1500 PSI gauges at test ports 5 and 6 and with pump running, the pressure should be at or near zero with hands removed from the propel joysticks and drill/propel select switch in PROPEL NORMAL mode.

2.

With pump still running, first lift one propel joystick and then release it and then lift and release the other propel joystick. Anytime either or both joysticks are lifted full up out of the DETENT position, the propel active valve (PAV) will energize and the pressure at test ports 5 and 6 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

3.

With drill/propel select rotated to DRILL mode, pressure at test ports 5 and 6 should be zero regardless of whether the joysticks are in or out of the DETENT position.

PROPEL BRAKE EMERGENCY RELEASE CHECK NOTE: This test must be performed with the pumps OFF. 1.

With 0-1500 PSI gauges at test ports 5 and 6, the bypass valve handle (located on the left side surface of left front jack housing) rotated fully CW, and with hand pump bypass valve CLOSED, manually operate pump handle to raise pressure on the gauge until the operator's display terminal screen displays: PROPEL BRAKE TOW RELEASE. Record the pressure that causes the operator's display terminal screen display to appear. (Pressure should be 500 PSI.)

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2.

With step 1 complete, continue to operate the pump until the gauge shows 1,000 PSI. Record the amount of pressure drop in 5 minutes (should not be more than 500 PSI).

NOTE: Pressures in step 1 and step 2 should also appear at test ports 5 and 6 on 0-1500 PSI gauges.

PROPEL PUMP MAIN RELIEF PRESSURE CHECK NOTE: Crawlers must be mounted and there should be no crawler movement during this test.

Main relief valves are on the top of the pump, as mounted on machine.

1.

With machine still raised on jacks and with a 7,500 PSI gauge at test ports 1 and 2 and a 01,500 PSI gauge at test port 59, disconnect the propel brake release line at the brakes and plug the hoses with a -6 o-ring seal plug. Leave the port on the brakes open; do not cap or plug the fittings.

NOTE: Use a 5 mm allen wrench and a 3/4" open end wrench to adjust main relief valves.

2.

With the pumps running, energize the propel active valve (PAV). Note the presence of 600 PSI at test port 59. Operate the left crawler control in the FORWARD direction by manually depressing coil PLV-FWD. Adjust relief as required to see 5,400 PSI on gauge at test port 1.

3.

Maintain step 1. Place the left crawler control in the REVERSE direction by manually depressing coil PLV-REV. Adjust pressure as required to see 5,400 PSI at test port 2.

4.

With machine still raised on jacks and with a 7,500 PSI gauge at test ports 3 and 4, check main relief pressures on right crawler pump.

5.

With the pumps running, operate the right crawler control in the FORWARD direction by manually depressing coil PRV-FWD. Adjust main relief valve as required to see 5,400 PSI on gauge at test port 4.

6.

Repeat step 5 but place the right crawler control in the REVERSE direction by manually depressing coil PRV-REV. Adjust pressure as required to see 5,400 PSI at test port 3.

7.

Reconnect the propel brake release hoses disconnected in step 1.

8.

De-energize propel active valve (PAV).

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CRAWLER FUNCTION CHECK NOTE: Check that the crawler boxes have each been filled with 7.5 gallons of 80W-90W oil.

1.

With propel selector in SLOW SPEED, check the left crawler function in FORWARD and REVERSE. Record time for 3 revolutions of crawler sprocket: 60 Hz should be 3 revolutions in 63 seconds.

50 Hz should be 3 revolutions in 75 seconds.

2.

Repeat step 1 with propel selector in NORMAL SPEED. Record time for 10 revolutions of crawler sprocket: 60 Hz should be 10 revolutions in 67 seconds.

50 Hz should be 10 revolutions in 80 seconds.

3.

Repeat step 1 for right crawler,

4.

Repeat step 2 for right crawler.

BIT VIEWING HATCH CHECK Check function of bit viewing hatch with switch in operator’s cab. Hatch should open and close smoothly with no chattering action.

BOARDING STAIR CHECK Check function of boarding stair with switch in operator’s cab. Stairway should raise and lower smoothly with no chattering action.

MAIN FLOW VALVE CHECK 1.

With 0-1,500 PSI gauge at test port 26 and with pumps running, set backpressure relief (nearest manifold at station 1) to see 300 PSI.

2.

With 0-1,500 PSI gauge at test port 23 and with pumps running and all valves de-energized, record pressure observed.

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3.

With 0-7,500 PSI gauge at test port 23 and with 0-1,500 PSI gauge at test port 26, start pump and energize main flow valve (MFV) via hydraulic test function. Adjust relief valve of center sandwich valve at station 1 to see 3,000 PSI at test port 23. Record pressure at ports 23 and 26.

NOTE: Top most sandwich valve of station 1 will be adjusted with water injection pump function check.

BREAKOUT WRENCH AND TOOL WRENCH CHECK Check function of breakout wrench and tool wrench with switches in operator’s cab.

DUST CURTAIN CYLINDERS 1.

Check function versus switch position.

NOTE: After 3 - 5 cycles, operation should be smooth with no jerkiness or chattering.

2.

Adjust door stops.

DUST SEAL SLIDER Operate in forward and reverse to check function. Record pressure observed at test port 24 on a 07,500 PSI gauge.

MAST LOCK (Station 6 of 7-station manifold) 1.

With 0-7,500 PSI gauge at test port 21, energize mast lock latch solenoid and check function.

2.

Adjust relief, as required, to see 1,000 PSI.

NOTE: Adjustment is facing away from left wall.

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3.

With gauge still at test port 21, energize mast lock unlatch solenoid. Observed pressure should be 3000 PSI.

4.

Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 21.

MAST BRACE LOCK CYLINDERS (Station 4 of 7-station manifold) 1.

With 0-7,500 PSI gauge at test port 23, energize Mast Brace Lock (MBLV) solenoid and check function.

2.

Adjust relief, as required, to see 1,000 PSI while mast brace lock (MBLV) is energized.

3.

Energize mast brace unlock (MBLV) solenoid. Observed pressure should be 3,000 PSI.

4.

Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 23.

A-FRAME LOCK CYLINDERS (Station 5 of 7-Station Manifold) NOTE: This test should not be run unless the mast is fully up or unless the mast is off the machine. Mast lock cylinder pins MUST be extended before conducting this test.

1.

With 0-7,500 PSI gauge at test port 22, energize A-Frame Lock (AFLV) solenoid and check function.

2.

Adjust relief, as required, to see 1,000 PSI. Adjustment is facing away from left wall.

3.

Energize A-frame unlock (AFLV) solenoid. Observed pressure at port 22 should be 3,000 PSI.

4.

Repeat steps 1 and 2 except with a 0-1,500 PSI gauge at test port 22.

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MAST LOCK CONSTANT PRESSURE CHECK 1.

With a 0-1,500 PSI gauge at test port 61, start pump.

2.

Rotate mast lock switch to UNLOCK and then return switch to NEUTRAL.

3.

With switch at NEUTRAL, pressure at test port 61 should be 0.

4.

Rotate mast lock switch to LOCK and then return switch to NEUTRAL.

5.

With switch at NEUTRAL, pressure at test port 61 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

MAST BRACE CONSTANT PRESSURE CHECK 1.

With a 0-1,500 PSI gauge at test port 60, start pump.

2.

Rotate mast brace switch to UNLOCK and then return switch to NEUTRAL.

3.

With switch at NEUTRAL, pressure at test port 60 should be 0.

4.

Rotate mast brace switch to LOCK and then return switch to NEUTRAL.

5.

With switch at NEUTRAL, pressure at test port 60 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

A-FRAME LOCK CONSTANT PRESSURE CHECK 1.

With a 1,500 PSI gauge at test port 65, start pumps.

2.

Rotate A-frame lock switch to UNLOCK and then return switch to NEUTRAL.

3.

With the switch in NEUTRAL, pressure at test port 65 should be 600 PSI.

4.

Rotate A-frame lock switch to LOCK and then return switch to NEUTRAL.

5.

With the switch at NEUTRAL, pressure at test port 65 should be the same as pressures noted in step 2 of CONTROL PRESSURE CHECK.

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MAST RAISE/LOWER NOTE: This adjustment limits the maximum lowering speed of the mast.

1.

With the pumps shut down, adjust the Hoist Flow Control located under the deck just forward of the rear torque tube. Loosen the setscrew and turn the adjustment in all the way.

2.

With step 1 complete, back out the adjustment 6 full turns and tighten the setscrew.

3.

Install a 0-7,500 PSI gauge at test port 16 and proceed as follows: a.

If mast is not mounted to machine, position mast/winch selector to MAST HOIST and operate master switch in MAST RAISE mode. If cylinders are connected, the cylinder rods should both be extending.

b.

When rods have fully extended, the pressure gauge reading will be 2,500 PSI.

c.

With master switch in LOWER mode, the cylinder rods will retract. The pressure gauge reading should then be 2,500 PSI.

d.

If mast hoist cylinders are not mounted, then pressures at step 3-b and step 3-c will be seen almost as soon as master switch is moved from NEUTRAL.

NOTE: Step 3-e is to be done with jacks FIRMLY on the floor. e.

If mast is mounted, check function carefully by raising mast 6 - 12 inches out of the rack while observing pressure on the 0-7,500 PSI gauge at test port 16. If more than 2,500 PSI is needed to lift mast from rack, adjust port relief on hoist side as necessary. Record pressure needed to raise the mast.

f.

With step 3-e complete, carefully position master switch to LOWER mode and observe “inching” capability of control.

g.

Raise mast to full vertical (with the deck level and on jacks).

h.

With a 0-7,500 PSI gauge at test port 16, observe pressure needed to pull mast out of vertical. Adjust lower mode port relief as necessary to generate enough pressure. Record observed pressure.

i.

With 0-7,500 PSI gauge still at test port 16, with mast in vertical position and with mast brace and mast lock pins engaged, operate mast hoist in raise and lower to set port relief valves to 200 PSI greater than pressures observed at steps 3-e and 3-h, respectively. Record set pressures.

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NOTE: An alternate way to accomplish step 3-i is to disconnect hoses at both mast hoist cylinders and then plug hoses with steel ORS plugs. With hoses plugged, start pumps and operate mast hoist in RAISE and LOWER mode to set port reliefs to 200 PSI greater than observed at steps 3-e and 3-h respectively. When reliefs are set, reconnect hoses and check function of mast hoist.

AUXILIARY WINCH With a 7,500 PSI gauge at test port 16, proceed as follows: NOTE: If the mast is not mounted, skip to step 4.

1.

With the mast mounted and in the rack (fully down), operate the winch with no rope on the drum to check function verses master switch position.

2.

Check the ability to smoothly start in the HOIST and LOWER mode.

3.

Check drum RPM in the HOIST and LOWER mode and record. Drum speed should be: 10 revolutions in 17 seconds (36 RPM).

4.

If mast is not mounted, set port relief so pressure gauge shows 3,000 PSI in the HOIST position when moving the master switch out of NEUTRAL. Moving hoist lever to full LOWER position will show 3,300 PSI on gauge.

NOTE: If mast is mounted, port relief setting may be observed by first disabling WACV electrically and then proceeding per step 4.

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HYDRAULIC CENTRAL LUBE DRIVE PRESSURE CHECK NOTE: Steps 1 through 3 apply to LINCOLN lube system with LINCOLN lube pump only.

1.

With Lube Cycle Control Valve (LCCV) electrically disconnected and with pumps running, energize Lube Enable Valve (LEV) solenoid.

2.

Adjust pressure reducing valve attached to lube pump manifold, as required, to see 450 PSI on gauge attached to manifold.

3.

With Lube Cycle Control Valve (LCCV) electrically connected and with pumps running, observe that the lube pump is functioning.

NOTES:

•

If grease is not pumped during test, then don’t run test step 3 any longer than necessary to see that the pump is cycling.

•

There should be NO external hydraulic oil leakage during test.

•

Steps 4 through 10 apply to LINCOLN lube system with GRACO lube pump.

4.

Attach a 0-1,500 PSI gauge at test port 64.

5.

Disconnect the hose from the upper run connection of the tee at test port 64. Plug and cap both open connections.

6.

With pumps running and Lubrication Timing Screen showing on the operator's display terminal, press F9 to energize Lube Enable Valve (LEV) solenoid.

7.

With step 6 complete, adjust reducing valve as required to see 900 PSI and then lock jam-nut on adjusting screw.

8.

With step 7 complete, press F9 on the operator's display terminal to de-energize (LEV) solenoid.

9.

Turn off pumps and re-connect line that had been disconnected in step 5.

10.

With step 9 complete, start pumps and engage Manual Lube Cycle (F9) to ensure that pump functions properly.

NOTE: If grease is not pumped during test, don’t run step 10 any longer than necessary to see that the pump cycles.

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WINDOW GUARD FUNCTION CHECK (Station 1 of 4-Station Manifold Assembly) CAUTION:

Before starting test, make sure there is nothing laying on window guard that could fall off to cause injury to personnel or damage to machinery. Keep personnel away from window guard area during test.

1.

With a 0-1500 PSI gauge at test port 75 and with Window Guard Valve (WGV) de-energized, energize Main Flow Increase Valve (MFV) via hydraulic test function on operator's display terminal screen.

2.

Adjust pressure reducing valve (same valve that test port 75 is attached to) to see 500 PSI.

3.

De-energize Main Flow Increase Valve (MFV) and energize Window Guard Valve (WGV) to check function. After 3 or 4 cycles, window guard should operate smoothly, without chatter.

CHECK JACKS IN AUTO LEVEL MODE 1.

Manually position all jacks such that they are midway between the ground and fully up.

2.

Position auto level switch to RETRACT mode and observe that all 4 jacks simultaneously retract.

3.

Maintain step 2 until all 4 jacks are fully up, at which time the operator's display terminal screen WILL SHOW THE JACKS TO BE FULLY UP and the retract solenoids at the jack valve control manifold have each turned off. Jack Loader Valve (JLV) will stay energized so long as the switch position is maintained in RETRACT. When the auto level switch is returned to NEUTRAL, solenoid JLV should turn off.

4.

With all jacks fully extracted, position the auto level switch to extend and observe that all 4 jacks extend simultaneously. Do not extend jacks all the way to the ground.

NOTE: If the crawlers are not mounted, use extreme care during step 5 through step 8.

5.

With step 3 and step 4 complete, run each jack down individually and manually check that each ground pressure switch activates and is shown on the operator's display terminal screen.

6.

With step 5 complete, repeat step 2 and step 3.

7.

With step 6 complete, position the auto level switch to EXTEND and observe the following actions of auto level while maintaining switch position:

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a.

Starting from full retract into extend, all cylinders will extend at once.

b.

As each cylinder pad is lowered enough to generate ground pressure, it will stop moving, until all four cylinder ground pressure indications are shown on the operator's display terminal.

c.

If the machine is out of level, it will level itself (first side to side and then front to back).

d.

The machine will raise up straight and level on all four jacks.

NOTE: Step 5, step 6, and step 7 must be done with EXTREME care if crawlers are not mounted to machine.

8.

With step 7 complete, position auto level switch to RETRACT to check function.

NOTE: If crawlers are unmounted, step 8 should not be run unless AT LEAST one observer is present outside the machine.

PIPE RACK POSITION CHECK With 0-7,500 PSI gauge at test port 16, with selector switches in operator’s cab set to DRILL mode, and at PIPE RACK/JOINTS, proceed as follows: 1.

Raise left joystick out of detent, without leaving NEUTRAL, until one second has passed.

NOTE: Step 1 is intended to allow sufficient time for the pipe rack lock pin to unlock the rack, before rack is allowed to be moved.

2.

With step 1 accomplished, move joystick to full stroke, first in one direction and then the other. Pressure should increase smoothly with increasing stick travel. Pressure should be 2,500 PSI at maximum stroke in STORE position. Adjust port relief, as required. Pressure should be 3,200 to 3,300 PSI at maximum stroke in OVER-THE-HOLE position.

3.

Re-check with selector rotated to all four positions.

PIPE RACK LOCK AND GATE CYLINDER PORT RELIEF SETTING With the mast in the vertical position, attach a 1,500 PSI gauge to test port 52. With pumps running, set the relief valve at station 3 of 8 station valve located directly above auxiliary winch, as required to see 600 PSI.

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Test Point Locations, Chart #1

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Test Point Locations, Chart #2

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Test Point Locations, Chart #3

Location Descriptions

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Section

6

Brakes and Couplings Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents BRAKE HUB INSTALLATION ........................................................................................................ 3 Hub Adapter Pre-Heat Advance Requirements Table .................................................................. 4

MOTOR COUPLING INSTALLATION ............................................................................................ 5 Motor Coupling Pre-Heat Advance Requirements Table ............................................................... 6

PARALLEL MISALIGNMENT .................................................................................................... 7 Checking for Parallel Misalignment ............................................................................................. 7

ANGULAR MISALIGNMENT ..................................................................................................... 8

Checking for Angular Misalignment ............................................................................................. 8

MISALIGNMENT EXAMPLES................................................................................................... 9

Parallel Misalignment Example .................................................................................................... 9 Angular Misalignment Example ................................................................................................... 9 Combination Misalignment Example ............................................................................................ 9

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Section

6

Brakes and Couplings

BRAKE HUB INSTALLATION Brake hubs must be shrunk onto tapered motor shafts in order to achieve the tension and lockup required for the torque values involved. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

Clean and dress the bore and shaft to remove any deformity and foreign matter.

Mount the cold hub onto the shaft and measure the position of the hub on the shaft carefully.

Measure from the end of the shaft to the end of the hub. The dimension derived during this step will be used later.

Remove the hub and pre-heat the item until the “estimated temperature difference” has been reached. Refer to table below.

Example: If the shaft temperature = 25° C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the hub must be heated to 125°C (257°F) for mounting.

CAUTION:

BRAKE HUB TEMPERATURE SHOULD NEVER EXCEED 190°C (374°F) FOR INSTALLATION.

CAUTION:

Pre-heated components temperatures will often be brought to temperatures that can be extremely hazardous to the human body.

USE EXTREME CARE AND ALWAYS WEAR APPROPRIATE SAFETY EQUIPMENT WHEN WORKING WITH PRE-HEATED COMPONENTS AND AROUND THE PROCESSES.

Wipe all oil from both the shaft and the bore of the hub prior to installation.

Replace the heated hub on the shaft once again and take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the hub and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

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The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact.

chhubadv

Hub Adapter Pre-Heat Advance Requirements Table NOTE:

This table makes reference to brake hubs only, motor coupling advance data appears in a separate table later within this section.

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MOTOR COUPLING INSTALLATION Motor couplings must be shrunk onto tapered motor shafts in order to transmit the torque values involved without slippage. The procedure described below is intended to develop sufficient frictional force to transmit the imposed torque without dependence on the keyway.

Clean and dress the bore and shaft to remove any deformity and foreign matter.

Mount the cold coupling onto the shaft and measure the position of the coupling on the shaft carefully.

Measure the distance from the end of the coupling to the end of the shaft. The dimension derived during this step will be used later.

Remove the coupling and pre-heat the item until the “estimated temperature difference” has been reached. Refer to table below.

Example: If the shaft temperature = 25° C (77°F) and the estimated temperature difference derived from the table is 100°C (180°F), the coupling must be heated to 125°C (257°F) for mounting.

CAUTION:

PINION OR BRAKE COUPLING TEMPERATURE SHOULD NEVER EXCEED 190°C (374°F) FOR INSTALLATION.

CAUTION:

Pre-heated components temperatures will often be brought to temperatures that can be extremely hazardous to the human body.

USE EXTREME CARE AND ALWAYS WEAR APPROPRIATE SAFETY EQUIPMENT WHEN WORKING WITH PRE-HEATED COMPONENTS AND AROUND THE PROCESSES.

Wipe all oil from both the shaft and the bore of the coupling prior to installation.

Replace the heated coupling hubs on the shaft once again and take care to note the amount of advance (further movement) onto the shaft that has been obtained. If the advance amount does not fall within the limits called out in the table it will be necessary to remove the coupling and re-heat it to the specified temperature. IN ALL APPLICATIONS THE PROPER AMOUNT OF ADVANCE MUST BE ACHIEVED!

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The taper fit between mating parts shall be checked at assembly with Dykem or Blueing to assure a minimum of 80% bearing contact by marking during initial fit-up and comparing to actual fit after assembly.

chcpgadv

Motor Coupling Pre-Heat Advance Requirements Table

MOTOR COUPLING ALIGNMENT Final alignment of direct-driven units is made by moving or shimming the unit so that misalignment of the unit and drive shafts is within required tolerance from the general arrangement drawing received with your machine. Misalignment can be either offset, angular, or a combination of both.

Misalignment can occur in both the vertical and the horizontal plane. Refer to the following illustrations to bring couplings within the maximum acceptable misalignment.

The following method of coupling alignment uses a dial indicator. Readings taken 180 degrees apart will measure the runout in one plane. It is important to rotate both shafts to avoid errors due to surface imperfections of the shafts or couplings.

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PARALLEL MISALIGNMENT

cpgpmaln

Checking for Parallel Misalignment 1.

Mount the indicator on this coupling hub.

2.

Take readings in the horizontal plane at 90 and 270 degree positions on the hub while turning the shafts.

3.

Correct offset misalignment in the horizontal plane by shifting inboard and outboard feet an equal distance.

4.

Take indicator readings in the vertical plane at 0 and 180 degree positions.

5.

Correct offset misalignment in the vertical plane by adding or removing an equal thickness of shims at each foot.

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ANGULAR MISALIGNMENT

cpgamaln

Checking for Angular Misalignment 1.

Mount the indicator between the coupling hubs.

2.

Measure the gap between the hubs at 90 and 270 degree positions.

3.

Shift the outboard feet until coupling faces are parallel in the horizontal plane.

4.

Take coupling readings at 0 and 180 degree positions.

5.

Raise or lower the outboard feet with shims to parallel coupling faces in the vertical plane.

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MISALIGNMENT EXAMPLES

cpgpmex

Parallel Misalignment Example

cpgamex

Angular Misalignment Example

The following condition is encountered often after major repairs have been made to a machine. To remedy this condition approach the problem from one aspect (either angular, or parallel) at a time. Once close perform the procedure for the other. Duplication of either, or both processes may be required. cpgcmex

Combination Misalignment Example

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Section

7

Compressed Air System Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents GENERAL MAINTENANCE ........................................................................................................... 4 INTAKE AIR FILTER ................................................................................................................. 4 Air Filter ...................................................................................................................................... 4

FILTER REPLACEMENT................................................................................................... 5 COMPRESSOR RADIATOR................................................................................................... 5

ROTARY SCREW COMPRESSOR ............................................................................................. 6 COUPLING ALIGNMENT ......................................................................................................... 7 START-UP PROCEDURE ...................................................................................................... 7 SHUTDOWN ........................................................................................................................... 8 CONTROLS AND INSTRUMENTS ......................................................................................... 9 AIR PRESSURE CONTROL SYSTEM ............................................................................. 9 INLET REGULATING VALVE ............................................................................................. 9 AIR PRESSURE CONTROL VALVE ............................................................................... 10 VACUUM BREAKER VALVE ........................................................................................... 11 INLET AIR FILTER MAINTENANCE INDICATOR ............................................................. 12 OIL FILTER MAINTENANCE INDICATOR ........................................................................ 12 OIL SEPARATOR MAINTENANCE INDICATOR .............................................................. 13 DISCHARGE AIR PRESSURE GAUGE .......................................................................... 13 RECEIVER AIR PRESSURE GAUGE ............................................................................. 13 DISCHARGE AIR TEMPERATURE GAUGE.................................................................... 13 OIL INJECTION TEMPERATURE GAUGE ...................................................................... 14 Miscellaneous Components on the Air / Oil Receiver ................................................................. 14

HIGH DISCHARGE AIR TEMPERATURE LIMIT SWITCH ............................................... 15

Air Compressor and Associated Components ............................................................................ 15

HOURMETER ................................................................................................................. 16 SAFETY RELIEF VALVE.................................................................................................. 16 SOLENOID BLOWDOWN VALVE .................................................................................. 16 REDUCED UNLOADED HORSEPOWER FEATURE .................................................... 17 VARIABLE VOLUME FEATURE (OPTIONAL) ................................................................. 19

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LUBRICATION SYSTEM ....................................................................................................... 21 COMPRESSION OIL SYSTEM ....................................................................................... 21 OIL SPECIFICATIONS ..................................................................................................... 21 FILLING THE OIL SYSTEM (INITIALLY) ........................................................................... 22 OIL LEVEL GAUGE .......................................................................................................... 22 ADDING OIL BETWEEN CHANGES ............................................................................... 23 OIL CHANGE INTERVALS ............................................................................................... 23 DRAINING THE OIL SYSTEM .......................................................................................... 23 REFILLING THE OIL SYSTEM ........................................................................................ 24 COMPRESSOR OIL STRAINER AND FILTERS ............................................................. 24 COMPRESSOR OIL COOLER ....................................................................................... 26 COMPRESSOR OIL SEPARATOR ................................................................................. 26 COLD WEATHER START SYSTEM (OPTIONAL) .......................................................... 27 SYSTEM OPERATION .......................................................................................................... 28 AIR FILTERS ......................................................................................................................... 29 INLET AIR FILTER ........................................................................................................... 29 FILTER SERVICE ............................................................................................................ 29 MAINTENANCE SCHEDULE................................................................................................. 31 EVERY 125 HOURS OF OPERATION ........................................................................... 32 EVERY 1000 HOURS OF OPERATION ......................................................................... 32

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Section

7

Compressed Air System The main air system supplies compressed air for bailing the hole during drilling. The air also cleans and cools the bearings in the bit. The air is compressed by a screw air compressor. Inlet air passes through a filter before entering the compressor. Compressed air leaving the compressor flows through the main air line and through an unloader directional valve to the mast air pipe. When the main air valve is activated, a butterfly valve in the mast air pipe is opened and the air flows through the main air piping and unloader valve to the air seal connection of the rotary gearcase. It flows down through the drill pipe, through the bit and out of the hole, carrying out the cuttings. When the main air valve is deactivated, the unloader directional valve exhausts the air through a muffler to the atmosphere.

When the machine is equipped with a vane compressor, it also closes a butterfly valve on the inlet side of the compressor. amain59R

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GENERAL MAINTENANCE The general maintenance required for the main air system consists mainly of inspection of the components of the system to see that they are working properly and that all liquids are at their proper levels.

INTAKE AIR FILTER This filter is a two-stage, dry-type filter as mounted on an AC Compressor Corp. screw compressor.

The pre-cleaner stage removes most dirt before it reaches the second stage. Dirt from the first stage is automatically exhausted through an injector valve. The second stage consists of a primary cleanable element and a safety non-cleanable element.

Air Filter

CAUTION:

Manual No. 10424

NEVER ATTEMPT TO CLEAN A SAFETY ELEMENT. Change the safety element after the cleaning of the primary element or when indicated by the filter maintenance service indicator. ALWAYS INSTALL A CLEAN PRIMARY ELEMENT. The primary element should be replaced if damaged, after six cleanings or one year of service, whichever occurs first.

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FILTER REPLACEMENT The primary element should be cleaned, inspected and re-installed or replaced as follows: 1.

Loosen the wing nut, Remove the nut and gasket washer.

2.

Carefully remove the primary element using care not to dent or damage it.

3.

Wash the element by soaking it for 15 minutes or more in warm water with a mild detergent.

Rinse the element thoroughly with clean water until the water is clear.

4.

Allow the element to air dry completely. Warm flowing air (not to exceed 160oF) can also be used for drying the element. Do not use compressed air or a light bulb for drying.

5.

Inspect the element for any ruptures, holes or cracks in the pleated media. This can be done by placing a bright light inside the element and rotating it slowly. Replace the element if any of the above situations are present. Also replace the element if the end gaskets are damaged.

Clean out the inside of the filter housing with a damp cloth. Before installing the primary element, check the service indicator wing nut on the end of the safety element. Replace safety element if indicator has turned red. Carefully slide the cleaned or new element into the housing. Install the gasket washer and tighten the wing nut until the element is secure against the filter housing.

The safety element should be replaced as follows: 1.

Loosen the wing nut. Remove the nut and gasket washer.

2.

Carefully remove the primary element.

3.

Remove the cotter pin and service indicator wing nut holding the safety element in place.

Remove the element.

4.

Carefully slide the new safety element inside the filter housing. Install the service indicator wing nut and tighten. Install the cotter pin.

5.

Carefully slide the new or cleaned primary element into the filter housing. Install the gasket washer and tighten the wing nut until the element is secure against the filter housing.

COMPRESSOR RADIATOR Inspect the compressor cooling system once every shift. Check that the radiator is full and the fins clear. Inspect the radiator and piping for leaks.

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ROTARY SCREW COMPRESSOR This compressor is an A-C Compressor corp. KS-40-LU. The air end of the screw compressor is an oil flooded, single-stage, twin screw, rotary type. The following illustration, viewed from the bottom inlet end of the compressor, shows how it works. The suction (inlet) port is located on the top, drive shaft (inboard) end of the compressor. The discharge port is located on the bottom (outboard) end.

As the male rotor is turned counterclockwise (by the clockwise rotation of the gear shaft and gears - not shown), it drives the female rotor clockwise. This action causes air to be drawn through the suction port completely filling the uncovered channels or grooves between the spiral (helical) lobes in the male and female rotors. As the rotors continue to turn, the lobes begin to intermesh at the bottom. This intermeshing causes the spiral grooves to become shorter, thus resulting in the compression of the air entrapped in the grooves. Compression continues until the grooves are uncovered by the discharge port.

During the compression process, cool oil is injected into the entrapped air by a gear-type oil pump, direct driven by the outboard end of the male rotor. The oil is injected for the following reasons: 1.

COOLING - The oil removes the heat of compression to maintain discharge air temperatures below 200oF.

2.

SEALING - The oil seals the internal clearances between the rotor, cylinder, and discharge end casing to prevent loss of air volume back to the inlet.

3.

LUBRICATION - The oil lubricates the rotors, bearings, gears, and mechanical shaft seal.

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COUPLING ALIGNMENT For all coupling information, refer to Section 6 - BRAKES AND COUPLINGS, in this manual.

START-UP PROCEDURE 1.

COMPRESSOR COUPLING ALIGNMENT - Check coupling alignment before initial start-up and re-align if necessary.

2.

COMPRESSOR OIL - The compressor air end, air/oil receiver, and radiator oil cooler must be filled with recommended oil.

NOTE:

After initial start-up, the oil level in the receiver will drop due to the oil filling the piping system. Shut down the compressor after approximately 15 minutes of operation. Check the oil level gauge. If the oil level is below the bull’s eye, refill the oil reservoir.

For accurate readings, the machine must be level when checking the oil level.

CAUTION:

THE RECEIVER CONTAINS HOT OIL UNDER PRESSURE. ALWAYS CHECK THE RECEIVER PRESSURE GAUGE TO MAKE CERTAIN THE PRESSURE IS AT ZERO PSI BEFORE OPENING THE FILL PLUG.

3.

DRAIN RECEIVER CONDENSATE – Open the receiver drain valve slightly to drain off any condensate. Close the valve securely when oil appears.

4.

ROTATION - Check rotation by momentarily starting (jogging) the motor. Compressor rotation is clockwise when facing its drive shaft end.

5.

OPEN BUTTERFLY VALVE - Open the butterfly valve located in the discharge air line downstream from the receiver.

CAUTION:

6.

START MAIN OIL PUMP - Press the compressor START button and the compressor main oil pump will start. When the oil pressure reaches 30 PSIG the compressor motor will start.

NOTE:

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NEVER START THE COMPRESSOR WITH THE BUTTERFLY VALVE CLOSED.

If the oil temperature in the tank is below -15oF a temperature switch will prevent the main oil pump from starting. The temperature switch will then turn on the tank heater and the tank oil circulating pump. When the oil reaches 15oF the heater and circulating pump will shut off and the main oil pump will start. When oil pressure reaches 30 PSIG the compressor motor will start.

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7.

OBSERVE DISCHARGE AIR PRESSURE - The minimum pressure orifice will maintain a minimum pressure of approximately 20 PSIG in the receiver. Pressure higher than this minimum will be regulated by the drill bit orifice size or air pressure control valve setting. The discharge air pressure must not exceed maximum rating plate pressure during the loaded cycle. However, momentary over-pressures up to the 85 PSIG safety relief valve setting are permitted (e.g. to blow out clogged drill bit orifices).

8.

OBSERVE DISCHARGE AIR TEMPERATURE - The maximum discharge air temperature must not exceed 200oF.

NOTE: The air temperature limit switch is factory set to shut down the unit at 225oF. 9.

OBSERVE THE OIL INJECTION TEMPERATURE - The oil injection temperature must not exceed 150oF.

10.

UNLOADING COMPRESSOR - To unload the compressor, close the downstream butterfly valve. The compressor inlet regulating valve will close automatically and the air receiver pressure will rise approximately 10 PSI above the air pressure control valve setting. The discharge air temperature must not exceed 200oF. Oil injection temperature must not exceed 150oF. Discharge air pressure should not be higher than 15 PSIG above the rating plate pressure.

11.

In cold weather, immediately after start-up, close the downstream butterfly valve to unload the compressor. The resulting higher receiver pressure will produce a faster oil heating rate and provide a greater driving force to push the oil through the oil cooler when the thermostatic valve opens.

SHUTDOWN Before shutting down the compressor, close the downstream butterfly valve to unload the compressor. This will avoid excessive foaming and oil carry-over past the oil separator caused by rapid venting of the receiver tank pressure. The solenoid blowdown valve will open upon shutdown and gradually reduce receiver pressure to zero PSIG in approximately one minute.

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CONTROLS AND INSTRUMENTS AIR PRESSURE CONTROL SYSTEM After starting the compressor with the discharge air line butterfly valve open, a minimum receiver pressure of approximately 20 PSIG will be maintained by the minimum pressure orifice if the pressure produced downstream from the receiver is less than 20 PSIG, but lower than the maximum allowable rating plate pressure setting of the air pressure control valve, the inlet regulating will remain fully open and thus deliver 100% of its rated volume to the drill bit.

If the pressure in the air receiver rises above the maximum setting of the air pressure control valve, the control valve will start to open to admit air to the top of the inlet regulating valve diaphragm. The diaphragm will then start to close the inlet valve. If the receiver pressure continues to rise, the air pressure control valve will continue to admit air to the diaphragm to close the inlet valve until the receiver pressure levels off.

When the butterfly valve downstream is closed to shut off the air supply to the drill bit, the air pressure control valve will completely open to permit the diaphragm to completely close the inlet valve. The pressure in the receiver will rise approximately 10 PSI above the air pressure control valve setting.

NOTE:

The receiver pressure should not go beyond 10 PSIG above the rated pressure. Readjust the air pressure control valve setting, if necessary, to lower the receiver pressure.

When the inlet valve is completely closed, some inlet bleed air must be provided to prevent excessive inlet vacuum. The vacuum breaker valve then opens to circulate (bypass) air from the receiver to the inlet.

INLET REGULATING VALVE At start-up, the rotation of the compressor rotors produces a vacuum downstream from the inlet regulating valve. This drop in pressure causes the atmospheric pressure upstream of the valve to “push” the inlet valve completely open and thus provides full flow of air into the compressor. As explained above, the inlet valve is closed by the air pressure control valve admitting air to the diaphragm. The orifice in the regulating valve is required to provide a continuous bleed of air through the air pressure control valve. This flow of air provides the necessary pressure differential across the control valve for it to operate properly.

In addition to regulating the inlet air volume, the inlet valve also acts as a check valve when the compressor shuts down. When the compressor shuts down, the regulating valve spring will rapidly close the inlet valve. This prevents the pressurized air and oil in the compressor and downstream system from flowing back through the inlet air filters.

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AIR PRESSURE CONTROL VALVE As explained above, the purpose of the air pressure control valve is to control the receiver pressure by opening or closing the inlet regulating valve.

v_aprctl

If the receiver air pressure is higher than 10 PSIG above the rating plate pressure when the inlet butterfly valve is closed, the air pressure control valve must be re-adjusted to a lower setting as follows: 1.

Open Butterfly valve.

2.

Loosen locknut on air pressure control valve stem.

3.

Rotate handle one turn CCW (when viewed from the top) to screw the stem out. This decompresses the internal spring and lowers the valve setting.

4.

Close butterfly valve. Observe pressure gauge. Repeat steps 1, 2, 3 and 4 until receiver pressure is less than 10 PSIG above the rated plate pressure.

5.

Tighten lock nut.

If it is desired to lower the receiver pressure while drilling (butterfly valve open), adjust the air pressure control valve as follows: 1.

Loosen locknut

2.

Turn handle CCW until desired lower receiver pressure is attained.

3.

Tighten locknut.

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VACUUM BREAKER VALVE The vacuum breaker valve is factory adjusted to maintain the proper inlet vacuum by circulating air from the receiver back to the compressor inlet. If the vacuum is too high, a hydraulic “hammering” noise will develop within the compressor and it will then become necessary to re-adjust the vacuum breaker valve to a lower vacuum setting.

v_vacbkr

Adjust the valve as follows: 1.

Shut down the compressor and install a vacuum gauge located in the oil scavenging line.

2.

Check the vent tube on the top of the vacuum breaker valve to make sure it is clean and open to the atmosphere.

3.

Start up the compressor.

4.

Loosen locknut on the vacuum breaker valve.

5.

Turn the adjusting screw out by rotating it CCW (viewed from the bottom) until the compressor becomes quiet and the vacuum is within the allowable range as follows: OPERATING ALTITUDE (Ft. Above Sea Level) 0 2500 5000 7500 10000 12000 -

-

ALLOWABLE UNLOADED INLET -

Vacuum Range (HgV) 22-16 19-23 17-21 15-19 14-18 12-16

-

6.

Tighten locknut.

7.

Shut down compressor and remove vacuum gauge. Plug the tee connection.

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INLET AIR FILTER MAINTENANCE INDICATOR Maintenance indicators are located on the outlets of each inlet air filter. The indicator shows red in its window when the filter requires servicing. After servicing filter depress the reset button on top of the maintenance indicator.

OIL FILTER MAINTENANCE INDICATOR This maintenance indicator is located on the instrument panel to indicate when the oil filter element should be replaced. The filter element should be replaced when the indicator shows completely red in its window while the compressor is running.

NOTE:

The red flag will disappear from the window when the compressor is stopped. It will reappear when the compressor is restarted if the filter element has not been replaced.

cpnl_59r

Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

OIL SEPARATOR MAINTENANCE INDICATOR A maintenance indicator is located on the side of the receiver to indicate when the oil separator should be replaced. The separator should be replaced when the indicator shows completely red in the window while the compressor is running loaded.

NOTE:

The red flag will disappear when the compressor is stopped. It will reappear when the compressor is re-started if the oil separator has not been replaced.

DISCHARGE AIR PRESSURE GAUGE A direct reading Pressure gauge is located on the instrument panel which indicates the air pressure at the compressor discharge flange.

CAUTION:

THIS READING MUST NOT EXCEED THE RATED PLATE PRESSURE WHILE RUNNING LOADED, OR 15 PSIG HIGHER THAN THE RATED PLATE PRESSURE WHILE UNLOADED.

RECEIVER AIR PRESSURE GAUGE A direct reading pressure gauge is located on the receiver which indicates receiver air pressure downstream from the receiver oil separator.

DISCHARGE AIR TEMPERATURE GAUGE A direct reading temperature gauge is located on the instrument panel which indicates the air temperature at the compressor discharge flange.

CAUTION:

August 2006

THIS READING MUST NOT EXCEED 200OF AT ANY TIME.

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Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

OIL INJECTION TEMPERATURE GAUGE A direct reading temperature gauge located on the instrument panel which indicates the temperature of the oil at the point of injection into the compressor (air end).

NOTE: This reading should not exceed 150oF. arcvr59r

Miscellaneous Components on the Air / Oil Receiver

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

HIGH DISCHARGE AIR TEMPERATURE LIMIT SWITCH A fast reacting electronic type temperature limit switch installed below the instrument panel and is factory set to shut down the compressor if the air temperature at the compressor discharge flange exceeds 225oF. This switch is also fail-safe. It will shut down the compressor if the sensing element circuit is damaged or if the control voltage to the switch is disrupted.

Air Compressor and Associated Components

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Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

HOURMETER A continuous reading (non-reset type) hourmeter is installed on the instrument panel and displays the accumulated operating time of the compressor. It provides a convenient means for scheduling the oil supply change-outs (every 1000 hours).

SAFETY RELIEF VALVE A pressure safety relief valve located on the side of the receiver and set to relieve the pressure at 85 PSIG. Periodic checks should be made to insure its proper operation.

CAUTION:

NEVER OPERATE THE UNIT WITHOUT A PROPER SAFETY VALVE SETTING.

SOLENOID BLOWDOWN VALVE A solenoid valve installed on the receiver outlet and wired to automatically open and blowdown the receiver, piping and compressor air end when the compressor is stopped. The blowdown time is approximately one minute to reduce the pressure down to 0 PSIG. NOTE:

Too rapid a blowdown would cause oil foaming and excessive oil carry-over past the oil separator.

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August 2006

BI616958

Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

REDUCED UNLOADED HORSEPOWER FEATURE The reduced unloaded horsepower feature reduces the compressor horsepower draw by reducing and maintaining the pressure in the receiver tank below 35 PSIG whenever the compressor is operated in the UNLOADED mode by closing the butterfly valve. The oil cooler and back pressure valve are on the discharge side of the pump to allow lower tank pressures.

The following items make up the reduced horsepower feature: Pressure switch, Pressure reducing valve, Solenoid valve, and air bleed orifice.

The pressure switch is set to open at 35 PSIG when pressure falls and is used to control the tank solenoid blowdown (vent) valve. If the tank pressure is above 35 PSIG when the compressor is unloaded, the pressure switch will open the solenoid valve and vent the tank pressure down to 30 PSIG and return to the valve’s closed position.

Simultaneously, a bypass air line around the air pressure control valve opens to admit air pressure from the receiver tank onto the inlet valve diaphragm to close the inlet valve. The solenoid valve normally keeps this bypass line closed during drilling, but will open whenever the operator unloads the compressor (using a signal from the butterfly valve actuator). The solenoid is set to delay the opening of the inlet valve approximately 2 seconds when switching from the UNLOADED to the DRILLING mode. This time delay is required because the compressor inlet valve opens faster than the butterfly valve. Otherwise, the tank pressure would overshoot and reach the pressure setting of the air pressure control valve. This results in a shortened life for the inlet valve diaphragm. If the time delay is too long, the compressor will shudder and vibrate. The time delay should only be long enough to prevent the tank pressure from overshooting and causing the inlet valve to cycle unnecessarily.

The pressure reducing valve, in the same line as the solenoid valve, prevents excessive pressure from acting on the inlet valve diaphragm. This valve is normally open, and closes as the diaphragm pressure builds-up and approaches the adjusted “lock-up” pressure setting of this valve. If the valve is properly adjusted after unloading the compressor, the diaphragm pressure should not go above 30 PSIG. The inlet valve is fully closed when the diaphragm pressure is approximately above 10-15 PSIG. If the lock-up pressure setting of the valve is too low, the inlet valve will not fully close when the compressor is unloaded. The tank pressure will rise to the setting of the air pressure control valve. The solenoid blowdown valve will stay open and continue to try to reduce the tank pressure to 30 PSIG. To reduce the tank pressure when the compressor is unloaded: 1.

Loosen the locknut on the pressure reducing valve and slowly turn the adjusting screw clockwise until the pressure gauge on the receiver tank shows the pressure is beginning to reduce.

2.

Continue turning the screw clockwise until the tank pressure reduces to 25-30 PSIG and the solenoid blowdown valve closes.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

3.

Re-tighten the locknut.

If the lock-up pressure setting of the valve is too high, pressures in excess of 30 PSIG will increase on the inlet valve diaphragm when the compressor is unloaded. This will result in shortened diaphragm life.

To reduce maximum pressure on the inlet valve diaphragm: 1.

Loosen the pressure reducing valve locknut and slightly turn the screw counter-clockwise.

2.

Install a 0-60 or 0-100 PSIG pressure gauge on top of the inlet valve to measure the diaphragm pressure.

3.

Unload the compressor and check if the diaphragm pressure exceeds 30 PSIG. If it does, continue to turn the screw counter-clockwise.

4.

Re-tighten the locknut.

With the reduced unloaded horsepower feature, the air pressure control valve no longer controls the receiver tank pressure when the compressor is unloaded, but only limits how high the tank pressure will rise when the tri-cone bit becomes plugged during drilling. If the bit becomes plugged, the valve should be adjusted to raise the tank pressure a minimum of 10 PSIG above normal to clear out the bit. Do not exceed the pressure rating on the compressor name plate.

To adjust the air pressure control valve: 1.

Simulate an open contact condition on the pressure switch by disconnecting a wire at the pressure switch contact to keep the tank solenoid valve closed.

2.

Disconnect the wire at the solenoid valve. This will keep the valve in a closed position.

3.

Close the butterfly valve to unload the compressor and observe at what pressure the tank stabilizes.

4.

To increase the tank pressure level, loosen the air pressure control locknut and rotate the Thandle clockwise when viewed from the top. Continue turning until the desired tank pressure is achieved without exceeding the pressure rating on the compressor name plate. Re-tighten the locknut.

5.

To reduce the tank pressure, open the butterfly valve to load the compressor. Loosen the locknut on the air pressure control valve and rotate the T-handle counter-clockwise. Close the butterfly valve to unload the compressor. Check the adjusted pressure level in the receiver tank. If the tank pressure still needs to be lowered, repeat this procedure. If the tank pressure needs to be raised, follow the procedure in step 4. Re-tighten the locknut.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

After the tank has been adjusted to the desired pressure level, reconnect the wiring at the pressure switch contacts and the solenoid valves. This will re-connect the reduced unloaded horsepower feature.

With the reduced unloaded horsepower oil piping arrangement, the oil pump flow rate can be controlled by adjusting the pressure setting of the back pressure valve. The valve is adjusted to the proper flow rate if the temperature rise across the compressor is approximately 54o to 58oF. This is measured by noting the discharge air/oil temperature and subtracting the oil injection temperature, using the two thermometer gauges on the compressor instrument panel. In cold weather, the oil is thicker at start-up and the pump discharge pressure provides the driving force to initiate oil flow through the oil cooler.

VARIABLE VOLUME FEATURE (OPTIONAL) The purpose of the variable volume feature is to decrease the bailing velocity to reduce/eliminate sandblasting of the drill pipe and bit, resulting in increased life of these components. To reduce the bailing velocities, reduce the air flow rate or CFM of the compressor. Turning in the square head setscrew, so that it protrudes through the inside face of the cover on the inlet valve, will push on the inlet valve and partially close it. This limits how far the inlet valve can open while drilling, resulting in the desired throttling of the air flow through the compressor.

The variable volume feature can be adjusted three ways: 1.

The operator can turn in the square head setscrew to reduce the compressor CFM and inspect the size of the chips produced from drilling, keeping track of the life of the bit and pipe to determine the optimum position of the setscrew.

2.

Many bit manufacturers have instructional literature available with bit pressure tables. These tables will show what the bit pressure should be based on the size of the orifices in the bit and the CFM produced by the compressor. Once the desired bailing velocity has been determined, this number should be converted to the desired CFM of the compressor.

Use the following formula:

Qd =.0055 (V) (Db2 - Dp2) Qd = Desired Compressor CFM V = Desired Bailing Velocity (ft./min.)

Db = Bit Diameter (inches) Dp = Pipe Outside Diameter (inches) Using this CFM formula, go into the bit pressure tables and determine what the expected bit pressure is for the type of bit and size of the orifices you are using. Then adjust the variable amount setscrew to obtain this desired bit pressure.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

3.

The third method uses the vacuum gauge in the kit to adjust the variable volume setscrew.

First, determine the desired bailing velocity and calculate the CFM required using the formula given in step 2 above. Look at the compressor rating plate to determine the original CFM rating of the compressor. Divide the desired CFM by the original compressor rated CFM, subtract from 1 and multiply by 30 to determine the number of inches of mercury vacuum that should show on the vacuum gauge when the variable volume setscrew is properly adjusted.

The following is an example of how to use this vacuum method:

Let’s assume that a 9-7/8" bit is used with 7-3/4" drill pipe and the compressor is a model KS31LU rated at 2150 CFM. This will result in a bailing velocity of 10,523 ft./min. Assume that we want to reduce the bailing velocity to 8,738 ft./min. Using the formula in step 2, this converts to a desired compressor rating of 1800 CFM. To determine what the reading should be on the vacuum gauge while drilling, we will use the above formula as follows:

V1 = 30 x (1 - Qd/Qo) V1 = 30 x (1 - 1800/2150) = 4.9 inches Hg vac.

Qd = Desired Compressor CFM Qo = Original Compressor Rated CFM V1 = Vacuum Gauge Reading (in. Hg vac.)

This third method, in most cases, is the best way to initially adjust the CFM. The adjustment can then be fine-tuned by watching the size of the chips and the wear-life of the drill pipe and bit.

NOTE: It is important that the sealing locknut be tightened until it has a metal-to-metal relationship against the cover. The plastic insert of this nut will seal and prevent the leakage of air pressure from the diaphragm chamber inside the inlet valve. This locknut is reusable and can be loosened and re-tightened many times.

After adjusting the setscrew, especially when reducing the compressor CFM by a large amount, make sure the tank pressure while drilling is greater than 20-25 PSIG. This will avoid excessive oil carryover.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

LUBRICATION SYSTEM COMPRESSION OIL SYSTEM The oil cools the compressor, lubricates the rotors, bearings, gears and mechanical shaft seal and seals the internal clearances in the compression chamber.

The oil return line from the receiver is connected to a pipe which internally extends near the bottom of the receiver. The oil pump draws the oil from the receiver and sends it through the back pressure regulator. As the oil heats up, the back pressure valve will close and the oil will pass through the oil cooler.

The oil pump raises the oil pressure to the proper level and forces the oil through the rotor and bearing oil filters into the compressor air end.

The oil passes through the compressor internal passages for lubrication, cooling and sealing during the compression cycle. The air-oil mixture is then discharged to the receiver where most of the oil is removed by impingement and velocity change. The air and oil mist remaining in it are then passed through the oil separator. The oil impinging on the outside of the separator drains back into the receiver. The remaining oil is coalesced on the inside of the separator and drawn from the separator bottom through the oil scavenging tube back to the compressor inlet.

OIL SPECIFICATIONS The following lubricants are recommended: •

Automatic Transmission Fluid can be used for year-round operation. It must meet General Motors specifications for DEXRON II fluid or Ford specification ESW-M2C33-F (Type F fluid).

•

Turbine-type oil can be used if the ambient air temperature is above 32oF at all times. It must have a minimum viscosity of 145-210 SSU at 100oF, maximum pour point of OoF, and must contain anti-rust, anti-oxidant, and anti-foam inhibitors. It must also contain demulsifiers to promote rapid separation from water and have a minimum flash point of 400oF.

NOTE:

August 2006

Cold ambient temperature may cause the lubricant to thicken in the oil cooler and result in unit shutdown after a short run. The use of a synthesized hydrocarbon lubricant may be required. Care should be taken to insure its viscosity, foam, oxidation, and corrosion properties that are equal to or exceed those of the recommended automatic transmission fluid. An acceptable synthetic lubricant for year-round operation is Conoco’s Syncon oil, ISO grade 46. Any other synthetic lubricant must be authorized by compressor manufacturer.

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Manual No. 10424

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

FILLING THE OIL SYSTEM (INITIALLY) To initially fill the compressor: 1.

Remove pipe plug from receiver oil fill connection.

2.

Fill the receiver with recommended oil to top of the gauge glass with approximately 75 gal. for model KS40AC.

3.

Replace and tighten pipe plug.

4.

Remove plug from fill connections on top of radiator cooler and fill to top.

NOTE: The capacity will vary with cooler size (from 7-13 gallons).

5.

Replace cooler fill plugs and tighten.

6.

Remove plug from oil (initial) fill connection on compressor. Fill the compressor body.

7.

Replace oil fill plug and tighten.

8.

Start compressor and run compressor for approximately 15 minutes. Shutdown compressor, check oil level, and replace oil if necessary.

OIL LEVEL GAUGE The receiver oil level gauge should be observed daily to check the oil level. If the oil level is below the level gauge bull’s-eye, while running, stop the compressor and check the level with the receiver at zero pressure. The oil level must be maintained within the bull’s-eye.

NOTE: The machine must be level when checking oil level.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

ADDING OIL BETWEEN CHANGES If the receiver oil level is below the level gauge bull’s-eye, while running, stop the compressor and allow the receiver to blow-down to zero pressure. If the oil level is below the bull’s-eye, add oil until the level is at the top of the bull’s-eye.

NOTE: The machine must be level when checking oil level CAUTION:

THE RECEIVER RESERVOIR CONTAINS HOT OIL UNDER PRESSURE. Before adding oil, the compressor must be stopped and the receiver at zero pressure before removing the fill plug. Make sure the plug is tight after filling.

OIL CHANGE INTERVALS The oil change interval is determined by air filter maintenance, operating conditions, and the quality of the oil. Change the oil often enough so that the drained oil is clean. Under good operating conditions, the recommended oil may be used up to 1000 hours for standard oils. If synthetic lubricants are used, the time between oil changes can vary between 4,000 and 8,000 hours depending on the lubricant used. Refer to oil manufacturer’s recommendations. When operating conditions are severe (high temperature, high humidity, or very dusty) it will be necessary to change oil more frequently.

Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user.

DRAINING THE OIL SYSTEM Before draining the oil system, compressor must be stopped and receiver at zero pressure. Always drain the complete system. Draining while the oil is hot will help to prevent varnish deposits and to carry away impurities. The KS40AC compressor, receiver, oil cooler and piping take approximately 165 gallons. To drain the system, use the following procedure: 1.

Stop compressor and wait until receiver pressure is zero.

CAUTION:

2.

August 2006

USE CARE NOT TO TOUCH HOT OIL WHILE DRAINING.

Open valve on oil reservoir and drain the oil. Close drain valve. Remove magnetic drain plug and clean it. Replace plug and tighten.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

3.

Open drain connections on oil cooler and drain completely.

NOTE: Open fill plugs slightly to vent the cooler while draining. Replace plugs and tighten.

4.

Remove plugs from oil drains on compressor air end sump and bearings, seal, and gear cavities. Drain oil completely.

NOTE: Place a large oil pan under drains before removing plugs. Replace and tighten plugs.

5.

Remove plug from compressor discharge pipe oil drain and drain oil completely.

NOTE: Place a large oil pan under drain before removing plug. Replace plug and tighten.

6.

Remove the plugs from the oil filter and drain oil completely.

NOTE: Place an oil pan under the filter before removing the plug. Replace the plug and tighten.

REFILLING THE OIL SYSTEM Refer to FILLING OIL SYSTEM (INITIALLY) procedure above. Follow steps 1 through 5 to fill the receiver and oil cooler. It will not be necessary to refill the compressor body with oil after the initial oil fill. After start-up, the oil pump will inject the required amount of oil into the compressor from the receiver. However, it will then be necessary to stop the compressor after approximately 15 minutes and refill the oil receiver to the top of the level gauge.

COMPRESSOR OIL STRAINER AND FILTERS The compressor oil system contains the following strainer and filters: 1.

PUMP INLET STRAINER - This Y-type strainer is installed at the pump inlet to prevent foreign material from entering the pump. The strainer basket should be removed, cleaned and inspected every time the oil is changed.

2.

OIL FILTERS (Rotors, 74 micron; Bearings; Seal and Gears, 20 micron) - These filters are installed to filter the oil supply to the compressor (rotors), bearings, mechanical seal, and gears where clean oil is especially desired for optimum life expectancy.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

The oil filters described above are constructed as shown. The fluid flow is always from the inside to the outside of the filter element. A diverter/bypass valve, located in the filter head, reduces turbulence and minimizes pressure drop. The diverter/bypass valve insures full-flow filtration until bypass is reached. The large size of the valve insures a low pressure drop when bypass setting is reached.

It is important that the filter element be changed as the red flag appears completely in the maintenance indicator window. As a preventative maintenance procedure, the user should consider changing the filter elements at least every oil change, even though the red flag may not be completely showing.

Clean oil is essential for maximum compressor life.

When replacing the filter element, use the following procedure: 1.

Shut down the compressor and relieve all pressure in the filter line.

2.

Loosen the cover hex head capscrews. Turn cover slightly to clear capscrews and remove cover. Allow excess fluid to drain.

3.

Remove diverter/bypass valve assembly from filter head. Filter element will be removed with the valve. Remove element from valve.

4.

Install new element on diverter/bypass valve assembly and re-install in filter housing. Make sure that the diverter o-ring seats properly into the head.

5.

Make sure the notch on the diverter/bypass valve assembly lines up with the notch in the head.

6.

Install the cover o-ring and replace it if necessary.

7.

Replace cover and tighten cover capscrews until they are snug. DO NOT over-torque these capscrews.

NOTE: Element can also be changed by removing the six capscrews which hold the bowl to the head. The bowl and element can then be removed from below.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

COMPRESSOR OIL COOLER The oil cooler is a radiator type which utilizes a pusher-type fan driven by a separate electric motor.

Do not obstruct air flow to and from the cooler. Keep both faces of the oil cooler core clean for efficient cooling of the compressor oil. Oil cooler malfunction may be diagnosed by a higher than normal oil injection temperature. This oil temperature normally should not exceed 150oF when the ambient air temperature is less than 100oF. CAUTION:

DO NOT INSTALL A THERMOSTATIC CUT-OUT ON THE RADIATOR FAN MOTOR. This causes thermal cycling of the radiator core which could result in cracks and subsequent oil leakage.

COMPRESSOR OIL SEPARATOR The oil separator is located in the inside, upper half of the receiver and provides the final removal of oil from the air stream. Oil impinging on the outside of the separator drains directly back into the receiver reservoir. The finer oil droplets are coalesced and collected on the inner wall where the liquid oil drains to the bottom of the separator. A scavenging tube continuously draws off this oil from the bottom and returns it to the compressor inlet through a Y-type strainer and orifice/sight flow indicator.

NOTE: A continuous flow of oil should be visible in the sight glass while running loaded.

Excessive oil carryover to the piping downstream from the receiver may be caused by a faulty oil separator, foaming oil, or an oil scavenging (return) line malfunction. Inspect the oil separator for failure only after it has been determined that the oil is not foaming and the oil return line is not malfunctioning. Check the sight glass in the scavenging line while the compressor is running. If little or no oil is visible, shut down the compressor. Disconnect the line at the sight glass inlet and clean the orifice using a wire or pin. Remove and clean the strainer basket upstream of the sight glass. Before reconnecting the sight glass, blow through the scavenging line into the receiver to make sure that the line is not plugged with solids. Re-connect the sight glass and restart the compressor. If oil flow is still not visible, remove and replace separator as described below.

Oil carryover malfunctions of the oil separator are usually due to using the element too long, heavy dirt or varnish deposits which are the result of inadequate air filter service, using improper oil, or using the oil for too long for existing conditions. Heavy deposits of dirt or varnish build-up on the element will cause it to rupture or collapse. The oil separator should be changed when the separator maintenance indicator shows a red flag in its window while running loaded. This will occur when the air pressure differential across the separator is approximately 10 PSI.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

COLD WEATHER START SYSTEM (OPTIONAL) A cold weather start system may be installed on the compressor to help eliminate the problems that can occur during start-up in extreme cold weather conditions. This system is required when the ambient temperature range drops below -10oF. The following components are added to the compressor system when the optional cold weather start system is used: 1.

BACK PRESSURE REGULATING VALVE - This valve replaces the thermostatic valve. The valve is used to route the oil around the radiator when the oil is cold and pressure drop through the radiator is excessive. The valve also permits the flow of oil through the radiator when oil pressure falls below 150 PSIG.

2.

74 MICRON OIL FILTER - For extra protection of the rotors, gears, bearings and seals, the 10 micron oil filter element is replaced with a 20 micron filter element and an additional filter with a 74 micron filter element is added to the system.

3.

CONOCO SYNCON ISO Grade 46 SYNTHETIC LUBRICANT - This lubricant is used in place of the standard lubricant and can be used year-round.

4.

RADIATOR CABIN LOUVERS - Inlet louvers are installed on the air suction side of the radiator and outlet louvers are installed on the air discharge side of the radiator to aid in keeping the oil warm on cold start application. The louvers are controlled by a signal produced from a resistance temperature detector (RTD) mounted in the radiator oil return line.

5.

RESISTANCE TEMPERATURE DETECTOR (RTD) - The RTD is mounted in the radiator return oil line to monitor the temperature of the oil. It will send a signal for the radiator fan motor to start and the cabin louvers to open at 130oF intervals.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

SYSTEM OPERATION Upon start-up of the compressor in cold weather, oil will be drawn from the receiver tank and discharged through the oil pump.

NOTE: If the oil temperature in the tank is below -150oF a temperature switch will prevent the main oil pump from starting. The temperature switch will then turn on the tank heater and the tank oil circulating pump. When the oil reaches -15oF the heater and circulating pump will shut off and the main oil pump will start. When oil pressure reaches 30 PSIG the compressor motor will start.

The pump suction will be 10-65 PSIG and the pump discharge will be 105-150 PSIG with the internal by-pass set at 95 PSID. If the oil viscosity becomes too high because of the cold temperatures, the pressure required to push the oil through the radiator lines will increase greatly. The pressure at the pump discharge will rise to the 150 PSIG set point of the back pressure regulating valve. This valve will route the oil around the radiator and send it to the oil filters. The first filter has a 74 micron element for protection of the rotors, and second filter has a 20 micron element for protection of the gears, bearings, and seals. Under cold start conditions, the expected pressure drop through the 74 micron element will be 10-15 PSID and the drop through the 20 micron element will be 30-35 PSID. The internal by-pass for both filters is 35 PSID. As the oil warms up, the viscosity will decrease, which lowers the pressure required to push the oil through the radiator. When the oil pressure drops below 150 PSIG, the back pressure regulating valve will close, allowing the oil to flow through the radiator and be cooled.

After the oil has warmed up, the resistance temperature detector (RTD) located in the radiator oil return line, will sense the temperature discharged from the radiator. When this temperature reaches 130oF, the radiator fan will start. When the oil reaches 130oF again, the oil inlet louvers will open.

When the oil reaches 130oF for the third time, the outlet louvers will open. This sequence is reset upon compressor shutdown.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

AIR FILTERS INLET AIR FILTER The inlet air filter is a heavy duty, two-stage, dry-type filter. The pre-cleaner stage removes most of the dirt before it reaches the primary element. The dirt is automatically ejected through the “Vacuator” ejector valve, eliminating frequent cleaning of the dust bin as used in other filter types.

The primary element is the second stage of filtration where the remaining particles of dirt are removed. This element is constructed with washable filter media. The primary element should be replaced if damaged, or after six cleanings, or one year of service, whichever comes first.

The safety element provides back-up protection in case of damage to the primary element during operation. It also guards the compressor during shutdown while the primary element is being cleaned.

It is a non-cleanable element.

CAUTION:

NEVER ATTEMPT TO CLEAN A SAFETY ELEMENT. Change the safety element after three cleanings of the primary element or when indicated by the service indicator wing nut on the end of the safety element.

FILTER SERVICE The primary element should be removed when the red flag appears in the service indicator window.

The element should be cleaned, inspected, and re-installed or replaced as follows: 1.

Loosen the wing nut. Remove the nut and gasket washer.

2.

Carefully remove the primary element using care not to dent or damage it.

3.

Wash the primary element by soaking it for 15 minutes or more in warm water with a mild detergent. Rinse the element thoroughly with clean water until the water is clear. A hose may be used, provided the water pressure does not exceed 40 PSIG.

4.

Allow the element to air dry completely. Warm, flowing air (not to exceed 160oF) can also be used for drying the element. Do not use compressed air or light bulbs.

5.

Inspect the primary element by placing a bright light inside of it and slowly rotating the element.

Replace the element if any ruptures, holes, or cracks are discovered in the pleated media.

Replace the element if the gaskets on the ends of the element are damaged.

6.

Using a damp cloth, wipe out all excess dust inside the filter housing before re-installing the primary element. Before re-installing the primary element, check the service indicator wing nut on the end of the safety element. Replace safety element if indicator has turned from green to red.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

Carefully slide the cleaned or new primary element into the filter housing. Install the gasket washer and tighten the wing nut until the element is secure against the filter housing.

The element should be replaced as follows: 1.

Loosen the wing nut. Remove the nut and gasket washer.

2.

Carefully remove the primary element. Clean or replace, if necessary, as described above.

3.

Remove the cotter pin and service indicator wing nut holding the safety element in place.

Remove the element.

4.

Carefully slide a new safety element inside the filter housing. Install the service indicator wing nut and tighten. Install the cotter pin.

5.

Carefully slide the primary element into the filter housing. Install the gasket washer and tighten the wing nut until the element is secure against the filter housing.

During intervals between servicing of the filter elements, perform the following inspection: 1.

Check to make sure that the filter inlets are clean and not clogged with paper, rags, or other debris.

2.

Check the connections between the filter and compressor inlet to make sure that all of the clamped and bolted connections are tight and leakproof.

Check the “Vacuator” ejector valve to make sure that it is not plugged or damaged and is sealing properly around the filter housing cups.

CAUTION:

Do not operate without a ‘Vacuator” valve on the filter, since this will cause short element life.

In addition to the above, the following precautions should be observed in the servicing of the air filters: 1.

Do not oil either the primary or safety element before installing.

2.

Do not wash the elements in other cleaning fluids.

3.

Never operate the compressor without both elements installed.

4.

Never use elements that are damaged, ruptured, or wet.

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5.

Never use elements with damaged gaskets.

6.

Keep a spare primary and safety element on hand at all times. Store the elements in a protected area where they will be free from damage, dirt, and moisture.

7.

Handle all filter parts with care.

MAINTENANCE SCHEDULE The following is the recommended maintenance schedule for the screw compressor: Daily or Every 8 Hours of Operation 1.

Check the receiver oil reservoir level with the compressor OFF and the drill in a level position.

Add oil, if required. Maintain the oil level within the level gauge bull’s-eye. If oil consumption is high, refer to troubleshooting section of the manufacturer’s publications.

CAUTION:

THE COMPRESSOR MUST BE SHUT DOWN AND THE RESERVOIR AT ZERO PRESSURE BEFORE CHECKING AND ADDING OIL.

2.

Drain the condensate from the receiver before compressor start-up when the oil is cold. Shut off the drain valve when oil appears.

3.

After start-up, check service indicators on inlet air filters, oil filter and oil separator. If indicators are completely red, while running, the oil filter elements and oil separator must be replaced.

The air filter primary element must also be cleaned or replaced. Refer to topics: OIL FILTER ELEMENT AND OIL SEPARATOR REPLACEMENT and AIR FILTER ELEMENT CLEANING AND REPLACEMENT.

4.

Observe the compressor loads and unloads properly.

5.

Observe the discharge air pressure, discharge air temperature and oil injection temperature.

If the air pressure exceeds either the rating plate pressure when unloaded, or is 15 PSIG above the rating plate pressure when unloaded, discharge air temperature exceeds 200oF, or when injection oil temperature exceeds 150oF, refer to TROUBLESHOOTING section.

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EVERY 125 HOURS OF OPERATION Check for dirt accumulation on radiator oil cooler core faces and on fan motor. Blow off the dirt if accumulation is excessive.

EVERY 1000 HOURS OF OPERATION 1.

Completely drain oil reservoir, compressor, and oil cooler (refer to topic: DRAINING OIL SYSTEM). Refill with the recommended oil (refer to topic: REFILLING OIL SYSTEM and OIL SPECIFICATIONS).

2.

Clean oil scavenging (return) line strainer and orifice. Clean oil pump inlet strainer.

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Section

8

Air Filtration Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents HOUSE FANS ............................................................................................................................... 3 INSPECTION ........................................................................................................................... 3 LUBRICATION ......................................................................................................................... 3 AIR CONDITIONER ...................................................................................................................... 4 DESCRIPTION ........................................................................................................................ 4 EVAPORATOR .................................................................................................................. 4 CONDENSER ................................................................................................................... 4 SPECIFICATIONS ................................................................................................................... 5

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Section

8

Air Filtration

HOUSE FANS INSPECTION Check the blades for grease and/or dirt accumulation. Clean if necessary. Blades should rotate freely without binding. If vibration is detected, check the following: 1. Bearing and drive alignment 2. Shaft straightness 3. Wheel or sheaves loose on shaft 4. Loose or worn bearings 5. Loose mounting bolts 6. Motor out-of-balance 7. Sheaves out-of-balance 8. Nose cap loose on wheel 9. Worn or corroded wheel 10. Accumulation of material on the wheel 11. Cracks on blades and/or at the hub 12. Worn fan blades and hubs

LUBRICATION All bearings are pre-lubricated and sealed at the factory. Under normal temperature condition (20oF to +150oF), when the fans are circulating clean air, the bearings are considered lubricated for life and additional lubrication is unnecessary. If the fans are circulating contaminated air, or operating at elevated temperatures, periodic lubrication is required.

For normal temperatures, a high quality, light neutral mineral grease is used. It is free of abrasive fillers and highly resistant to oxidation. When the fans are operating at elevated temperatures (166oF or higher), silicone or lithium soap-based grease should be used. This high temperature grease should have a breakdown point above 350oF. Use a low pressure grease gun for fan bearings. It is preferable that either the gun or the fitting be vented. To prevent overfilling apply only a small amount of grease. This is especially important when extended lubrication piping is used and the bearing cannot be observed.

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AIR CONDITIONER DESCRIPTION SIGMA MPV9 climate control units are heavy duty systems designed to be roof mounted on the cabs of industrial and mining equipment. These units will provide superior performance in a variety of climate conditions and under the most harsh environment.

EVAPORATOR Air is drawn from beneath the unit, passes over the heat exchanger coil and the heating elements into a double inlet wheel fan deck. It is then discharged through the base of the unit into the conditioned space below. Facility is also available to have supply and return air out the front face of the evaporator unit. Refrigerant flow is metered by an externally equalized TX valve, and is cut off by a liquid line solenoid valve. Heat exchange coil is large, with heavy gauge tubing and coarse fin pitch to reduce clogging. Fan motor is single shaft and of totally enclosed, fan cooled motor construction. Drain pan is large and of “V” design for ease of cleaning and to facilitate draining.

All pressure controls within the evaporator unit are fully sealed, preset and o-ring connected.

CONDENSER The compressor is a heavy duty, fully sealed scroll device. The assembly is mounted to heavy flexible mounts to reduce noise transmission to the structure and provide some damping of shock. Connections are either soldered, o-ring or rotalock. A large filter drier is mounted in the liquid line to filter and remove moisture from the refrigerant. Isolation valves are installed on either side to enable refrigerant to be “pumped down” and thus enabling core to be replaced without total loss of refrigerant. Condenser fan is single speed.

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SPECIFICATIONS Nominal Cooling Capacity: 31,000 Btu/hr @ 460V/60Hz 27,000 Btu/hr @ 380V/50Hz Heating Capacity:

12 kw @ 460V 60HZ 10 kw @ 380V 50HZ

Power requirements:

380V / 3ph / 50Hz 17.5 Amps (Norm)

Refrigerant:

HFC 134a – 24 lbs.

Oil:

POE Variety Mobil Arctic EAL22CC or ICI Emcarate RL32CF

Compressor:

Fully sealed, scroll compressor

Condenser Coil:

5 row, 3/8 inch copper tube with 8 aluminum fins per inch

Evaporator Coil:

4 row, 3/8 inch copper tube with 10 aluminum fins per inch

Condenser Fan:

Multi-blade axial, 17¼” inch diameter, two speed, 35o pitch to provide in excess of 3000 cfm @ 60 Hz.

Supply Air:

One forward curve double inlet fan supplies a nominal 1300 cfm (610 l/s) @ 60 Hz 1100 cfm (190 l/s) @ 50 Hz

415V / 3ph / 50Hz 19.0 Amps (Norm)

460V / 3ph / 60Hz 21.0 Amps (Norm)

NOTE: Further information on the MPV9 can be found in the vendor’s documentation that accompanies your machine and the General Arrangement drawings provided by Bucyrus International, Inc.

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Section

9

Engineering Data Always refer to the safety information in Section 1 of this manual before starting any maintenance procedure on this machine.

Table of Contents CAPSCREW (BOLT) GRADE ...................................................................................................... 3 BOLT TIGHTENING ....................................................................................................................... 4 TORQUE WRENCH METHOD ............................................................................................... 4 Table 1 - Lubricated or Plated Threads or with Hardened Washers .............................................. 4 Table 2 - Dry Threads .................................................................................................................. 4

TURN-OF-NUT METHOD ....................................................................................................... 5

Table of Snug Tight Torque Values ............................................................................................. 5

WIRE LOCKING CAPSCREWS ................................................................................................... 6 Patterns for Wirelocking Capscrews ........................................................................................... 6

GEAR INSPECTION ..................................................................................................................... 7 Gear Tooth Surface Failures ....................................................................................................... 8

AEROQUIP ORS CONNECTIONS ............................................................................................... 9 ORS Connection Assembly ........................................................................................................ 9

SEALS ......................................................................................................................................... 10 SEAL INSTALLATION ............................................................................................................ 10 GEARCASE SEALING .......................................................................................................... 12 MAINTENANCE WELDING ......................................................................................................... 13 WELDING ELECTRODES ................................................................................................... 14 REPAIR WELDING OF CRACKS ......................................................................................... 15 Joint Preparation for Repair of Cracks .......................................................................................15

PREHEAT ........................................................................................................................ 16 WELDING TECHNIQUE .................................................................................................. 16 REPAIR WELDING OF BROKEN PARTS ............................................................................ 17 WELDING AND CUTTING EQUIPMENT ..................................................................................... 18 STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT ....................................... 18 WIRE ROPE CARE AND MAINTENANCE .................................................................................. 20 STORAGE ............................................................................................................................. 20 CHECKING DIAMETER ........................................................................................................ 20 Correct Method for Checking Wire Rope Diameter .....................................................................20

HANDLING WIRE ROPE ...................................................................................................... 21 Improper Methods for Uncoiling Wire Rope ................................................................................ 22

END PREPARATIONS/TERMINATIONS ............................................................................... 23 WIRE ROPE CLIPS .............................................................................................................. 24 WIRE ROPE CLIP APPLICATION ................................................................................... 24 WEDGE SOCKETS ........................................................................................................ 26

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INSPECTION OF SHEAVES AND DRUMS ........................................................................... 27 Examples of Sheave Groove Conditions .....................................................................................27 Groove Gauge for New or Re-Worked Sheaves .......................................................................... 27 Inspecting for Worn Sheave .......................................................................................................28

BREAKING IN A NEW WIRE ROPE ..................................................................................... 28 INSPECTION DATA ............................................................................................................... 29 GUIDELINE TO INSPECTIONS AND REPORTS ........................................................... 30 Wire Rope Stretch vs Rope Life .................................................................................................32 Examples of Broken Wires ........................................................................................................ 35

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Section

9

Engineering Data

CAPSCREW (BOLT) GRADE The grade classification of a capscrew (bolt) is identified by the marks on the head as shown below:

Use the SAME GRADE washer and nut as the capscrew. NEVER SUBSTITUTE A LESSER GRADE CAPSCREW IN PLACE OF THAT WHICH IS SPECIFIED.

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BOLT TIGHTENING TORQUE WRENCH METHOD The following tables show torque values for bolt grades 2, 5 and 8 with UNC threads only. Table 1 lists torque values for lubricated or plated threads and for using hardened washers. Table 2 lists those for dry threads.

The bolts should be tightened to the specified total value in increments, alternating from bolt to bolt to assure gradual, even pull-up of mating parts.

Tightening should progress systematically from the most rigid part of a joint to its free edges.

Circular bolt patterns should be tightened in a diametric crosshatch pattern while applying torque in increasing values to ensure proper pull-up of parts.

Table 1 - Lubricated or Plated Threads or with Hardened Washers

Table 2 - Dry Threads

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TURN-OF-NUT METHOD CAUTION:

THIS TIGHTENING PROCEDURE IS ONLY APPLICABLE FOR BOLT GRADES 5 AND 8 WITH UNC THREADS. For bolts with other than UNC threads, contact the Bucyrus International Service Department.

NOTE: When using this procedure the bolt threads and the surfaces under the bolt head and nut must be lubricated. This procedure is applicable only if the joint and under head surfaces for bolt and nut are machined for parallelism.

1.

The bolts should be brought to a “snug tight” condition to insure that the parts of the joint have good contact with each other. “Snug Tight” is defined as the tightness attained by torquing a bolt to the value specified in the table on the following page. Snug tightening should progress systematically from the most rigid part of the joint to its free edges while alternating from bolt to bolt to assure gradual even pull up of the mating parts. After all bolts have been snugged, the first bolts tightened at the most rigid part of the joint should be rechecked for proper torque retention. If these bolts are loose due to pull up of the joint, the snug tightening sequence should be repeated for all bolts in the connection. This rechecking and re-torquing procedure should be repeated as many times as is required until the joint is completely pulled up and all bolts are at the specified “snug tight” torque. Tightness of the mating surfaces of the joint should then be verified by using feeler gauges.

Table of Snug Tight Torque Values

2.

The nuts and bolts should then be matched marked by center punching the bolt end and nut.

On rod bolts match mark both rod ends and nuts. The bolts and nuts should then be tightened additionally by the applicable amount of nut rotation as specified in Table 4. It is not necessary to follow any particular bolt to bolt sequence during this portion of the “turn of the nut” tightening.

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NOTE: Nut rotation is read between the punch mark on the bolt and the punch mark on the nut.

For rod bolts, nut rotation is the cumulative total rotational movement between punch marks on both ends of the rod bolt.

WIRE LOCKING CAPSCREWS Wire locking of capscrews is used when maximum lock assurance is required when periodic visual inspection is not possible.

The illustrations below show the recommended wire locking methods for various right hand thread capscrew patterns. For patterns not shown, wire lock the screws “in pairs”. For odd numbered patterns, wire lock the screws in pairs except the remaining 3 capscrews wire lock together

Patterns for Wirelocking Capscrews

Use 14 gauge soft annealed lockwire. Thread the wire through the capscrew head so that tightening stress on the wire will exert a tightening torque on the direction of capscrew thread. (The illustrations show lock wire threading for right hand threaded capscrews. Reverse the lock wire patterns shown for left hand capscrews.)

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GEAR INSPECTION An important part of machine maintenance is regular inspection of gears. This should include the gears and pinions of the pulldown, rotary and propel machinery.

Listen for any unusual noises or vibrations which would indicate excessive wear patterns of gears and pinions. Usually this would necessitate prompt attention before complete failure occurs.

Of primary importance in proper gear operation is correct lubrication. Always check to see that all the gears are adequately lubricated. See the Lubrication Section in this manual for further information on correct lubricants and their application.

A condition of normal wear should result when gears do not operate at excessive loads or temperatures and correct lubricants are used.

Gears are designed to function satisfactorily during the entire life of the machine. Their failure to do this indicates some unusual conditions. Regardless of gear design, size or construction, correct lubrication is essential to assure minimum wear, quiet operation and long service life. Gear tooth shapes are very accurately manufactured, nevertheless there will always be microscopic surface irregularities which cause frictional resistance. With the gears in proper mechanical condition and with correct lubrication, friction is reduced, wear is practically eliminated and gears should operate efficiently. However, even with correct lubricants properly applied, certain mechanical or operating conditions can cause wear and destruction of teeth. Destruction seldom takes the form of tooth breakage, but usually shows up as damage to the contact surfaces.

Such surface failure may rapidly destroy the original tooth contour, preventing smooth, quiet operation.

This failure may be directly attributable to overloading, overheating, shock, abrasives, chips, improper alignment, loose bearings or deflection of shafts or housing.

Many terms are employed to graphically describe the appearance of damaged tooth surfaces. The terms pitting, abrasion, scratching, spalling and galling are the major types of failures under which all of the other failures can be grouped. These five types of failure have different basic causes.

From the lubrication point of view, the cause of the failure is of major interest rather than the appearance of the surfaces. These gear-tooth failure classifications are shown in the figure.

Gears and pinions may show some minor pitting which is usually normal. However, any heavy pitting or spalling or any abnormalities as shown will necessitate replacement.

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Gear Tooth Surface Failures

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AEROQUIP ORS CONNECTIONS The Aeroquip ORS type connection is used throughout the hydraulic system of this machine.

The ORS connection has an o-ring groove machined into the flat male face. This flat face and oring mate with the connection’s other machined face to form a virtually leak-free seal.

The face-seal concept allows the components to be installed or replaced without moving mating components or applying strain on tube and hose lines. The swivel nut can be retracted to inspect seal placement and joint fit prior to assembly.

When using this connection, remove the o-ring from the male face and fill the groove with a high quality multipurpose grease, then install the o-ring in the groove. The grease will additionally seal around the o-ring while helping to retain the o-ring in the groove. The grease will also lubricate the connection while it is being assembled.

There is no need for special torque of the connection as the installer can “feel” when the fitting is tight.

ORS Connection Assembly

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SEALS Oil and grease seals are critical to machine availability. Careless storage, handling, removal and installation can contribute to reduced service life of machine components and higher cost of operation.

Seals come in all sizes, shapes and materials. Wherever possible, Bucyrus has specified the use of the most common solid molded element type seals for use on Bucyrus machines.

All types of oil and grease seals have a limited shelf life. Store seals in a cool, dry location protected from direct sunlight. Keep in sealed containers or packaging until ready to use. Seals keep lubricant clean and contained in their respective housings, bearings or passageways. Always handle seals carefully to prevent exposure to nicks, bends or pinching. Do not wash them in solvents as some solvents may destroy properties of the seal.

SEAL INSTALLATION Solid molded seals are installed at time of manufacture with interference fit between seal and bore.

This method of installation creates an oil tight fit. When partial disassembly of a machine component involves removal of solid molded seal before reassembly inspect it carefully for cuts, nicks or cracking. Replace with a split seal if complete disassembly is inconvenient or with a new solid molded seal. Split seals, especially those made with interference fit at butt, also install with compression at the joint. Split seals used as substitutes for solid molded seals should be replaced at next major component overhaul.

CAUTION:

Do not cut a solid seal and reuse for a split seal.

Check shaft for scratches, burrs or surface roughness that may cut or score the lip of seal. Be aware of sharp threads keyways or splines over which the seal must travel. Protect seal lip by covering these interferences with tape.

Inspect the bore area for surface roughness, dirt or burrs. Remove and clean as required. The bore and shaft need 0.0625 in. (1.588 mm) chamfer to accommodate a leak free installation. If shaft or bore do not have chamfer, carefully provide one by trimming inside flange of seal.

Determine the correct direction for lip installation and start the seal into the cavity by finger pressure, then tap evenly all around until seated or flush with the housing face. (Tap only on outer edge of seal with hammer on wood block.)

A double seal, installed back to back can be used to retain grease or oil plus be more effective in preventing egress of contaminants.

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Follow this installation procedure for split seals: •

Remove garter spring and separate at the hook and eye.

•

Open the seal, ends sideways, for installation on shaft as shown by moving the butt ends along the axis of the seal.

•

Lubricate spring and install around shaft. Connect ends and insert spring in lip groove with spring ends 90o away from butt joint.

SPLIT SEAL INSTALLATION CAUTION:

Do not trim or cut ends of split seals or pull ends apart. This will destroy seal.

Gearcase seals used for all oil tight gearcase assemblies require surface preparation on one side of case flanges with a 1/100 inch thick Form-a-Gasket #3 (Permatex Co.) coating. If using a manila paper gasket always replace with a new one, never reuse. Apply Form-a-Gasket #3 to both sides of the paper gasket. Tighten gearcase cover bolts until seal material “squeezes out” at joint.

When surface finishes range up to 250 microinches, a compression type gasket seal is recommended. This material (VELLUMOID) available in standard thickness inches (mm) 1/64 (.397), 1/32 (.794), 1/16 (.063), and 1/8 (.125) should also be installed with Permatex applied to both sides.

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GEARCASE SEALING Use the information in the following image to properly seal gearcase halves and /or covers.

NOTE: Before applying any sealants or gaskets, clean all mating surfaces of all dirt, rust and scale.

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MAINTENANCE WELDING These recommendations for repair welding apply to the major structural members of the machine.

The high cyclic loading characteristics of the machine are considered in the design and material selected for the construction of the machine. However, due to unusual operational conditions that may be encountered and to the great number of cyclic loadings that may be applied to the machine, fatigue cracks or other abnormalities may occur. Early detection of these conditions through regular machine inspection helps to avoid problems or emergency breakdowns.

Maintenance welding is applied to the repair of cracked or broken structural components.

Reconditioning of broken parts by the application of heating, cutting and welding processes requires attention to a number of details, careful adherence to the repair procedure and observance of federal, state and local safety regulations.

CAUTION:

WELDING AND THERMAL-CUTTING OF METALS INVOLVE THE GENERATION OF TEMPERATURES UP TO THOUSANDS OF DEGREES AT WHICH METALS MELT AND VAPORIZE. When proper precautions are taken to protect personnel and property against the heat, evolved gases and fumes, electric shock and radiation, no harm will result either to personnel or property. In gas heating and cutting, the handling and storage of compressed gases present other hazards that also must be protected against to provide a safe working environment.

Safety precautions should conform to the latest edition of ANSI standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society.

Reconditioning of failed members requires attention to a number of details and careful application of the repair procedure. Only in certain cases is it necessary to strengthen members by added reinforcement.

WARNING:

REINFORCING STRUCTURAL MEMBERS SHOULD BE MADE ONLY UPON RECOMMENDATION BY BUCYRUS INTERNATIONAL, INC. IMPROPERLY APPLIED REINFORCEMENTS CAN HAVE AN ADVERSE EFFECT ON THE PERFORMANCE AND LIFE OF THE STRUCTURE.

A broken member is best repaired by making a complete penetration weld, preferably by welding from both sides, using the correct welding electrode and observing all precautions such as preheat, back-gouging, etc. The complete penetration groove weld should be ground flush with the base metal on both sides to remove all surface irregularities. An alternate procedure incorporates backup bars to ensure sound, complete penetration welds in the repair area. Be sure to follow all applicable safety measures and federal, state and local regulations.

A complete penetration weld repair conditioned by grinding instead of adding reinforcement is favored to maintain the original pattern of stress flow designed into the structural members. Addition of reinforcement which is not part of the design can reduce fatigue strength because of the change in geometry from the original structure.

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Effective repair welding of cracked, broken or bent structural members of the machine involves knowledge of the types of steel used, proper welding electrodes and recognized good welding practice. The chemical composition, mechanical properties and thickness of the steel determine the welding electrode to be used and the preheat temperature required. Refer to the STEEL TYPES Table later in this section for the types of steel used and the recommended electrode and preheat.

WELDING ELECTRODES With the exception of the boom, weld repairs on the various structures of the machine can be made with two basic classifications of shielded metal arc electrodes: E7018 and E8018-C1. Both are low hydrogen electrodes which deposit weld metal having excellent properties at strength levels with 70,000 to 80,000 PSI, and impact properties from -20o to -75oF. These are all-position electrodes which produce high quality welds for repairing the structural components of heavy machinery.

NOTE: Although these electrodes are of superior quality, care must be exercised in their application.

Low hydrogen electrodes are highly susceptible to moisture pickup after removal from sealed containers. To maintain low hydrogen, crack-resistant properties, they must be stored in electrode ovens at 250oF up to the time of use. Small portable rod ovens at the welder’s side are ideal. Use of dry low hydrogen electrodes cannot be overemphasized.

Cracks caused by hydrogen are extremely fine and occur invisibly below the surface in the base metal heat affected zone, as shown. Therefore, they are not detectable at the time of welding.

These cracks can propagate in service and lead to ultimate failure of the part. It is necessary to adhere strictly to recognized good welding practice regarding the handling, storage and use of low hydrogen electrodes. To avoid underbead cracks, remove all oil or grease or other contaminates from the surface and be sure the steel is dry.

Preheat to the required temperature. Use only dry electrodes taken from the electrode oven. After exposure to the air, the electrodes must be returned to the oven. Time limit outside the oven is four hours for E7018 and two hours for E8018C1 electrodes.

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REPAIR WELDING OF CRACKS

Joint Preparation for Repair of Cracks

Remove the entire crack by arc air-gouging or grinding. Prepare a V-groove of approximately 4560o included angle for rewelding. If cracked through the full thickness and if it is possible to make the repair from both sides, a double V preparation is preferred. When welding from both sides, back-gouging for complete penetration is always recommended.

When it is not physically possible to back-gouge and weld the second side, an alternate approach must be taken. Sometimes it is possible to gouge through to completely remove the crack, then fit a backup bar on the underside to facilitate making a complete penetration weld.

NOTE: The backup bar must fit tightly to the underside otherwise poor welding conditions conducive to cracking may occur.

When it is not possible to fit a backup due to limited accessibility to the underside, it is advisable to remove a portion of the defective plate and weld in a new piece, using back up bars on all sides to ensure complete penetration welds.

A further alternative is to gouge through, removing the crack, and then weld small stringer beads to close the gap and prepare a groove for a repair weld. In this case, the repair weld will be essentially full penetration, but will be less than perfect on the under side. The other methods are preferred in the order described, that is, welding both sides, welding against a backup bar, or completely replacing a section of plate.

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PREHEAT When preheating, apply heat to a broad, general area surrounding the repair location. A soaking heat which thoroughly penetrates the material through the full thickness is preferred to high surface temperature quickly applied. Electrical resistance or radiant heating is suggested since the heat source can be left operating during welding to maintain the minimum preheat temperature. Preheat temperatures up to 400oF, depending upon the steel analysis, are adequate under most conditions for major repairs. As previously stated, preheat temperatures are determined by the type of steel in the structure. Temperatures should be measured with temperature indicating crayons.

WELDING TECHNIQUE Maximum electrode sizes are 1/4 inch for flat position, 3/16 inch for horizontal position and 5/32 inch for vertical and overhead positions. Use a split weave as soon as bead width is large enough to accommodate beads side by side. Throughout all welding be certain thorough fusion with the base metal and adjacent weld beads is obtained on all weld passes. Clean off all slag between passes and all craters before starting the next electrode.

Inspect closely for cracks, undercut or overlap of beads, and gouge out or grind flaws where they occur before continuing. It is very important on highly loaded parts, particularly members subject to cyclic or dynamic stresses, to obtain sound repair welds.

The presence of any stress risers on the surface of a part is detrimental to fatigue life and can result in future cracking. Therefore, it is essential that the finished repair be smooth and well blended into the base metal. Repair weld any undercuts, grind off overlapped weld beads and blend out any notches or gouges. The best condition in a repair weld location is provided by grinding the repair smooth and flush with the surface of the base metal. Final grinding direction is to be identical with the direction of applied load on the structure. Refer to the figure.

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REPAIR WELDING OF BROKEN PARTS All recommendations given for repair of cracks apply to repair of broken parts, with additional corrections. Depending on the size and cross-section of the part, a specific sequence of welding procedures may be required in making the repair. These techniques include back-step welding sequence, block welding sequence, alternating from side to side, welding simultaneously on opposite sides, etc. All of these precautionary measures are intended to minimize shrinkage stresses and subsequent distortion or cracking during welding. The method to follow should be determined after a careful analysis of the situation and by approaching the problem with common sense. Generally a procedure which has proven successful in previous experience could logically be applied in most cases.

Use of doubling plates, stiffeners or other reinforcements to strengthen a member which has cracked in service, must be carefully considered before that repair measure is decided upon. Additional material added for strengthening alters the configuration and geometry of the member, possibly with a pronounced effect on the fatigue life of that structure. Many times, such attempts at strengthening by added plates only serves to “chase the crack someplace else.” The stress flow in the part has been altered, creating a location for stress concentration. Attachments requiring fillet welds across a tension member for example, are poor repair methods. A sound repair weld, carefully made and smoothly blended into the base metal on all sides, is preferable to additional reinforcements. Any application of reinforcements requires careful consideration regarding total overall effect on the structure during service, and should be done only after consulting Bucyrus International, Inc.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

WELDING AND CUTTING EQUIPMENT The welding and cutting equipment needed for general repair welding is listed below.

WELDING MACHINES, Arc - 600 ampere (for Welding and Air Arcing) OXY ACETYLENE TORCHES with Gauges - 150' Long Hoses HEATING TORCHES, Butane (for Boom Welding) ARC AIR ATTACHMENTS (for use with 600 Ampere Welding Machines) WELD RODS - E7018, E8018, E11018 - 1/8", 5/32". 3/16", 1/4" C02 - Welding Grade - 45oF Max. Dew Point OXYGEN - Cutting, and Heating ACETYLENE WELD FLUX CHIPPERS - Pneumatic with Chisels and Spare Parts BLOWERS, Ventilating (for Compartment Welding,) GRINDERS, Wheel - Air Powered w/Wheels TARPAULINS - Fireproof (for Boom Welding Shelters) ASBESTOS GLOVES CUTTING GOGGLES, Dark SOAPSTONE MARKERS ANTI-SPATTER COMPOUND TEMPILSTIKS - 200o and 400o

STRESS RELIEVING & TEMPERATURE MEASURING EQUIPMENT The equipment recommended for stress relieving, after repair welding, is listed below.

TEMPERATURE MEASURING EQUIPMENT SPEEDOMAX, “W” Multipoint, Potentiometer Recorder POWER REQUIREMENT - 120 Volts, 60 or 50 Hz. RANGE - 0 to 1500oF CALIBRATION - Chromel-Alumel Thermocouple Wire ACCURACY RATING - 0.3% of Electrical Span CHART SPEED - 2" per Hour THERMOCOUPLE SELECTION - Six (6) Points FLUORESCENT LIGHTING MANUFACTURER - Leeds & Northrup Company THERMOCOUPLE EXTENSION WIRE

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

DUPLEX WIRES - Chromel-Alumel - Type K - 16 AWG Stranded LENGTH - Total External Resistance for both Wires including Thermocouple not to exceed 2500 Ohms or 410 Feet.

WIRE RESISTANCE - Nominal Resistance, Ohm per Foot at 20oC (66oF) - Chromel - Ohms Alumel - 0.0683 Ohms.

WIRE INSULATION - each Conductor Enamel, Asbestos (Twisted Pair) Overall Asbestos Braid WIRE CODE -Alumel, Negative Wire (Red); Chromel, Positive Wire (Yellow) OVERALL COLOR - Yellow CATALOG No. 16-59-17 POLARITY DISCONNECT CHROMEL-ALUMEL COMPENSATED CONNECTION JACK Color Code (Yellow) - Catalog No. 040419 PLUG Color Code (Yellow) - Catalog No. 040434 CABLE CLAMP - Catalog No. 072513 ADAPTER - Catalog No. 076794 THERMOCOUPLE ELEMENT CHROMEL-ALUMEL - Type K - Swagged One (1) Inch Stripped CHROMEL POSITIVE WIRE Color Code (None) ALUMEL NEGATIVE WIRE Color Code (Red) CATALOG No. 8784-K-1-3-12"-D 1.

588003 Kaopak Flex Heaters

2.

588004 Kaopak Collector Streamer Type

3.

Kaopak Blankets 3, 5, or 6 Pocket Size as needed for Size Pipe being Stressed Relieved

Thermocouple Assembly, Complete Catalog No. 8784-K-1-3-12"-Q Temperature Heating Pellets Range: 1050oF 1100oF - 1200oF 1250oF Mean Accuracy: +/-1% These Tempil Pellets will begin to melt at the temperature specified.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

WIRE ROPE CARE AND MAINTENANCE STORAGE Reels of wire rope stock may be kept on hand for a considerable length of time. This is particularly true of slow-moving special ropes that may not be disposed of completely for several years.

Consequently, wire rope should be stored in an are that is well-ventilated and stable with regard to temperature and humidity.

Do not store rope in contact with the bare ground or expose it to the elements. Excessive atmospheric vapors will condense moisture on the rope causing corrosion. If exposed to the direct sun, next to a boiler or in similarly warm conditions, the original lubrication will dry out and lose its preservation properties.

Similarly, storage in a dusty or chemical laden environment may coat the surface of the rope with corrosive materials or even deteriorate the fiber core. If it should be necessary to store rope outside, the reel should be set on blocks or raised off the ground, and covered with a waterproof covering.

CHECKING DIAMETER It is critical to check the diameter of the delivered rope BEFORE installation on the machine. This is to ensure that the rope diameter meets the specified requirements for the given machine or equipment. An UNDERSIZE diameter rope will bring about a condition where stresses are exceeding design limitations. This will increase the possibility of injury or machine damage as the chances of breaking the rope will be increased. Use of an OVERSIZE diameter rope will bring about premature wear of that rope. The rope constantly being pinched and compressed in the grooves of the sheaves and drum causes this.

Correct Method for Checking Wire Rope Diameter

When checking it is imperative that the actual rope diameter is measured. This is defined as the diameter of the circumscribing circle, or its largest cross-sectional dimension. To ensure accuracy this measurement should be made with a wire rope caliper to obtain the outside dimension of 2 diametrically opposing strands of the rope. When measuring a rope with an odd number of outer strands, special techniques must be employed. Refer to the manufacturer of the product for accurate information.

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HANDLING WIRE ROPE When re-reeling wire rope from a horizontally supported reel to a drum, keep in mind that a wire rope has a “memory” to be considered. If at all possible, it is preferable for the rope to travel from the top of the reel to the top of the drum during this process. The same would hold true for the bottom of the reel to the bottom of the drum. Re-reeling in this manner will avoid putting a reverse bend into the rope as it is being installed. If a rope is installed so that a reverse bend is induced, it may cause the rope to become “cranky” and, consequently, more difficult to work with.

There are several methods, which can be used to uncoil rope from a spool or coil. The particular situation, or application, will determine the method used.

One method begins by placing the coil or spool on a vertical unreeling stand. The stand consists of a base with a fixed vertical shaft. On this shaft there is a “swift” or rotating sleeve” consisting of a plate with inclined pins. This is positioned so that the coil or spool may be placed over them allowing the coil or spool to rotate in the horizontal axis. The whole swift and coil then rotate as the rope is pulled off without adding twist or the possibility of kinks. This method is particularly effective when the rope is to be wound on a vertical drum.

The most common, and the easiest uncoiling method is merely to hold one end of the rope while rolling the coil along the ground like a hoop.

NOTE: Avoid unreeling and uncoiling methods that are likely to provide kinks. Such IMPROPER procedures should be strenuously avoided in order to prevent the occurrence of loops. These loops, when pulled taut, will inevitably result in kinks. No matter how a kink develops, it will damage strands and wires, resulting in a kinked section that must be cut out. Proper and careful handling will keep the wire rope free from kinks.

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Improper Methods for Uncoiling Wire Rope

While there are numerous ways to cut wire rope, in every case, certain precautions must be observed. It is critical that before any cut is made proper seizings must be applied on both sides of the location where the cut is to be made. Carelessly or inadequately seized, ends may become distorted and flattened. This will also prevent the strands at the ends from loosening or fraying.

Subsequently, when the rope is installed there may be an uneven load distribution to the strands.

This will create a condition that will significantly shorten the life of the rope.

There are two widely accepted methods of applying a seizing, which are illustrated. The seizing material itself should be soft, or an annealed wire or strand. Seizing wire diameter, and the length of the seize, will be dependant on the diameter of the wire rope. But the length of the seize should never be less than the diameter of the rope in use. Normally, for a preformed rope, one seize on each side of the cut is sufficient. For ropes that are not preformed, a minimum of two seizings on each side is recommended; and these should be spaced six rope diameters apart.

For larger wire ropes: lay one end of the seizing wire in the groove between two strands; wrap the other end tightly in a close helix over a position of the groove using a seizing iron (a round bar 1/2" to 5/8" dia. x 18" long) as shown. Both ends of the seizing wire should be twisted together tightly, and the completed seize should appear as shown. Seizing widths should not be less than the rope diameter.

The procedure illustrated below is the second of the two accepted methods for placing seizing on wire rope. This method is normally used on smaller ropes.

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END PREPARATIONS/TERMINATIONS There may arise a need for special end preparations in order to compensate for certain applications such as tight drum openings, or other complicated reeving systems. When these situations are encountered a number of basic designs (and combinations) are available to choose from. Whenever possible end preparations should be removed after final installation.

“Beckets” are what is referred to when we discuss a termination utilized to pull the operating rope into place. The rope end must be fastened to a mechanism so that force and motion are transferred efficiently without distortion of the wire rope. End terminations become items of great importance for transferring these forces. Each basic type of termination has its own individual characteristic.

Hence, one type will usually fit the needs of a given installation better than the others. It should be noted that not all end terminations will develop the full strength of the wire rope being utilized. To lessen the possibility of error, the wire rope industry has determined terminal efficiencies for various types of end terminations. Four commonly used beckets are illustrated.

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WIRE ROPE CLIPS Wire rope clips are widely used for making end terminations.

Clips are available in two basic designs; the U-BOLT and FIST GRIP. The efficiency of both types is approximately the same.

NOTE: When using U-BOLT clips, extreme care must be exercised to make certain that they are positioned correctly. The important factor is that the U-BOLT clip be applied in order that the “U” section is in contact with the dead end of the rope. Also, the tightening and retightening of the nuts must be accomplished as required.

WIRE ROPE CLIP APPLICATION The following is the recommended method of applying U-Bolt clips in order to get the maximum holding power from the installation: 1.

Turn back the specified amount of rope from the thimble. Apply the first clip a distance of one base width from the dead end of the wire rope (U-bolt over the dead end - live end rests in the clip saddle). Tighten nuts diametrically and evenly to recommended torque.

2.

Apply the next clip as near the loop as possible. Snug down the nuts, but do not tighten.

3.

Space additional clips (if required) equally between the first two. Turn on nuts evenly to take up rope slack. Continue to tighten all nuts evenly (on all clips) until recommended torque is reached.

NOTE: Apply the initial load to the strand of rope, and then retighten nuts to the recommended torque. This is accomplished because the rope will stretch and be reduced in diameter when loads are applied. Inspect periodically and tighten to recommended torque each time.

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A termination complying with the above instructions, using the number of clips shown, has approximately an 80% efficiency rating. This rating is based upon the nominal strength of the wire rope. If a pulley is used in place of a thimble where the rope turns back, add one additional clip.

The number of clips shown is based upon using right regular or lang lay wire rope, 6 x 19 class or 6 x 37 class, fiber core or IWRC, IPS or EIP. If Seale construction is to be used for sizes 1 inch and larger, or similar large outer wire type construction in the 6 x 19 class, add one additional clip.

The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or EIP, size 1-3/4 inch and smaller.

For other classes of wire rope not mentioned, it may be necessary to add additional clips to the number shown. If a greater number of clips are used than shown in the table, the amount of rope turn-back should be increased proportionately. THE ABOVE IS BASED ON THE USE OF CLIPS ON A NEW ROPE. IMPORTANT: Failure to make a termination in accordance with the aforementioned instructions, or failure to periodically check and retighten to recommended torque, will cause a reduction in the efficiency rating.

The correct spacing and number of clips is shown above.

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WEDGE SOCKETS One of the more popular field end attachments for wire rope is the wedge socket. Attachment, and the dismantling of this device is both easy and simple.

1.

Inspect the wedge and socket; remove all rough edges/ burrs that might damage the rope.

2.

Welded ends of the rope should be cut off prior to assembly. This will allow the rope strands to distort slightly as they bend sharply around the wedge. If the welded end were not removed the minimal sliding of the strands would be restricted and evidenced further up the rope. This may result in the development of high strands, wavy rope and uneven loading.

3.

Place the socket in an upright position and bring the rope around it in a large, easy to handle loop. Care must be taken to make certain that the live-loaded-side of the rope is in line with the ears.

4.

The dead end of the rope should extend from the socket for a distance of six to nine times the rope diameter. The wedge is now placed in the socket.

5.

Secure the socket and carefully apply a gradually increasing load to the live side of the rope in order to pull the wedge into position. Only tension sufficiently to hold the pieces in place.

6.

After checking alignment increase the load GRADUALLY until the wedge is properly seated.

IMPORTANT: Avoid sudden shock loads.

NOTE: This is the recommended procedure. If variations are made to suit special conditions, they should be carefully evaluated beforehand.

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INSPECTION OF SHEAVES AND DRUMS Machines should receive periodic inspections, and the results concerning their overall condition recorded. Such inspections usually include the drum, sheaves, and any other parts that may come into contact with the wire rope. These are considered high wear items. As an additional precaution, any rope-related working parts, particularly those in the areas described below, should be reinspected prior to the installation of a new wire rope.

Examples of Sheave Groove Conditions

These cross-sections are illustrating three sheave-groove contact areas. “A” is correct, “B” is too tight, and “C” is too loose.

The very first item to be checked when examining sheaves and drums is the condition of the grooves. To accurately check the size, contour and amount of wear, a groove gauge is used. As shown in the figure, the gauge should contact the groove for about 150 degrees of arc when in optimal condition.

There are two types of groove gauges in general use. The two differ by their respective percentage over nominal.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

For new or re-machined grooves, the groove gauge is nominal plus the full oversize percentage.

The gauge carried by most wire rope representatives today is used for worn grooves and is made nominal plus 1/2 the oversize percentage.

This latter gauge is intended to act as a sort of “no-go” gauge. Any sheave with a groove smaller than this must be re-grooved or, in all likelihood, the existing rope will be damaged.

Inspecting for Worn Sheave

These sheave-groove cross-sections represent three wire rope seating conditions: “A” - a new rope in a new groove; “B” - a new rope in a worn groove; and “C” - a worn rope in a worn groove.

BREAKING IN A NEW WIRE ROPE A new wire rope requires careful installation. Adherence to the previously covered procedures is highly recommended. After the rope has been installed, and the ends secured in the applicable manner, the mechanisms should be started carefully and then permitted to run through a complete cycle of operation at greatly reduced speed. During this trial operation, a very close watch should be kept on all working parts such as sheaves, drums and rollers to ensure the rope runs freely. Be vigilant to ensure there are no obstructions as it makes its way through the system. If no problems are apparent, the next step should include several run-throughs of the normal operational cycle under light load conditions at a reduced speed. This procedure allows the component parts of the new rope to gradually adjust to the actual operating conditions.

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Bucyrus International, Inc. 59HR ELECTRIC BLAST HOLE DRILL

INSPECTION DATA It is essential to maintain a well-planned program of periodic inspection. Frequently, there are statutory and/or regulatory agencies who incur additional requirements that must be adhered to.

Refer to the suggested procedures that follow.

Abrasion - Bending and crushing represent the ABC’s of wire rope abuse. It is the primary goal of a good inspection practice to uncover such conditions early enough that corrections may be made, or ropes replaced safely with minimum effort. When any sudden degradation indicates a loss of original rope strength, a timely decision is required as to allowing the rope to remain in service.

Such a decision can only be made by an experienced inspector. And his/her determination should be based on: 1.

Details of the equipment’s operation.

2.

Frequency of inspection.

3.

Maintenance history.

4.

Consequences of failure.

5.

Historical records of similar equipment.

To ensure sufficient information can be obtained, the following pages contain guidelines that should be adhered to.

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GUIDELINE TO INSPECTIONS AND REPORTS (Equipment, Wire Rope and Wire Rope Slings) 1.

Maintain all inspection records and reports for the length of time deemed appropriate.

2.

Prior to daily use, the following procedure should be followed.

3.

4.

a.

Check all equipment functions.

b.

Lower load blocks and check hooks for deformation or cracks.

c.

During lowering procedure and the following raising cycle, observe the rope and the reeving. Particular notice should be paid to kinking, twisting or other deformities. Drum winding conditions should also be noted.

d.

Check wire rope and slings for visual signs of any unsafe condition; to include, broken wires, excessive wear, kinking or twisting, and severe corrosion. Particular attention should be given to any new damage during operation.

Periodic inspections consistent with applicable standards are recommended with a signed report by an authorized and competent inspector. These Periodic Reports should include inspection of the following: a.

All functional operating mechanisms for excessive wear of components, brake system parts and lubrication.

b.

Limit switches.

c.

Crane hooks for excessive throat opening or twisting, along with a visual for cracks.

d.

Wire rope and reeving for conditions causing possible removal.

e.

Wire rope slings for excessive wear, broken wires, kinking, twisting and mechanical abuse.

f.

All end connections such as hooks, shackles, turnbuckles, plate clamps, sockets, etc. for excessive wear, and distortion.

At least one annual inspection with signed report must be made for the following: a.

Crane hook for cracks.

b.

Hoist drum for wear or cracks.

c.

Structural members for cracks, corrosion and distortion.

d.

For loose structural connections such as bolts, rivets, and weldments.

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Wire Rope Inspection Criteria The following is a fairly comprehensive listing of critical inspection factors. It is not, however, presented as a substitute for an experienced inspector. It is rather a user’s guide to the accepted standards by which ropes must be judged.

Abrasion Rope abrades when it moves through an abrasive medium or over drums and sheaves. Most standards require that rope is to be removed if the outer wire wear exceeds 1/3 of the original outer wire diameter. This is not easy to determine and discovery relies upon the experience gained by the inspector in measuring wire diameters of discarded ropes.

Reduction in Rope Diameter: Any marked reduction in rope diameter indicates degradation. Such reduction may be attributed to: •

Excessive external abrasion.

•

Internal or external corrosion.

•

Loosening or tightening of rope lay.

•

Inner wire breakage.

•

Ironing or milking of strands.

In the past, the determination on the continued service of a rope was largely dependant on the rope’s diameter at the time of inspection. Recently this practice has undergone significant modification.

Previously, a decrease in the rope’s diameter was compared with published standards of minimum diameters. The amount of change in diameter is, of course, useful in assessing a rope’s condition.

But, comparing this figure with a fixed set of values can be misleading. These long-accepted minimums are not, in themselves, of any serious significance since they do not take into account such factors as: •

Variations in compressibility between IWRC and Fiber Core.

•

Differences in the amount of reduction in diameter from abrasive wear, or from core compression, or a combination of both.

•

The actual original diameter of the rope rather than its nominal value.

As a matter of fact, all ropes will show a significant reduction in diameter when a load is applied.

Therefore, a rope manufactured close to its nominal size may, when it is subjected to loading, be reduced to a smaller diameter that stipulated in the minimum diameter table. Yet, under these circumstances, the rope would be declared unsafe although it may, in actuality, be safe.

As an example of the possible error at the other extreme, we can take the case of a rope manufactured near the upper limits of allowable size. If the diameter has reached a reduction to nominal or slightly below that, the tables would show this rope to be safe. But it should, perhaps, be removed.

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Evaluations of the rope diameter are first predicated on a comparison of the original diameter when NEW and subjected to a KNOWN load with the current reading under comparable circumstances.

Periodically, throughout the life of the rope, the actual diameter should be recorded while the rope is under equivalent loading and in the same operation section. This procedure, if followed carefully, reveals a common rope characteristic: after an initial reduction, the diameter soon stabilizes. Later, there will be a continuous, albeit small, decrease in diameter throughout its life.

Core deterioration, when it occurs, is revealed by a more rapid reduction in diameter and is time for removal.

Deciding whether or not a rope is safe is not always a simple matter. A number of different, but interrelated conditions must be evaluated. It would be dangerously unwise for an inspector to declare a rope safe for continued service simply because its diameter had not reached the minimum arbitrarily established in a table, while at the same time, other observations lead to an opposite conclusion.

Because criteria for removal are varied, and because diameter in itself, is a vague criterion, the table of minimum diameters has been deliberately omitted from this publication.

Rope Stretch All ropes will stretch when loads are initially applied.

Wire Rope Stretch vs Rope Life

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As a rope degrades from wear, fatigue, etc. (excluding accidental damage), continued application of a load of constant magnitude will produce varying amounts of rope stretch. A “stretch” curve plotted for stretch vs. time displays three distinct phases: PHASE 1. - Initial stretch, during the early (beginning) period of rope service, caused by the rope adjustments to operating conditions (constructional stretch).

PHASE 2. - Following break-in, there is a long period-the greatest part of the rope’s service lifeduring which a slight increase in stretch will take place over an extended time. This results from normal wear, fatigue, etc. On the plotted curve stretch vs. time-this portion would almost be a horizontal straight line inclined slightly upward from its initial level.

PHASE 3. - Thereafter, the stretch occurs at a quicker rate. This means that the rope has reached the point of rapid degradation; a result of prolonged subjection to abrasive wear, fatigue, etc. This second upturn of the curve is a warning indicating that the rope should soon be removed.

Corrosion Corrosion, while difficult to evaluate, is a more serious cause of degradation than abrasion. Usually, it signifies a lack of lubrication. Corrosion will often occur internally before there is any visible external evidence on the rope surface. Pitting of wires is a cause for immediate rope removal. Not only does it attack the metal wires, but also prevents the rope’s component parts from moving smoothly as it is flexed. Usually, a slight discoloration because of rust merely indicates a need for lubrication.

Severe rusting on the other hand, leads to premature fatigue failures in the wires necessitating the rope’s immediate removal from service. When a rope shows more than one wire failure adjacent to a terminal fitting, it should be removed immediately. To retard corrosive deterioration, the rope should be kept well lubricated. In situations where extreme corrosive action can occur, it may be necessary to use galvanized wire rope.

Kinks Kinks are permanent distortions caused by loops drawn too tightly. Ropes with kinks must be removed from service.

Bird Caging Bird caging results from torsional imbalance that comes about due to mistreatment such as sudden stops, rope being pulled through excessively tight sheaves, or wound on too small a drum for a given rope diameter. This is cause for rope replacement unless the affected section can be removed.

Localized Conditions Careful attention must be paid to wear at the equalizing sheaves. During normal operation this wear is not visible. Excessive vibration, or whip can cause abrasion and/or fatigue. Drum crossover and flange point areas must be carefully evaluated. All end fittings, to include splices, should be examined for worn or broken wires, loose or damaged strands, cracked fittings and worn or distorted thimbles and tucks of strands.

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Heat Damage After a fire, or exposure to elevated temperatures, there may be discoloration, or an apparent loss of internal lubrication. Fiber core ropes are particularly vulnerable. Under these circumstances the rope should be replaced.

Protruding Core If, for any cause, the rope core protrudes from an opening between the strands, the rope is unfit for service and should be removed.

Damaged End Attachments Cracked, bent, or broken end fittings must be eliminated. The cause should be sought out and corrected. In the case of bent hooks, the throat openings must be measured at the narrowest point and should not exceed 15% over normal. Twisting be no greater than 10 degrees.

Peening Continuous pounding is one of the causing of peening. The rope can strike against an object, such as some structural part of the machine, or it beats against a roller, or itself. Often this can be avoided by placing protectors between the rope and the object it is striking. Another common cause of peening is continuous working under high loads over a sheave or drum. Where peening action cannot be controlled it is necessary to have more frequent inspections and be prepared for premature rope replacement.

Scrubbing Scrubbing refers to the displacement of wires and strands as a result of rubbing against itself or another object. This, in turn, causes wear and displacement of wires and strands along one side of the rope. Corrective measures should be taken as soon as this condition is observed.

Fatigue Fracture Wires that break with square ends and show little surface wear, have usually failed as a result of fatigue. Such fractures can occur on the crown of the strands, or in the valleys between the strands where adjacent strand contact exists. In almost all cases, these failures are related to bending stresses or vibration.

If diameter of the sheaves, rollers or drum cannot be increased, a more flexible rope should be used. But, if the rope in use is already of maximum flexibility, the only remaining course that will help prolong its service life is to move the rope through the system by cutting off the dead end. By moving the rope through the system, the fatigued sections are moved to less fatiguing areas of the reeving.

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Broken Wires The number of broken wires on the outside of a wire rope are an index of 1) its general condition, and 2) whether or not it must be considered for replacement. Frequent inspection will help determine the elapsed time between breaks.

On occasion, a single wire will break shortly after installation. However, if no other wires break at that time, there is no need for concern. On the other hand, should more wires break, the cause should be immediately investigated.

On any application, valley breaks (where the wire fractures between strands) should be given serious attention. When two or more such fractures are found, the rope should be replaced immediately.

NOTE: No valley breaks are permitted in elevator ropes.

Once broken wires appear within a rope operating under normal conditions many more will show up within a relatively short period. Attempting to squeeze the last measure of service from a rope that is beyond the allowable number of broken wires, will create an intolerably hazardous situation.

A wire broken under a tensile load that has exceeded its strength is recognized by the “cup and cone” configuration at the fracture point (Rope A). The necking down of the wire at this point shows that failure occurred while the wire retained its ductility.

Shear-tensile fracture (Rope B) occurs in wire subjected to a combination of transverse and axial loads. Fatigue breaks are usually characterized by squared-off ends perpendicular to the wire either straight across or Z-shaped (Ropes C and D).

Examples of Broken Wires

Electric Arc Rope that has either been in contact with a live power line or been used as “ground” in an electric welding circuit, will have wires that are fused, discolored and/or annealed, and must be removed.

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