PDF Operator’s Manual CAT BUCYRUS 59R Electric Blast Hole Drill - 1 MB
The operator's manual for the CAT Bucyrus 59R Electric Blast Hole Drill is the primary resource for safe and efficient operation.
This massive piece of mining equipment requires specialized knowledge, which is detailed in this guide.
It covers all controls, operating procedures, safety warnings, and daily maintenance checks.
This manual is indispensable for ensuring the safety of the crew and the productivity of the drill.
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BI005586
© Bucyrus
All Rights Reserved
BUCYRUS R
Technical Manual
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BUCYRUS INTERNATIONAL Inc.
59R ELECTRIC BLAST HOLE DRILL
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BUCYRUS
UNCONSOLIDATED MATERIALS 93
WET OR STICKY FORMATIONS 95
ANGLE DRILLING 96
PROGRAMMED DRILL CONTROL DRILLING 97
Controls for Programmed Drill Control 97
PREPARING TO MOVE 98
MACHINE SHUTDOWN 100
SHUTDOWN PROCEDURE 100
SHORT TERM STORAGE 101
LONG TERM STORAGE 102
ATTENDED LONG TERM STORAGE 103
UNATTENDED LONG TERM STORAGE 103
TOOL RECOVERy 104
PIPE SIZE LIMITATIONS 106
STANDARD CRANE HAND SiGNALS 107
MACHINE PLACARDS 110
Manual No. 10052 Operator's - 4 Feb. 2000
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59R ELECTRIC BLAST HOLE DRILL
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MAST COMPONENTS:
STANDARD MAST FOR DRILL PIPE AND ONE RACK 60'-0" (18.29m)
Computer Analyzed, tubular lattice construction with back braces.
RAISING and LOWERING Two-9" (220mm) diameter hydraulic cylinders
ANGLE HOLE DRILLING (1)to 25° off-center in 5° increments
HOISTIPULLDOWN:
Chainless rack and pinion driven by head-mounted excavator grade DC motor.
BIT LOADING UP TO: 140,0001bs (63,500 kg)
FEED RATE UP TO: 25 fpm (7.62m/min)
HOIST RATE UP TO: 100 fpm (30.48m/min)
LOWERING RATE UP TO: 100 fpm (30.48m/min)
AUXILIARY WINCH STANDARD CAPACITY: 12,000 Ibs (5,433 kg)
PIPE RACKS:
SINGLE RACK STANDARD
1 PIPE RACK 10.75" TO 17.5" (273-445mm)
2 PIPE RACKS 10.75" TO 17.5" (273-445mm)
4 PIPE RACKS to 10.75" (273mm)
ROTARY DRIVE:
CONTINUOUS OUTPUT 205 hp (153kw)
MAXIMUM BIT SPEED 120 rpm
AIR COMPRESSOR:
A-C Compressor Corporation KS46AC Screw Type
4,600 CFM (130.2m 3/min) free air @ 80 psi (552 kPa) (2)
or
A-C Compressor Corporation KS40AC Screw Type
3,600 CFM (1 01.9m 3/min) free air @ 70 psi (483 kPa) (2)
Feb. 2000 Operator's - 9 Manual No. 10052
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59R ELECTRIC BLAST HOLE DRILL '~"l.
Safety must always be paramount!
Consult your supervisor when safety is in doubt.
SAFETY PRECAUTIONS
Safe operation of a rotary blast hole drill promotes personal safety and minimizes delays and costly
damage to equipment. Carefully study and follow all recommended procedures in this manual.
Safety guidelines are intended to help prevent accidents from occurring and are provided in the
interest of all mine personnel. Overall safety depends upon a good sense of jUdgment and alertness
on the part of the entire mining crew.
The following is a list of some important safety rules relating to prestart and operation of the 59R
drill. The safety instructions given in this manual cover normal daily operations of the machine.
Additional precautions may be necessary to cover unusual circumstances. Be constantly alert for
any potentially dangerous conditions and take action as necessary to correct the conditions
immediately.
General Precautions:
• The employment of qualified maintenance personnel, through a scheduled maintenance
program, is the best way to minimize machine downtime and maximize productivity of
equipment.
• Keep hands, feet, and clothing away from rotating parts.
• Wear a hard hat, safety shoes and protective lenses at all times.
• Replace any and all safety and warning placards if they are defaced or removed from the
machine.
• Think before you act. Carelessness is one luxury the service man cannot afford.
• Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In
case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the
suggested method of cleanup.
• Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip
off of the hook if they are not functioning properly.
• If a heavy item begins to fall, let it fall, don't try to catch it.
• Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep
tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping.
• Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure
all spillage is cleaned up.
• Electrical cords and wet metal floors make a dangerous combination.
Manual No. 10052 Operator's - 14 Feb. 2000
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A CAUTION: Death or serious injury could result should any part of the drill come
.. within the minimum distance specified of an energized power line.
PRESTART CHECKS
Before starting the drill, inspect it to ensure it is ready to be put into operation. Failure to make such
a routine check could result in unnecessary downtime. For example, an undetected oil leak could
result in a dry gear case, which would lead eventually to excessive gear wear or destruction,
seized bearings, or other mechanical problems. A few minutes spent inspecting the machine often
results in considerable savings in time and machine efficiency. This inspection should be performed
before each shift.
EXTERNAL INSPECTION
1. Check areas around and under the machine for signs of water or lubricant leaks. If single
droplets of water or lubricant are noticed, leakage is minimal. Determine the source of the
leak and make note of it on the log sheet. If pooling of water or lubricant is noticed, determine
the source and take remedial action immediately.
2. Inspect the crawler belts for broken or cracked pads, missing lock pins, loose track pins, and
proper crawler belt tension.
3. Check the drive tumbler gearcase, hydraulic motor and hoses for leaks. Check the lubricant
level in the drive tumbler gearcase.
4. Inspect the crawler frames for cracks and dirt or ice buildup. Check the rollers and tumblers
for proper lubrication, free operation, and dirt or ice buildup. Check axle attachment pins and
bolts.
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19. Inspect the tool string for excessive wear, dirt accumulation, bent pipe and secure joints. The
bit cones and bearing should be in good condition. Manually turn the cones to make sure they
turn freely.
20. Inspect the rotary gear case for lubricant leaks, damaged lines, dirt accumulation and other
damaged or missing parts. Check the lubricant level in the gearbox. Fill to the recommended
level with an approved gear lubricant. Check the rotary motor ventilation inlets for leaves,
paper, rags, etc. blocking the flow of air.
21. Inspect the rotary drive unit for excessive wear or dirt accumulation. Inspect the guide rollers
for proper adjustment and excessive wear. Check for loose or missing bolts and bent or
cracked structural members.
22. Inspect the pulldown unit for excessive wear or dirt accumulation. Inspect the rack pinions for
excessive wear, proper lubrication, and tight retainer bolts. Inspect the guide rollers for proper
adjustment and excessive wear.
23. Inspect the pulldown gearcase for lubricant leaks, dirt accumulation and other damaged or
missing parts. Check the lubricant level in the gearbox. Fill to recommended level with an
approved gear lubricant. Check the pulldown motor ventilation inlets for leaves, papers, rags,
etc. blocking the flow of air.
24. Check the hoist brake for proper operation.
25. Check the dust or chip deflector for loose or missing parts, excessive wear or dirt
accumulation. The deflector should seal around the drill pipe securely.
26. If the machine is equipped with a fire suppression system, perform any applicable checks or
inspection as described in the fire suppression system owner's manual.
PRESTART LUBRICATION
Lubrication of the 59R blasthole drill is an extremely important job. Most drills come equipped with
automatic lubrication systems that lubricate most of the necessary points at regular intervals.
These systems, although automatic, are not foolproof. Broken lines, dirty lubricant, faulty feeders,
and a whole range of other problems can cause wearing parts to loose lubrication. For this reason,
it is important that all lubrication points be inspected every shift to verify that they are receiving
lubrication. Also, there are several points for lubrication that either need lubrication very infrequently,
or are not possible to pipe into the automatic system. These points will need lubrication applied
manually.
The lube charts in Appendix 3 gives the location and frequency of lubrication.
Manual No. 10052 Operator's - 24 Feb. 2000
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59R ELECTRIC BLAST HOLE DRILL
MAIN CONTROL PANEL
9 11
ocmn 59r
1
1. Hoist Pulldown Rheostat 8. Pipe Rack Selector Switch
2. Rotary Speed Rheostat 9. Pipe Rack JoysticklLH Propel
3. Drill/Propel "ON" Pushbutton 10. Winch/Mast Selector Switch
4. Drill/Propel "OFF" Pushbutton 11. MasVWinck JoystickiRH Propel
5. HoisVPulldown Speed Selector Switch 12. Tool Wrench Switch
6. Rotary Speed Selector Switch 13. Dust Curtain Switch
7. Hoist Brake Switch 14. Bit View Hatch Switch
Main Control Panel
Feb. 2000 Operator's - 29 Manual No. 10052
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TOOL WRENCH SWITCH
The tool wrench switch (12) is a three-position spring return switch. Turning the switch to the
EXTEND position will cause the tool wrench to extend to clamp the drill pipe. Turning the switch to
the RETRACT position will retract the wrench, releasing the drill pipe. This switch is functional
whenever the hydraulic pumps are running.
DUST CURTAIN SWITCH
The dust curtain switch (13) is a three-position switch. Turning the switch to the UP position will
raise the dust curtains. Turning it to the LOWER position will lower the dust curtains.
In the AUTO position, the curtains are raised automatically when the operating mode selector
switch on the propel control panel is in the PRIMARY PROPEL, SECONDARY PROPEL, or
REMOTE PROPEL position. The curtains are not lowered automatically, but must be lowered by
moving the switch to the LOWER position.
BIT VIEW HATCH SWITCH
This is a two-position switch (14) that is used to move the hatch for viewing the drill bit on the
ground. Moving the switch to the CLOSE position will close the hatch. Turning the switch to the
OPEN position will open the hatch.
Manual No. 10052 Operator's - 34 Feb. 2000
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MAST LOCK SWITCH
The mast lock switch (6) is a three-position spring-return switch. Turning the switch to the LOCK
position will extend the mast lock cylinder. Turning the switch to the UNLOCK position will retract
the cylinder. Before this switch can become operable the hydraulic pumps must be running and
the masUwinch selector switch must be in the MAST position. For the switch to be functional in the
UNLOCK position, the rotary head assembly must be at the lower limit point. On machines with the
angle hole drilling feature, the A-frame locking pins must also be in place before this switch can
become operable.
BOARDING STAIRS SWITCH
The boarding stairs switch (7) is a two-position switch. A like switch is located at the stairs. Depending
upon the position of the stairs, the switch must be moved from its present position to the opposite
position for the stairs to change position.
PEDESTAL HEATER SWITCH
The pedestal heater switch (8) is a two-position switch used to turn the heater ON or OFF.
FIRE SUPPRESSION SYSTEM INDICATORS
The fire suppression system indicators (9) show the status of the fire suppression system.
RADIO
The radio (10) is standard equipment.
Feb. 2000 Operator's - 39 Manual No. 10052
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MACHINERY HOUSE CONTROLS
NOTE: The controls shown on the following illustrations are typical of the controls on a
machine. Because of the variations of controls that can be supplied for customers
needs, be sure to become acquainted with the controls on the cabinets of your
machine. All controls will be identified with nameplates.
LIGHTING LOAD CENTER
The lighting load center is located on the right side of the front wall of the
machinery house.
The lighting load center contains the breakers to control the interior and
exterior lights and various auxiliary functions.
Each breaker is labeled as to its particular function on any particular machine.
The controls are three-position lever operated circuit breakers. Moving the
lever in one direction (ON) will close the circuit, while moving it in the opposite
direction (OFF) will open the circuit. The center position is the tripped position.
The breaker may be reset by moving the lever to the OFF position and then
back to the ON position.
---- Main Air
CONTROLS ON THE LOW VOLTAGE START CABINET Compressor
Breaker
The low voltage start cabinet contains the breaker for the
main compressor. Turning the breaker to the ON position will
activate the compressor circuits, allowing the compressor to
be started.
Manual No. 10052 Operator's - 44 Feb. 2000
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PROPEL PROCEDURE
Before beginning the propel operation, the operator should first inspect the travel route for large
rocks, deep ruts, or uneven contours. When working on a grade, verify the slope and compare to
the allowable maneuvering slope limits (see ApPENDIX 5).
ACAUTION: Do not attempt to maneuver or steer the machine on grades which
exceed the allowable maneuvering slopes without consulting the
special propel LIMITATIONS CHARTS AT THE END OF THIS SECTION.
Failure to follow these instructions could result in a machine tip-over,
damaging the equipment and resulting in possible serious injury or
death.
The operator's display terminalleveling/propel screen should be monitored during propel to make
sure the allowable machine stability limits are not exceeded.
Once it has been verified that the travel route is in good condition, the machine is now ready to
propel.
NOTE: The drill should only be propelled with the mast fully lowered, fUlly raised and locked, or
locked at an ANGLE HOLE setting.
For long propels of 1,000 feet (304.8 meters) or more, or if the machine is to be propelled over
grades which approach the allowable stability limits, the tool string should be disassembled, the
rotary drive unit lowered, and the mast lowered. This achieves the most STABLE condition for a
machine against tipping and also reduces stresses in the mast structure.
If while propelling with the MAST-DOWN and the HEAD-DOWN the drill starts to list, it will continue
to list until the upper works contacts the pivotal axle. The machine will reach equilibrium when the
upper works contacts the pivotal axle and WILL NOT TIP OVER. With the mast-down and the
head-down, full listing will NOT cause the machine to tip over. The operator should attempt to
propel toward a more level area on the bench to correct this condition.
All of the stability values shown are based on a fully loaded machine (Le. full water tank, cable on
cable reel, full compliment of specified pipe, all oils and operating fluids) as originally specified by
the Customer and shipped by Bucyrus International, Inc.
The 59R is propelled using the controls on the operator's console in the operator's cab or radio
controlled from the remote propel station outside the machine.
Feb. 2000 Operator's - 53 Manual No. 10052
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TOWING PROCEDURE
A CAUTION: Be sure crawlers are securely blocked before disengaging gearbox
clutch for towing.
1. Secure the machine by blocking crawlers.
2. Secure the tow bar to the towing vehicle.
7
1. Tow Bar
2. Tow Bar Pin
3. Lanyard
4. Safety Valve
5. Hand Pump
6. Hydraulic Pressure Gauge
7. Gearbox Disengaging Knob
8. Blocking
3. Fasten a lanyard to the towing safety valve lever. The valve is mounted to the left front jack
casing. Run the lanyard down the casing, along the tow bar and secure it to the towing
vehicle. If during towing the tow bar should come loose from either the drill or the towing
vehicle, the lanyard will trip the safety valve and set the drill propel brakes.
4. Disconnect the drive tumbler gearbox from the propel motor as follows:
a. Ensure that the propel pump controls are in neutral position
b. Loosen shifter lever lock screw
c. Pull out shifter lever to disengage clutch
d. Tighten shifter lever lock screw
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ACAUTION: Limitations exist as to the length, diameter, wall thickness and number
of drill pipes that may be stored in the pipe racks when raising or
lowering the mast. Refer to the pipe size limitation chart in the appendix
before attempting to raise or lower the mast. Failure to comply with
these limitations will overload the mast, mast support and hydraulic
system possibly causing loss of control of the mast.
1. Inspect the mast and machine exterior to ensure that all wires, hoses, cables, etc. are clear
of the machine to prevent damage to the machine or equipment during the raising procedure.
Check that the mast cylinder pins, mast hinge pins, and mast brace pins are in place and
secured. Verify on the operator's display terminal operator's display screen that no reference
to A-frame pins is shown. Verify that the operating mode selector switch is in the DRILL
mode.
2. The main air compressor motor must be energized. Move the winch/mast selector switch to
the MAST position. Slowly raise the mast by lifting and then slowly pushing the masUwinch
joystick, located on the main control panel, forward. As the mast reaches an angle of 70
degrees it will begin to go over center and tend to come into the vertical position by itself.
Care should be used once the mast has gone over center since the speed of the mast will
increase sharply.
ACAUTION: The mast joystick should be moved away from and returned to the neutral
position very slowly. Sudden starts and stops can be damaging to the
mast and hydraulic system. Be extremely cautious as the mast
approaches 70 degrees as once the mast goes over center only a very
slight movement of the joystick is necessary to cause motion in the
mast.
1. Mast Lock Switch
2. Operating Mode Selector Switch
3. Drill/Propel "ON" Pushbutton
4. Winch/Mast Selector Switch
5. Mast Joystick
6. Mast Brace Lock Switch
Controls for Raising or Lowering the Mast
NOTE: Pay close attention to the hoses, wires and cables that run between the mast support
and the mast to prevent damage to the machine as the mast is being raised. Have a
helper watch from a safe position on the left side of the machine as the mast is going
up.
Feb. 2000 Operator's - 63 Manual No. 10052
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3. To hoist the auxiliary winch line, lift and move the masUwinch
joystick, located on the main control panel, forward. To stop the
line, return the joystick to the NEUTRAL position.
4. To lower the winch line, lift and move the joystick rearward. To
stop the line, return the joystick to the NEUTRAL position.
PIPE RACK OPERATION
/1 ,
,~/
The machine can be equipped with 1 to 4 pipe racks and depending upon the number of pipe racks
the pipe rack configuration and operation will be different.
• On a machines with one pipe rack, the rack will be on a swing out arm and will be in #1
position.
• On a machine with two pipe racks, the racks will be on swing out arms and will be in #1 and
#4 positions.
• On a machine with three pipe racks, two pipe racks will be located on a carousel that swings
out and then is rotated. This carousel houses pipe racks in #1 and #2 positions as shown.
The third pipe rack is a swing out rack that will be in #4 position.
• On a machine with four pipe racks, there are two swing out carousels with two racks in each
carousel. The carousels rotate to make each rack available for use. The left carousel houses
racks #1 and #2 and the right carousel racks #3 and #4.
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3. Position the pipe to be installed in such a position so as to be accessible to the crane. Normal
placement of the drill pipe is on the left side of the machine, laying at right angles to the
machine. This allows the crane to lift the pipe and swing without excessive boom hoisting and
lowering. The pipe may be stored on suitable blocking on the ground, or on a truck or trailer.
A
CAUTION: Make sure the drill pipe is secured against unwanted or unexpected
movement. Failure to secure the pipe properly may result in the pipe
shifting and causing death or serious injury to personnel in the area.
4. The upper gate is open when the pipe rack is empty. This function is controlled by a limit
switch in the lower pocket of the pipe rack.
5. Using suitable rigging, attach the crane to the drill pipe. The pipe should be rigged so that it
will remain horizontal while being lifted. Attach suitable tag lines to the pipe. Remove the
thread protectors and clean and lubricate the threads and shoulders on each end of the pipe.
Install an approved lifting bell to the pin (upper) end of the pipe. Lift the pipe into position over
the mast.
6. Using a tag line guide the pipe into the desired pipe rack. Place suitable blocking beneath the
pipe to allow the sling to be removed from the pipe.
A CAUTION: Block the pipe securely to prevent it from moving unexpectedly.
7. Remove the slings from the pipe. Attach a sling to the lifting bell on the pin end of the pipe and
lift the pipe sufficiently to remove the blocking.
8. Slide the pipe down the pipe rack until it rests on the bottom of the pocket. Lay the pipe in the
pipe rack and remove the sling and lifting bell.
9. When the pipe rest in the bottom of the pocket it will trigger the limit switch and close the
upper gate.
10. Repeat the procedure for additional lengths of pipe.
11. Unloading the pipe is the reverse of the procedure used for loading the pipe.
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the pipe, clean and lubricate the threads and shoulder on the lower end of the pipe and the
upper end of the stabilizer.
A
CAUTION: Before working around the tool string set the hoist brake. Depress the
drill/propel control OFF push-button.
Stabilizer
Stabilizer Installation
11. Release the hoist brake and lower the rotary/pulldown unit until the drill pipe is approximately
1 foot above the upper end of the stabilizer. Reset the hoist brake.
12. Turn the rotary rheostat clockwise until the drill pipe begins to turn at approximately 5 RPM as
shown on operator's display terminal operator's display screen. Release the hoist brake and
carefully lower the rotary drive unit until the drill pipe contacts the stabilizer. Allow the rotary
drive unit to continue to lower under gravity while the drill pipe is threading onto the stabilizer.
13. When the stabilizer begins to turn with the drill pipe, check the joint between the stabilizer and
the pipe. The shoulders on the pipe and stabilizer must be together. If there is clearance
between the shoulders, it will be necessary to tighten the joint some more before the stabilizer
is released. If the shoulders of the pipe and stabilizer are contacting, the joint is made up.
Installation of the drill bit is the last step in preparing the tool string.
Manual No. 10052 Operator's - 78 Feb. 2000
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ADDING ADDITIONAL DRILL PIPE
Installation of additional sections of drill pipe is necessary when the depth of the hole is to be
greater than the total length of one section of pipe. Installation of the second and third sections of
pipe is essentially the same procedure as installation of the first. The rotary/pulldown unit is raised
above the pipe racks, a pipe rack with pipe moved over the hole, the rotary coupling threaded to the
pipe, and the pipe removed from the rack and the rack stored.
To add an additional section of drill pipe, proceed as follows:
1. The first part of the hole should be drilled as deep as possible with the first section of pipe.
The hole should be drilled deep enough to place the joint between the rotary drive unit and the
top of the first section of the pipe even with the top of the tool wrench. After completing this
section of the hole, turn the main air stream off.
2. Raise the tool string until the slots in the top of the first section of pipe are aligned with the tool
wrench. Clamp the tool wrench firmly around the drill pipe.
3. Quickly turn the rotary rheostat to the left (counterclockwise) to approximately one-half offull