Orion Operators Manual

Operators Manual
Orion Megamatic Drill 10189
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 2005
Printed In Canada
Table of contents
1.2 Objectives ........................................................................................................................ 1
1.3 Orientation ....................................................................................................................... 2
2.1 Major Components and Subassemblies ........................................................................... 3
2.2 Hydraulic System........................................................................................................... 14
3.1 Tramming....................................................................................................................... 22
3.2
Set-Up ...................................................................................................................... 24
3.3 Drilling........................................................................................................................... 29
4.1
Operating Procedure for Tramming and Start-Up ................................................... 32
4.2 Drilling Preparation ....................................................................................................... 35
4.3 Drilling Recommendations ............................................................................................ 36
4.3. Air Supply.................................................................................................................... 38
4.3.6.1 Hammer Installation Procedure ....................................................................... 38
4.3.6.2 Hammer Removal Procedures using Breakout Wrench .................................. 41
4.3.6.3 Bit Removal and Installation for 4" Hammer .................................................. 43
4.4.3.2 Grease Injection Operating .............................................................................. 54
4.4.3.3 Adjusting Flow Rate ........................................................................................ 56
4.4.5.1 Collaring The Drill Hole.................................................................................. 59
4.4.5.2 Hole Deviation ................................................................................................. 59
4.4.5.3 Drill Pressure ................................................................................................... 59
4.4.5.4 Collaring .......................................................................................................... 59
4.4.5.5 Hole Deviation ................................................................................................. 60
4.4.5.6. Adjusting Drill Pressure and Monitoring the Machine................................... 61
4.4.5.7 Feed Pressure ................................................................................................... 62
4.4.5.8 Bit and Rock Blockages................................................................................... 62
4.4.5.9 Hole Blockage.................................................................................................. 62
4.5 Preventive Maintenance................................................................................................. 65
5.1 Pre-Operation Safety Precautions .................................................................................. 66
5.2 Operation Precautions.................................................................................................... 66
Lubrication........................................................................................................................... 72
Inspection............................................................................................................................. 72
6.1 TROUBLESHOOTING THE TRAM DRIVE .............................................................. 76
6.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM............................................... 77
6.3 TROUBLESHOOTING THE WATER INJECTION PUMP ....................................... 79
6.4 TROUBLE SHOOTING THE AIR DRIVEN OIL INJECTION PUMP...................... 80
6.5 TROUBLESHOOTING THE AIR DELIVERY SYSTEM .......................................... 81
6.6 TROUBLE SHOOTING OF THE ELECTRICAL SYSTEM....................................... 82
6.7 TROUBLESHOOTING THE HAMMER..................................................................... 83
6.8 TROUBLESHOTING THE DRILL BIT....................................................................... 85
Section 1: Introduction
DESCRIPTION: The Orion is a track mounted ITH drill designed to drill with In-TheHole hammers powered with high air pressure.
PERFORMANCE: The Orion can be used to drill from 3.5 in (89 mm) to 6 3/4 in.
(171 mm) diameter holes to a depth greater
than 330 ft (100 m). WITH OPTIONS: It can
also be used for drilling 8 in. (216 mm)
holes and occasionally reaming up to 17
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 Orion drill and is intended to be used as a training aid for Cubexs
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).
Front
Carousel
Mast
Compressor
Engine
Left
Operator
Rear
Figure 1.1 Drill Orientation
Section 2: Description of Equipment

2.1 Major Components and Subassemblies
2.1.1 Mast and Undercarriage
1. 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.
Grade ability is 65% and ground clearance 7 (178mm).
2. Leveling Jacks
(Optional) Allows for easy and safe leveling of unit on uneven ground.
3. Slide over
For quick positioning over the holes collar position, the drill has a
horizontal slide over feature with 30 in (760mm) of travel. This has a
50,000lb capacity for the feed.
4. Swing-out Centralizer Assembly
Hydraulic operated split swing-out centralizers along with a hydraulically
operated slip plate (size varies on drill pipe used).
5. Divertor
A removable cutting deflector that catches the drill cuttings returning out of
the hole and discharges them through the side port. Sample collection can
be done at the 6 in. (152mm) side port.
6. 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.
Figure 2.1 Left Side of Drill
7. 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.
8. Hose Loop
Protects and routes the hosing on the mast of the drill.
9. Dump Cylinders
For positioning the feed from horizontal to 15 past vertical.
10. Rotary Actuator
This rack and pinion rotary actuator can swing the feed 360 and has a
torque capacity of 300,000 in-lbs (33,900 Nm).
11. Feed Extension Cylinders
The feed is extended to bring it into contact with the rock face using these
cylinders. These cylinders have 39 in. (990mm) of stroke.
Figure 2.2 Back of feed
11
10
Note: Unit shown with

optional carousel
2.1.2 Right Side

1. Drilling Valve Bank
Contains manual controls for drilling functions. See figure 2.4 for details.
2. Nitrogen Bottle
Nitrogen bottle for fire suppression.
3. Towing Hitch
(Optional) Heavy duty towing hitch for towing optional equipment
(booster).
4. Hydraulic Tank
Hydraulic tank with sight glass level indicators.
2
3
9
4
6
Figure 2.3 Right Side
8
10
5. Hydraulic Fluid fill Pump

(Optional) Electric pump for filling the hydraulic tank.
6. Compressed Air Inlet Pipe
Inlet for high pressure drilling air.
7. Slide-over Frame Mounted Laser
Laser for optional Terra A20 alignment system.
8. Water Pump
9. Fire Suppression Actuator
Actuator for manual fire suppression system.
10. ITH Grease Injection
(Optional) Grease injection system for lubricating the ITH hammer when
drilling (See Figure 2.12 for.
Solenoid
Figure 2.4 Drilling Control Panel
Air Filter
Regulator
Injector
LS A-Port
Relief
Lubricator
LS B-Port
Relief
Breather
Cap
Tank
LS A-Port
Relief
Fill Cap
Sight
Glasses
Figure 2.12 Grease Injection
2.1.3 Rear
Figure 2.5 Rear
2
3
1. Main Electrical Panel

A watertight enclosure containing electrical controls (see fig 2.6 for
breakdown).
2. Fire suppression Module
Module for SCN-2 automatic fire suppression system.
3. Tram Valve Bank
Manual valve bank for Tram and levelling jacks (see fig 2.7 for details).
Figure 2.6 Main Panel
Figure 2.7 Tram Valve Bank
10
2.1.4 Left Side
Figure 2.9 Left Side
1
4
1. Cable Reel
Cable reel with electrical cord for hooking drill up to Mine electrical
power.
2. Main PLC Panel
Main enclosure for PLC Processor.
3. Set-Up Valve Panel
Valve bank containing all set-up functions (see Figure 2.10 for Details).
4. Gauge Panel
Main panel with gauges and controls for reverse drilling valve and
torque adjustment (see Figure 2.11 for Details).
11
Figure 2.10 Set-up Control Panel
Figure 2.11 Gauge Panel
12
2.2 Hydraulic System
Manual Fill
Pump
Sight Gauge
Electric Fill Pump
5
4
13
2.2 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 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 2.10 and their operations are explained in Section 3.0, 4.0 and
5.0.
14
2.3 Water System
Water Pump
High Pressure
Air Supply
Connection
Mine Water
Connection
Air Regulator
Wash Down
Hose
Connection
Drilling Air Line
Air On/Off
Valve
Top Drive
Oil Pump
Relief Valve
Check Valve
Water
Metering Valve
15
2.3 Water and Lubrication Systems

Water and oil/grease delivery systems are illustrated in Fig. 2.3
1. Water Delivery System
Water is fed through a strainer/regulator by the mine supply to the
hydraulically driven water pump. The flow is pumped through a metering
valve into the water 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 (Optional)
An alternative to the oil injection is the grease injection system. It produces less
mist into the atmosphere and reduces 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.
16
2.4 Air Delivery System
2.
3.
4.
5.
1.
On the Cubex drills, the air is delivered either by an onboard booster or by a

booster mounted on a separate trailer package with its own electric motor and
control panel.
The gauges for the suction pressure, discharge pressure and compressor oil
pressure are located on the booster trailer or on the drill itself (if the booster is
onboard).
1. Suction Line
Air is drawn either from the mine air supply or from the atmosphere. In both
modes the air is passed through a filter. A Three Way Valve does the selection of
air supply. The air is sent from the Three Way Valve to the suction manifold to
the compressor with either pressurized or atmospheric air supply.
2. Booster Compressor
The compressor boosts the pressure of the mine air supply to the required drilling
pressure. The booster is an air cooled single stage-reciprocating compressor.
Lubrication is achieved by an integral oil pump that draws oil from the crankcase.
17
3. Discharge Line
The compressor feeds air to the air receiver through the discharge manifold and
then through the high temperature hose. The discharge manifold contains a high
temperature shut-off sensor to shut down the compressor when its temperature
reaches a pre-set limit and a discharge air temperature gauge.
4. After- cooler Assembly
The after-cooler is a plate seal heat exchanger. Air travels from the booster
discharge manifold to the after-cooler and then to the air receiver. Water is fed to
the after-cooler from the mine water supply and passes through a
strainer/regulator before entering the after-cooler. Water discharge is regulated
with a temperature-actuated valve that is set to dump water when it reaches
125F (52C).
Caution:
Turn water supply on before starting the compressor.

Drain after-cooler when exposed to freezing conditions.
Adjusting the Temperature Actuated Valve

When the drill is operating at high pressure, the operator must monitor the
temperature actuated valve occasionally to ensure that water is flowing from the
discharge hose connected to the temperature actuated valve. When the operator
turns the drilling air off, the air compressor unloads, causing the discharge air
flow to stop. This reduces the discharge air temperature. The temperature
actuated valve senses the temperature change and stop the water flow.
Adjust the temperature actuated valve as follows:
1. Locate the temperature-actuated valve (See Fig.2.9).
2. Adjust the temperature-actuated valve to open when water discharge is
approximately 125F (52C). Turn temperature adjusting screw clockwise
to decrease opening temperature set point. Turn it counter clockwise to
increase opening temperature.
3. Check that water is being discharged steadily when compressor is
operating at high pressure.
18
5. Air Receiver
The air receiver is a tank which holds the air. Pressure is regulated with the
unloading valve system which is composed of a pilot unload valve and a manual
unload valve. The pilot is set to unload at a pre-set pressure. The air receiver
comes complete with an air safety relief valve set at the rated pressure of the
receiver.
The air delivery line supplies air to the top drive and to the DTH hammer. This
line contains an on-off valve and a check valve. The check valve keeps the water
and oil, which is injected into the line from being pushed back into the air delivery
system.
19
2.5 Controls
Tramming Controls
Two spring return valves actuate 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.2.10.1).
The valve may also contain outrigger and cable reel sections.
When the remote is plugged into the drill, the operator must select Tram Mode
before they will be able to Tram by using the manual levers at the Tram Stop or from
the remote.
Figure 2.51
20
Figure 2.52
21
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.2.7). 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/remote operating station.
22
Drive Sprocket
Face Nipple Outwards

For Tramming
Torque Hub
Figure 3.1
Face Nipple Inwards

For Towing
Figure 3.2
23
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. 2.10. is
pushed right to move right and pushed left to move left.
The total slide-over movement on Cubex Orion drill is 30" (762mm).
Figure 3.2
24
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. 3.3. 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. 2.5.2 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 3.3
25
3.2.3 Swing
The mast swing refers to the 360 horizontal rotation Fig. 3.4. 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. 2.5.2 determines whether the mast moves
clockwise or counter clockwise.
Figure 3.4
26
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. 3.5.
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 Orion drill is 54" (1371mm).
54 (1371mm)
Figure 3.5
27
3.2.5 Stinging
Mast stability is increased by extending the stinger cylinders Fig. 3.6 until they
contact the rock face. The upper and lower stingers operate independently and
may be used simultaneously.
The upper stinger switch Fig. 2.5.2 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 3.6
28
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 when the main power
switch is turned on, the Power On light will illuminate. This switch will
automatically trip when the amperage exceeds a pre-determined setting
and the motor O/L light will turn on.
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 button to start the electric motor.
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.
29
30
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 of the drill pipe, 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 forward 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 80
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 or the rear of the drill at the main
electrical panel.
31
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.
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 drop 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 excessively
plugged air filter.
12. Check all gauges for proper operation.
32
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.
Step 3: Position the

mast horizontally on
the T rest.
Step 2: Raise the

top drive to the top
of the mast
Figure 4.1
Step 1: Retract the

feed extension fully
33
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 slideover 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 side wall 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.
34
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.
35
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 favourable
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) per minute the recommended rotation is about 20
rpm. The calculations are listed below.
8" per minute
------------------------ =
3/8" per revolution
8
---3/8
= 21.3 rpm
200mm per minute

----------------------------10mm per revolution
200
---10
= 20 rpm
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
36
Incorrect drilling weight will result in the following:

1. Loss of air pressure in the tool.
2. Erratic tool behaviour 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 maximum. Then increase the
hold back pressure until the tool begins erratic behaviour. 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 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.
2.
3.
4.
Reduction in dust damage to drilling equipment.

Protects the health of the operator.
Reduces high temperatures in drilling equipment.
Aids cleaning the hole when the formation is producing small
amounts of water.
5. Acts as a seal on worn parts.
37
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 mix with the water and this creates a 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. 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.
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. From the operators station position yourself away from the top drive.
Open and close the drill air by operating the 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.
38
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.
39
Caution: The hammer parts may get damaged if the tool

is operated with insufficient lubrication.
Fig 4.3.1
40
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.
Warning:
Stand clear when breaking the joint to avoid possible

injury in the event the chain Wrench 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.
41
Note: During hammer removal, cover the drill hole to avoid losing of any parts down
the hole.
42
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.
2.
3.
4.
Slow penetration rate

Decrease in the volume of cuttings
Binding
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
43
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. Slow reverse top drive rotation 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
44
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 manufacturers 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 manufacturers specifications.
45
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. 4-3-10 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.
46
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 and spline in the rods 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.
47
Figure 4.3.10
48
Remove grease from threads
Clean the threads
Use a file to repair damaged threads
Figure 4-3-11
49
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. 4-3-11).
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.
50
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, which
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.
51
Water solenoid valve

Strainer/pressure regulator
Relief Valve
Water metering valve

Wash down hose
connection
Mine water supply
Water pump
350 psi (24.2 bar) air from

booster compressor.
52
Strainer/pressure regulator
4.4.2 Oil Injection Operating Procedure

The air supply line to the oil injection pump is designed so that the pump will
operate only when the rotation is on. The oil injection operating procedure (Fig.
4.4.2) is as follows:
1. Close ball valve on air supply line. Remove top of tank and fill with rock
drill oil. Reinstall top and turn on air.
2. Set the air supply regulator at the tank to 60 psi.
3. Adjust the oil flow with the metering valve located on the discharge line of
the pump. Open it 1/4 turn to start.
4. Check if the oil is coming out of the shank at the water swivel with rotation
on. If not, open the valve further until there is noticeable oil in the drilling
air.
Air driven oil pump

Air regulator set for 60 psi
(4.1 bar)
Exhaust
Outlet
Oil metering
valve
Check valve
90 psi (6.2 bar)

mine air supply
Drilling air to top

drive
53
4.4.3 Grease Injection Operating Procedure

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

1. Close ball valve on air supply line. Remove top cap (12) and fill tank with
rock drill grease. Reinstall top cap and turn on air.
2. Set the air supply regulator (7) to 60 - 100 psi (refer to air schematic).
3. Turn vent plug at the pump (2) 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.
4.4.3.2 Grease Injection Operating
The pre-determined lubrication cycle frequency is set by the PLC.

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 injectors 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.
54
Electric solenoid valve

Grease Injector
Regulator
Air Lubricator
Air Filter
Injection Pump
Grease Tank
Figure 4.4.3
55
4.4.3.3 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.

Adjustment Screw
Figure 4.4.3.3
Lock Nut
Grease Inlet
Injector Body
Grease Outlet
56
4.4.4 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 back pressure 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.
57
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.
58
4.4.5 Drilling Recommendations

4.4.5.1 Collaring The Drill Hole
The collar of a hole will directly determine the quality of the hole.
4.4.5.2 Hole Deviation
Some of the causes of hole deviation are Incorrect feed pressure and rotation
speed.
4.4.5.3 Drill Pressure
Feed 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.
4.4.5.4 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 the least 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. F
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
59
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.
4.4.5.5 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'. Methods of combating hole deviation are '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 realigned with the hole to allow the threads to be un-wound.
60
4.4.5.6. 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.
61
4.4.5.7 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.
4.4.5.8 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.
4.4.5.9 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
62
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.
63
4.4.6 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 checkpoint #4 after the first joint is drilled and adjust as required.
64
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
(65C) 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.
65
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
66
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.
67
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.
Arrow must be lined up

with mark in sight glass
to ensure proper tension
of the cable.
To reset the switch after it is

tripped it must be moved to
run position marked 1.
If the switch will not remain
is this position, check for
proper cable tension and
adjust if necessary. Refer to
cable tension adjustment
procedure on next page for
details.
68
When the cable is pulled

the switch will move to
the shutdown position,
marked 0 shutting
down the drill as
described above.
Safety Shutdown Tension Adjustment Procedure

Take up initial slack in cable using the adjustment on the eyebolt that anchors the
cable at the top of the mast.
The cable can then be finely adjusted using the cable tensioner.
Note: Move the blue knob to the run position before tensioning with
adjuster.
Insert an allen key in the
adjustment hole on the side of the
tensioner.
Turn the allen key clockwise to

tighten the cable.
Do not exceed a maximum of
11.8" (300 mm) of cable
adjustment with the tensioner.
Using the fine

adjustment with the
cable tensioner, turn the
allen key clockwise until
the arrow tip is in line
with the line is the sight
glass
After adjusting the

shutdown it should
always be tested for
proper functionality.
69
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:
General Maintenance Chart:
Lubrication and inspection points
Fastener Torque Table: Refer to this table when no specific rating is specified
Fluid Crossover List:
70
Refer to this list for approved fluid types
5.4.1 Lubrication Points
71
Lubrication
Key
Lubricant
Interval
1
2
3
4
Water Pump Coupling

Dump Cylinder Pins
Pillow Block Bushing
Air Swivel Top Drive
Extreme Pressure Grease

Operator
Operator
Operator
Operator
Track Tension
Adjustment
Rotary Actuator Bearings
Esso NUTO H46

SAE 80W-90
Rock Drill Grease
50 Hours
8 Hours
8 Hours
250
Hours
250
Hours
250
Hours
8 Hours
50 Hours
8 Hours
Esso NUTO H46
8 Hours
Operator
SAE 80W-90 low temp.

SAE 140 high temp.
Lithium Grease
8 Hours
Operator
250
Hours
8 Hours
Electrical
6
7
8
9
Lubrication Point
11
Water Pump Oil Level

Torque Hub Oil Level
Grease Tank Grease
Level
Hydraulic Tank Oil
Level
Top Drive Oil Level
12
Electric Motor Bearing 1
13
Centralizer Swingout
Cylinder
10
Service by
Operator
Maintenance
Operator
Maintenance
Operator
Electrical
Inspection
Key
14
15
16
17
18
19
20
Inspection Point
Drill
Drill
Drill
Drill
Details
Wash and clean

Inspection for leak bolts
Inspection for leaks
Check that air hoses are
secured with safety
devices
Cylinder Rods
Wash and clean
Top Drive
Check bearing endplay
Top Drive Mounting Plate Inspection slider
adjustment
Interval
Service by
50 Hours
50 Hours
50 Hours
50 Hours
Operator
Maintenance
Maintenance
Maintenance
50 Hours
50 Hours
50 Hours
Maintenance
Maintenance
Maintenance
Do not over grease. Excessive grease may cause overheating.
72
Lubrication Points
A scheduled lubrication program is required to extend the Drills 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)
Grease Tank
Esso AROX NM 000
8.4 gal (32 l)
Hydraulic Tank
Esso NUTO H46
70 gal. (265.0 l)
Torque Hubs (1.3L)
Gear Oil SAE 80W-90
Half full 44 fl.oz.
Water Pump
Esso NUTO H46
40 fl. oz. (1.2 l)
73
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
A #59/NR
A #79/NR
Rock-Drill Oil 340
Rock-Drill
Swepco SAE 30
Swepco
Non-Fluid Oil Corp.
A #89/NR
E.F. Houghton & Co. 370

Southwestern Petroleum
SAE 50
Swepco SAE 10
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 RockDrill Oil 381
Molub-Alloy RockDrill Oil 297
Molub-Alloy
Drill Oil 297
Champlin Purrol Co
Grade 10
Grade 30
Grade 50
Chevron Oil Co.
Vistac 30X
Vistac 220X
74
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
Grease
SHELL OIL
ESSO (MOBIL)
Spirax HD
SAE 80W-90
Darina
XLEP2
Tellus T-37
Mobil
HD 80W-90
Petro Canada
Gear Lube
80W-90
Mowhawk
Gearlube GL5
80/90 HP
Mobilux
Precision EP2
N/A
Mobil
NUTO H46
Harmony
HVI-36
Mohawk
HV132
75
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 gear box.
4. Check if tram motor is running.
5. Check for Tram lockout valve blockage
CRAWLER DOES NOT TRAM STRAIGHT
76
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.
77
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.
78
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. 1.Check for restrictions in the suction line.
2. 2.Check if suction line valve is closed.
79
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.
80
6.5 TROUBLESHOOTING THE AIR DELIVERY SYSTEM

AIR PRESSURE BUILDS TOO SLOWLY
2. Check for leaks in airline.
3. Check for restrictions in the air filter or inlet.
4. Check for improper operation of 3-way valve on air inlet. Ensure that the
valve opens and closes fully.
5. Check for worn suction or discharge valves. The valve cover that feels the
hottest may indicate a leaking valve.
6. Check for unloader plunger being stuck in open position.
7. Check for damaged copper valve seat.
8. 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.
81
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.
82
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.
83
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.
84
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.
Gauge 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.
85
UNEVEN WEAR CONDITIONS

Uneven wear conditions may be due to the following:
1. Check for uneven wear spots at the gauge row buttons.
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.
86

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Operators Manual

Orion Megamatic Drill 10189

Phone: (204) 694-5505

MAJOR COMPONENTS AND SUB-ASSEMBLIES OF DRILL

Orion Megamatic Drill 10189

Figure 1.1 Drill Orientation

Orion Megamatic Drill 10189

Section 2: Description of Equipment

Orion Megamatic Drill 10189

Figure 2.1 Left Side of Drill

Orion Megamatic Drill 10189

Protects and routes the hosing on the mast of the drill.

For positioning the feed from horizontal to 15 past vertical.

10. Rotary Actuator

11. Feed Extension Cylinders

Orion Megamatic Drill 10189

Figure 2.2 Back of feed

Note: Unit shown with

Orion Megamatic Drill 10189

2.1.2 Right Side

Orion Megamatic Drill 10189

5. Hydraulic Fluid fill Pump

Figure 2.4 Drilling Control Panel

Figure 2.12 Grease Injection

Orion Megamatic Drill 10189

1. Main Electrical Panel

Orion Megamatic Drill 10189

Figure 2.6 Main Panel

Figure 2.7 Tram Valve Bank

Orion Megamatic Drill 10189

2.1.4 Left Side

Figure 2.9 Left Side

Orion Megamatic Drill 10189

Figure 2.10 Set-up Control Panel

Figure 2.11 Gauge Panel

Orion Megamatic Drill 10189

2.2 Hydraulic System

Electric Fill Pump

Orion Megamatic Drill 10189

2.2 Hydraulic System

Orion Megamatic Drill 10189

2.3 Water System

Drilling Air Line

Orion Megamatic Drill 10189

2.3 Water and Lubrication Systems

Orion Megamatic Drill 10189

2.4 Air Delivery System

On the Cubex drills, the air is delivered either by an onboard booster or by a

Orion Megamatic Drill 10189

Turn water supply on before starting the compressor.

Adjusting the Temperature Actuated Valve

Orion Megamatic Drill 10189

Orion Megamatic Drill 10189

Orion Megamatic Drill 10189

Orion Megamatic Drill 10189

Section 3: Drill Operation

Push both levers forward

Pull both levers back

Push left lever forward

Push right lever forward

Hard right rotation

Pull right lever back and push left lever forward

Hard left rotation