6200 operators manual 10218 - english

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Operators Manual

6200 Megamatic Drill 10218

6200 Megamatic Drill 10218 2

Cubex Limited 1218 Redonda St.

Box 13, Group 524, RR 5 Winnipeg, Manitoba

Canada R2C 2Z2

Phone: (204) 694-5505 Fax: (204) 633-0665

www.cubex.net

Copyright © 2004

Printed In Canada

http://www.cubex.net/�

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Table of contents

Section 1 Introduction......................................................................................................... 1 1.2 Objectives ..................................................................................................................... 1 1.3 Orientation .................................................................................................................... 2 2.1 Major Components and Subassemblies ........................................................................ 3

2.1.1 Feed (Figure 2.1).................................................................................................... 3 2.1.2 Right Side (Figure 2.2) .......................................................................................... 5 2.1.3 Rear (Figure 2.4).................................................................................................... 9 2.1.4 Left Side............................................................................................................... 14

2.2 Hydraulic System........................................................................................................ 17 2.3 Water System.............................................................................................................. 19

2.3.1 Water and Lubrication Systems ........................................................................... 20 2.4 Controls....................................................................................................................... 21

2.4.1 Drill/Set-up Controls............................................................................................ 22 2.4.2 Drilling Controls .................................................................................................. 23

Section 3: Drill Operation................................................................................................ 24 3.1 Tramming.................................................................................................................... 24 3.2 Set-Up ................................................................................................................... 26

3.2.2 Dump.................................................................................................................... 27 3.2.3 Swing ................................................................................................................... 28 3.2.4 Feed Extension..................................................................................................... 29 3.2.5 Stinging ................................................................................................................ 30

3.3 Drilling........................................................................................................................ 31 3.3.1 Start up ................................................................................................................. 31 3.3.2 Drill String Make-Up and Breakout .................................................................... 33 3.3.3 Drilling................................................................................................................. 33

Section 4: Operating Procedures...................................................................................... 34 4.1 Operating Procedure for Tramming and Start-Up ................................................ 34

4.1.1 Pre-drill Inspection and Drill Start-Up ................................................................ 34 4.1.2 Tramming Operation............................................................................................ 35 4.1.3 Set-Up .................................................................................................................. 36

4.2 Drilling Preparation .................................................................................................... 37 4.2.1 Drill Site Preparation ........................................................................................... 37 4.2.2 Drilling Lubrication ............................................................................................. 37 4.3 Drilling Recommendations ..................................................................................... 38 4.3.1 Rotation Speed ..................................................................................................... 38 4.3.2 Weight on Bit ....................................................................................................... 38 4.3.3 Tool Lubrication .................................................................................................. 39 4.3.4 Water Injection..................................................................................................... 39 4.3.5 Air Supply............................................................................................................ 40 4.3.6 Pipe and Hammer Installation/Removal .............................................................. 43 4.3.6.1 Hammer Installation Procedure ........................................................................ 44 4.3.7 Field Procedure .................................................................................................... 49

4.3.8 Shop Procedure ........................................................................................................ 50


4.3.9 Pipe Make-up Procedure...................................................................................... 51 4.3.10 Pipe Breakout Procedure.................................................................................... 51 4.3.11 Drill Pipe Thread Preparation ............................................................................ 55

4.4 Drilling Procedure....................................................................................................... 56 4.4.1 Water Injection Operating Procedure .................................................................. 56 4.4.2 Grease Injection Operating Procedure ................................................................. 58 24VDC Manual Timer – Underground Units ............................................................... 61 4.4.3 Drilling Procedures .............................................................................................. 63 4.4.4 Drilling Recommendations .................................................................................. 65 4.4.5 Drilling Accuracy................................................................................................. 70

4.5 Preventive Maintenance.............................................................................................. 71 4.5.1 Daily Maintenance Procedure.............................................................................. 71 4.5.2 Weekly Maintenance Performed by Operator ..................................................... 71 4.5.3 Lubrication........................................................................................................... 71

Section 5: Safety Procedures ........................................................................................... 72 5.1 Pre-Operation Safety Precautions ............................................................................... 72 5.2 Operation Precautions................................................................................................. 72

5.2.1 Safety Shutdowns................................................................................................. 73 5.2.2 Safety Shutdowns................................................................................................. 74

5.3 Maintenance and Repair Safety .................................................................................. 77 5.4 Maintenance Specifications ........................................................................................ 77 Section 6: TROUBLESHOOTING.................................................................................. 83 6.1 TROUBLESHOOTING THE TRAM DRIVE ........................................................... 83 6.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM............................................ 84 6.3 TROUBLESHOOTING THE WATER INJECTION PUMP .................................... 86 6.4 TROUBLE SHOOTING THE AIR DRIVEN OIL INJECTION PUMP............... 87 6.5 TROUBLESHOOTING THE AIR DELIVERY SYSTEM ....................................... 88 6.6 TROUBLE SHOOTING OF THE ELECTRICAL SYSTEM.................................... 89 6.7 TROUBLESHOOTING THE HAMMER.................................................................. 90 6.8 TROUBLESHOTING THE DRILL BIT.................................................................... 92


Section 1 Introduction

DESCRIPTION: The 6200 is a track mounted ITH drill designed to drill with In-The-Hole hammers powered with high air pressure.

PERFORMANCE: The 6200 can be used to drill from 3.5 in (89 mm) to 6 in. (165 mm) diameter holes to a depth greater than 330 ft (100 m).

WITH OPTIONS: It can also be used for drilling 8 ½ in. (216 mm) holes and occasionally reaming up to 17 ½ in. (445 mm) diameter holes with a 12 in. hammer and up to 30 in. (762 mm) diameter holes with the V-30 raise attachment. The range of drilling includes 360˚ ring in 105˚ of plane from horizontal to 15˚ past vertical.

1.2 Objectives

This manual covers the operation of the Cubex 6200 drill and is intended to be used as a training aid for Cubex’s Operator Training Course.

The Objectives of the Operator Training Course and this manual are to familiarize operators with the following • MAJOR COMPONENTS AND SUB-ASSEMBLIES OF DRILL

• LAYOUT OF CONTROLS AND WHAT THEY OPERATE

• DRILLING

• MAINTENANCE

• OPERATOR SAFETY

• TROUBLESHOOTING


1.3 Orientation

The operator's right hand side is the drill's right hand side with the operator standing at the tram step facing forward (Fig. 1.1).

Figure 1.1 – Drill Orientation

Operator

Mast

Front

Rear

Left

Hydraulic Pump

Water Pump

Right


Section 2: Description of Equipment

2.1 Major Components and Subassemblies

2.1.1 Feed (Figure 2.1)

1. Slide over • For quick positioning over the hole’s collar position, the drill has a

horizontal slide over feature with 28.5 in (724mm) of travel.

2. Centralizer Assembly • Maximum opening of 8.5 in. (216 mm) with jaws sized to the drill tools

used, along with a hydraulically operated slip plate. (Size varies on drill pipe used).

• Manual swing-out feature that allows passing of a 12 in. ITH hammer when swung out of the way.

3. Top Drive

• Hydraulically driven by two high torque motors, the Top Drive has a torque capacity of 4225 ft-lbs (5730 Nm) @3000psi (207bar) standard or an option of 6280 ft-lbs (8517Nm).

• The speed is infinitely variable between 0 to 80 rpm. • Incorporated into the Top Drive is the splined piston breakout system,

which eliminates the need for wrenches to breakout drill pipe.

4. Feed Cylinder • A two stage telescopic feed cylinder having 84 in. (2134mm) of stroke and

15,800 lbs (70kN) @ 3000 psi of hoisting and pulldown power.

5. Stinger Cylinder • For fixing the feed in place for drilling. The cylinder is made up of two

opposite acting cylinders with an extension of 48 in. (1220mm) to an overall length of 17 ft 10 in. (5436mm). If the unit has a carousel it will have a second stinger for the carousel.

6. Mast

• The feed overall length is 11 ft. 9 in. (3581 mm) for 6 ft. (1.83 m) drill pipe.

7. Top Drive Connection Plate • Top drive mounting plate has long wearing replaceable sliders for

positive control of top drive rotation unit movement up and down mast. V-notched sliders run on replaceable steel V-designed guide bars.


8. Emergency Stop Shutdown • Shuts the drill power and rotation off when activated by an operator.

9. Rotary Actuator

• This rack and pinion rotary actuator can swing the feed 360° and has a torque capacity of 150,000 in-lbs (16.950 Nm).

10. Feed Extension Cylinder

• The feed is extended to bring it into contact with the rock face using this cylinder. This cylinder has 39” (991mm) of stroke.

1

8

7

6

5

4

3

2

Figure 2.1 Feed

9

6


2.1.2 Right Side (Figure 2.2)

1. Set-Up Valve Bank • Contains manual controls for Set-Up functions. See figure 2.4 for

details.

2. Hydraulic Pump • Electrically driven hydraulic pump. Size depends on configuration.

3. Fuel Fill Cap • (Optional) Point for filling diesel fuel tank.

4. Diesel Engine • (Optional) Diesel engine for tramming and drilling without power.

Duetz BF4M1012C.

5. Undercarriage and Chassis • The Caterpillar® tracks use a sealed and lubricated take-up

system. The shoes are triple grouser 12 in. (305 mm) wide. • Brakes are spring applied/hydraulic released. • Gradability is 65° and ground clearance 7” (178mm).

6. Leveling Jacks • (Optional) Allows for easy and safe leveling of unit on uneven ground.

7. Battery Compartment • Battery compartment for optional diesel engine.

8. Master Switch • Master switch for diesel batteries.

9. Oil Cooler • Oil cooler for hydraulic system. Uses mine water.

10. Air cleaner • For optional diesel engine

11. PLC Panel

• Contains PLC and PLC disconnect switch

12. Fuel Filters • For optional Diesel engine

13. Oil filter

• For optional diesel engine


5

2

1

4

6

7

3

Figure 2.2 Right Side

9

8

11

13

12 10


Figure 2.3 Set-Up valve bank


3

1

2

4

Figure 2.4 Rear

5

6


2.1.3 Rear (Figure 2.4)

1. Main Electrical Panel • A water tight enclosure containing electrical controls (See fig 2.6 for

breakdown).

2. Fire suppression Actuator • Manual actuator for optional fire suppression system.

3. Tram Valve Bank

• Manual valve bank for Tram and leveling jacks (See fig 2.8 for details).

4. Engine Control Panel • Control panel for engine containing switches and Murphy shutdown

gauges (See fig 2.9 for details).

5. Grease Injection • Grease injection system for ITH hammer lubrication. (See fig 2.5 for

details).

6. Towing Hitch • Heavy duty hitch for towing booster compressors.


Figure 2.5 Grease Injection

Tank

Air Filter

Lubricator

Electrical Box

Injector

Solenoid

Regulator

Fill Cap

Sight Glasses

Breather Cap


Figure 2.6 Main Panel

Indicator Panel See fig. 2.7

Main Power Disconnect Switch

Signal Cable Load/ Unload

Function Hydraulic Pump

Overload Reset

High Hydraulic Oil Temperature

Warning Light

Low Hydraulic Oil

Level Warning Light

120 VAC Plug


Figure 2.7 Indicator Panel


Figure 2.9 Engine Control Panel

Figure 2.8 Tram / Jack Valve Bank


2.1.4 Left Side

1. Thermal Dump Valve • Ensures cold water for hydraulic cooler

2. Water Inlet

• Inlet for mine water supply

3. Water Outlet • Water outlet for wash wand

4. Pressure Reducing Valve

• Reduces pressure of incoming mine water.

5

1 7

6

3 4

2

11

10

9

8

13

Figure 2.10 Left Side

12


5. Ball Valve – Hydraulic Shut-Off • 3” full throat ball valve for shutting off supply from hydraulic tank.

Control Circuit Regulator • Regulator for Air control circuit.

6. Hydraulic Pump

• Diesel driven hydraulic pump. Size depends on configuration.

7. Drilling Valve Bank • Contains manual controls for set-up functions. See figure 2.11 for

details.

8. Traming Lights • 24 volt lights for tramming.

9. Gauge Panel

• Contains gauges and controls for drilling pressures. See figure 2.12 for details.

10. Water Pump

• Supplies pressurized water for drilling.

11. Fire Suppression (Optional) • Optional fire suppression system.

12. Warning Beacons (Optional)

• Red is for ‘Brake On’. Amber is for ‘Anti-Jam On’.


Figure 2.11 Drilling Valve Bank

Figure 2.12 Gauge Panel


2.2 Hydraulic System

2

3

5

4

Level Indicators

Electric Fill Pump

1

6

Figure 2.13 Hydraulic System


1. Hydraulic Oil Tank

This tank holds the hydraulic fluid. It is also part of the frame and has several components mounted on it. One of these components is the electrical or manual pump used to fill the tank.

2. Suction Line

The suction line goes from the tank to the pump. There is a ball valve near the tank when space permits, which can be closed to keep the oil in the tank while changing the pump.

3. Pump and Drive Assembly

The variable displacement piston pump supplies pressure to the load sensing hydraulic system. It is driven by an electric motor with a flexible coupling or by diesel engine.

4. Discharge Line

The line goes from to the pump to the high pressure filter and then continues to the various control valves.

5. Return Manifold

All return lines are connected to this manifold, which forces the oil through the filter and then back into the tank.

6. Control Circuits

The tramming, set-up, rotation and feed circuits are described in the Section 2.4 and their operations are explained in Section 3.0 and 4.0.


2.3 Water System

High Pressure Air Supply Connection

Mine Water Connection

Wash Down Hose

Connection

Air On/Off Valve

Drilling Air Line

Top Drive

Water Metering Valve

Check Valve

Water Pump

Air Regulator

Oil Pump

Relief Valve

Figure 2.14 Water System


2.3.1 Water and Lubrication Systems

Water and oil/grease delivery systems are illustrated in Fig. 2.14

1. Water Delivery System

Water is fed through a strainer/regulator to the hydraulically driven water pump. The water is pumped through a metering valve into the air line to the hammer.

2. Oil Delivery System

The oil injection pump is air driven. It draws rock oil from the tank and injects it into the air line that feeds drifter/down the hole hammer. A needle valve located after the tank controls the oil flow.

3. Grease Delivery System

An alternative to the oil injection is the grease injection system. It produces less mist into the atmosphere and reduces used lubricant volume. The grease injection pump is air driven. It draws rock grease from the tank and injects it into the air line that feeds drifter/down the hole hammer. An injector located after the pump controls the grease flow. An electronic device controls the frequency of injection.


2.4 Controls

Tramming Controls Two spring return valves actuate drive motors turning the drive sprockets. The left valve actuates the left sprocket and the right valve actuates the right sprocket. The tramming valve automatically disengages the brakes when tramming is required. With the electric/hydraulic controls tramming may be done from the tram step or from the set-up panel (See Fig.2.16). The valve may also contain outrigger and cable reel sections.

Figure 2.16

Figure 2.15


2.4.1 Drill/Set-up Controls

These controls consist of eight-section valve bank mounted on the drill deck. The control valve may also come with a seven to nine section valve bank depending on the drill options.

E-Stop Button

Feed/Rotation Joystick

Start/Stop Buttons

Brake On Joystick

Lamp Test / Reset Button

Push to Brake Button

Stinger Joystick

Left / Right Selector Switch

Centralizer / Slips Joystick

Breakout In/Out Joystick

Power On Light

Splined Piston IN Light

Tramming JoysticksMast Dump Joystick

Feed Extension Joystick Local/Setup/Remote/Tram Switch

Local Drill/Set-up control Panel


2.4.2 Drilling Controls

These controls consist of six-section valve bank mounted on the drill deck. This panel is mounted on a remote console.

Left Front Down/Up Joystick

Right Front Down/Up Joystick

Left Rear Down/Up Joystick

Right Rear Down/Up Joystick

Jack Control Station

Fire SuppressionOn/Off Buttons

Emergency Stop Button

Drill Air On/OffWater On/Off Accra Feed On

Feed Switch

Drilling Control Panel


Section 3: Drill Operation

3.1 Tramming

The first Set-Up procedure is the tramming or drill positioning. Before tramming can be done the lock plates on both torque hubs must have the nipple facing outward as shown in Fig.3.1. This engages the torque hubs. With the nipple facing inward (Fig.3.2), the rig is ready for towing. The torque hubs should always be engaged unless it is being towed. The operator stands on the tram step and controls the tramming valves, which are mounted on the hydraulic tank (Fig.2.15). At this point, the lights and the system power switch are turned on. The valve levers control the movement and steering of the track carrier as follows: Straight forwards Push both levers forward Straight reverse Pull both levers back Right turn Push left lever forward Left turn Push right lever forward Hard right rotation Pull right lever back and push left lever forward Hard left rotation Pull left lever back and push right lever forward The tram levers are spring activated and will return to neutral when released. This stops the track motion. Also the load sensing components of the hydraulic systems maintains the torque on the tracks at a constant level. The brakes are always on except when the tram levers are operated allowing the hydraulic oil pressure to release the brakes. On models with electric/hydraulic controls, tramming controls are also found with the set-up controls on the articulating swing arm.


Figure 3.1

Drive Sprocket

Face Nipple Inwards For Towing

Torque Hub

Face Nipple Outwards For Tramming

Figure 3.2


3.2 Set-Up

Set-up or mast positioning has five distinct phases and are as follows: I. Slide-over

II. Dump III. Swing IV. Feed Extension V. Stinging

These actions are controlled from the set-up panel Fig.2.10. 3.2.1 Slide-over The slide-over Fig.3.3 refers to the lateral (right-left) movement of the mast assembly. It allows drilling close to walls without repositioning the drill. It also makes final positioning of the mast over the hole much easier. The slide-over action is done by the slide-over cylinders that move the slide plate with actuator from side to side. These slide plates are retained on two cylindrical slides of the slideover assembly. The slide-over switch on the set-up panel Fig. 2.3. is pushed right to move right and pushed left to move left. The total slide-over movement on Cubex 6200 drill is 30" (762mm).

Figure 3.3


3.2.2 Dump

The mast dump refers to the movement of the mast assembly from the horizontal position to 15° past the vertical position Fig. 3.4. This allows drilling of angled holes and is used in conjunction with the mast swing. The dump action is done by two dump cylinders. The dump switch Fig. 2.3 is pushed up to extend the cylinders and thereby rotating the mast forward to vertical. The switch is pushed down to rotate the mast backwards to horizontal.

Figure 3.4


Figure 3.5

3.2.3 Swing

The mast swing refers to the 360° horizontal rotation Fig. 3.5. This allows drilling of angled holes in conjunction with the mast dump. The swing action is done by the rack and pinion movement in the actuator. The action of the swing switch Fig. 2.3 determines whether the mast moves clockwise or counter clockwise.


3.2.4 Feed Extension

The feed extension refers to bringing the mast foot in contact with the rock face to stabilize the drill Fig. 3.6. The extension movement is done by the feed extension cylinder on the mast mounting plate. The sliders on the mounting plate guide the mast. The feed extension switch on the control panel is pushed down to extend the cylinder and pushed up to retract the cylinder. The total feed extension movement on Cubex 6200 drill is 39" (991mm).

Figure 3.6


3.2.5 Stinging

Mast stability is increased by extending the stinger cylinders Fig. 3.7 until they contact the rock face. The upper and lower stingers operate independently and may be used simultaneously. The upper stinger switch Fig. 2.3 is pushed up to extend the cylinder and pushed down to retract. The lower stinger switch operates the lower stinger in a similar fashion. The stinger movement on a 10-foot mast is shown below.

Figure 3.7


3.3 Drilling

Once the drill is trammed to its proper location and the mast is set up with the proper drilling angle, the operator controls the actual drilling from the drilling control panel. However, the water, oil and air delivery systems have to be in operation before drilling. These systems employ controls that are used in conjunction with the controls on the panel. This section describes these controls and operating sequence.

3.3.1 Start up

To start the drill, controls on the electrical panel are operated in the following sequence:

1. The main circuit is turned to the "ON" position. This switch will automatically trip when the amperage exceeds a pre-determined setting.

2. Turn off the main circuit immediately if the phase reverse light comes on.

This indicates that the wiring is incorrectly connected. Call an electrician to correct the problem.

3. The lamp test/reset button is pushed to check that warning lights are

working. Replace the lights that fail to light.

4. Push the start/stop switch to start the electric motor. The power on light will illuminate.

Refer to section 2.1.3 figure 2.6 for details of electrical panel. The remaining indicator lights and switches on the electrical panel are for monitoring the drill operation. When they are lit up they indicate the following: Motor O/L Light indicates that the motor is overloaded. Phase Reversal Light indicates an improperly wired power supply. Note: The electric motor will shut down, or will not start if any of the above indicators are lit and call the electrical maintenance personnel to repair the problem.


At the top left on the electrical panel is the digital voltmeter that reads the voltage across the 3-phase line selected. The 3-phase selector switch is below. To the right of the voltmeter is the digital ammeter, which reads the amperage across the 3-phase line selected with the 3-phase selector switch. The voltmeter and ammeter are used in trouble shooting the electrical system.

Figure 3.8


3.3.2 Drill String Make-Up and Breakout

The make-up and breakout refers to the screwing and unscrewing of the threaded joints on the rods and hammer. This is described in detail in the Operating Procedure (Section 4). Slip Switch actuates the slip cylinders, which move the slip plate. To bring the slips into the flats, the switch is pushed to the "IN" position. To reverse this action push the switch to the "OUT" position. Rotation Lever actuates the rotation motors to rotate the drill string. This lever is pushed forward for rotation and pulled back to reverse the rotation. The position of the lever controls the rotation speed and it may be set from 0 to 50 rpm in either direction, depending on the torque motor used. Rotation Pressure Gauge is used to monitor the rotation pressure in forward only, as well as to set the maximum forward rotation.

3.3.3 Drilling

This section describes the controls used in drilling. Air Switch turns the flushing air on and off by energizing the air valve actuator. Feed Lever actuates the feed cylinder to engage the top drive. This lever is pushed forward to move top drive down. This brings the drill bit down the hole and in contact with the rock for drilling. Pull the lever back to move the top drive up and lifting the drill string out of the hole. Pull Down Valve sets the pressure applied to force the top drive down. This force applies pressure to the drill bit. Hold Back Valve is used to relieve part of the weight of the drill string while drilling. It improves drilling accuracy, steel bit life and drilling control. Water Switch controls the flow of water down the hole. Emergency Shut Down Button shuts down the drill immediately. Start Button starts the motor from the drilling panel.


Section 4: Operating Procedures

4.1 Operating Procedure for Tramming and Start-Up

The drill operator must be completely familiar with the system and its safety procedures before operation.

4.1.1 Pre-drill Inspection and Drill Start-Up

The equipment may have to be moved several times during drilling but not all procedures have to be repeated. These procedures are as follows:

1. Examine the electrical cable and connections for damage or unsafe cable location. Connect the cable; turn on the power at the sub station and drill. Check for phase reversal, which ensures proper rotation of the electric motor.

2. Examine the mine air line and blow the line to eliminate any water, condensate and scale.

3. Connect and secure the mine air supply. Use of proper whip checks is critical to prevent injury in the event a hose breaks.

4. Examine the mine water line and flush it before connecting it to the drill. 5. Check water pump oil level. 6. Check and fill the lubricator tank as required using only clean oil or

grease. See Fig. 4.4.2 or Fig 4.4.3 7. Check hydraulic fluid level on both tanks. 8. Grease all points on the drill. 9. Ensure that all operating, set-up and tramming controls are in the off or

neutral positions. 10. Check drill over for loose bolts, leaks, damage etc. 11. Check the mine air filter gauge. Check for pressure between gauges on

filter. This must be done when the air valve on the drill has been opened allowing air through to the filter. 10psi differential indicate plugged air filter.

12. Check all gauges for proper operation.


4.1.2 Tramming Operation

When tramming, the mast must be in the horizontal position resting on the "T" support Fig.4.1. Tie the mast down if the drill is to move a long distance. The procedure is as follows:

1. The torque hubs must be disengaged before towing the drill. Ensure that the engagement plate nipples in both torque hubs are facing inward for towing, outward for powered tramming.

2. Ensure that the path is clear and that side and over head clearance are

sufficient.

3. Start the electric motor.

4. Check that all hydraulic hoses, air lines, water lines and electrical cables are clear of the tracks.

5. Stand on the tram step and move the drill into position.

Note: It is recommended that the drill be placed on a skid for long moves.

Lower Mast into rests

Figure 4.1


4.1.3 Set-Up

The mast may be positioned for drilling holes in a vertical, horizontal or angular position and this is done as follows:

1. Move the mast to the proper position where the drill hole is required using mast slide-over.

2. Move the mast to the proper vertical or horizontal position by moving the

slide over dump.

3. Move the mast to the proper "Side to Side" angle position using the mast swing.

4. When the mast is positioned, use the feed extension to bring the mast into

contact with the drilling surface. Note: The mast feed extension keeps the foot of the mast in contact with the ground

or the sidewall during drilling. Wood cribbing may be required under the foot and stinger to stabilize the mast. Also wood cribbing may be required to level the drill from side to side.

5. If possible, use the Mast Stinger Cylinders and set the stinger rod ends

against the back and bench.


4.2 Drilling Preparation

Before operating the drill, the operator must be familiar with the drill site preparation, drilling recommendations and drilling procedures. It is also necessary to know overall efficiency and performance of the drill.

4.2.1 Drill Site Preparation

First, check for any potential problems or hazards around, below and ahead of the drill. Now the drill site preparation may begin. To operate at the drill site the following is required:

1. Power supply. These units are equipped with an overload and phase reversal protection.

2. A supply of clean dry mine air is required. The drill is equipped with a mine

air filter to ensure proper air quality.

3. A supply of clean water with a minimum flow of 10gpm (40 l/min.) The water flushing system is equipped with a strainer/regulator.

4.2.2 Drilling Lubrication

Drilling operation is performed from the control panel. However, the water injection system and the oil or grease injection system must be set into operation before drilling. These injection systems employ inlet control valves that are used in conjunction with controls on the panel.


4.3 Drilling Recommendations

Maximum performance and drill life is described below.

4.3.1 Rotation Speed

Carbide wear rate on the drill bit are directly related to the rotation speed. Hard and abrasive formation requires a slower drill rotation than more favorable drilling conditions. Increased rotation speed in hard rock effects the penetration rate only minimally but increases the wear rate enormously. Caution must be taken with a higher drilling rate because hard layers, cracks and crevices do exist in the formation. The following may serve as a guideline in determining the initial rotation speed. For example in a formation where the drilling rate was determined previously to be 8" (200mm) the recommended rotation is about 20 rpm. The calculations are listed below. 8" per minute 8 ------------------------ = ---- = 21.3 rpm 3/8" per revolution 3/8 200mm per minute 200 ----------------------------- = ---- = 20 rpm 10mm per revolution 10 The above is recommended as a starting point and optimum RPM with maximum bit life is determined in the field. Usually the operating RPM falls within 5 RPM of the suggested speed as shown above.

4.3.2 Weight on Bit

The weight on the bit must be applied to the hammer to contact the formation. This load is to be sufficient to keep the bit closed or shouldered in the tool. The minimum weight required is calculated by multiplying the piston area of the tool by the air pressure. Additional force is required for maximum drilling. The extra loading is determined by the type of drill bit used and the condition of the formation. The recommended forces are as follows: 1800 lbs (820 kg) for 4 1/2" (115mm) dia. holes 4600 lbs (2090 kg) for 6 1/2" (165mm) dia. holes


Incorrect drilling weight will result in the following:

1. Loss of air pressure in the tool. 2. Erratic tool behavior such as rattling or missing. 3. Reduction in penetration rate.

To exert the proper force on the tool, increase the pull down pressure until the tool sounds steady and the penetration rate is at the maximum. Then increase the hold backpressure until the tool begins erratic behavior. Then increase the pull down pressure until consistent tool operation is noticed. A reduction in hydraulic force is required for each drill pipe that is added on a down hole. When the desired weight on the bit is obtained, the operator should take note of the values on the pressure gauges.

4.3.3 Tool Lubrication

Correct lubrication is the most important factor in maintaining the hammer operation. Inadequate lubrication will increase tool wear and the possibility of part failure. The drill uses a positive feed type lubricator to inject oil or grease into the airline. Follow the lubrication recommendation listed below.

A minimum of: 1qt. (1 l) of oil per hour for a 4" hammer, 2-½ qt. (2.5 l) of oil per hour for a 6" hammer, 0.7qt (0.7 l) of grease per hour for a 6” hammer (75% of full adjustment), 0.3qt (0.3 l) of grease per hour for a 4” hammer (30% of full adjustment).

When using a new drill pipe or a pipe that has not been coated previously with oil, pour 1 qt (1 l) of oil down the drill pipe each time a joint is added.

4.3.4 Water Injection

The injection of water into the air line during drilling is recommended for all hammers. This does not harm the tool but it is beneficial to the tool performance. Water injection offers the following advantages:

1. Reduction in dust damage to drilling equipment. 2. Protects the health of the operator. 3. Reduces high temperatures in drilling equipment. 4. Aids cleaning the hole when the formation is producing small amounts of

water. 5. Acts as a seal on worn parts.


A major problem encountered in air drilling is the seepage of small amounts of formation water into the hole. After drilling through the seepage zone, the drill cuttings will mix with the water and will create slurry, which adheres to the drill pipe and hole wall. This "collaring" or "bridging" results in the loss of circulation. The injection of 2 - 5 gpm (8 - 20 l/min.) of water wets the cuttings and washes them out of the hole. See drilling Procedures for proper operation of the water injection system.

4.3.5 Air Supply

For maximum performance and penetration, Cubex booster compressor supplies 350-psi air pressure. Although the tool will operate with the pressure supplied from the mine air line, the performance is improved with the booster.

Pipe Arm Operation This section describes how to operate the single-axis pipe arm required to load drill pipe into the drill. This operation can be done using the ERIS control panel or using the manual control valve. CAUTION: when operating the pipe arm, make sure that there are no personnel are near the pipe arm. A. Pipe Arm Operation using the ERIS Control Panel: The following functions are available using the ERIS control station:

• Arm in / Arm out (LX on joystick)

• Clamp Open / Clamp Closed (LY on joystick)


1. To access the pipe arm functions, switch to the DRILL mode.

2. Select the Pipe Arm Clamp mode (ARM CLMP) and use the left joystick to navigate the pipe arm functions.

B. Pipe Arm Operation using the pipe arm control valve:

The same functions are available using the pipe arm control valve:

• Arm in (left) / Arm out (right) • Clamp Open (left) / Clamp Closed (right)


Procedure to load/unload drill pipe:

1. Swing pipe arm out. 2. Open pipe arm clamp. 3. Load drill pipe into pipe arm 4. Close Clamp 5. Swing pipe arm in. 6. Reverse operations and order in steps one through five to unload drill pipe.

4.3.6 Pipe and Hammer Installation/Removal

The tool that creates the drilling hole is the hammer and the bit. The drill pipe allows drilling of holes that are deeper than the hammer and bit assembly.


4.3.6.1 Hammer Installation Procedure

There are many different types of hammers available but they all have a piston that hammers on the bit. The difference is piston size, air porting and assembly requirements. The installations are similar and are done as follows:

1. Slowly operate the top drive while opening and closing the drill air switch located on the control panel. This clears the system of foreign matter that could damage the hammer.

2. Examine the exhaust air from the top drive for lubricant. If no oil or grease

is detected, adjust the injection system until it appears (See Fig. 4-3-1).

3. Stop the top drive and raise it to the top of the mast using the feed joystick.

4. Turn the slip switch at the control panel to close the holding slips.

Note: For units with centralizer: Hold the bit with centralizer jaws.

5. Place the hammer on the slip plate bit basket and slide the guide bushing over the hammer.

6. Lubricate the top sub thread and the thread in the drive shaft on the top drive.

7. Slowly lower and rotate the top drive to make up the thread connection

with the driver sub. Ensure that the threads are tightly screwed together using the top drive.

8. Raise the hammer and retract the holding slip.

9. Lower the hammer until the bit is below the breakout plate but just above

the ground. Make sure centralizer is closed around the hammer.

10. Start the rotation slowly and turn on the drill.

11. Check the hammer exhaust for lubricating oil being carried through the tool (See Fig. 4.3.1). If the lubricant feed is lean or too rich, adjust the injection system.


Caution: The hammer parts may get damaged if the tool is operated with insufficient lubrication.

Figure 4.3.1


4.3.6.2 Hammer Removal Procedures using Breakout Wrench If the hammer needs to be disassembled, use the top drive's power to loosen the top sub and driver sub connections before removing the hammer (See Fig. 4.2.9 to Fig. 4.2.10). The procedure is as follows:

1. Position the hammer so that the flats on the top sub are aligned with the slip plate.

2. Pull the slip switch on the control panel to engage the slip plate with the

flat on the top sub.

3. Pull the rotation lever to reverse the top drive. Allow it to rotate slowly until the drive shaft thread is loose from the hammer. Re-tighten the thread by hand.

4. Push the slip switch to disengage the slip plate.

5. Raise the top drive and hammer until top of the piston case is just above

the level of the breakout chain and cylinder.

6. Connect the chain wrench to the piston case so that the top sub joint can be broken by the breakout cylinder. Connect the pipe wrench to the top sub and swing wrench handle against the mast for backup.

7. Push the breakout switch on the panel to extend the breakout cylinder

until the joint is broken loose. Note: Stand clear when breaking the joint to avoid possible injury in the event

the chain breaks.

8. Remove the pipe wrench and chain from the hammer.

9. Raise the top drive and hammer until the bit is just bellow the drilling table.

10. Retract centralizer jaws.

11. Pull the slip plate in and clamp bit with centralizer jaws.

12. Use the chain wrench and breakout cylinder to the driver sub from the piston case.

13. Remove the chain wrench from the piston case.

14. Hold the top sub by hand and slowly reverse it to unscrew it from the drive

shaft. Make sure that the top drive is moved up to prevent thread damage. Note: During hammer removal, cover the drill hole to avoid losing of any parts down

the hole.


4.3.6.3 Bit Removal and Installation for 4" Hammer Bit Removal and Installation refers to Fig. 4-3-5 and Fig. 4-3-6. Avoid using dull bits and check for the following:

1. Slow penetration rate 2. Decrease in the volume of cuttings 3. Binding 4. Chattering due to uneven rotation

Pull loose hammer up until bit lies up with centralisers

Activate Centralisers and Spline Piston to Break Driver Sub

Break Joint - Top Drive to Hammer Pin End

Figure 4.3.5 Figure 4.3.6


Bits must be handled with care to prevent chipping and fracturing of the carbide inserts. Failures may be traced to improper drilling, handling or regrinding (See Troubleshooting Drill Bits section 6.8).

4.3.7 Field Procedure

The field procedure is as follows:

1. Position the hammer so that the flats on the top sub are aligned with the slip plate.

2. Pull the slip switch on the control panel to engage the slip plate with the

flats on the top sub.

3. Pull the rotation lever to reverse the top drive. Allow it to rotate slowly until the drive shaft thread is loose from the hammer. Re-tighten the thread by hand.

4. Push the slip lever to disengage the slip plate.

5. Feed the hammer up the mast until the bit is just below the drilling table.

6. Open centralizer.

7. With the slip switch at the control panel, close the slip plate and clamp bit

with centralizer jaws.

8. With the splined piston switch, engage the splined piston into top sub.

9. Pull the rotation lever to reverse the top drive to breakout the drive sub.

10. Slowly remove the top drive to unscrew the driver sub from the piston case. Make sure that top drive moves up as the connection is unscrewed. The “float” in the top driver should be used to prevent thread damage.

11. Remove the driver sub from the bit.

12. Inspect the driver sub for cracks or galling. Polish out galled spots and

replace cracked driver subs.

13. Coat the splined section of the new bit with thread compound to prevent premature galling. Drop the driver sub over the bit shank and install the bit retainer ring or rings.


14. Make sure that the guide bushing is still on the hammer.

15. Lubricate the drive sub threads with thread compound and screw it into the piston case. Consult the hammer manufacturer’s specifications for the required makeup torque.

16. Raise the hammer with the top drive until the bit is above the slip plate.

Then retract the slip plate. Note: Each time the bit is removed, examine the shank for damages. Also check the splines for proper lubrication. Look into the end of the hammer to inspect the striking face of the piston for wear. When changing any bits, be sure that the gauge diameter of the replacement bit is not larger than the one it replaces. This prevents pinching of the bit in the existing hole.

4.3.8 Shop Procedure

The joint between the driver sub and the piston case must be broken before removing the hammer from the rig. The procedure is as follows:

1. Secure the hammer in a vice and remove the driver sub and the bit.

2. Remove the bit from the driver sub and inspect the driver sub for cracks or galling. Polish the galled spots out or replace cracked units.

3. Coat the splined section of the new bit with rock drilling oil to prevent early

galling. Drop the driver sub over the bit shank and install the bit retainer ring or rings.

4. Lubricate the driver sub threads and shoulder with thread compound. Then

screw it into the piston case and torque it to the manufacturer’s specifications.


4.3.9 Pipe Make-up Procedure

Additional pipe sections are added; after the hole has been collared and is deep enough to stop the top drive at the bottom of the mast. Follow the instructions below:

1. Raise the top drive until the flats on the top of the drill pipe are aligned with the slip plate.

2. Stop the rotation and flush the hole.

3. Turn the drill air off by pulling the air switch back.

4. Pull the slip switch on the control panel and close the slip plate on the

pipe.

5. Slowly reverse the top drive to break the thread connection between the pipe and drive shaft.

6. Stop the top drive and raise it to the top of the mast using the feed lever.

7. Take the next joint of drill pipe and stab it on the preceding pin.

8. Slowly lower the top drive then tighten the thread connection between the

drive shaft and the pipe. Use the top drive to tighten the joint.

9. Retract the slips and continue drilling. Note: Make sure that the thread connection is tight before drilling. Use the full power of the top drive, which has been pre-set for the make-up operation. Do not allow the rotary action of the drilling to tighten the threaded connection because this may result in thread damage and require a higher breakout force.

4.3.10 Pipe Breakout Procedure

The Breakout utilizes the reverse rotation and the splined piston features in the top drive assembly. This patented device eliminates the need for extra wrenches. Fig. 4-3-7 illustrates the breakout procedure for pulling the drill string from the hole. The procedure is as follows:

1. Raise the top drive until the flats on the top of the drill pipe are aligned with the slip plate.


3. Turn off the drill air by pulling the drill air switch back.


4. Close the slip plate to engage the flats on the drill pipe by pulling the slip switch back.

5. Pull the rotation lever back and rotate the top drive in reverse slowly to

break the thread joint. Note: This operation breaks (loosens) the threaded connection only, leaving the pipe still attached to the top unit. Do not allow the drive shaft to rotate more than 60°.

6. Open the slip plate on the pipe by pushing the slip plate forward.

7. Raise the drill string using the feed lever until the flats on the next drill pipe are aligned with the slip plate.

8. Pull the slip switch and close the slip plate to engage the pipe.

9. Push the splined piston switch forward to engage the spline piston into the

end of the drill pipe. Note: The splined piston must be fully engaged. Rotate the drive shaft slowly while listening for the piston to snap into place.

CAUTION: The splined piston may be damaged if the drive shaft is rotated too quickly.

10. With the splined piston engaged in the first pipe, reverse the top drive. This operation unscrews the bottom connection between the first and second drill pipe. Make sure the top drive is being moved up as the connection unscrews. The “float” in the top drive mounting plate should be used to prevent thread damage.

11. Cover the pin connection on the drill pipe with a wood block or metal cup

to guard against thread damage or foreign matter.

12. Pull the splined piston switch to disengage splined piston.

13. Unscrew the loosened drill pipe from the top drive. CAUTION: The splined piston should be engaged only when breaking out a pipe using the reverse rotation. Never rotate the drill string in forward rotation (drilling) with the splined piston engaged.


Figure 4.3.7


Remove grease from threads

Clean the threads

Use a file to repair damaged threads

Figure 4.3.8


4.3.11 Drill Pipe Thread Preparation

The following procedure must be followed when any new threaded parts are connected to the drive shaft, hammer and drill pipe (See Fig. 4-3-8).

1. Remove any grease on the drive shaft threads, drill and drill pipe.

2. Inspect all threads for damage and repair if necessary.

3. Coat the threads and thread shoulders with a recommended tool joint compound (See Maintenance Section 5.4).

4. Connect the threaded joints lightly then back them off and retighten them

lightly. Repeat this procedure approximately 10 times. The top drive must be in the “float” position to allow free movement during this operation.

5. Disconnect the joints and inspect the threads and shoulders for any shiny

spots or steel slivers. CAUTION: On the box threads, coat the shoulder only with compound because any excess could fall into the hammer and foul its operation. Thread compound must be kept free of dirt and water. Cover the container after using it.


4.4 Drilling Procedure

Drilling operations are performed from the control panel. However, the water injection system and the oil injection system must be set into operation before drilling. These injection systems employ inlet control valves that are used in conjunction with controls on the panel.

4.4.1 Water Injection Operating Procedure

The water operating procedure (Fig.4.4.1) is as follows:

1. Connect the water sunction line to the supply of clean water. It is recommended to let the water run and allow any dirt or scale in the line to discharge before hook-up. The suction line has a strainer/regulator that filters the water and prevents water pressure of more than 70psi (5bar) reaching the pump.

2. Turn on the drill.

3. Turn on the water by pushing the switch on the drilling control panel. This

activates the hydraulic valve that directs oil to the pump drive motor and simultaneously opens the solenoid valve on the suction line.

4. Open the water injection needle valve to meter the water flow. The water

flow must be sufficient to properly flush the hole. Water pressure is adjusted with the regulator on the discharge line and should be done by a mechanic. The water injection system reduces dust, assists in cleaning the drill hole and cools the bit as well as the couplings on the drill steel.

CAUTION: Do not use a water hose of smaller size than the inlet piping.


Water metering valve

Relief Valve

Water metering valve

Check valve

Water pump

Strainer/pressure regulator

Wash down hose connection

Mine water supply

Strainer/pressure regulator350 psi (24.2 bar) air from booster compressor.

Water solenoid valve

Figure 4.4.1


4.4.2 Grease Injection Operating Procedure

The air supply line to the grease injection pump is designed so that the pump will operate only when the air is on. 4.4.2.1 Priming System

1. Close ball valve on air supply line. Remove top cap and fill tank with rock drill grease. Reinstall top cap and turn on air.

2. Set the air supply regulator to 60 - 100 psi (refer to air schematic).

3. Turn vent plug at the pump counter clockwise one complete turn and

operate pump by the PLC until lubricant flows freely from opening in vent plug to expel air trapped between the pump and the supply line. Tighten vent plug.

4. Disconnect grease supply hose from injector to air line at injector end.

Continue pumping until grease flows from the injector outlet. Connect and tighten the supply hose.

5. Check the injector for proper operation. Injector stem moves when injector

discharges lubricant. Adjust injector regulator for the volume required.

6. Disconnect grease supply hose from injector to air line at air line end. Continue pumping until grease flows from the hose. Connect and tighten the supply hose.

4.4.2.2 Grease Injection Operating System The pre-determined lubrication cycle frequency is set with a timer in the electrical box in the grease injection system (see figure 4.4.3). When a lubrication cycle is initiated the air solenoid valve is energized and air is admitted to the pump. Lubricant is delivered to the injectors and the injector’s discharge lubricant to the drill air line. When air solenoid valve is de-energized, air is admitted to the opposite side of the pump air cylinder. As pump & plunger returns to its retracted position, the lubricant pressure in the system is relieved, permitting the injectors to recharge. System is now ready for the next lubrication cycle.

Refer to 4.4.3 for layout of grease injection panel.


Figure 4.4.3 Grease Injection

Tank

Air Filter

Lubricator

Electrical Box

Injector

Solenoid

Regulator

Fill Cap

Sight Glasses

Breather Cap


Figure 4.4.3.3

4.4.2.3 Adjusting Flow Rate

The maximum setting (flow of grease) is achieved with the adjustment screw backed all the way out (Counter clockwise). Setting for a 4” Hammer: To set the flow of grease for a 4” hammer, which is approximately 0.3 quarts of grease per hour you must set the adjustment screw to 30 percent of maximum adjustment.

- Loosen locknut see Figure 4.4.3.3. - Turn adjustment screw in clockwise with a wrench until it stops

(approximately 12-1/2 turns if the adjustment screw is backed all the way out). Note: Be careful not to over torque the adjustment screw. It should take minimal force to turn the screw clockwise. This will be the minimum injection setting.

- Turn the adjustment screw counter counter-clockwise 4 turns. - Lock in setting on adjustment screw with locknut.

Setting for a 6” Hammer: To set the flow of grease for a 6” hammer, which is approximately 0.7 quarts of grease per hour you must set the adjustment screw to 70 percent of maximum adjustment. - Loosen locknut see Figure 4.4.3.3. - Turn adjustment screw in clockwise with a wrench until it stops

(approximately 12-1/2 turns if the adjustment screw is backed all the way out). Note: Be careful not to over torque the adjustment screw. It should take minimal force to turn the screw clockwise. This will be the minimum injection setting.

- Turn the adjustment screw counter-clockwise 9 turns. - Lock in setting on adjustment screw with locknut.

Lock Nut

Adjustment Screw

Injector Body Grease Outlet

Bleed

Grease Inlet


24VDC Manual Timer – Underground Units

ON-time display window

ON-time display window and selector (select one from 0.1s, 1s, 0.1m, 1m, 0.1hr, 1hr) NOTE: This sets the timescale.

Off-time display window

OFF-time display window and selector (select one from 0.1s, 1s, 0.1m, 1m, 0.1hr, 1hr) NOTE: This sets the timescale.

Output ON/OFF indicator When the output is ON: Orange When the output is OFF: Green

ON-time setting dial

Lock for On-time setting dial

Lock for On-time scale selector

Off-time setting dial

Lock for OFF-time setting dial

Lock for OFF-time scale selector


The timer settings for either grease or oil are as follows: Oil 8 seconds on 6 seconds off ON-time set to 8 OFF-time set to 6

Timescale set to 1s Timescale set to 1s Grease 12 seconds ON 24 seconds off ON-time set to 2 OFF-time set to 4

Timescale set to 0.1m Timescale set to 0.1m


4.4.3 Drilling Procedures

Now all systems are in operation and are ready for drilling. Drilling is performed as follows:

1. Turn the air unloader valve to the unload position. This permits collaring the hole using pressure from the mine air supply.

2. Push the air switch to the on position.

3. Start the top drive slowly by pushing the rotation lever forward. Then

adjust the speed to 15 rpm.

4. Push the feed lever forward (slow feed) to lower the hammer until it contacts the rock.

5. Turn the pull down valve (clockwise) until the hammer starts drilling. As

the bit start breaking the rock, increase the down feed slowly otherwise the bit may move and change the drill angle.

6. After the hole is collared, increase the down feed until the tool runs

smoothly. The recommended pull down pressure is between 500 to 700 psi with the backpressure being at zero.

Note: Additional weight on bit will not increase the penetration substantially but it would reduce the hole accuracy and drastically reduce bit life.

7. Turn the air unloader valve to the load position to utilize the additional pressure supplied with the booster.

8. Continue drilling until the top plate contacts the mast stop

9. Pull the feed lever back to raise the tool until the flats on the top sub of the

hammer are aligned with the slip plate.


11. Pull the air switch back to stop the drilling.

12. Close the slip plate on the top sub. Break the connection and follow the procedure for installing the first joint as described in section 4.3.6.

13. Push the switch forward to open the slip plate, which releases the

hammer.


Note: The top drive may have to be raised to get the weight off the slip plate before the slips will open.

14. Turn on the air and activate the feed down to resume drilling. CAUTION: Do not jam the bit against the bottom of the hole which could damage equipment.

15. Increase the weight on the bit and adjust the rotation as outlined in Section 4.3.1.

16. Continue drilling until the top drive base plate contacts the mast stop.

17. Repeat steps 9 to 13 to add additional length of drill pipe.

18. Each time a drill pipe is added, use the full power of the Top Drive to

tighten the threads. Increase the Holdback pressure by 12 psi for each additional pipe section added when using 3-1/2" (90mm) diameter pipe.

Note: Excessive weight on a drill bit will increase the torque, which increases the rotation pressure. This may create a jerky rotation. The holdback pressure gauge also indicates the hoisting pressure (force) when pulling the drill string from the hole.


4.4.4 Drilling Recommendations

4.4.4.1 Collaring The Drill Hole The collar of a drill will directly determine the quality of the hole. 4.4.4.2 Hole Deviation The major cause of breakage of drill consumables is deviation of the drill hole. There is very little tolerance in the drill string for any deviation given the extremely high-energy output of the Drifter. 4.4.4.3 Drill Pressure Feed and hammer pressure and rotation flow can and should be adjusted to suit different rock conditions. Optimum settings are reached when the maximum penetration rate is achieved with minimal heat and vibration being generated through the drill string. Incorrect drill pressure settings can be directly related to the hole deviation and consumable breakage. 4.4.4.4 Collaring The aim of the collaring process is to drill through and hold up any broken ground at the top of and during a drill hole. Water injection is required at varying intervals to create a paste when mixed with the drill hole cuttings. Once enough paste has been created through a wet-dry process, the bit should be rotated out of the hole with the flushing air off, forming the 'collar'. A lot of water will be required in particularly bad, broken ground situations. It is important to note that during 'collaring' and drilling through broken ground, the collaring circuit (low impact) must be engaged. If the collaring process is done correctly there should be little or no deviation at the top of the hole. 'Centre-Punching' is the process of hammering the bit through the initial stages of the hole (broken ground) with no rotation (rotation can be flicked on and off in an attempt to keep the drill string torqued as much as possible). It should be remembered that 'Centre-Punching' should be only applied where necessary (broken, uneven ground) and be utilized for as shorter length of time as possible while still ensuring that there is no 'run-off'. 'Centre-Punching' causes loosening of the drill string heads and as such can eventually have an adverse effect on the life of the drilling consumables. Feathering the feed and 'Centre-Punching' will greatly reduce the risk of deviation at the top of and as a consequence throughout the drill hole. Another good practise is to regulate the flushing air pressure down the hole. Less air pressure can be used at the top of the hole to ensure that the collar isn't blown away. Once the drill bit is into fresh rock the valve should be opened fully. When pulling out of a hole the flushing air should always be turned off prior to reaching the surfaces and the bit rotated to protect and help hold up the collar.


In a situation where the ground is broken or cracked to such an extent that it is impossible to create enough returns (drill hole cuttings) to form a collar, clay from the track frames or cuttings from nearby drill holes can be put down the hole. This will enable enough 'paste' to be formed, with water injection, to seal the cracks in the ground and create collar. In circumstances where there is large volume of ground water, 'Collar Piping' may be required. 'Collar Piping' involves drilling through the initial broken stages of the hole with large enough diameter bit to enable the required length and diameter poly pipe to be hammered into the hole. The larger bit can then be replaced with one of the original diameter (bit must obviously be smaller than I.D. of poly) and the feed rail correctly aligned over the hole. The whole collaring process can be applied to any broken or cracked ground that may be encountered throughout a drill hole. 4.4.4.5 Hole Deviation A MAJOR CAUSE OF BREAKAGE OF DRILL CONSUMABLES IS HOLE DEVIATION It is imperative that while drilling there is no or only very slight deviation in the hole. As well as placing a great deal of added stress on the drill string, deviation will have an adverse effect on blasting. The burden from the toe of a hole that has deviated, to other surrounding holes can be significantly higher. Correct collaring techniques will help to ensure there is no 'run-off'. Method of combating hole deviation is 'centre-punching' and feathering the feed through any broken or cracked ground. The collaring circuit should be always engaged when drilling through broken ground. The resultant reduction in feed and impact pressures while the collaring circuit is engaged will help to reduce run-off. Therefore, it is good practice to leave the collaring circuit engaged until the bit is well into the fresh rock, especially when drilling angle holes. If the hole has deviated after collaring then the feed rail needs to be lifted off the hole and small adjustments made so as the rods are central and the drifter is square to the hole. If deviation in the hole becomes too great the operator should consider pulling out and starting another. Too much feed pressure will also increase the likely hood of hole deviation or run-off. Drilling with too little feed pressure however will cause 'chattering' in the drill string which in turn will cause breakage of consumables. Hole deviation can also make it difficult to uncouple the rods. If this occurs the feed rail again needs to be lifted and re-aligned with the hole to allow the threads to be un-wound.


4.4.4.6. Adjusting Drill Pressure and Monitoring the Machine For clay and soft rock, feed and impact should be adjusted to lower pressure settings and increased for harder rock. The aim in the adjustments of pressures should simply be to facilitate smooth drilling and maximize penetration rate by: -Minimizing heat in the drill string -Eliminating 'under/over feeding' -Minimizing rotation pressure. Rotation flow should be increased in softer rock/decreased in harder rock indicated by penetration rate. Bit size also needs to be considered when adjusting rotation flow. A larger diameter bit will require substantially reduced the rotation. The cuttings should be constant size and not fine. The pressure should be minimized while drilling and any substantial increase indicates either jamming situation or hole deviation. Excessive heat in the drill string is always the first indicator that the rotation speed is too high. The gauges on a drill bit will also wear out quickly if the rotation is too fast. The cuttings also will be very fine through the bit 'double striking' on the bottom of the hole. Clay or soft ground may facilitate the need for lower feed pressure. To maintain the correct differential between feed and impact (hammer) pressures and to avoid shortened hammer seal and consumable life, impact pressure needs to be lowered accordingly. To maximize penetration rate in solid rock, higher impact pressure is required. To maintain the correct differential between impact and feed pressures and to prevent 'under-feeding' feed pressure needs to be raised accordingly.


4.4.4.7 Feed Pressure 'Under Feeding' is a particularly common and bad practice on LH1 drill rigs. Feed pressure must be kept to the bit at all possible times while impact is being utilized. 'Free Hammering' and 'Under Feeding' can shorten the life of both drill consumables and hammer seals. 4.4.4.8 Bit and Rock Blockages If the bit blocks while drilling, an attempt to unblock the bit down the hole can be made by rattling the rods (breaking out) and/or by feathering the feed. If this is unsuccessful within a couple of minutes, pull the rods out to avoid jamming and unblock by rattling the bit on the ground. If this is still unsuccessful it is likely the blockage has gone up into the rod. To clear the rod it should be rotated out of the bit and flushing air turned on. The rod should be then clear itself, which enables the bit to be cleared. The bit should never be rattled on or through the centralizers. Monitoring of the machine is critical at all times. Monitoring 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 situation. 4.4.4.9 Hole Blockage The operator should obviously listen very closely to the machine while it is in operation. An experienced operator can pick minute changes in sound while drilling and what they signify. Care should be taken when there are any changes in sound while drilling indicating changes in ground conditions and adjustment in pressures made accordingly to prevent blockage or jamming in the hole. If returns from the hole start to decrease the operator should immediately reverse the feed and turn impact off to clean the hole. In the event that there is blockage in the hole the operator should first try and envisage what is happing down the hole and what is causing the obstruction. There are a number ways to free up the rods and clear the obstruction specific to blockage situation. As general rule if the rods are still able to be rotated then it should be always possible to retrieve the rods. The system that can be applied in a lot of blockage situations is to feather the reverse feed with impact off and rotation on relatively fast. The operator must be patient in this scenario and try not to put excessive force on to the reverse feed. This process can be done with the flushing air or off until the rod are free. Water injection can also be used in particularly bad jamming situations to help loosen the blockage behind the bit. If the process of reversing the feed with rotation on, back through broken ground can be achieved with the flushing air off it will help preserve the quality of the drill hole. The operator should then attempt to 'collar' the broken section of ground with the use of air and water. As mentioned in the section on collaring it is good practise to reduce the volume of flushing air used


whenever the bit is being retracted back through any areas of broken or fractured rock. If full flushing air is used in this situation it can have the effect of loosening the rock and forming a cavity down the hole, which in turn can be difficult to hold up (or 'collar'). Maintaining full flushing air when attempting to retrieve jammed rods without getting any returns (cutting) from the drill hole, can also have the effect of creating excessive air pressure in the hole. As a consequence the obstruction in the hole is compacted and retrieval of the rods is made more difficult.


4.4.5 Drilling Accuracy

The production holes are drilled as per engineering layout issued for each block. An extremely important part of drilling with the Cubex drill is to obtain a high degree of accuracy. To achieve this the proper alignment of the holes are essential. After the initial set up do the following:

1. Check that the set up is at the proper location

2. Check that the set up is at the correct angle of dip

3. Check the set up for the correct degree of strike

4. Recheck the degree of dip and strike after the hole has been collared.

5. Repeat check point #4 after the first joint is drilled and adjust as required.


4.5 Preventive Maintenance

Preventive maintenance is necessary to maximize availability and reduce costly down time.

4.5.1 Daily Maintenance Procedure

1. Drain the moisture from the air filter.

2. Check the oil level in the rock oil tank or in the In-Line Oilier.

3. Be aware of any unusual noises from the drifter, pumps and motors.

4. Check the hydraulic oil level.

5. Periodically check the oil temperature. If the temperature exceeds 150 F

(65°C) have the unit inspected.

6. Grease all lubrication points as described in the maintenance section.

7. Check for hydraulic leaks and repair them immediately.

8. Push the lamp test button to illuminate all safety circuit lamps. Call the maintenance personnel to repair any problems.

9. Insure that all safety straps are in place.

4.5.2 Weekly Maintenance Performed by Operator

1. Repeat the daily maintenance.

2. Check the complete drill for loose bolts and nuts.

3. Drain and inspect the mine air filter.

4. Check sliders for wear and adjust as required.

5. Check track tension. Pump grease to adjust to maximum 1"(25mm) sag.

4.5.3 Lubrication

The lubrication schedule must be followed to achieve proper performance and to reduce costly down time. See the instruction in Section 5.


Section 5: Safety Procedures

These procedures must be followed to safeguard the personnel and equipment. Failure to comply may result in serious or fatal injuries.

5.1 Pre-Operation Safety Precautions

1. Turn all valves and controls off prior to turning on the air supply.

2. Check the safety chains and anchoring of all hoses before turning on the main air supply.

Warning: If safety chains/wires are not properly attached, the air supply line could uncouple and whip. This would endanger the safety of the personnel.

3. Before starting the hydraulic pump, make sure that all hoses are

connected properly.

4. Prior to tramming insure that the plate nipples in both torque hubs are facing outwards.

Note: The torque hubs must be engaged unless the drill is being towed.

5. Position the mast on T-rest before tramming.

5.2 Operation Precautions

1. Always wear proper safety headgear, work gloves and safety boots. Do not wear loose clothing that may become entangled in the feed or tracks.

2. Keep hands away from the drill feed, rotating head and drill pipe during

operation.

3. Keep clear of mast and slide-over assemblies when positioning the drill.


5.2.1 Safety Shutdowns

Your Cubex drill is equipped with feed mounted safety shutdowns. In the event of an emergency, either cable can be pulled to shutdown drill power and rotation instantly.


Functionality: When the cable is pulled in any direction along its length the switch is tripped and power is cut to the electric motor on the unit. The 24 volt power to the drilling functions is cut at the same time providing immediate stopping of the rotation and feed. The drill will not start until the shutdown switch or switches are reset. Operator Checks and Maintenance: The Safety Shutdown System should be tested each time before drilling by the operator to ensure that it is functioning properly. Maintenance personnel should inspect the system as part of a regular maintenance schedule to ensure proper functionality. 5.2.2 Safety Shutdowns

Fig 5.2.1 -E-Stop

E-Stop


Your Cubex drill is equipped with feed mounted safety shutdowns. In the event of an emergency, either cable can be pulled to shutdown drill power and rotation instantly

1. . Install spring on top eye and secure one end of cable with supplied cable clamp as shown below.

Envelops

2. Cut the cable to length at the button in order to obtain the length necessary for correct winding. (1.5 turns minimum)

3. Engage the cable on the tensioner.

4. Turn the adjustment nut clockwise until the index is in the center of the operating zone. Reset, release and repeat the operation. Check the position of the index and re-center if necessary. Indicator on left should be showing green when E-Stop is set and yellow when pulled (set off).


5. To slacken the cable, push on the retainer then loosen the nut.

Operating zone for indexer

Indexer

Push retainer outwards to allow cable to be loosened

Turn nut counter-clockwise to loosen cable.

Reset button


6. Remove the front cover of the new E-stop assembly to access the wiring terminals. Connect existing wiring to terminals 21 and 22 of the new E-stop assembly. Re-install cover and gasket.

5.3 Maintenance and Repair Safety

1. Observe cleanliness and safety during any type of servicing. Keep all inflammable liquids in covered containers. Discard any rags saturated with flammable liquids. Obey all fire regulations.

2. Before removing any components from the drill, ensure that the machine is

safe to work on. Use the necessary tools and equipment to prevent any parts to shift or fall.

3. Disconnect the air supply to the drill unit and relieve the pressure in the air

system before servicing the air system.

5.4 Maintenance Specifications

Preventative Maintenance Program The PM Program includes scheduled inspections and overhauling of drill components. Read this section carefully. This section contains the following:

Figure 5.2.1


General Maintenance Chart: Lubrication and inspection points Fastener Torque Table: Refer to this table when no specific rating is specified Fluid Crossover List: Refer to this list for approved fluid types


Lubrication Points A scheduled lubrication program is required to extend the Drill’s service life using high quality lubricants. Keep the lubricants in seal able containers marked with their contents and store these according to fire regulations. The lubrication points and intervals are shown in Fig. 5-4-1. The recommended lubricants and system capacities are listed in Fig. 5-4-2. Substitute lubricants must meet these specifications. Mixing of different types of gear lubrication should be avoided. Lubrication Types/System Capacities - Fig. 5-4-2 Equipment Lubrication Capacities Top Drive Gear Oil SAE 80W-90 2 qts. (2.0 l) Rock Oil Tank See Fig. 5-4-3 5.0 gal (19.0 l) Grease Tank Esso AROX NM 000 8.4 gal (32 l) Hydraulic Tank Shell Tellus T 37 70 gal. (265.0 l) Torque Hubs (1.3L) Gear Oil SAE 80W-90 Half full 44 fl.oz. Water Pump Shell Tellus T 37 40 fl. oz. (1.2 l)


Rock Drill Oils The specifications on Rock-drill Oils are essentially identical. Field experience has shown good performance may be obtained from most of the available Rock oils. Rock Oil Drills – Fig. 5-4-3

Manufacturer Grade 10 Grade 30 Grade 50

Texaco 1541 EPL 1542 EPM 1543 EPM

Exxon Arox EP 45 Arox EP 65 Ster-Mar 90

Mobil Almo #1 Almo#3 Almo #5

Gulf Rock-Drill 63

Sinclair D

Air Drill Oil B Air Drill Oil

Cities Services 75A

Neptune 50A Neptune

D-A Lubricant Co. 500

Rock-Drill Lubricant Rock-Drill 5

Non-Fluid Oil Corp. A #89/NR A #59/NR A #79/NR

E.F. Houghton & Co. 370 Rock-Drill Oil 340 Rock-Drill

Southwestern Petroleum SAE 50

Swepco SAE 10 Swepco SAE 30 Swepco

Kendall Refining Co. Kenoil 065EP

Shell Oil Co. 72

Tonna R Oil 27 Tonna R Oil 41 Tonna R Oil

Lubrication Engineers 6305

Monolec 6301 Monolec 6303 Monolec

Imperial Oil Co. Rock- 50

Molub-Alloy Rock- Drill Oil 381

Molub-Alloy Rock- Drill Oil 297

Molub-Alloy Drill Oil 297

Champlin Purrol Co Grade 10 Grade 30 Grade 50

Chevron Oil Co. Vistac 30X Vistac 220X


Refer to this Crossover list for alternate suppliers. If these brands are unavailable, your local supplier will be able to recommend alternatives using these specifications.

Lubrication Chart Fluid Type SHELL OIL ESSO

(IMPERIAL OIL) HUSKY OIL (MOBIIL)

Petro Canada Mowhawk

Rotella S30 Essolube HD 30

Delvac 1230 Maximum 5W 30

N/A

Spirax HD SAE 80W-90

Esso Gear Oil GX 80W-90

Mobil HD 80W-90

Gear Lube 80W-90

Gearlube GL5 80/90 HP

Grease Darina XLEP2 LONA XEP2H Mobilux NLGI #2

Precision EP2 N/A

Tellus T-37 Univis N 32 Mobil DTE 13M

Harmony HVI-36

Mohawk HV132


Section 6: TROUBLESHOOTING

If the performance is lacking, action must be taken to correct any problems. The operator is expected to be able to repair minor problems that are within his/her responsibilities. Any problem beyond that must be repaired by certified maintenance people. This section is intended for the use of the operator and a more detailed Troubleshooting Guide can be found in the Maintenance Manual. It is the operator's responsibility to report any apparent problems to the maintenance personnel.

6.1 TROUBLESHOOTING THE TRAM DRIVE

CRAWLER DOES NOT RUN BUT TRAMMING MOTORS ARE OPERATING

1. Check position of dimpled locking plates in torque hubs. Dimples have to be facing out to engage gear.

2. Check for sheared off bolts at the final drive sprocket.

3. Check for mud build up at the crawler tracks.

4. Check if the tracks are off the front idler. Loosen the track and move it

back onto the wheel. Adjust tracks to proper tension.

5. Check for frozen tracks and thaw the ice as required.

CRAWLER DOES NOT MOVE AND TRAMMING MOTOR DOES NOT RUN

1. Check items 3,4 and 5 as above

2. Check for track adjustment being too tight. Adjust tracks to proper tension.

3. Check for damaged parts in the tram drive and the final drive gearbox.

4. Check if tram motor is running.

5. Check for Tram lockout valve blockage

CRAWLER DOES NOT TRAM STRAIGHT

1. Check if both torque hubs are engaged.


2. Perform Checks as outlined in "Crawler does not move".

6.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM

PUMP DOES NOT DELIVER OIL

1. Check for proper fluid level and appropriate oil viscosity in hydraulic reservoir. In extreme cold conditions it may be necessary to heat the oil.

2. Check for proper pump rotation as marked on pumps identification tag.

3. Check for flow restriction by inspecting the suction line, strainer and

reservoir.

4. Check for air leaks at pump intake. Oil level must be above bottom of sight glass.

5. Check for sheared off pump drive shaft or damaged drive coupling.

6. Check pump load sense line for oil flow. Test each function separately.

PUMP IS RUNNING HOT

1. Check for any function stuck open system pressure at “no load” should be 400 psi.

CAVITATION OR PUMP NOISE

1. Check for air leaks at the pump intake or shaft packing. Pour oil on joints and around drive shaft then listen for change in operation.

2. Check for proper oil viscosity.

INSUFFICIENT PRESSURE

1. Check for proper oil level in reservoir.

2. Flow may not meet system demands due to system leakage system.

3. Pumps standby pressure set to low.


4. Pump maximum pressure set to low. SLOW ROTATION AT TOP DRIVE

1. Check for low pump delivery (See "Pump not delivering oil").

2. Check for malfunctioning of hydraulic motor.

3. Check maximum rotation pressure

NO ROTATION AT TOP DRIVE ASSEMBLY

1. Check for hydraulic motor malfunctioning.

2. Check for damaged gears or bearing.

3. Check for pump flow (See "Pump not delivering oil").

SLOW OR NO FEED

1. Check for low pump delivery (See "Pump not delivering oil").

2. Check for oil insufficient pressure.

3. Check pull down relief valve for high setting. Pull down pressure must be approximately 100 psi (6.9 bar) higher than hold back pressure.

4. Check for high setting of hold back relief valve.

5. Check for internal leaks in feed cylinder.

6. Check for binding in top drive mounting plate.

7. Check reverse drilling valve is in proper position.

MAST DOES NOT ROTATE

1. 1.Check for restrictions in set up control valve by removing hoses.

2. 2.Check for collapsed hydraulic hose to actuator.

3. 3.Check main pressure in hydraulic pump.


ACTUATOR ALLOWS MAST TO MOVE AFTER BEING SET

1. Check for bypassing of directional control valve. Inspect the valve spool.

2. Check for damaged counterbalance valve cartridge.

6.3 TROUBLESHOOTING THE WATER INJECTION PUMP

DISCHARGE PRESSURE IS TOO LOW

1. Check for restrictions in suction line or relief valve.

2. Check for incorrect valve adjustment or damaged relief valve.

3. Check for low pump speed. Pump should run at 225 rpm to deliver 3 gpm (12 l/min). Adjust the hydraulic control valve.

CAVITATION PROBLEMS Cavitation occurs in the pump when the cylinders do not fill completely with water during the suction stroke. This condition creates a pressure pulsation, which may damage the pump and equipment if not repaired immediately.

1. Check for proper diameter of water supply line. This line must be the same

or larger than pump suction plumbing.

2. Check for air leaking into the suction system by tightening fittings and inspecting hoses.

3. Check for weak or worn plunger packing. Partially worn plunger packing

may draw air on the suction stroke but these may not leak during the discharge stroke creating a similar condition as in cavitation.

NO WATER DISCHARGE

1. Check for restrictions in the suction line.

2. Check if suction line valve is closed.


EXCESSIVE PUMP NOISE

1. Check for loose suction line connection.

2. Check for over speeding of pump. Reduce the flow to the hydraulic motor by adjusting the flow control valve.

6.4 TROUBLE SHOOTING THE AIR DRIVEN OIL INJECTION PUMP

AIR MOTOR DOES NOT OPERATE

1. Check for restrictions in the air supply line.

AIR SEEPAGE FROM AIR EXHAUST WHILE PUMP IS NOT WORKING

2. Check for leaking inlet valve.

LOSS OF PRESSURE, VOLUME OR CONTINUOUS OPERATION OF PUMP WHEN NOT IN NORMAL USE

1. Check for foreign particles on the piston seat or on the ball of the foot valve.

2. Check for damaged piston or foot valve.

3. Check for scorn pump tube wall and replace if required.

EXCESSIVE AMOUNT OF AIR IN LUBRICANT OR EXCESSIVE AMOUNT OF LUBRICANT IN AIR EXHAUST

1. Check air leakage at gland packing, gland gasket, O-ring and U-cup packing.

Note: Some lubricant in the exhaust air is required.


6.5 TROUBLESHOOTING THE AIR DELIVERY SYSTEM

AIR PRESSURE BUILDS TOO SLOWLY

1. Check for leaks in air line.

2. Check for restrictions in the air filter or inlet.

3. Check for improper operation of 3-way valve on air inlet. Ensure that the valve opens and closes fully.

4. Check for worn suction or discharge valves. The valve cover that feels the

hottest may indicate a leaking valve.

5. Check for unloader plunger being stuck in open position.

6. Check for damaged copper valve seat.

7. Check for low oil pressure (See "Low oil pressure").

COMPRESSOR DOES NOT UNLOAD

1. Check for restrictions in the air supply.

2. Check for cracks in unloader line.

3. Check for sticking of unloader valve.

4. Check for plugged pilot valve filter.

5. Check for broken intake valve.

6. Check for worn seals or unloader plunger.

NOISY VALVES

1. Check for loose retainers by removing and inspecting them. The copper gasket must be replaced when reinstalling them.

2. Check for broken Intake valve spring or fork.


SHORT VALVE LIFE

1. Check for low air pressure in the mine line. It might be necessary to reduce the number of equipment drawing air from the mine line.

2. Check for foreign matter in the mine air filter. Replace or clean the mine

filter.

3. Check for excessive oil consumption, which would create carbon build up. This condition may indicate that the compressor requires an overhaul.

4. Check for rapid loading and unloading of compressor. This may require

resizing of choke in hammer to suit the air supply.

5. Check for compressor Over-speed to insure that the drive sheaves are the correct size for the type of hammer being used.

LOW OIL PRESSURE

1. Check the oil lever

2. Check of proper operation of pressure gauge.

3. Check if correct oil type is being used (See lubrication specs).

6.6 TROUBLE SHOOTING OF THE ELECTRICAL SYSTEM

NO POWER TO DRILL

1. Check if the breaker in the panel has tripped. This is done by turning the circuit breaker handle at the electrical control panel to the off position and then back to the on position.

2. Check if the breaker has tripped in the power sled or sub station

3. Check the ground fault protector in the power sled or sub station.


SYSTEM DOES NOT START AT NEW LOCATION AND "PHASE REVERSAL" LIGHT IS ON

1. Reverse power connection by switching the leads.

Note: This repair is to be done only by a qualified electrician.

DRILL STOPS WITH THE "MOTOR OIL" LIGHT ON AT THE CONTROL PANEL

1. Check for overload conditions. Overloading of the motor may have tripped the relay.

DRILL STOPS WITH "HIGH AIR TEMP" LIGHT ON AT THE BOOSTER'S CONTROL PANEL

1. Check for overheating of air compressor in "Troubleshooting the Air System".

DRILL STOPS WITH "LOW OIL PRESSURE" LIGHT ON AT THE BOOSTER'S CONTROL PANEL

1. Check for low oil level (See "Troubleshooting the Air system").

6.7 TROUBLESHOOTING THE HAMMER

TOOL DOES NOT START

1. Check for correct assembly of tool.

2. Check if piston is binding in the piston case or against the valves. Remove all burrs, gal marks and scratches.

3. Check for damaged check valves springs. Clean rust, burrs and scratches

from valve dart.

4. Check for broken foot valve assembly.


TOOL STOPS OPERATING

1. Check for "collared" or "bridged" hole. Lift the drill assembly off the bottom of the hole then clean the hole with water injection.

2. Check for damaged parts such as piston case, pistons, driver sub and drill bit.

Polish galled spots and replace parts as required. Insure that the piston slides freely inside the piston case.

3. Check for clogged air passages in the drill bit.

4. Check for obstructions in the drill pipe, air hoses and top drive.

OPERATING PRESSURE IS LOWER THAN SPECIFICATIONS

1. Check if correct type of choke is installed.

2. Check for wear of choke. Install a smaller choke to bypass less air. If wear is excessive replace any worn parts.

3. Check for restrictions in the air delivery system.

LOW PENETRATION RATE

1. Check for dull drill bit.

2. Check for broken or missing carbides in bit. Before using a new bit, clean out the drilling hole.

3. Check for excessive back pressure in the drill hole. Remove any collaring around

the hole then flush the hole with the drill's water injection.

GALLING OF INTERNAL PARTS

1. Check for proper lubrication and adjust the oil injection rate.

2. Check for uneven lubrication. Repair injection pump if required.

3. Check for foreign material inside of tool.

4. Check for warpage in the piston case.


6.8 TROUBLESHOTING THE DRILL BIT

ABRASIVE WEAR

1. Check for worn carbides in bit. Use the proper rotation speed and drill weight to suit the drilling conditions.

LOSS OF CARBIDES IN BIT

1. Check the bit for loss of carbides. If any are missing and no damage is apparent it indicates that the piston was striking the bit while the bit was not in full contact with the rock formation. This force tends to loosen the inserts. This condition may occur when the bit encounters broken or loose formation. To avoid these conditions, control the drill to minimize these heavy blows when the bit is not in full contact.

BIT BREAKAGE AND CARBIDE FAILURE

1. Check for hairline cracks and breakage around the buttons in the bit. auge buttons are most prone to such failures. This condition may be due to excessive weight on bit, improper rotation speed or a lack of sharpening the bit.

Inspect the bit face periodically and sharpen the bits when required.

CARBIDE BREAKAGE

Breakage may occur due to the following:

1. A piece of carbide may have been left in the socket when a new bit was installed.

2. The carbide may have been pinched while being pushed into an undersized carbide hole.

3. The bit may have been pushed through a bent drill hole casing.

4. Excessive use between recommended sharpening periods.

Note: Drilling in hard formation requires more frequent sharpening.

UNEVEN WEAR CONDITIONS

Uneven wear conditions may be due to the following:


1. Check for uneven wear spots at the gauge row buttons (See Fig. 5.5).

The drill bit may remove the rock chips too slowly. Increase the air volume to avoid this condition.

Check for a bent drill rod and replace as required then check the machine set-up.

2. Check for bit erosion just above the gauge buttons.

This creates spiralling into the rock and poor hole cleaning. Adjusting the rotation speed and frequent hole cleaning may help but the bit should be replaced at this time.

3. Check for excessive button wear or breakage indicating dry drilling conditions.

The buttons may overheat due to extreme weight on the bit or due to improper rotation speeds.

Increase the water injection and adjust the drilling speed to avoid these problems.

4. Check for powdery cuttings, which indicate that the bit requires sharpening.

5. Check for squealing of bit during drilling. The bit steel at gauge may be rubbing.

Grind any projections or deformations on the bit steel. Cutting relief slots in the bit skirt may also be helpful.

6. Check for shank failure due to insufficient drill weight, uneven drill feed or

excessive operating pressure.

Operate the drill at the proper air pressure and maintain a steady down pull on the bit to prevent shock loading.

6.6 ERIS Control Panel

ON/OFF SWITCH

Figure 6.2


6.6.1 Starting up

When the operators console starts up, the screen will appear as shown above. Shortly after starting, the live light should become green, indicating that a connection has been made to the Aries unit.

Figure 6.3


6.6.2 Joysticks

Most operations and descriptions in this manual will be given in terms of joystick operations. L1-6 refer to the buttons on the left joystick, R1-6 refer to the buttons on the right joystick. LX is the left-right axis; LY is the up-down axis. RX and RY refer to the same actions on the right joystick. L1 is a special reserved button for mode selection; refer to the relevant section for details.

RY

LX RX

LY

R2

R4 R1

R3

L4

L3

L1

L2

L5 L6 R5 R6

Figure 6.4


6.6.3 Direction Convention

All directions indicated on the control panel are based on the assumption that the operator is at the front of the Aries unit facing rearward.

Figure 1.1 – Drill Orientation


6.6.4 General Concepts

6.6.4.1 – Live Light The Live Light acts as an indicator for the connection between the operator console and the Aries unit. Shortly after startup, the light should become green. If after 60 seconds, the indicator is still grey, or has become orange, refer to the trouble-shooting guide.

6.6.4.2 – Control Light The control light indicates that this operator console is the current controller for the Aries unit. In situations where there are multiple consoles attached to an Aries unit, only one will be active at a given time. If the live light is lit (orange or green) control can be acquired though the system mode.

6.6.4.3 – Error Lights The master error and/or master warn light will be lit when there are conditions on the Aries unit. Generally speaking errors must be attended to before any work can be done with the Aries unit, while warnings are temporary conditions preventing one or more operations from being carried out. Errors and warnings can be referred to in the system mode.

6.6.4.4 – Mode Selecting Fi


The operator console for the Aries is designed around a small set of modes. Each mode contains the functions for some subset of drilling operations. Modes can be selected by holding the mode select button (L1) and scrolling with LX, or with the mode scroll buttons R1 & R3

6.6.4.5 – Layers Each mode is typically broken down into a series of layers, typically separated into right and left. Each layer will provide a series of functions. Each layer will be bound to a particular joystick button, pressing the button will activate the layer, and deactivate the currently selected layer.

6.6.4.6 – Switches Each mode will have a set of bound switches, and additionally there is one switch, which is permanently, bound as a mode selector button and will never be used inside any of the modes. For each mode, the switches will be labeled as to their use, and will either switch layers inside the mode, or toggle a function on or off.


6.6.5 Feedback

The highlighted area shows where feedback from the Aries unit appears. Pulldown, Holdback, Rotation, and Drill Air are all pressure values in PSI. Notes: Swing and Dump are angle values, for the drill mast.

Figure 6.8


6.6.6 The System Mode

Action Equipment Occurrence

L3 Error Current Layer

L4 Error Trace Layer

R4 Compressor Will toggle the compressor on the Aries unit On or Off

R5 HYD Pump Will toggle the hydraulic system on the Aries unit On or Off

R3 Control Will acquire control of unit. The system mode contains functions, which are only used at startup, or intermittently through the operation of the unit.

Figure 6.9


6.6.6.1 Current Errors/Warnings

This layer will display any currently active errors or warnings. Errors will be lit with a red indicator, and warnings lit with a yellow indicator.

Figure 6.10


6.6.6.2 Tracing Errors

This screen can be used to display the current status of any errors, listing on and off times. Errors that are still active will have a red indicator next to them; inactive ones will have a green indicator.

Figure 6.11


6.6.7 Tram Mode


L6 Tramming Layer On/Off

R5 Laser Indicator On/Off The tramming mode begins with no active layers. The tramming layer can be selected with the L6 button.

Figure 6.12


6.6.7.1 Tramming

The tramming screen allows the operator to move the Aries with the left joystick. All controls are aligned around the operator being in front of the Aries facing towards the unit. Pulling the joystick back will move the Aries towards the operator, pushing forward will move the unit away from the operator. The tram enable button L6 must be held down to make the joystick axis active for tramming. If released the crosshairs will disappear and tramming will be disabled.

Figure 6.13


6.6.8 Setup Mode


L2 Swing Layer

L3 Stingers Layer

L4 Jacks Layer

R5 Laser off/on When setup mode is selected, the swing layer is enabled by default.

Figure 6.14


6.6.8.1 Swing Layer


LX Swing Left/Right

LY Dump Up/Down

RX Default Primary Slide Left/Right (While holding down R2 the secondary slide over will become active)

RY Feed Extension Up/Down

RZ Upper Slide Left/Right

R5 Laser off/on

R2 Activate secondary slide over The Swing Layer contains all the operations to setup on a drill hole once the Aries has been correctly positioned. Indicators in the left side display the current angle readouts for Swing and Dump angle, these values have been converted into coordinates with 90° straight up and down to 0° on the horizontals.

Notes: The blue dot should display the current location of the drill bit.

Figure 6.15


6.6.8.2 Stingers Layer


LX Lower Left Stinger In/Out

LY Upper Left Stinger In/Out

RX Lower Right Stinger In/Out

RY Upper Right Stinger In/Out

Figure 6.16


6.6.8.3 Jacks Layer


LX Rear Jack Up/Down

LY Left Front Jack Up/Down

RY Right Front Jack Up/Down

Figure 6.17


6.6.9 Drill Mode

By default when entering drill mode manuals control of pulldown and holdback is enabled. Other drilling functions can be accessed using the following axis and buttons: Note Buttons will turn red indicating the function is active.


LX Holdback Increase/Decrease

LY Pull down Increase/Decrease

L2 Acrafeed off/on

L3 Manual pull down/holdback

L4 Carousel Rotation Layer

L5 Carousel Arm/Clamp layer

L6 Slip plate / Centralizer layer When the Accra Feed mode is selected, the default layers will be selected. Layers and switches work as usual, select the appropriate button to turn ON or OFF Semantics for enabling Accra Feed are slightly different; refer to the relevant section for details.

Figure 6.18


6.6.9.2 Arm and Clamp Layer


LX Carousel Arm Clamp Open/Close

LY Carousel Arm In/Out When this layer is enabled, control of the Carousel Arm will go to the Y Axis of the left joystick, and the Carousel Arm Clamp to the X Axis of the left joystick. When this layer is enabled, the controls on the right for feed and rotation remain the same.

Figure 6.20


6.6.9.3 Slips and Centralizer Layer


LX Centralizer In/Out

LY Slip In/Out When this layer is enabled control of the Slip plate will go to the Y Axis of the Left joystick, and the Centralizer to the X Axis of the Left Joystick. When this layer is enabled, the controls on the right for feed and rotation remain the same.

Figure 6.21


6.6.9.4 Make/Break Layer

When the “Make Break” button R2 is enabled on the right joystick, control of the feed will be switched to “fast feed” mode to speed up breakout procedures without effecting the current feed settings for drilling. The button R4 will also switch from drill lock to thread off/on to enable access to the automatic makeup/breakout screen covered later in this section. When the “Make Break” button R2 is turned off, all settings will revert back to your last drilling settings used. The button R4 will switch back to Drill Lock function being available.

Figure 6.22


6.6.9.5 Thread on/off


RX Wrench or split centralizer in/out

RY makeup/breakout drill pipe The thread on/off layer gives access to the automatic makeup / breakout function for changing drill pipe. It also gives access to the breakout wrench or swinging centralizer jaws depending on what is hooked up to this function. There are hydraulic quick release lines on the table of the drill that can either be hooked up to the breakout wrench or the swinging centralizer jaws.

Figure 6.23


6.6.9.6 Enabling Drill Lock

To enable Drill Lock, the operator must set both a forward feed and a rotation before Drill Lock can be turned on. When Drill Lock has been turned on, the available controls will change.

Figure 6.24


6.6.9.7 Drill Lock On

When Drill Lock has been enabled the available controls on the default layer of the right joystick will change


RX Rotation Increase/Decrease

RY Nothing

Figure 6.25


6.6.10: Troubleshooting The ERIS System

Q. The Live Light does not come on. (Primary Console) A. Check that the cabling between the operator console and the Aries unit is plugged in properly. If the cable was incorrectly plugged in, the console should become active within a minute after begin plugged in. If the problem persists, try another cable should one be available. If cabling seems to be correct

Q. The Live Light does not come on. (Secondary Console) A. If the primary console is working properly, follow the directions for the Primary Console, otherwise, follow the directions for the primary console, but diagnose the primary console first.

Q. The Live Light stays orange. A. If the light had previously been green on this unit, check cabling. Otherwise, notify maintenance.

Q. Joystick behaves strangely. Q. Switches turn themselves on or off at random. Q. Joystick causes things to move on its own at random. A. Joystick is probably bad, avoid use of console until it can be examined and replaced. Notify maintenance.

Q. Joysticks do not work. A. One or more joysticks are not responding. If after a restart joysticks are not operational, or operation is intermittent, notify maintenance.

Q. Console will not shutdown properly. A. Hold power switch in for ~10sec. until console shuts down.

Q. Live light is green, and joysticks operational, but either cannot alter anything on Aries, or cannot see feedback from Aries. A. Restart console. If problem persists, notify maintenance.

6200 operators manual 10218 - english

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