Вы находитесь на странице: 1из 120

Model R30C Hydraulic Track Drill

Operator and Maintenance Manual P/N 435120

Bucyrus Mining Equipment, Inc.


3501 S. FM Hwy 1417 Denison, Texas 75020 USA

PARTS ORDERING AND PRODUCT SUPPORT


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

IDENTIFICATION OF THE MACHINE


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

PART NUMBER AND DESCRIPTION


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

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

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

PRODUCT SERVICE AND WARRANTY


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

Bucyrus Mining Equipment, Inc. 3501 S. FM Hwy 1417, Denison, TX 75020 www.bucyrus.com 2010 Bucyrus International, Inc. All Rights Reserved

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

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

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

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

California Proposition 65 Warnings


The following warning applies to equipment supplied with lead-acid batteries: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. The following warning applies to equipment supplied with diesel powered engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Specications are subject to change without notice. Information contained in this manual was current at the time of printing. Revised 05/13/2010
Introduction i

Contents
INTRODUCTION SAFETY...................................................................................................................SECTION 1 GENERAL INFORMATION .....................................................................................SECTION 2 OPERATOR CONTROLS .......................................................................................SECTION 3 START-UP, TRAMMING AND SHUTDOWN ...........................................................SECTION 4 DRILLING PROCEDURES .....................................................................................SECTION 5 LUBRICATION AND MAINTENANCE ....................................................................SECTION 6

Drill Serial No. : Date Drill Delivered : Dealer : Customer :

ii

Introduction

Section 1

Safety

Safety

1-1

Notes

1-2

Safety

Hazard Classication
The hydraulic track drill is a heavy moving machine with a boom capable of extending its reach vertically and horizontally. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly operated, inspected, and maintained. The operator's must read this manual and have been trained to use the machine in an appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact the manufacturer.

Safety Alert Symbol


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

Safety Alert Symbol

Hazard Classication
A multi-tier hazard classication system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specic level of severity of the potential hazard. All are used as attention-getting devices on decals and labels xed to the machine to assist in potential hazard recognition and prevention. Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

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

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

Safety

1-3

Safety Sign Symbols


Potential Hazard
Safety Alert Symbol. Used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Entanglement Hazard. Death or serious injury can result from contact with rotating drill steel and drivelines. Entanglement Hazard. Rotating parts can cause personal injury.

Prevention
See Operator's Manual for instructions. If you do not understand the information the manuals, consult your supervisor, the owner, or the manufacturer. Keep clear of rotating drill steel and drivelines. Switch off engine before performing service. Keep away from fan and belt when engine is running. Stop engine before servicing.

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

Keep all open ames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt. READ MANUALS Read all manuals prior to operation.

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

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

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

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

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

Keep away from ames.

Relieve all pressure.

Allow to cool before performing service on compressor.


1-4 Safety

Safety Sign Symbols


Potential Hazard
Flying Object & Spray Hazard. Death or serious injury can result from release of pressurized liquids.

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

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

Use guards. Keep in place.

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

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

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

Maintain required clearance. See Table 1-1 in this manual.

Burn Hazard. Hot uid under pressure can scald.

Allow to cool before opening.

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

Keep off top of machine.

Fall Hazard. Death or serious injury can result from falling.

Use the access system provided when servicing the machine.

Safety

1-5

Safety Sign Symbols


Potential Hazard
Inhalation Hazard. Compressor discharge air is hazardous if inhaled. Death or serious injury may result.

Prevention
Keep clear of compressor air discharge area.

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

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

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

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

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

Keep clear of moving machine.

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

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

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

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

Always raise the drill feed and feed table clear of all obstacles before moving the machine. Raise them high enough to allow for rough ground or small hills. Do Not allow anyone under the drill feed or feed table unless machine parts are not moving and are supported. Do Not attempt to repair a pivot pin that has failed or has been sheared.

1-6

Safety

Safety Information
Before Operation Do study this manual and fully understand the controls. Do be sure all safety guards are securely in place. Replace any damaged or missing guards. Do be sure all nameplates and decals pertaining to safety, operation, and maintenance are in place and not damaged. Replace any damaged or missing nameplates or decals. Refer to decal locator drawings in this section. Do be sure all personnel are clear of the machine and work area before starting the engine or operating the machine. Do be sure drill area is clear of all obstructions before operating machine. Do attach safety chain when using towbar. Do wear safety helmet, glasses and hearing protection when operating or working on machine. Do Not operate machine with: Hydraulic or air leaks. Damaged hydraulic hoses or ttings. Broken or damaged electrical wiring. Damaged or missing guards and shields. Damaged structural members. Worn or damaged mechanical parts. Damaged or missing fasteners. Broken, damaged, or malfunctioning controls. Do examine the surface before drilling to determine the possible presence of unred explosives. Do provide sufcient ventilation when running the engine in an enclosed area. Exhaust gases contain carbon monoxide, a deadly poison, which is colorless and odorless. Do keep work area clean and clear of mud, snow, ice, uids, hand tools and other objects. Do raise the drill feed before moving the machine. Raise it high enough to allow for rough ground or small hills. Drill feed can fall causing serious injury or death. Do wear seat belt and operate machine with door closed on cab machines. Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g. safety helmet, safety glasses, hearing protection, gloves, respirator. Do maintain minimum clearance from high voltage wires (see Table 1-1). Check with power company and local regulations for specic guidelines and safety information. Do Not use the machine for any other purpose than what it was designed for. Do Not wear loose clothing or jewelry; keep clothing and hands clear of moving parts. Do Not travel on steep inclines, soft or unstable ground, or close to unsupported excavations. Do Not move boom or machine if it is in a potentially unstable position. Do Not stand directly under a boom or feed. Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.

Operation

Safety

1-7

Safety Information
After Operation Follow Shutdown Procedures given in Section 4 of this manual.

Maintenance Two people shall be present when performing service work, both being fully trained on safety issues. One person shall supervise from the operator's position and have immediate access to an emergency stop in all situations. Visual, audible or verbal communication signals shall be established and understood by both persons. Do relieve pressure in the hydraulic or pneumatic systems before loosening connections or parts.
Do use only proper tools to make repairs or adjustments. Do be sure of adequate lighting when performing service work at night. Do maintain a metal-to-metal contact between the ll nozzle and fuel tank when lling the fuel tank. This will prevent sparks and the possibility of explosion. Do be sure each person is adequately trained to perform service and maintenance procedures. Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.

Do be sure machine and components are well supported before servicing or replacing parts. Do Not service, or perform maintenance, while machine is running, or capable of being started. Do Not hammer bit or drill steel. Use only proper tools to make repair or adjustments. Do Not weld or grind near oil, air, fuel lines, or batteries. Do Not smoke or use an open ame near batteries. Batteries can give off hydrogen which is a highly explosive gas. Do Not direct high pressure cleaning agents or water on electrical connections.

Equipment Transfer If all or part of the equipment is shipped to a new destination, always include a complete Operator's Manual or a copy of the following topics: Safety Section Operation Instructions including: Pre-Start Checks Clearances from High Voltage Lines Start-up Line Voltage Minimum Clearance After Start Checks Shutdown Procedure 0 to 50 kv 10 ft (3 m) Tramming Machine 50 to 200 kv 15 ft (4.6 m)
200 to 350 kv 350 to 500 kv 500 to 750 kv 750 to 1000 kv 20 ft (6.1 m) 25 ft (7.6 m) 35 ft (10.7 m) 45 ft (13.7 m)

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

1-8

Safety

Safety Sign List


Machines Without Enclosures
Refer to Figures 1-1 to 1-4 for locations Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 26 27 28 Description DANGER - Electrocution Hazard WARNING - Flying Object Hazard WARNING - Operation/Maintenance, Read Manual WARNING - Flying Object & Spray Hazard DANGER - Entanglement Hazard, Rotating Drill Steel NOTICE - Hydraulic Oil Requirements DANGER - Explosion Hazard NOTICE - Fueling WARNING - Burn Hazard, Hot Fluid DANGER - Inhalation Hazard WARNING - Burn Hazard DANGER - Flying Object Hazard WARNING - Fall Hazard, Operator's Seat WARNING - Drill Feed and Table Can Fall WARNING - Crush Hazard, Centralizer WARNING - Crush Hazard, Feed Mast NOTICE - Do Not Weld NOTICE - Grease Instructions WARNING - Explosion Hazard, Engine WARNING - Explosion Hazard, Compressor WARNING - Entanglement Hazard, Fan and Belt CAUTION - High Pressure Spray on Elect. Connections DANGER - Crush Hazard WARNING - Injection Hazard WARNING - Crush Hazard, Centralizer (Clear) DECAL - R30 Maintenance Summary Part No. 429116 429082 428892 429141 429115 429106 428896 429471 428897 429491 429405 429119 429087 409485 429438 429084 429489 427967 429494 429493 428893 429468 428884 428898 429938 435214 Qty. 1 2 3 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 4 2 1 1

(Ref. 431329 rev. C)

Safety Sign Maintenance


Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety sign material.

Safety

1-9

Safety Sign Location


Without Enclosures

Fig. 1-1 Right Side of Machine

Fig. 1-2 Left Side of Machine

1-10

Safety

Safety Sign Location


Without Enclosures

Fig. 1-3 Top View of Machine

Fig. 1-4 Front and Rear of Machine

Safety

1-11

Notes

1-12

Safety

Safety Sign List


Machines With Enclosures
Refer to Figures 1-5 to 1-9 for locations Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Description DANGER - Electrocution Hazard WARNING - Flying Object Hazard WARNING - Operation/Maintenance, Read Manual WARNING - Flying Object & Spray Hazard DANGER - Entanglement Hazard, Rotating Drill Steel NOTICE - Hydraulic Oil Requirements DANGER - Explosion Hazard NOTICE - Fueling WARNING - Burn Hazard, Hot Fluid DANGER - Inhalation Hazard WARNING - Burn Hazard DANGER - Flying Object Hazard WARNING - Fall Hazard, Operator's Seat WARNING - Drill Feed and Table Can Fall WARNING - Crush Hazard, Centralizer WARNING - Crush Hazard, Feed Mast NOTICE - Do Not Weld NOTICE - Grease Instructions WARNING - Explosion Hazard, Engine WARNING - Explosion Hazard, Compressor WARNING - Entanglement Hazard, Fan and Belt WARNING - Fall Hazard CAUTION - High Pressure Spray on Elect. Connections DANGER - Crush Hazard WARNING - Trip & Fall Hazard WARNING - Injection Hazard WARNING - Crush Hazard, Centralizer (Clear) DECAL - R30 Maintenance Summary Part No. 429116 429082 428892 429141 429115 429106 428896 429471 428897 429491 429405 429119 429087 409485 429438 429084 429489 427967 429494 429493 428893 428885 429468 428884 429548 428898 429938 435214 Qty. 1 2 3 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 4 4 2 1 1

(Ref. 431331 rev. B)

Safety

1-13

Safety Sign Location


With Enclosures

Fig. 1-5 Right Side of Machine

Fig. 1-6 Left Side of Machine

1-14

Safety

Safety Sign Location


With Enclosures

Fig. 1-7 Top View of Machine

Fig. 1-8 Front and Rear of Machine

Safety

1-15

Safety Signs

429119

428884

429491

429115

429116

428896

1-16

Safety

Safety Signs

428892

429494

429493

429082

428893

429405
Safety 1-17

Safety Signs

429548Enclosure Machines Only 428885Enclosure Machines Only

429438 429938Clear Background

428897

429141 428898
1-18 Safety

Safety Signs

429084

429468

409485 429087

Safety

1-19

Safety Signs

429471

429489

427967

429106

435214
1-20 Safety

Section 2

General Information

General Information

2-1

Introduction
This manual contains detailed instructions, maintenance information, and technical data which the operator will need in order to properly operate the R30C Track Drill, and to perform the various maintenance services that are required for keeping the equipment in good working condition at all times. Included herein are complete descriptions of each operating control and step-by-step instructions on how to start, operate, and stop the equipment, and recommended operator's maintenance procedures. The maintenance procedures and service instructions in this manual are included as recommendations only and are based on normal equipment working conditions. Changes should be initiated by the user in order to compensate for other than normal conditions and to meet the working requirements of any specic job application. By faithfully using this manual as a guide, and observing the instructions and recommendations, the R30C Track Drill will provide many years of dependable and efcient service at a minimum cost for operation.

Receiving and Inspection


Upon receipt of the machine, Owner/Operator is required to inspect the machine and all items listed on the Warranty Registration/Delivery Service Report included with the machine, complete the report and return to the manufacturer within 15 days of the In Service date.

R30C Hydraulic Track Drill

2-2

General Information

Component and Machine Specications


Track Undercarriage Two (2) hydraulic motor-driven compact planetary gear drives with manual disconnect for towing. Complete with hydraulic released, spring applied automatic disc brakes, 15 in. (38 cm) wide, overlapping, triple grouser tracks with mud/snow relief. Tram speed is 2.4 mph (4 km/hr.) Engine Caterpillar C9 300 hp (224 kW) diesel engine, 6-cylinder, water cooled, air-to-air aftercooled turbocharger. The engine speed is automatically controlled by power demand. Cab Certied ROPS/FOPS pressurized xed cab complete with heater, air conditioner, wiper, drilling lights, electronic two axis angle indicator and all necessary drilling controls. AM/FM stereo with CD player. Hydraulic System The system consists of two (2) direct driven pressure-compensated variable displacement, axial piston pumps, two (2) two-speed variable displacement traction drive motors. SmartDrill drilling control system. Air System 350 cfm @ 150 PSI (8.2 m3/min @ 10.2 bar) Gardner-Denver Rota-Screw Compressor driven by a xed displacement axial piston hydraulic motor. Feed System Model UHF16 Chain Feed, powered by a hydraulic piston motor complete with a power centralizer. The feed will accept a 20 ft. (6.1 m) drill steel for single pass without a hose reel. Rock Drill Model HPR45 hydraulic percussion drill, 25 hp (19 kW), standard on R30C. For drilling holes up to 5 in. (127 mm) diameter. . Boom A 12.5 ft. (3.81 m) swing boom with 5 ft. (1.5 m) telescopic system complete with a drill positioner, a 3 ft. (0.9 m) feed extension and a feed table with retaining device. Boom swing angle capability of 70 L, 33 R deg.

General Information

2-3

Component and Machine Specications

Rod Changer Linear rod changer for 5 (45 mm) or 4 (51 mm) 12 or 14 ft. (3.7 or 4.3 m) round rods for up to 72 ft.* (21.9 m) drill steel capabiltiy. Carousel rod changer for 5 (38 mm), 5 (45 mm) or 4 (51 mm) 12 or 14 ft. (3.7 or 4.3 m) round rods for up to 88 ft.* (26.8 m). A single rod changer is also availabe for starter and one rod. * Depth capacity includes a 20 ft. starter rod. Additional Standard Features Fully Enclosed Canopy Power Pickup Pot Angle Inclinator Dust Collector Options Detergent System HPR51 Hydraulic Percusion Drill, 30 hp (23 kW)

2-4

General Information

Component and Machine Specications

Fig. 2-1 Right Side View of R30C 1. Detergent Tank 2. Engine Air Filter 3. Hydraulic Tank Filters 4. Cab Air Filter 5. Dust Collector 6. Boom Swing Cylinder 7. Feed Dump Cylinder 8. Feed Extend Cylinder

9. Feed Table Assembly 10. Dust Collector Precleaner 11. Feed Swing Cylinder 12. Boom Lift Cylinder 13. Air Receiver Tank 14. Hydraulic Tank 15. Hydraulic Pumps (2) 16. Pump Drive

Fig. 2-2 Left Side View of R30C 17. Drill Slide Assembly 18. Feed Assembly 19. Upper Rod Rack 20. Cab 21. Electrical Enclosure 22. Engine Radiator Shunt Tank 23. Radiator/Cooler

24. Track Oscillation Cylinder (2) 25. Outer Boom Tube 26. Inner Boom Tube 27. Positioner 28. Hydraulic Rock Drill 29. Rod Wrench

General Information

2-5

Component and Machine Specications

Fig. 2-3 Top View of R30C 30. Feed Drive Assembly 31. Breather, Hydraulic Tank 32. Batteries 33. Caterpillar C9 Diesel Engine

34. Fuel Tank 35. Air Receiver Tank 36. Air Compressor

Fig. 2-5 Boom Mounted Angle Indicator

Fig. 2-4 Lower Boom/Feed 1. Lower Rod Rack 2. Rope Pull Shutdown Switch 3. Pickup Pot

4. Pendulum 5. Centralizer

2-6

General Information

Component and Machine Specications

Fig. 2-6 Valve Locations 1. Tram Valve 2. Boom/Feed Valve

Fig. 2-7 Manifold Locations 1. Rod Changer Manifold 2. Auxiliary Manifold

General Information

2-7

Component and Machine Specications

Fig. 2-8 Dust Collector Regulator and Blow Air Valve 1. Regulator (set at 80 PSI (5.5 bar)) 2. Ball Valve

Fig. 2-9 1. Electronic Control Module (ECM) 2. Plug-InsDisconnect from ECM before welding

Fig. 2-10 Hose Reel

2-8

General Information

Section 3

Operator Controls

Operator Controls

3-1

Notes

3-2

Operator Controls

Control Panel
OFF to Start, ON to Tram

Fig. 3-1 Cab Control Panel 1. Cab Temperature Control 2. Air Conditioner ON/OFF 3. Cab Fan Speed 4. Warm Oil ON/OFF 5. Washer FRONT/TOP 6. Rear Drill Lights ON/OFF 7. Front Drill Lights ON/OFF 8. Control System ON/OFF 9. Not Used 10. Feed Force 11. Dust Collector ON/OFF 12. Engine Idle LOW/HIGH Adjusts temperature for heater/air conditioner Turns air conditioner on/off Controls fan speed

NEUTRAL to Start

Warms the hydraulic oil in cold conditions 32o F (0o C) or less Turns on windshield washer Turns rear drill lights on and off Turns front drill lights on and off Powers up machine electronic controls; must be OFF when starting engine Rotate knob CW to increase pressure on drill bit, CCW to decrease pressure Turns dust collector on; with air on, dust collector is fully operational, with air off, dust collector operates in pulse mode to clean dust collector lters Switch on LOWengine runs at 1000 RPM (for startup/shutdown), increases to 1500 RPM (for system load) Switch on HIGHengine runs at 1800 RPM (for drilling/tramming functions) Selects rod changer or setup mode while in drill mode. Selects tram or drill mode; tram is disabled in drill mode; drill is disabled in tram mode; must be in neutral position when starting engine Turns on detergent system (if supplied), dust collector must be off Locks or unlocks track oscillation cylinders for different tramming conditions Switch ON activates automatic drilling Shuts down machine engine in case of an emergency Lights when engine start is engaged; shuts off when engine is warmed to start Starts engine
3-3

13. Rod Changer/Setup 14. Tram/Neutral/Drill 15. Water ON/OFF 16. Oscillation LOCK/UNLOCK 17. Smart Drill ON/OFF 18. Engine Stop Switch 19. Cold Start Lamp 20. Engine Start Switch
Operator Controls

Joystick ControlsLinear Rod Changer

L.H. Tram Joystick

Fig. 3-2 Joysticks

One Joystick Tram


1. L.H. Joystick Controller Located on the left arm rest, the L.H joystick performs the following functions (ref. g.3-3): Tram/Drill switch in TRAM (14, g. 3-1) tram, oscillation, counter rotate, 2-speed Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) feed dump, feed swing, feed extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER rod lock, rod unlock, rod wrench in, rod wrench out

2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following functions (ref. g.3-3): Tram/Drill switch in TRAM (14, g. 3-1) boom down, boom up, boom swing left, boom swing right Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER carriage out, carriage in, car riage unlock

3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-3): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading

3-4

Operator Controls

Joystick ControlsLinear Rod Control


One Joystick Tram

Fig. 3-3 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot

Operator Controls

3-5

Joystick ControlsLinear Rod Changer

Tram Joysticks Fig. 3-2 Joysticks

Two Joystick Tram


1. L.H. Joystick Controller Located on the left arm rest, the L.H joystick performs the following functions (ref. g.3-4): Tram/Drill switch in TRAM (14, g. 3-1) tram left track forward/reverse, oscillation forward/backward, 2speed Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) feed dump, feed swing, feed extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER rod lock, rod unlock, rod wrench in, rod wrench out

2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following function (ref. g.3-4): Tram/Drill switch in TRAM (14, g. 3-1) tram right track forward/reverse Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER carriage out, carriage in, car riage unlock

3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-4): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading

3-6

Operator Controls

Joystick ControlsLinear Rod Control


Two Joystick Tram

Fig. 3-4 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot

Operator Controls

3-7

Joystick ControlsCarousel Rod Changer

L.H. Tram Joystick

Fig. 3-2 Joysticks

One Joystick Tram


1. L.H. Joystick Controller Located on the left arm rest, the L.H joystick performs the following functions (ref. g.3-3): Tram/Drill switch in TRAM (14, g. 3-1) tram, oscillation, counter rotate, 2-speed Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) feed dump, feed swing, feed extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER jaw clamp, jaw unclamp, carousel swing in, carousel swing out

2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following functions (ref. g.3-3): Tram/Drill switch in TRAM (14, g. 3-1) boom down, boom up, boom swing left, boom swing right Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER carousel counterclockwise, carousel clockwise

3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-3): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading

3-8

Operator Controls

Joystick ControlsCarousel Rod Control


One Joystick Tram
TRAM MODE
LEFT JOYSTICK
FORWARD BOOM SWING LEFT BOOM UP

RIGHT JOYSTICK
BOOM DOWN BOOM SWING RIGHT

LEFT

RIGHT

JOYSTICK BUTTONS

REVERSE OSC FORWARD 2-SPEED COUNTER ROTATE OSC BACKWARD

L.H. ARMREST SWITCHES

DRILL JOYSTICK
RIGHT JOYSTICK
BOOM DOWN FEED UP BOOM SWING RIGHT BOOM UP BOOM EXTEND OUT BOOM EXTEND IN

SET-UP MODE
LEFT JOYSTICK
FEED DUMP IN FEED SWING LEFT FEED SWING RIGHT FEED DUMP OUT FEED EXTEND UP OFF CLOSE DOWN FEED EXTEND DOWN BOOM SWING LEFT

AIR ON

CENTRALIZER OPEN

PICK-UP POT UP

ROTATION FORWARD FEED DOWN COUPLING GREASE COLLAR SYN THREAD FULL HAMMER

ROD CHANGER MODE


LEFT JOYSTICK RIGHT JOYSTICK
CAROUSEL COUNTER CLOCKWISE FEED UP

AIR ON

CENTRALIZER OPEN

PICK-UP POT UP

JAW CLAMP

JAW UNCLAMP

ROTATION FORWARD FEED DOWN

ROTATION REVERSE

CAROUSEL CLOCKWISE SWING IN SWING OUT

COUPLING GREASE OFF CLOSE DOWN COLLAR SYN THREAD FULL HAMMER

DECAL P/N: 440863

1
2 3

Fig. 3-3 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot

Operator Controls

3-9

Joystick ControlsCarousel Rod Changer

Tram Joysticks Fig. 3-2 Joysticks

Two Joystick Tram


1. L.H. Joystick Controller Located on the left arm rest, the L.H joystick performs the following functions (ref. g.3-4): Tram/Drill switch in TRAM (14, g. 3-1) tram left track forward/reverse, oscillation forward/backward, 2speed Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) feed dump, feed swing, feed extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER jaw unclamp, jaw clamp, carousel swing in, carousel swing out

2. R.H. Joystick Controller Located on the right arm rest, the R.H joystick performs the following function (ref. g.3-4): Tram/Drill switch in TRAM (14, g. 3-1) tram right track forward/reverse Tram/Drill switch in DRILL, Rod Changer/Setup switch in SETUP (13, g. 3-1) boom down, boom up, boom swing left, boom swing right, boom extend Tram/Drill switch in DRILL, Rod Changer/Setup switch in ROD CHANGER cariage counterclockswise carousel clockwise

3. Drill Joystick Controller Located on the right arm rest, the drill joystick performs the following functions (ref. g.3-4): Tram/Drill switch in DRILL (14, g. 3-1), Rod Changer/Setup switch in SETUP or ROD CHANGER (13, g. 3-1) feed up, feed down, rotation forward, rotation reverse, coupling grease, collar, full hammer, synchronized threading

3-10

Operator Controls

Joystick ControlsCarousel Rod Control


Two Joystick Tram
TRAM MODE
LEFT JOYSTICK
FORWARD

RIGHT JOYSTICK
FORWARD

LEFT TRACK

REVERSE OSC FORWARD 2-SPEED OSC BACKWARD

REVERSE

L.H. ARMREST SWITCHES

DRILL JOYSTICK

SET-UP MODE
LEFT JOYSTICK
FEED DUMP IN FEED SWING LEFT FEED SWING RIGHT FEED DUMP OUT FEED EXTEND UP OFF CLOSE DOWN FEED EXTEND DOWN BOOM SWING LEFT BOOM UP BOOM EXTEND OUT BOOM EXTEND IN

RIGHT JOYSTICK
BOOM DOWN BOOM SWING RIGHT FEED UP

AIR ON

CENTRALIZER OPEN

PICK-UP POT UP

ROTATION FORWARD FEED DOWN

ROTATION REVERSE

COUPLING GREASE COLLAR SYN THREAD FULL HAMMER

ROD CHANGER MODE


LEFT JOYSTICK RIGHT JOYSTICK
CAROUSEL COUNTER CLOCKWISE FEED UP

AIR ON

CENTRALIZER OPEN

PICK-UP POT UP

JAW CLAMP

JAW UNCLAMP

ROTATION FORWARD FEED DOWN

ROTATION REVERSE

CAROUSEL CLOCKWISE SWING IN SWING OUT

COUPLING GREASE OFF CLOSE DOWN COLLAR SYN THREAD FULL HAMMER

DECAL P/N: 440864

Fig. 3-4 Joystick Functions and L.H Armrest Switches 1. Air ON/OFF 2. Centralizer OPEN/CLOSE 3. Pickup Pot UP/DOWN Adjusts amount of air down the hole by holding the switch ON Opens and closes centralizer Raises or lowers pickup pot

Operator Controls

3-11

Joystick Button Controls

Fig. 3-5 L.H. Joystick Buttons TRAM MODE 9. Oscillation Backward 10. Counter Rotate 11. Oscillation Forward 12. 2-Speed DRILL/SET UP MODE 9. Not Used 10. Not Used 11. Feed Extend Up 12. Feed Extend Down DRILL/ROD CHANGER MODE 9. Rod Wrench Out OR 9. Carousel Sing Out 10. Rod Wrench In OR 10. Carousel Swing In 11. Not Used 12. Not Used

Fig. 3-6 R.H. and Drill Joystick Buttons TRAM MODE DRILL/ROD CHANGER MODE 1. Not Used 1. Full Hammer 2. Not Used 2. Coupling Grease 3. Not Used 3. Collar 4. Not Used 4. Synchronized Threading 5. Not Used 5. Not Used 6. Not Used 6. Not Used 7. Not Used 7. Not Used 8. Not Used 8. Carriage Unlock DRILL/SET UP MODE 1. Full Hammer 2. Coupling Grease 3. Collar 4. Synchronized Threading 5. Boom Extend In 6. Boom Extend Out 7. Not Used 8. Not Used

3-12

Operator Controls

Cab Displays
Drilling Displays

Fig. 3-7 Control Panel Drilling Pressure Readings 1. Hammer Pressure 2. Feed Pressure 3. Rotation Pressure 4. Air Pressure

Fig. 3-8 Cab Mounted Angle Indicator

Operator Controls

3-13

Cab Displays
Engine Displays

Fig. 3-9 Control Panel Engine Readings 1. Engine RPM 2. Engine Hours 3. Compressor Temperature in Fahrenheit 4. Drill Hours

5. 6. 7. 8.

Engine Temperature in Fahrenheit System Operating Voltage Engine Oil Presure Fuel Quantity in Percent

3-14

Operator Controls

Remote Operation
For Emergency Use Only. Owner/Operator must contact manufacturer for proper operation.

Stay clear of moving machine, death or serious injury can result

Fig. 3-10 Tram Control Valve

Fig. 3-11 Boom/Feed Control Valve

Operator Controls

3-15

Notes

3-16

Operator Controls

Section 4

Start-up, Tramming and Shutdown

Start-up, Tramming and Shutdown

4-1

Notes

4-2

Start-up, Tramming and Shutdown

Pre-Start Checklist
CHECK FOR obstructions before moving feed or machine. DO NOT allow any part of the machine to contact or come near electrical power lines (see Table 4-1). BE SURE the feed is high enough to clear ground obstacles and low enough to clear overhead obstacles when tramming.

BE SURE all hydraulic controls are in the OFF or NEUTRAL position BEFORE placing the control system ON/OFF switch to ON. DO NOT operate the machine unless thoroughly familiar with controls and functions. WEAR a protective helmet and eye protection when on or near the machine. WEAR noise reducing ear protectors when near the machine for extended periods while the machine is running. CHECK operation of the brakes before tramming. REMOVE the drill steel and center the drill over the positioner before tramming over rough terrain.

BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. BE SURE machine is OFF and the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts. SHUT OFF engine BEFORE refueling. Clean up any fuel spills immediately. Failure to observe this warning may result in re.

Clearances from High Voltage Lines Line Voltage Minimum Clearance 0 to 50 kv 10 ft (3 m) 50 to 200 kv 15 ft (4.6 m) 200 to 350 kv 20 ft (6.1 m) 350 to 500 kv 25 ft (7.6 m) 500 to 750 kv 35 ft (10.7 m) 750 to 1000 kv 45 ft (13.7 m)
Table 4-1 Minimum Safe Distances From High Voltage Lines

Start-up, Tramming and Shutdown

4-3

Pre-Start Checklist
Overall Machine A. Check underside of machine. Look for broken or loose hoses. Tighten any loose hose connections and any loose bolts. If dripping fuel, oil or water is evident, do not operate the machine until the leak is found and corrected. B. C. D. E. Replace any missing or damaged bolts, pins or other retainers. Check tracks for proper tension and clear any debris. Lubricate machine according to Maintenance Schedule and Grease Points chart in Section 6. Check battery cable connections and battery electrolyte level. Switch battery disconnect switch (located behind battery box) to the ON position.

Fuel A. Always shut off engine before refueling. B. C. Wipe up any fuel spills immediately or re may result. Use No. 2-D diesel fuel. Consult engine manual for specic recommendations.

Engine, Gearcases and Hydraulic Fluid Types A. Check engine crankcase oil level. Add oil if necessary. Do not mix types of oil. The machine is factory lled with 15W-40 motor oil unless specied otherwise. B. C. D. E. Check radiator coolant level. Add a 50/50 mixture of anti-freeze and water if necessary. Check battery electrolyte level and ll with distilled water if necessary. Check for clean, tight connections. Check for adequate diesel fuel. To avoid priming and restarting problems, do not allow engine to run out of fuel. Drain water from water separator prior to starting. Check oil level in feed planetary drive assembly. Add HD 80W-90 wt. gear oil if necessary. Do not mix types of oil. Set feed in upright position and remove plug at the 3 o'clock position. Oil level should be at bottom of plug hole. Fill through plug at the 12 o'clock position. Check oil level in track planetary drive. Add gear oil if required. Do not mix types of oil. Machine is factory lled with HD 80W-90 wt. gear oil (see Service Manual for list of approved gear oils). With machine on level surface, position unit so drain plug is at bottom, ll plug will be at about the 2 o'clock position. Oil level should be at bottom of ll plug. Check alternator/water pump drive belt condition. Replace if cracked or worn. See engine manual. Check oil level in hydraulic reservoir. Add oil if necessary. When checking hydraulic uid level, be sure: Reservoir is level Boom is retracted and level Feed is dumped back and extended Do not overll. Machine was factory lled with Chevron AW MV ISO 100 unless specied otherwise. Do Not Mix Hydraulic Fluid Types.

F.

G. H.

NOTE

4-4

Start-up, Tramming and Shutdown

Pre-Start Checklist
Pneumatic System A. Be sure hydraulic and pneumatic systems are not pressurized before loosening any connections or parts. Check oil level in compressor receiver. Add oil only if gauge reads in the Add Oil range. Machine is factory lled with Chevron ATF. Boom, Feed and Drill A. Operator must be sure to check all pivot points for signs of wear or damage and grease daily. B. C. D. E. F. Check for loose drill hose retainers. Check feed chain for proper tension (see service manual). Drill ChuckCheck for excessive shank side play indicating chuck wear. Grease chuck end cap after shank is inserted (see Drill Service Manual). Drill ShankInspect shank threads often. Badly worn threads can cause tight steel and premature coupling breakage. CentralizerCheck centralizer alignment with drill shank. Clamp a coupling between the centralizer jaws. Lower the drill so the shank aligns with the coupling. Adjust centralizer as necessary.

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

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

Start-up, Tramming and Shutdown

4-5

Pre-Start Checklist

Fig. 4-1 Feed Table Pivot Pin 1. Grease Fittings (2) 2. Retaining Bolts (6)Torque to 282 ft. lbs. (384 Nm) 3. Retaining Cap, Feed Table Pin

Feed Table Pivot Pin


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

Weekly Checks 1. Be sure to check torque on the six pivot pin cap retaining bolts weekly. Torque to 282 ft. lbs. (384 Nm). Check for excessive play, cracking or other damage. 2. Check for end play by inserting a feeler gauge between the retaining cap and positioner casting. The gap should be in the range of 0.005 to 0.015 in. (0.13 to 0.38 mm). Retaining cap will have to be removed and shims installed until the correct clearance is obtained. Procedure in service manual must be followed. Check for side play by raising the feed to a 45 degree angle. Have someone watch the pivot pin while you dump the feed back and forth. There should be no rocking of the pin. If so, report to maintenance personnel. Feed table will have to be removed and pin and bushing inspected and necessary repairs made.

3.

4-6

Start-up, Tramming and Shutdown

Engine Starting With Jumper Cables


Batteries give off ammable fumes that can explode. DO NOT smoke when observing the battery electrolyte levels. Improper jumper cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. DO NOT allow jumper cable ends to contact each other or the engine. ALWAYS wear protective glasses when working with batteries. Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.

Jump Starting Instructions


1. 2. 3. 4. Turn start switch OFF and turn off all electrical accessories. Turn battery disconnect switch ON (g. 4-2). Always use the same voltage system for jump starting, in this case, 24V negative ground. Connect one end of the cable to the POSITIVE (+) terminal of the battery being started (g. 4-3). Connect the other end to the POSITIVE (+) terminal of the power source. Connect one end of the cable to the NEGATIVE () terminal of the power source. Connect the other end to the engine block or chassis ground. This prevents sparks from igniting combustible gases produced by some batteries. After starting engine, disconnect NEGATIVE () cable from engine block or chassis ground. Disconnect other end from the NEGATIVE () terminal of the power source. Disconnect the cable from the POSITIVE (+) terminal on the battery of the engine being started. Disconnect the other end from the POSITIVE (+) terminal of the power source.

5. 6.

Fig. 4-2 Battery Disconnect Switch (OFF disconnects batteries)

Fig. 4-3 Battery Connections on Model R30C

Start-up, Tramming and Shutdown

4-7

Start-up Procedure
OFF to Start, ON to Tram

NEUTRAL to Start Fig. 4-4 Cab Control Panel 1. Cab Temperature Control 2. Air Conditioner ON/OFF 3. Cab Fan Speed 4. Warm Oil ON/OFF 5. Washer FRONT/TOP 6. Rear Drill Lights ON/OFF 7. Front Drill Lights ON/OFF 8. Control System ON/OFF 9. Not Used 10. Feed Force 11. Dust Collector ON/OFF 12. Engine Idle LOW/HIGH 13. Rod Changer/Setup 14. Tram/Drill 15. Water ON/OFF 16. Oscillation LOCK/UNLOCK 17. Smart Drill ON/OFF 18. Emergency Stop Switch 19. Cold Start Lamp 20. Engine Start Switch

Fig. 4-5 Hydraulic Tank Temperature Gauge

Fig. 4-6 Hydraulic Pumps and Gauges 1. Pump No. 1 2. Pump No. 2 3. Dust Collector Pump 4. Pump No. 1 Gauge 5. Pump No. 2 Gauge

4-8

Start-up, Tramming and Shutdown

Start-up Procedure
DO NOT use ether on engines equipped with an air intake heater. DO NOT put ether into compressor intake.

After completing the pre-start checklist, use the following procedure to start the machine: (ref. g. 4-4) 1. 2. 3. 4. 5. Turn battery disconnect (g. 4-2) located behind battery box to ON position. Be sure all controls are in the OFF or NEUTRAL position. Be sure the Tram/Drill Switch (14) is in the NEUTRAL (center) position. Be sure Control System Switch (8) is in the OFF position. Turn Ignition Switch (20) to START position. When engine starts, release switch to ON position.

NOTE

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

DO NOT begin drilling until hydraulic oil has been warmed up, especially when ambient temperature is below 32oF (0oC). When hydraulic oil tank temperature gauge (g. 4-5) reaches 60oF (15.6oC), oil is warm enough to begin drilling. 6. 7. 8. Let machine warm up for a few minutes and then switch Control System Switch (8) to ON position. Check pump pressure gauges (g. 4-6) . Normal pressure when pumps are loaded is 3200 PSI (241 bar). If not, check hydraulic system. Observe engine RPM displayLow idle is 1000 RPM, System Load (Intermediate) is 1500 RPM, and High idle is 1800 RPM.

Cold Start Procedure


The Caterpillar C9 engine is equipped with an air intake heater. DO NOT use ether to try to start this engine. The Cold Start Lamp (19) comes on when the air intake heater is on. After the engine has started, the air inlet heater may continue to operate in the "continuous" or "intermittent" mode. The air inlet heater will turn OFF when the sum of the coolant and air inlet temperatures exceed 127oF (35oC). Allow engine to idle for about 3 minutes or until you see the water temperature reading begin to rise. Check all readings during warm-up period.

Hydraulic Oil Warming


In cold temperatures, switch the Warm Oil Switch (4) to ON. Usually during engine warm up (15 to 30 minutes), this will allow enough time for the hydraulic oil to warm up. Turn off the switch before operation of the track drill. When hydraulic oil tank temperature gauge (g. 4-5) reaches 60oF (15.6oC), oil is warm enough to begin drilling.

Start-up, Tramming and Shutdown

4-9

Tramming
DO NOT allow feed to come in contact with or come near high voltage lines. See minimum clearances from high voltage lines chart in Safety Section.

DO NOT tram machine on steep inclines, or horizontal to grades; this greatly increases risk of machine rollover. DO NOT tram machine on soft or unstable ground, or close to unsupported excavations. When tramming on slopes with cab machines equipped with ve or six rod changer, the Oscillation Control Switch MUST BE in the LOCK position.

Retract the telescopic boom when tramming over rough ground and during long moves. Place feed in horizontal position with top of feed resting on mast rest (if equipped).

One Joystick Tram


1. 2. Place Tram/Drill Switch (14, g. 4-4) in the TRAM position. Place feed in horizontal position when tramming over rough ground and during long moves. Normally when tramming, the track oscillation cylinders are in the unlocked condition, however when tramming on slopes with a cab machine equipped with a ve or six rod changer the track oscillation cylinders must be in the locked condition.

NOTE

3. 4.

Oscillation Lock Switch (16, g. 4-4) should be in the UNLOCK position when tramming and oscillation is automatically locked in drill mode. Engine Idle Low/High Switch (12, g. 4-4) controls high engine idle speed and low engine idle speed. The engine idle speed increases or decreases maximum ow available for tramming. High engine idle provides approximately 2.5 m.p.h. Low engine idle provides approximately 1.2 m.p.h. To maneuver the machine, the Function switch must be in TRAM mode and the Control System switch must be ON. Using the L.H. joystick, squeeze the dead-man switch to release the brakes, then move it forward or backward (very slowly). To turn the drill, start forward or backward rst and then move the joystick to right or left without allowing the joystick to return to the center position. When tramming on side slopes, swing boom to the uphill side of the machine for better stability. Keep cab on uphill side of machine. For close maneuvering of machine place the Engine Idle Switch in LOW position.

5. 6.

NOTE

4-10

Start-up, Tramming and Shutdown

Tramming
Two Joystick Tram
1. 2. Place Tram/Drill Switch (14, g. 4-4) in the TRAM position. Place feed in horizontal position when tramming over rough ground and during long moves. Normally when tramming, the track oscillation cylinders are in the unlocked condition, however when tramming on slopes with a cab machine equipped with a ve or six rod changer the track oscillation cylinders must be in the locked condition.

NOTE

3. 4.

Oscillation Lock Switch (16, g. 4-4) should be in the UNLOCK position when tramming and oscillation is automatically locked in drill mode. Engine Idle Low/High Switch (12, g. 4-4) controls high engine idle speed and low engine idle speed. The engine idle speed increases or decreases maximum ow available for tramming. High engine idle provides approximately 2.5 m.p.h. Low engine idle provides approximately 1.2 m.p.h. To maneuver the machine use the L.H. and R.H. joystick controls. To turn machine, push one joystick forward while pulling the other joystick back. Pushing both joysticks forward will move the machine forward, pulling both joysticks back will move the machine in reverse. When tramming on side slopes, swing boom to the uphill side of the machine for better stability. Keep cab on uphill side of machine. For close maneuvering of machine place the Engine Idle Switch in LOW position.

5.

NOTE

Start-up, Tramming and Shutdown

4-11

Shutdown Checklist
BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. DO NOT operate or shutdown the machine with the feed positioned over the operator. Plant (sting) the feed prior to extended shutdowns. 1. 2. 3. 4. 5. 6. Set feed on ground. Place all tramming and drilling controls in the OFF or NEUTRAL position. Place Control System ON/OFF Switch to OFF, this will allow engine to run at low idle. Switch Drill/Tram switch to NEUTRAL or OFF position. Let engine idle at low speed for about 3 minutes, then turn ignition switch to OFF position. If machine will be shut down for an extended period, switch the Battery Disconnect switch to OFF (g. 4-2). This will prevent excess battery drain.

4-12

Start-up, Tramming and Shutdown

Section 5

Drilling Procedures

Drilling Procedures

5-1

Linear Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-2

Drilling Procedures

Linear Rod Changer


Loading Drill Rod
ALWAYS check for obstructions before moving feed or machine. DO NOT allow any part of the machine to contact or come near electrical power lines.

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

Never wear loose tting clothing when working around machinery.

NOTE

Three people are required to perform this procedure. One operator and two people loading drill rod.

1. 2. 3. 4.

Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean. Grease threads with coupling grease on upper end of drill rod and install coupling. Make sure each piece of drill rod has a coupling on the upper end. Select DRILL position with switch (14, g. 5-3). Select ROD CHANGER position with switch (13, g. 5-3). Push lower left button (8) on R.H. joystick to UNLOCK rod rack carriage. Move R.H. joystick FORWARD to move carriage out. Use Drill joystick to run drill to bottom of feed so drill shank is positioned just above centralizer. Be sure drill shank is aligned with centralizer when it is closed, if not refer to Service Manual for alignment procedure. Open centralizer jaws. Tilt the feed to a suitable angle which will allow insertion of drill rod through dust collector pick-up pot and be able to align with the drill shank. Open the centralizer (L.H. armrest middle switch) and position drill rod through dust collector pickup pot and hold in alignment with the shank. Use Drill joystick and synchronize thread button (4) to thread the shank into the coupling. Raise the drill and rod so coupling is above the centralizer and close the centralizer. Move L.H. joystick to LEFT to swing wrench IN and clamp the drill rod. Move L.H. joystick RIGHT slightly to open the wrench so it is not clamped on the drill rod. The wrench is now in the "guide" position for the drill rod. Continue to raise the drill up towards the top of the feed so the top coupling is above the upper rack. Press and hold button (8) to UNLOCK rod rack carriage. Move R.H. joystick BACK to move rod carriage IN towards feed. Position rod rack so drill rod is aligned with the outermost socket (farthest from the feed). Release button (8) lock pin will lock into next position. Using the Drill joystick, lower the drill rod until the coupling is level with the upper rod rack. Move the L.H. joystick to RIGHT to LOCK drill rod. This pulls the rod lock bar to lock on the coupling. Slowly reverse the rotation and raise the drill to unthread the shank from the coupling.

5. 6. 7. 8. 9.

10.

11. 12.

Drilling Procedures

5-3

Linear Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-4

Drilling Procedures

Linear Rod Changer


Loading Drill Rod (cont.)
13. 14. 15. 16. Push L.H. joystick button (9) to unclamp and swing rod wrench OUT. Press and hold lower left button (8) to UNLOCK rod rack carriage. Move R.H. joystick FORWARD to move rod rack carriage OUT. Using Drill joystick, run drill down the feed and repeat steps 513 until all drill rod is loaded in rod rack. Leave the last rod coupled to the drill. Grease the threads and install drill bit.

Drilling Procedures

5-5

Carousel Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-6

Drilling Procedures

Carousel Rod Changer


Loading Drill Rod
ALWAYS check for obstructions before moving feed or machine. DO NOT allow any part of the machine to contact or come near electrical power lines.

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

Never wear loose tting clothing when working around machinery.

NOTE

Three people are required to perform this procedure. One operator and two people loading drill rod.

1. 2. 3. 4.

Do not lay drill rod on ground. Put wood blocks under drill rod and keep threads clean. Grease threads with coupling grease on upper end of drill rod and install coupling. Make sure each piece of drill rod has a coupling on the upper end. Select DRILL position with switch (14, g. 5-3). Select ROD CHANGER position with switch (13, g. 5-3). Move L.H. joystick RIGHT and push the yellow button (9) to swing jaws into store position. Move R.H. joystick FORWARD to move carriage out. Use Drill joystick to run drill to bottom of feed so drill shank is positioned just above centralizer. Be sure drill shank is aligned with centralizer when it is closed, if not refer to Service Manual for alignment procedure. Open centralizer jaws. Tilt the feed to a suitable angle which will allow insertion of drill rod through dust collector pick-up pot and be able to align with the drill shank. Open the centralizer (L.H. armrest middle switch) and position drill rod through dust collector pickup pot and hold in alignment with the shank. Use Drill joystick and synchronize thread button (4) to unthread the coupling. Raise the drill and rod so coupling is above the centralizer and close the centralizer. Push the white (10) to swing the jaws in and then move the L.H. joystick to the LEFT to clamp the drill rod. Move L.H. joystick RIGHT slightly to open the jaws so they are not clamped on the drill rod. The jaws are now in the "guide" position for the drill rod. Continue to raise the drill up towards the top of the feed so the top coupling is above the upper rack. Move L.H. joystick LEFT to clamp rod with jaws. Push the white (10) button to swing rod into the carousel. Move L.H. joystick RIGHT until jaws are fully open. Push R.H. joystick back to rotate carousel clockwise to move rod out of the way of the jaws. Move the L.H. joystick to RIGHT to LOCK drill rod. This pulls the rod lock bar to lock on the coupling. Slowly reverse the rotation and raise the drill to unthread the shank from the coupling.

5. 6. 7. 8. 9.

10. 11. 12. 13.

Drilling Procedures

5-7

Carousel Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-8

Drilling Procedures

Carousel Rod Changer


Loading Drill Rod (cont.)
14. 15. Using Drill joystick, run drill down the feed and repeat steps 512 until all drill rod is loaded in rod rack. Leave the last rod coupled to the drill. Grease the threads and install drill bit.

Drilling Procedures

5-9

Drill Positioning Procedure

Fig. 5-4 Vertical Indicator Mounted in Cab

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

To Position Feed for Vertical Drilling 1. There are two options available: A. The vertical indicator (g. 5-4)Follow the instructions for setting the feed plumb. B. Pendulum (g. 5-5) Position feed plumb by watching the pendulum. When pendulum is centered in the ring, feed is plumb. 2. When feed is plumb, plant the stinger rmly into ground using the Drill joystick. This will prevent the feed from "kicking out" when collaring the hole.

Vertical Indicator The angular display is connected to the sensor mounted on the feed. There are 10 display lights in each axis (Y+, Y, X+ and X). The maximum angle from plumb is + or 6 degrees, thus each light represents 0.6 degrees. The lights remain lit if the feed is more than 6 degrees from plumb. The lights will go out successively as the feed approaches plumb in each direction. Vertical Adjustment 1. 2. Position feed vertical (plumb) and adjust the sensor to indicate plumb (no lights on). Move feed to non-vertical position, then move back until all lights go out (plumb). Feed should be plumb within + or - 0.6 degrees.

5-10

Drilling Procedures

Drill Positioning Procedure


To Position Feed for Angle Drilling 1. There are two options available: A. The use of an electronic angle indicator is recommended if much angle drilling is to be done. B. If only a few angle holes are required, you can measure the feed angle with magnetic base adjustable protractor. 2. When feed is set at desired angle, plant the stinger rmly into ground using the Drill joystick. This will prevent the feed from "kicking out" when collaring the hole.

Final Checks When machine is in position and feed is set at the desired angle for drilling you are ready to begin drilling the rst hole. Refer to drilling procedures in this section. Check to be sure that: Track Oscillation Cylinders are Locked. Drill/Tram Selector Switch is in DRILL position. System display readings are in normal operating range. Drill steel is loaded and secured in rod rack. Adequate supply of sharp drill bits. Adequate supply of coupling grease is on hand for greasing drill steel, shank and coupling threads. Grease gun and grease (PG55, P/N 312810 recommended) on hand to grease drill front end every two hours of drill operation. Drill accumulator charge pressure has been checked.

Drilling Procedures

5-11

Drilling Practices
Tips for top drilling performance
Collaring The collar of the drill hole will directly determine the quality of the hole. Hole Deviation The major cause of drill steel breakage is deviation of the drill hole. There is very little tolerance in the drill string for any deviation, due to the high energy output of the rock drill. Feed Pressure "Under-feeding" is a particularly common and bad practice. Feed pressure must be kept to the bit at all times while drilling. "Free-hammering" (hammering with no load on the bit) and "under-feeding" will shorten the drill string life and the hammer seals. Drill Pressures Feed and hammer pressures and rotation ow can and should be adjusted to suit different rock conditions. Optimum settings are reached when the maximum penetration rate is achieved with minimal heat and vibration being generated through the drill string. Incorrect drill pressure settings can be directly related to hole deviation and drill string damage and breakage. Adjusting Drill Pressure and Monitoring the Machine The operator should attempt to maintain a minimum amount of feed pressure, just enough to keep the drill steel couplings tight. This will ensure smooth drilling and maximize penetration rate by: Minimizing heat in the drill string Eliminating "under and over feeding" Minimizing rotation pressure Rotation ow should be increased in softer rock and decreased in harder rock as indicated by the penetration rate. Monitoring of the machine is critical at all times. Monitoring of the machine gauges is especially critical for those unfamiliar with the drill. Increases in air and /or rotation pressures indicate developing blockage and / or jamming situations. Plugged Bit and Stuck Drill Steel Always be alert of air and cuttings coming out of the hole, if not STOP DRILLING. If bit becomes plugged. When blowing air is stopped by a plugged bit, the drill string can become stuck quickly. Work the bit up and down the hole with hammer and rotation on until air and cuttings can be seen coming out of the hole. If bit remains plugged, raise bit out of hole and place bit against solid rock or hard wood and turn hammer on in short bursts with air on to dislodge obstruction. If bit still remains plugged, shut down machine and relieve all air pressure before removing bit. Clear bit manually and reinstall. If drill steel becomes stuck, use the reverse percussion option (if equipped) to "hammer out" of the hole. If machine is not equipped with this option, use the feed override lever to apply extra reverse feed pressure. Work the drill string up and down using slow rotation speed with blowing air on until it is free. Using the "smart drill" option (if equipped) will help prevent stuck steel due to bad ground. Refer to "smart drill" system operation in this section.

5-12

Drilling Procedures

Drilling Practices

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

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

Drilling Procedures

5-13

Manual Drilling

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-14

Drilling Procedures

Manual Drilling
KEEP all non-essential personnel away from the hole and machinery while drilling is in progress. DO NOT re-drill a hole that has contained explosives. DO NOT strike drill rod to dislodge it while drill is operating. Fragmentation of the drill rod may result.

WORN THREADS on the drill string can cause premature wear and breakage to new parts mated with the drill string. USE sharp bits. Check for broken or loose carbides. Dull bits can cause stress in drill components. APPLY adequate lubricant to all couplings and drill rod threads before loading. CHECK rock conditions before operating drill rotation and feed at full throttle. Over feeding and over rotation can cause breakage of drill rotation parts and drill string. Place WARM OIL switch (4) in ON position before starting to drill. Drill will not operate when oil is cold. Leave control in WARM OIL position for a few minutes until oil reaches a minimum of 60oF (15.5oC).

Collaring the Hole


It is not normally possible to immediately start drilling a new hole at full rotation and feed pressure. At full power the bit will tend to jump around enlarging the hole and possibly changing the sting location and angle. Collaring allows accurate drilling by eliminating bit jumping. Initial drilling is performed at low rotation and feed pressure until the hole is deep enough so that the bit is guided by the hole. Hole depth should be about 3 in. (76.2 mm) deep in solid rock. 1. 2. 3. 4. Turn dust collector switch (11, g. 5-3) to ON position or turn water switch (15, g. 5-3) ON and adjust metering valve (behind seat) to regulate water ow if using detergent system. Slowly start forward drill rotation by placing Drill joystick in LEFT position about 1/2 way. Slowly engage feed DOWN with Drill joystick (back) to lower drill. Stop when bit contacts ground. Position air switch so blowing air is about 1/2 way open. Push collar button (3) on Drill joystick after oil has warmed up. Apply some feed pressure, using Drill joystick (back) to collar the hole. Stay in "collaring" mode until the hole is about 3 in. (76.2 mm) deep in solid rock.

Drilling Procedures

5-15

Manual Drilling

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-16

Drilling Procedures

Manual Drilling
1. 2. 3. Once hole is collared, move air switch to fully OPEN position. Move Drill joystick to full LEFT position and push full hammer button (1). Maintain proper feed pressure. If rod starts to bow, you are using too much feed pressure. If drill starts to bounce, or excessive heating in coupling is evident, you are not using enough. Use feed force knob (10, g. 5-3)) to adjust feed pressure. ALWAYS shutdown machine and let air pressure bleed off before removing a plugged bit. NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury. If air and cuttings stop coming out of the hole, the bit is becoming plugged and must be pulled back immediately. When the blowing air is stopped by a plugged bit, the bit and drill rod can become stuck very quickly. Work the bit up and down with the drill and rotation ON until cuttings can be seen coming from the hole. If the bit cannot be cleared, the drill rod and bit must be pulled out of the hole. Try placing bit on solid rock or hard wood and push full hammer button (1) on Drill joystick to clear bit. If bit remains plugged, you will have to shutdown the machine and let the air pressure bleed off and then remove bit and manually unclog bit and or drill rod. If the downward movement of the drill rod increases suddenly, this may mean that the bit has drilled into a void, crack or some soft material. Use Drill joystick to slow down the forward travel of the bit. If the rotation begins to slow down or stops, the bit must be pulled back immediately. Reduce the feed speed to drill through broken ground. If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.

NOTE

Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole. Shut off dust collector if water is coming out of the hole. This will plug the dust collector lters. Turn dust collector on after water stops coming out of the hole. It may be necessary to remove the dust collector hose from the pickup pot to avoid clogging the hose with mud. Connect the hose when dry drilling resumes.

4. 5.

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

Drilling Procedures

5-17

Smart Drill Feature

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-18

Drilling Procedures

Smart Drill Feature


General Description
The "Smart Drill" feature allows for assisted drill control. The system senses rotation and air pressure changes and automatically adjusts feed force and hammer power output. It operates as an anti-jam system and greatly reduces the possibility of stuck drill rod. If the bit becomes plugged, the air pressure rises and shuts off the hammer and reverses the direction of the feed. If the drill rotation slows, rotation pressure rises which sends a signal to the feed. The feed force is then adjusted accordingly until normal drill rotation resumes. This system greatly enhances drilling efciency and reduces operator error. The driller can override the "Smart Drill" system by turning off the smart drill switch (17, g. 5-3) and manually adjusting the feed force with the Drill joystick.

Operation
Begin drilling the same as you would for manual drilling as described previously. 1. 2. 3. Once hole is collared, move air switch to fully OPEN position. Move Drill joystick to full LEFT position. Turn smart drill switch (17, g. 5-3) ON. ALWAYS shut down machine and let air pressure bleed off before removing a plugged bit. NEVER hammer on drill bit or rod. Fragmentation may occur, causing serious injury. If bit keeps getting plugged or the rotation continues to jam, pull out the drill rod and start another hole a safe distance away.

NOTE

Never continue drilling if cuttings stop coming from the hole. Always pull back the bit. Do not restart drilling again until air is coming from the hole. Shut off dust collector if water is coming out of the hole. This will plug the dust collector lters. Turn dust collector on after water stops coming out of the hole.

4. 5.

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

Drilling Procedures

5-19

Linear Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-20

Drilling Procedures

Linear Rod Changer


Adding Drill Rod
After the rst length of drill rod has been drilled to depth (coupling and shank even with top of centralizer jaws): 1. With full blowing air ON, raise the bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it. It is a good idea to run the bit up and down the hole a few times with full blowing air on and forward rotation on. This will clear the hole of loose cuttings to prevent stuck drill rod.

NOTE

2. 3. 4.

Move Drill joystick to NEUTRAL position and place air switch to OFF position. Press full hammer button (1) to turn OFF. Turn hammer on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound (hammer frequency) of the drill string. Use the centralizer switch to close centralizer around the drill rod coupling. Use the synchronized threading button (4) on the Drill joystick to unthread rod. When drill shank is in line with automatic thread grease nozzle (g. 5-6), push coupling grease button (2) to grease drill shank thread. Raise drill towards top of feed, so drill shank is above upper rod rack.

5. 6.

7.

Fig. 5-6 UFH Chain Feed 1. Grease Nozzle 2. Centralizer

Drilling Procedures

5-21

Linear Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-22

Drilling Procedures

Linear Rod Changer


Adding Drill Rod (cont.)
NOTE
8. The rod changer switch (13, g. 5-3) MUST be in the ROD CHANGER position.

Press and hold carriage unlock button (8) on R.H. joystick to UNLOCK rod rack carriage. Move right joystick BACK to move carriage IN towards feed to position rst drill rod under drill shank. Release unlock button (8) on R.H. joystick, locking pin will automatically locate the drill rod position. Use synchronized threading button (4) on Drill joystick to thread rod. Continue until coupling is tight. Push L.H. joystick button (10) to move Rod Wrench to IN position. This swings wrench into position and clamps around the drill rod. Push L.H. joystick button (9) slightly to open the wrench so it is not clamped on the drill rod. The wrench is now in the "guide" position for the drill rod. Raise the drill to clear the coupling from the upper rod rack. Move R.H. joystick to LEFT to UNLOCK drill rod. This moves the lock bar IN towards feed to release the drill rod. Press and hold carriage unlock button (8) on R.H. joystick to UNLOCK rod rack carriage. Move the right joystick FORWARD to move rod carriage OUT. Release the carriage unlock button (8), the locking pin will automatically engage in next position in the rod rack. Move R.H. joystick to RIGHT to LOCK drill rod. This moves the lock bar OUT away from feed to lock the drill rod in place. Lower the drill until the threads of the drill rod are in line with the automatic thread grease nozzle (g. 5-4), activate coupling grease button (2) on Drill joystick to grease threads. Use Drill joystick to slowly lower drill rod into coupling. Use synchronized threading button (4) and pull toward operator until all couplings are tight. Place centralizer switch in OPEN position and resume drilling. When coupling clears the centralizer, close centralizer and swing rod wrench out of the way by pressing L.H. joystick button (9). Repeat the above steps for all additional rods to be added.

9. 10.

11. 12. 13.

14. 15. 16. 17. 18.

Drilling Procedures

5-23

Linear Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-24

Drilling Procedures

Linear Rod Changer


Removing Drill Rod
When desired hole depth has been reached: 1. With full blowing air ON, raise bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it. If rod is stuck in hole, move Drill joystick to LEFT to turn on rotation and slowly work feed up and down until unstuck when air is on. Do not run drill in free oscillation mode (no feed pressure on hammer) for extended periods of time to prevent damage to the drill.

NOTE

2. 3. 4.

Place Drill joystick in NEUTRAL. Place drill rotation and full hammer button (1) in OFF (NEUTRAL) position. Turn full hammer (1) on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound of the drill string and air escaping from around coupling. Once loose, raise the drill until the coupling below the last drill rod is aligned with the centralizer jaws. Do not close centralizer jaws. Place air switch in OFF position. Swing the rod wrench into position around the drill rod by pushing button (10) on L.H joystick. The wrench will clamp drill rod automatically. Slowly begin forward (counterclockwise) rotation to slightly tighten the upper coupling on the drill rod. Stop rotation and push button (9) on L.H. joystick to use wrench as a guide. Place centralizer switch in CLOSE position around the coupling. Slowly begin reverse (clockwise) rotation at the same time utilizing the feed UP to unthread drill rod from coupling in centralizer and making sure you are not unthreading upper coupling. Raise the drill and rod until the coupling on the shank clears the upper rack level. Stop feed and rotation. Move R.H. joystick LEFT to UNLOCK the rod rack. Move joystick BACK while pushing button (8) to move rod rack IN towards feed and position the last empty socket of the rod rack in line with the drill rod. Release unlock button, locking pin will automatically engage in next position. Pull the Drill joystick BACK to lower the rod until the coupling is level with the upper rod rack. Move L.H. joystick to RIGHT to engage lock bar on the coupling, slowly reverse the rotation and raise the drill to unthread the drill shank from the coupling. Move L.H. joystick LEFT to UNLOCK the rod rack. Move R.H. joystick FORWARD and press button (8) to move rod rack OUT away from feed. Release unlock button, locking pin will automatically engage in next position. Using feed DOWN, run drill down the feed and use forward (counterclockwise) rotation to thread the drill shank into the coupling in the centralizer. When shank is threaded into coupling, open centralizer and raise drill up until next coupling is centered between centralizer jaws. Repeat steps 713 until all of the drill rod has been removed from the hole.

5. 6. 7.

8. 9.

10.

11. 12.

13.

14.

Drilling Procedures

5-25

Carousel Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-26

Drilling Procedures

Carousel Rod Changer


Adding Drill Rod
After the rst length of drill rod has been drilled to depth (coupling and shank even with top of centralizer jaws): 1. With full blowing air ON, raise the bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it. It is a good idea to run the bit up and down the hole a few times with full blowing air on and forward rotation on. This will clear the hole of loose cuttings to prevent stuck drill rod.

NOTE

2. 3. 4.

Move Drill joystick to NEUTRAL position and place air switch to OFF position. Press full hammer button (1) to turn OFF. Turn hammer on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound (hammer frequency) of the drill string. Use the centralizer switch to close centralizer around the drill rod coupling. Use the synchronized threading button (4) on the Drill joystick to unthread rod. When drill shank is in line with automatic thread grease nozzle (g. 5-6), push coupling grease button (2) to grease drill shank thread. Raise drill towards top of feed, so drill shank is above upper rod rack.

5. 6.

7.

Fig. 5-6 UFH Chain Feed 1. Grease Nozzle 2. Centralizer

Drilling Procedures

5-27

Carousel Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-28

Drilling Procedures

Carousel Rod Changer


Adding Drill Rod (cont.)
NOTE
8. 9. 10. 11. 12. 13. The rod changer switch (13, g. 5-3) MUST be in the ROD CHANGER position.

Move L.H joystick LEFT to clamp rod with jaws. While holding L.H. joystick LEFT, push the white (10) to swing rod into place. Lower the drill until the threads of the drill rod are in line with the automatic thread grease nozzle, activate coupling grease button (2) on Drill joystick to grease threads. Use Drill joystick to slowly lower drill rod into coupling. Use synchronized threading button (4) and pull toward operator until all couplings are tight. Move L.H. joystick RIGHT to unclamp rod until jaws are fully open. Push yellow (9) on L.H. joystick to swing jaws out. Place centralizer switch in OPEN position and resume drilling. When coupling clears the centralizer, close centralizer and swing rod wrench out of the way by pressing L.H. joystick button (9). Repeat the above steps for all additional rods to be added.

Drilling Procedures

5-29

Carousel Rod Changer

Fig. 5-2 R.H. and Drill Joystick Controls

Fig. 5-1 L.H. Joystick Control

Fig. 5-3 Cab Control Panel

5-30

Drilling Procedures

Carousel Rod Changer


Removing Drill Rod
When desired hole depth has been reached: 1. With full blowing air ON, raise bit just above the bottom of the hole. Be sure bit is not plugged or jammed with loose material above it. If rod is stuck in hole, move Drill joystick to LEFT to turn on rotation and slowly work feed up and down until unstuck when air is on. Do not run drill in free oscillation mode (no feed pressure on hammer) for extended periods of time to prevent damage to the drill.

NOTE

2. 3. 4.

Place Drill joystick in NEUTRAL. Place drill rotation and full hammer button (1) in OFF (NEUTRAL) position. Turn full hammer (1) on and off in short bursts until drill string is loose. Use some reverse (clockwise) drill rotation if necessary. Loosening of the drill rod can be noted by a change in sound of the drill string and air escaping from around coupling. Once loose, raise the drill until the coupling below the last drill rod is aligned with the centralizer jaws. Do not close centralizer jaws. Place air switch in OFF position. Swing the rod wrench into position around the drill rod by pushing button (10) on L.H joystick. The wrench will clamp drill rod automatically. Slowly begin forward (counterclockwise) rotation to slightly tighten the upper coupling on the drill rod. Stop rotation and push button (9) on L.H. joystick to use wrench as a guide. Place centralizer switch in CLOSE position around the coupling. Slowly begin reverse (clockwise) rotation at the same time utilizing the feed UP to unthread drill rod from coupling in centralizer and making sure you are not unthreading upper coupling. Raise the drill and rod until the coupling on the shank clears the upper rack level. Stop feed and rotation. Move R.H. joystick LEFT to UNLOCK the rod rack. Move joystick BACK while pushing button (8) to move rod rack IN towards feed and position the last empty socket of the rod rack in line with the drill rod. Release unlock button, locking pin will automatically engage in next position. Pull the Drill joystick BACK to lower the rod until the coupling is level with the upper rod rack. Move L.H. joystick to RIGHT to engage lock bar on the coupling, slowly reverse the rotation and raise the drill to unthread the drill shank from the coupling. Move L.H. joystick LEFT to UNLOCK the rod rack. Move R.H. joystick FORWARD and press button (8) to move rod rack OUT away from feed. Release unlock button, locking pin will automatically engage in next position. Using feed DOWN, run drill down the feed and use forward (counterclockwise) rotation to thread the drill shank into the coupling in the centralizer. When shank is threaded into coupling, open centralizer and raise drill up until next coupling is centered between centralizer jaws. Repeat steps 713 until all of the drill rod has been removed from the hole.

5. 6. 7.

8. 9.

10.

11. 12.

13.

14.

Drilling Procedures

5-31

HPR45 & HPR51 Drill Shank Replacement


DO NOT attempt lubrication or service while the machine is running. BE SURE the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts. Two people are required to change the drill shank when the drill is mounted on the feed. KEEP AWAY from moving or rotating parts. DO NOT wear loose clothing or jewelry that could get caught in moving or rotating parts. 1. Lower the boom and feed while keeping the feed as horizontal as possible. Remove the drill steel by unthreading the coupling from the drill shank and then sliding the free steel down the feed channel onto the ground. Position the drill on the feed at a height above the ground that will allow working on the drill's front end comfortably (without excessive bending or reaching). Unload the hydraulic pump (make sure the hydraulic system gauge goes to zero). Turn off the engine and bleed any remaining air by opening the drill air valve at the drill console or in cab. Remove the air/water hose from the water swivel housing. Remove the four bolts and lock nuts that retain the water swivel to the chuck end using 1-7/16 and 1-1/2 in. wrenches. Slide off the water swivel housing and thrust plate. Remove the shank. Inspect drill front end parts for wear. See drill service manual for detailed instructions and wear tolerances. Pay particular attention to chuck splines, thrust plate, thrust washer, shank bushing and front end bushing. Shank mis-alignment can cause rapid wear of hammer face. Apply grease (PG55, P/N 312810 recommended) to rear diameter of shank and shank splines. Before installing a new shank, remove the rust prevention coating on the bearing and seal surfaces, using steel wool or ne sandpaper. If this is not done, the coating will build up on the seals, causing them to heat up an wear out rapidly.

2. 3. 4. 5. 6. 7. 8.

9.

NOTE

10.

Install a new drill shank into the drill chuck, being sure to align the splines on the shank with those in the chuck and being careful not to damage the seal in the bearing plate behind the chuck driver. Install thrust plate. Slide the air swivel into position. Install the four bolts, spring washers and lock nuts. Torque to 483 ft. lbs. (657 Nm). Connect air/water hose to connection on water swivel housing. Apply a liberal coat of coupling grease to the drill shank threads before attaching the drill steel. Be sure to keep rotation housing of drill greased well (every 2 hours with a hand grease gun). If automatic lubrication system is used, check reservoir daily. It is recommended that a new coupling be used whenever replacing the shank. Grease coupling and shank before drilling.
Drilling Procedures

11. 12. 13. 14.

NOTE

5-32

HPR1H-ATW Drill Shank Replacement


DO NOT attempt lubrication or service while the machine is running. BE SURE the hydraulic and pneumatic systems are not pressurized before loosening any connections or parts. Two people are required to change the drill shank when the drill is mounted on the feed. KEEP AWAY from moving or rotating parts. DO NOT wear loose clothing or jewelry that could get caught in moving or rotating parts. 1. Lower the boom and feed while keeping the feed as horizontal as possible. Remove the drill rod by unthreading the coupling from the drill shank and then sliding the drill rod down the feed channel onto the ground. Always place drill rod on wood blocks, keep threads clean. Position the drill on the feed at a height above the ground that will allow working on the drill's front end comfortably (without excessive bending or reaching). Turn off the engine and bleed any remaining air from system (open blowing air valve). Remove the air/water hose from the water swivel housing. Remove the front-end side rod nuts. Slide off the water swivel housing and thrust plate. Remove the shank. Inspect drill front end parts for wear. See drill service manual for detailed instructions and wear tolerances. Pay particular attention to chuck splines, thrust plate, thrust washer, shank bushing and front end bushing. Shank mis-alignment can cause rapid wear of hammer face. Apply grease (PG55, P/N 312810 recommended) to rear diameter of shank and shank splines. Before installing a new shank, remove the rust prevention coating on the bearing and seal surfaces, using steel wool or ne sandpaper. If this is not done, the coating will build up on the seals, causing them to heat up an wear out rapidly.

2. 3. 4. 5. 6. 7. 8.

9.

NOTE

10.

Install a new drill shank into the drill chuck, being sure to align the splines on the shank with those in the chuck and being careful not to damage the seal in the bearing plate behind the chuck driver. Install thrust plate. Slide the water swivel housing into position. Tighten side rod nuts. Torque to 500 ft. lbs. (680 Nm). Connect air/water hose to connection on water swivel housing. Apply a liberal coat of coupling grease to the drill shank threads before attaching the drill rod. Be sure to keep rotation housing of drill greased well (every 2 hours with a hand grease gun). If automatic lubrication system is used, check reservoir daily. It is recommended that a new coupling be used whenever replacing the shank. Grease coupling and shank before drilling.

11. 12. 13. 14.

NOTE

Drilling Procedures

5-33

Notes

5-34

Drilling Procedures

Section 6

Lubrication and Maintenance


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

Lubrication and Maintenance

6-1

Notes

6-2

Lubrication and Maintenance

Hydraulic Oils for Percussion Drills


In general, oils recommended or approved by hydraulic pump manufacturers are suitable for operating hydraulic percussion drills. Optimum viscosity in a temperature stabilized system is 150 to 300 SUS (extended range is 500 SUS) for continuous operation. The following oils meet the requirements: ISO EQUIVALENT ISO 150/220 ISO 100 ISO 46 OIL TYPE Mobil DTE 19M Mobil DTE 18M Mobil DTE 15M OPTIMUM RANGE Between 175oF and 135oF (79.4oC and 57.2oC) Between 145oF and 115oF (62.7oC and 46.1oC) Between 110oF and 80oF (43.3oC and 26.7oC) EXTENDED RANGE 115oF (46.14oC) 100oF (37.8oC) 60oF (15.6oC)

If stabilized system temperatures have not been established, the oil can be selected based on anticipated ambient temperature range. AMBIENT OPERATING TEMPERATURE oF (32.2oC) or higher 90 32oF to 90oF (0oC to 32.2oC) 20oF to 32oF (28.9oC to 0oC) Under 20oF (28.9oC) OIL SELECTION DTE 19M or equivalent DTE 18M or equivalent DTE 15M or equivalent Consult Manufacturer ISO EQUIVALENT ISO 150/220 ISO 100 ISO 46

These selections assume "normal operating conditions" as expected in quarry or quarry-like operations. Pioneering and secondary drilling normally result in a lower than average operating temperature; the necessity to drill out of the hole to remove stuck steel, as found in badly broken ground, will result in higher than normal operating temperatures. NOTE Since the determining factor for safe and efcient operation is the viscosity of the oil, nal selection for the oil (or changing the oil) should be based on the stabilized oil temperature in your specic drilling application.

In addition to the viscosity at stabilized oil temperature, we also have to consider viscosity at start-up conditions. Limitations are cavitation of the pumps and sluggish controls, and extended warm-up periods that may be required to avoid pump cavitation and to provide adequate control. Oils with high viscosity index (above 120) are better able to cover a wide range of temperatures. Oils with lower viscosity index may need more frequent change of oil based on ambient temperature or may require an oil heater to improve start-up conditions In general, cold starts may be made at a temperature of at least 30oF (16.9oC) warmer than the pour point of the uid. All cold starts should be made at low pressure, low ow, and low speed.

Lubrication and Maintenance

6-3

Lubrication and Inspection


Recommended Engine Oils
The following oils are recommended by Caterpillar: Caterpillar Diesel Engine Oil (DEO) 10W-30preferred Caterpillar Diesel Engine Oil (DEO) 15W-40preferred API CH-4 multigrade oilacceptable API CI-4 multigrade oilacceptable API CG-4 multigrade oilacceptable
Lubricant Viscosities for Ambient Temperatures Oil Viscosity SAE 0W-20 SAE 0W-30 SAE 0W-40 SAE 5W-30 SAE 5W-40 SAE 10W-30* SAE 10W-40 SAE 15W-40 Min -40 -40 -40 -22 -22 0 0 15
o

Max 50 86 104 86 122 104 122 122

Min -40 -40 -40 -30 -30 -18 -18 -9.5

Max 10 30 40 30 50 40 50 50

* SAE 10W-30 is the preferred viscosity grade when the ambient temperature is above 0oF (-18oC) and below 104oF (40oC)

NOTE

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

To avoid unnecessary machine repairs, keep the following in mind when handling fuel and lubricants: Clean grease ttings with a clean cloth before greasing. Keep all fuels and lubricants stored in clean and tightly sealed containers. Keep ller caps clean of dust and oil. Replace lters inside a shop or when no dust is in the air. Never reuse paper lters. Wash metal parts of lters with clean oil. Do not wipe the parts with a cloth. Keep dirt and dust from entering any uid system. Keep the fuel storage containers and system lled. Watch for metal lings on any magnetic drain plugs. Filings are a sign of internal component wear or misadjustment. If the source can be determined and repaired as a part of scheduled maintenance, costly down time can be avoided later. Ensure that clean fuel of correct grade for winter/summer is used.

6-4

Lubrication and Maintenance

Lubrication and Inspection


General Hydraulic System
The hydraulic system is lled at the factory with Chevron AW MV ISO 100. Any other oils used, must meet the specications listed on page 6-3. Diesel fuel or kerosene used as dilutants for cold weather operation are not recommended, as they are not sufciently rened products. Do not use any re resistant uids or non-petroleum oils without consulting the manufacturer. Keeping the hydraulic oil clean is by far the most effective method to help provide long hydraulic system component life with minimum downtime. Adding hydraulic oil to the tank is one source of contamination. Insure the oil you add is clean, and do not let any dirt or water fall into the ll spout, etc. when you are adding oil. The second, and larger cause of contamination is possible any time hydraulic ttings or hoses are disconnected. Never leave any open path for contamination to get into the oil. Always cap and plug any open ttings, hoses, etc., with clean ttings.

Daily Operational Checklist


In addition to the daily scheduled maintenance listed in the Maintenance Schedule, several mechanical checks should be added to ensure long, safe and trouble-free operation. Each day the minimum items to be checked include: All daily interval hours checkpoint items. Check underside. Look for broken or loose hoses. If dripping fuel, hydraulic oil or coolant is evident, do not continue until leak is found and corrected. Check that tracks are tensioned properly. Clear any rocks, mud or snow from tracks to prevent overtensioning or other damage. Check for clean, tight battery connections. Check that the battery is fully charged. With the ignition switch in the ON position, the battery voltage reading should indicate 2425 volts. When the engine is running, the voltage should increase slightly to indicate alternator charging. Look for loose or missing bolts. Replace all missing bolts and tighten loose bolts. Tighten bolts per torque specication in this section unless otherwise stated in the Parts List. Lubricate chuck end of drill every 2 to 3 hours during drilling. Look for excessive play due to worn wear pads on the boom, drill and feed. Check ll caps, tank covers and dipstick. They should be in place and seated properly. Check the engine intake and exhaust clamps, be sure they are tight to prevent damage to the turbocharger. Check the radiator coolant level by oscillating machine forward and removing radiator cap. Do not remove if engine is hot. Drain water from fuel/water separator.

Lubrication and Maintenance

6-5

Lubrication and Inspection


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

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

Safety Sign Maintenance


Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners as they may damage the safety sign material. Refer to Section 1 for safety sign locations on the machine.

Hydraulic Drill Accumulator Charge PressureCheck Monthly


The drills used on the R30C are the HPR45 and the optional HPR51. Some machines are equipped with the HPR1H-ATW drill. The drill accumulator's must be charged with dry nitrogen before drilling. Check accumulator charge pressure monthly. Each time charge pressure is checked, a little charge pressure is lost, therefore don't check any more than necessary. If drill hoses vibrate excessively, this is an indication that charge pressure is low, and must be checked and recharged. Refer to Service Manual Drill Section for correct procedure for checking and charging accumulators. Or, refer to Charging Instructions (1053068) that comes with Drill Charge Kit (1HPR781X).

6-6

Lubrication and Maintenance

Maintenance Schedule
Interval Hours
Every 2 Hours

Service Points
Drill Chuck End Engine Oil Caterpillar C9 Engine Coolant

Service or Maintenance
Lubricate and Inspect (see Drill Service Manual) Check Level - Rell as required

Lubricant
PG55 Grease, P/N 312810 14 oz. tube *SAE 15W-40 See "Recommended Engine Oils" in this section. Water/Permanent Anti-Freeze 50:50 Ratio Chevron AW MV ISO 100

Capacity

32 Qt. / 30 L

Check Level - Rell as required Check. Drain if required Check Level - Rell as required

12 Gal./ 45.4 L

Every 10 Hours or Daily

Engine Fuel/Water Separator Hydraulic Oil Air Compressor Oil Engine Air Filter Air Compressor Air Filter Hydraulic Oil Filters Radiator / Oil Cooler Case Drain Filter Batteries Track Chain Tension

*107 Gal. / 405 L 7 Gal./ 26.5 L

Check Level - Rell as required *Chevron ATF Check - Clean or Change if required Check - Clean or Change if required Check Indicators - Change if required Check - Clean if required Initial Change at 24 hours, thereafter every 500 hours Check Level - Rell as required Check and Adjust as required NLGI No. 2 Grease

Every 50 Service Hours

Drill Slide Wear Pads Feed Table Wear Pads Feed Table Pivot Pin Dust Collector Filters Detergent "Y" Strainer Track Drive Gearcase Oil Engine Oil Engine Oil Filter Engine Fuel Filter Engine Belts / AC Belts Fuel Tank Engine Coolant Conditioner Feed Motor Gearcase Track Drive Gearcase Oil

Check and Adjust as required Check and Adjust as required Check End Play (0.005 in. max.) Torque Retaining Cap Bolts to 282 ft. lbs. (384 Nm) Check - Replace as required P/N 419090 4.8 Qts./ 4.5 L 32 Qt./ 30 L

Every 250 Service Hours

Every 500 Service Hours Every 1200 Service Hours Every 1500 Service Hours Every 2400 Service Hours

Check - Clean as required Check Level - Rell as required *HD 80W-90 Gear Oil Drain Oil and Replace *15W-40 Replace P/N V012941 Replace P/N V001775 Check and Adjust Drain Water and Sediment Replace P/N 1405131 Check Level, Rell as required *HD 80W-90 Gear Oil Initial Change, then every 1500 *HD 80W-90 Gear Oil hours Compressor Air Receiver Pres- Check and Adjust sure Dust Collector Air Filters Replace P/N 419090 Canopy Hinges Lubricate SAE 30 wt Oil Hydraulic Rock Drill Check for loose bolts Engine Air Filter Replace P/N 1156422 (P), 1156421 (S) Compressor Air Filter Replace P/N 1157641 (P), 1405631 (S) Compressor Oil Drain Oil and Replace *Chevron ATF Compressor Oil Filter Replace P/N 1157245 Hydraulic Oil Filters Replace P/N 99703 Case Drain Filter Replace P/N 1157245 Feed Table Bushing Check and Replace (if necessary) Engine Fuel/Water Separator Drain and Replace P/N V007584 Fan Hub Inspect Track Drive Gear Case Oil Drain Oil, Flush and Replace *HD 80W-90 Gear Oil Every 12 months Engine Coolant Replace Water/Permanent Anti-freeze 50:50 ratio Hydraulic Oil Drain and Replace *Chevron AW MV ISO 100 Compressor Oil Separator Replace P/N 411747 Element Feed Gear Case Oil Drain and Replace *HD 80W-90 Gear Oil

2 Qts. / 1.9 L 17 Oz. / 503 ml 4.8 Qts./ 4.5 L

7 Gal. / 26.5 L

4.8 Qts./4.5 L 12 Gal. / 45.4 L 107 Gal. / 405 L

17 Oz./503 ml

* Normal Factory Fill

Lubrication and Maintenance

6-7

R30C Grease Points


Service Location
Hydraulic Rock Drill Centralizer Feed Chain Sprockets Feed Drive Sprocket Positioner Boom Pivot Boom Swing Cylinder Boom Lift Cylinder Feed Swing Cylinder Feed Extend Cylinder Feed Dump Cylinder Rod Wrench Rod Rack Driveline Lower Rod Rack Upper Rod Rack Hose Reel Mainframe Lube Dust Collector Swing Pin Engine Fan Drive Bearing * NLGI No. 2 Grease

Lube Points
4 4 2 2 4 3 3 2 2 2 3 5 6 5 5 1 10 2 1

Frequency
Every 2 hours Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Monthly Weekly Bi-Monthly 250 hours or 6 months

Notes
PG55 grease * 2 cylinder clevis * 1 upper, 1 lower * * * attaches to mainframe * 2 clevis, 1 pivot pin * each clevis * each clevis * each clevis * 2 mounting blocks, 1 clevis * 3 wrench, 2 cylinder clevis * 3 couplings, 3 bearings ( 1 ea. lower, middle, upper) * 4 rollers, 1 rod lock pin * 4 rollers, 1 rod lock pin PG55 grease or equivalent * See Fig. 6-1 * Special Purpose Grease (SPG) See Fig. 6-2

6-8

Lubrication and Maintenance

R30C Grease Points

Fig. 6-1 Mainframe Lube Points (Viewed from Front of Machine) Right Track Left Track 1. Oscillation Cylinder Top 6. Oscillation Cylinder Top 2. Oscillation Cylinder Bottom 7. Oscillation Cylinder Bottom 3. Inner Frame Track Pivot 8. Inner Frame Track Pivot 4. Middle Frame Track Pivot 9. Middle Frame Track Pivot 5. Outer Frame Track Pivot 10. Outer Frame Track Pivot

Fig. 6-2 Engine Fan Drive Bearing Lube Fitting

Lubrication and Maintenance

6-9

Engine Oil Filter


BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. SHUT DOWN machine and relieve pressure before attempting lubrication or service. AVOID prolonged and repeated skin contact with used engine oil. Prolonged and repeated contact with used oil can cause serious bodily injury. Use only authorized waste disposal facilities to dispose of used engine oil and other lubricants. The engine oil lter (g. 6-3) is the spin-on type. To replace: 1. 2. 3. 4. Shutdown engine and clean area around lters. Spin off and properly discard used oil lter (1). Use caution to avoid burns from hot oil. Clean mounting base and be sure old gasket is not stuck to base. Lubricate the gasket on the new lter with engine oil. Spin on the new lter, tighten 3/4 of a turn further after the lter gasket makes contact with lter base. Add oil through ll tube (2). Check oil level with dipstick (3).

Fig. 6-3 Rear View of Machine 1. Oil Filter 2. Oil Fill Tube 3. Oil Dipstick

6-10

Lubrication and Maintenance

Engine Fuel Filter


The engine fuel lter (g. 6-4) is a spin-on lter located on the right side of the engine. To replace: 1. 2. 3. 4. 5. Shutdown engine, clean area around the lter, ange. Spin off and discard the old lter (1) and rubber gasket. Clean mounting base and be sure old gasket is not stuck to base. Lubricate the lter gasket with clean diesel fuel, or oil. Spin on a new lter, tightening 3/4 turn after the gasket has contacted the base. If necessary, open the fuel priming pump valve (2) by unscrewing the handle and then pump to prime the system. Screw handle back on tight.

Fuel/Water Separator Drain water from fuel water separator daily (g. 6-5).

Fig. 6-5 Rear View of Machine 3. Fuel/Water Separator

Fig. 6-4 Rear View of Machine 1. Fuel Filter 2. Fuel Priming Pump 3. Fuel/Water Separator

Lubrication and Maintenance

6-11

Engine Air Cleaner Filter


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

The engine air cleaner should be cleaned when the service indicator (g. 6-7) indicates the lter is clogged (check daily or every 10 hours). There is a service window on the indicator that will gradually turn red as the lter restriction increases to a maximum of 30" of H20. After cleaning the lter, reset the service window to green by pressing the rubber diaphragm on top of the service indicator. To replace or clean the engine air cleaner lter: 1. Shutdown the machine. 2. 3. Undo the clamps and remove the lter cover. The primary and safety element are a press t inside the housing. Carefully move the primary element from side to side and slide the element from the air cleaner housing to avoid dislodging dust from element when removing. Be careful not to knock the element against the side of the housing. Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a poor seal. Check seal area of housing for foreign material or damage. Remove safety element in the same manner. Clean the inside of the housing and vacuator valve with a clean cloth. Clean the primary element (up to 6 times) with water, household detergent or compressed air. Do not use more than 40 PSI (2.8 bar) water or 90 PSI (6.2 bar) air. Install new safety element (if need be) and primary element. Push all the way in and be sure the elements are seated against the back of the housing. Install cover and secure with clamps.

4. 5. 6. 7.

Fig. 6-7 Engine Air Filter Indicator

Fig. 6-6 Right Rear of Machine 1. Engine Air Cleaner Filter 2. Dust Collector
6-12 Lubrication and Maintenance

Compressor Air Cleaner Filter


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

Check lter daily or every 10 hours. To replace the compressor air cleaner lter: 1. 2. 3. Shutdown the machine. Loosen the wingnut and remove the lter cover. Clean inside of lter cover with a clean cloth. Unscrew the wing nut and carefully slide the primary element from the air cleaner housing to avoid dislodging dust from element when removing. Be careful not to knock the element against the side of the housing. Check condition of element, if you see a streak of dust on the clean air side, it is an indication of a poor seal. Check housing for foreign material or damage. Clean the inside of the housing with a clean cloth. Install safety element (if removed) and primary element and secure with wingnuts. Reinstall lter cover.

4. 5.

Fig. 6-8 Compressor Air Filter

Fig. 6-9 View From Front of Machine 1. Filter Cover 2. Dust Collector

Lubrication and Maintenance

6-13

Compressor Oil Filter


BEFORE attempting to operate or service this machine, read and understand the warnings and cautions listed in Section 1. SHUTDOWN machine and relieve pressure before attempting lubrication or service. Allow compressor to cool down and stabilize at least 5 minutes before starting any work. Use recommended oil type only; do not mix different oils. Dispose of waste oil according to local regulations regarding handling of waste oil.

1. 2. 3. 4. 5.

Remove lter element with lter wrench. Have a cloth handy to catch any oil that may drain from lter. Clean mounting base and be sure old lter gasket is not stuck to base. Lubricate sealing ring on new lter element with clean oil. Screw on new lter element and tighten by hand only. Check oil level in air receiver tank (g. 6-11). Add oil as required through ller neck (g. 6-10). Normal factory ll is Chevron ATF.

Fig. 6-10 Compressor Oil Filter 1. Oil Filter 2. Oil Filler Neck 3. Air Receiver Tank

Fig. 6-11 Air Receiver Tank Sight Gauge (Check Daily)

6-14

Lubrication and Maintenance

Hydraulic Fluid Fill Pump and Filter


RELIEVE all pressure before attempting service or maintenance procedures to this machine. DO NOT attempt any service or maintenance procedures while the machine is running. To Add Hydraulic Fluid 1. 2. Shutdown the engine and wait for pressure to relieve. Be sure to use correct type of uid. Refer to maintenance chart in this section or machine maintenance records for correct oil type. Do not mix different oil types. Always store oil in clean containers. Clean any dirt from around oil container opening and ll pump connection (3). Connect pump hose to hydraulic oil container. Pump handle to draw oil out. Oil passes through lter (1) before going into tank. Fill to proper level on tank gauge (4). Start the engine and bring the system to full pressure. Recheck uid level on gauge. If more uid needs to be added, shut down machine and add more oil. Check oil level daily. Change lter annually.

3. 4. 5. 6.

Fig. 6-12 Right Rear View of Hydraulic Tank 1. Hydraulic Oil Filter 2. Oil Fill Pump 3. Oil Inlet 4. Oil Level and Temperature Gauge
Lubrication and Maintenance 6-15

Hydraulic Return Filter Indicators


If indicator ring is in the Bypass (orange) zone, DO NOT OPERATE MACHINE until lter(s) is changed.

There are two (2) hydraulic lter indicators located on the hydraulic oil return lter housings (g. 6-13). Both indicators should be checked daily. Normal operation is the indicator ring in the Clean (green) zone. If the indicator ring (g, 6-14) falls into the Change (yellow) zone, the lter(s) must be changed. Otherwise, replace the lters at 500 hours (See Service Manual for procedure).

Fig. 6-13 Top of Hydraulic Tank 1. Hydraulic Oil Return Filters 2. Filter Indicators

Fig. 6-14 Hydraulic Oil Indicator Zones

6-16

Lubrication and Maintenance

Coolant System
DO NOT check coolant level when coolant is hot. KEEP AWAY from rotating fan and belts. DO NOT wear jewelry or loose tting clothing when working around machinery.

Check the radiator, hydraulic oil and compressor oil coolers (g.6-15) daily. Clean out any accumulation of dirt, leaves and other debris that would block air ow through the coolers and cause overheating of the engine. Check coolant level through sight glass (g. 6-16) daily. Add 50/50 mix of water/anti-freeze to shunt tank to proper level if required.

Fig. 6-15 Left Rear View of Machine 1. Radiator/Oil Coolers 2. Radiator Shunt Tank

Fig. 6-16 Radiator Shunt Tank 1. Shunt Tank 2. Coolant Sight Glass 3. Radiator Cap/Coolant Fill Neck

Lubrication and Maintenance

6-17

Bolt Torque Specications


Procedure No. 1-87 REVISION A
Torque Values: Bolts, Screws and Studs (Lubricated or Plated) Tolerance Values in all cases to +5 % - 0 % of the Value listed below. Note: K = .15 for plated or lubricated fasteners. Nominal Diameter 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 also UNS 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 SAE Grade 5 ASTM A-449 Tightening Torque Ft. Lbs. (Nm) Newton meter 6 (8.2) 13 (17.7) 23 (31.3) 35 (47.6) 57 (77.5) 82 (111.5) 113 (153.7) 200 (272) 322 (437.9) 483 (656.9) 596 (810.6) 840 (1142.4) 1102 (1498.7) 1462 (1988.3) 1714 (2331) 2576 (3503.4) 3768 (5124.5) 5155 (7010.8) 6996 (9514.6) 9231 (12554.2) 7 (9.5) 14 (19) 26 (35.4) 40 (54.4) 64 (87) 91 (123.8) 127 (172.7) 223 (303.3) 355 (482.8) 528 (718.1) 668 (908.5) 930 (1264.8) 1254 (1705.4) 1645 (2237.2) 1879 (2555.4) 2857 (3885.5) 4127 (5612.7) 5726 (7787.4) 7693 (10462.5) 10064 (13687) SAE Grade 8 Tightening Torque Ft. Lbs. (Nm) Newton meter 9 (12.2) 18 (24.5) 33 (44.9) 55 (74.8) 80 (108.8) 115 (156.4) 159 (216.2) 282 (383.5) 455 (618.8) 681 (926.2) 966 (1313.8) 1363 (1853.7) 1786 (2429) 2371 (3224.6)

UNC

UNF

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

UN

6-18

Lubrication and Maintenance

Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY

Lubrication and Maintenance

6-19

Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY

6-20

Lubrication and Maintenance

Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY

Lubrication and Maintenance

6-21

Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY

6-22

Lubrication and Maintenance

Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY

Lubrication and Maintenance

6-23

Maintenance Record
DATE HOUR METER MAINTENANCE PERFORMED WORK WORK PERFORMED AUTHORIZED BY BY

6-24

Lubrication and Maintenance

Bucyrus Mining Equipment, Inc. 3501 S. FM Hwy 1417, Denison, TX 75020 Telephone 1-800-854-9030 Telefax 1-800-582-6570 within U.S.A.