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INSTRUCTION MANUAL For

AIR DRILL

Read this Instruction Manual before operating this equipment.

Model: MW-140 / MW-120

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TABLE OF CONTENTS

WARRANTY TERM 31. GENERAL INFORMATION 52. TECHNICAL FEATURES 53. AIR CONSUMPTION 6

3.1 AIR PRESSURE AND VOLUME 73.2 AIR HOUSE AND FITTINGS 7

4. FUNCTIONAL DESCRIPTION 75. LUBRICATION REQUIREMENTS 86. ROCK DRILL LUBRICATING OIL SPECIFICATIONS 8

6.1 LIST OF OIL 99

6.3 THREAD LUBRICATION 96.4 CORRECT OIL CONSUMPTION 96.5 DIESELING 10

7. WATER REQUIREMENTS 108. OPTIONAL EQUIPMENT 10

8.1 STRIKING BAR 109. BASIC OPERATING PRINCIPLES 1110. DRILL PISTON RECIPROCATION 1111. DRILL STEEL ROTATION 1112. OPERATING CONTROLS 11

12.1 REMOTE AIR CONTROL MANIFOLD 1113. DRILLING PROCEDURES 12

13.1 CONNECTING THE SHANK PIECE TO THE DRILL 1213.2 CONNECTING DRILL TO THE STRIKING BAR 1213.3 DRILLING 1213.4 ADDING EXTENSION RODS 1213.5 REMOVING THE ROD SYSTEM FROM THE HOLE 1313.6 DRILLING TIPS 13

13.6.1 SUGGESTION FOR DRILLERS 1413.6.2 CARE AND USE OF BITS 14

14. PREVENTIVE MAINTANCE 1415. DISASSEMBLY AND REASSEMBLY INSTRUCTIONS 15

15.1 PRELIMINARY DISASSEMBLY INSTRUCTIONS 1515.2 DRILL DISASSEMBLY 1615.3 ROTATION MOTOR DISASSEMBLY 1815.4 INSPECTION OF PARTS 1815.5 PRELIMINARY REASSEMBLY INSTRUCTIONS 1815.6 ROTATION MOTOR REASSEMBLY 1915.7 DRILL REASSEMBLY 19

16. PERFORMANCE TESTING 2217. TROUBLE SHOOTING 22

6.2 AIR LINE LUBRICATOR

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WARRANTY TERM WOLF – Metalúrgica, warrants that all replacement parts supplied by it will be free from defects in materials and workmanship for a period of six months from date of supply when operating under normal working and environmental conditions. If a failure occurs which is due to defects in materials or workmanship during the period, WOLF - Metalúrgica will replace the item. This Warranty shall not apply to any WOLF - Metalúrgica product which shall have been altered, or modified in any way. We shall not in any event be liable for the cost of any special, indirect or consequential damage to any one. WOLF will provide a new part or repaired part, at its election, in place of any part which is found upon its inspection to be defective in material and workmanship during the period prescribed above. All warranty parts will be replaced FOB Wolf factory in Indaiatuba-SP, Brazil. This warranty does not apply to failures occurring as a result of abuse, misuse, negligent repairs, corrosion, erosion and normal wear and tear, alteration or modification made to the product without express written consent of WOLF – Metalurgica; or failure to follow the recommend operating practices and maintenance procedures as provided in the product’s operation and maintenance publication. Equipment and part furnished by WOLF – Metalurgica, but manufactured by others, shall carry whatever warranty the manufactures have conveyed to WOLF – Metalúrgica and which can be passed on to the initial user. WOLF - Metalúrgica shall not be liable for loss of time, manufacturing cost, labor, material, loss of profit, consequential damages, direct or indirect, because of defective products, whether due to right arising under the contract of sale or independently thereof, and whether or not such claim is based on contract, tort or warranty. The customer agrees to care for the equipment properly, to use it within its rated capacity, to restrict its use to the customer’s qualified personnel and to prohibit anyone other than the buyer's qualified mechanic from making repairs to, modifying, or adjusting the equipment.

The customer assumes full responsibility for damage, loss or destruction of the equipment from the date of delivery. The customer, at his own expense, shall maintain the equipment and replace or change all spare parts or perform all necessary labor according to the equipment's Operator's Service Manual. The customer further agrees to pay for all damage to the equipment resulting from causes other than normal wear and tear upon receipt of invoice from the WOLF - Metalúrgica cost and expense for the repair. The customer shall take care of normal needs of the equipment including supplying fuel, grease, tires, oils, cooling system, water, recharging batteries, etc. The customer will perform any other routine service and preventive maintenance set forth in the Operators Service Manual for the equipment. If the customer requires for further assistance or service from the factory, the cost is for customer account.

Written permission of any warranty claim return must be first obtained from authorized WOLF personnel. All returns must be accompanied with a complete written explanation of claimed defects and circumstances of operational failure.

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Products manufactured or sold by WOLF are not warranted expressly or implication for merchantability or fitness or for any measure of service or suitability of for a specific purpose notwithstanding any disclosure to WOLF of the use to which the product is to be put. This express warranty is to solve warranty of WOLF there are no warranties which extend beyond the warranty herein expressly set forth. The sales of products of WOLF under any other warranty or guarantee express or implied is not authorized.

This Warranty shall not apply to any WOLF - Metalúrgica product which shall have been altered, or modified in any way. We shall not in any event be liable for the cost of any special, indirect or consequential damage to any one.

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1. GENERAL INFORMATION 1.1 BEFORE EQUIPMENT START WORKING Before start working with the equipment, new or used that stay a long time stopped, we recommend:

1. Take out the percussion hose from the drifter; 2. Wait for the Lubrification star get in, should through this hose; 3. Can be fitting over the Air Tank Lubrification. 4. Keep this oil getting out for minimum 5 minutes;

1.2 BE CAREFULL WITH THE FOLLOWING ITENS

a) check the air, is clean and dry; b) check the air in the exit hose is clean; c) check the oil request, for all of the equipment;

Blow few minutes the hoses before connect in the equipment; The MW-140 Drill is a 140mm and MW-120 is 120mm bore, valveless, hammer drill that incorporates an independently controlled, gear type, air powered rotation motor to rotate the drill steel in place of the conventional rifle bar, rifle nut rotation. The MW-140 Drill is capable of drilling 2.1/2” (64mm) to 4” (102mm) and MW-120 is capable of drilling 2.1/2” (64mm) to 3.1/2” (89 mm) diameter holes in all types of grounds formations. It is recommended for use on our “Crawlair” self-propelled mountings, and for surface applications with chain feed mountings on any type of fixed or mobile drilling rig. The MW-140 and MW-120 is a valveless tool. An air distributor, controlled by an extension on the piston head, is used in place of conventional valve chest assembly. This is a much simpler design, and therefore, reduces the number of parts and critical tolerances. A double blower tube construction is standard on the MW-140 and MW-120. It includes a 9/16 in. (14.3mm) O.D. Plastic blower tube within a 3/4 in. (19mm) O.D. Steel tube support. The standard chuck parts (jaw, aligner, and retainer) accommodate a four splined striking bar with 1.3/4” (45mm) shank and stem diameters. The MW-140 and MW-120 drill is equiped with an independently controlled, air powered gear type rotation motor. This heavy duty 3 hp motor is mounted on top of the drive gear cover at the lower end of the dril. The rotation motor is independently controlled, and is designed to provide continous drill steel rotation. The operator controls the speed and direction of rotation (conventional forward [L.H.], neutral [no rotation], or reverse [R.H.] from a remote control manifold). 2. TECHNICAL FEATURES

Drill Specifications

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Rotation Motor

Shipping Information

3. AIR CONSUMPTION The total air consumption of the MW-140 and MW-120 consists of three parts. The are:

a) Drill: This is the air required to reciprocate the piston. It depends only on the pressure at the drill main air inlet.

b) Blow: This is the air passed through the drill steel to blow the chips out of the hole.

The amount consumed depends on the pressure at the blow inlet in the backhead and the number of the steels in the string. In some instances, when drilling in hard uniform rock, the operator uses more blow air then necessary. In such cases, improved drill performances can be obtained by throttling back the blow air to divert additional air to the hammer, so that the drill runs at higher pressure.

c) Rotation: This is the air required to rotate the drill steel and bit. The operator can

control the power and air consumption of the rotation motor by controlling the pressure supplied to the motor. If he runs the rotation wide open, the motor will run at maximum speed and air consumption. If he throttles back on the pressure to the motor, it will run slower and consume less air. The air conserved by throttling back the rotation air pressure will be diverted to the drill hammer and will improve drilling performance by increasing the operating air pressure. The total amount of air used is, therefore, dependent upon several factors. However, the following can be expected when using a 600cfm (17.0 cu/m min) compressor in good condition at sea level.

English Metric

Weight of Drill (net) 421lb 191kgOverall Lenght 44 in. 1118 mmBore of Cylinder 5-1/2 in. 140 mmWorking Stroke 3-5/8 in. 92 mmSize of Main Air Inlet Hose Required 1-1/2 in. 38 mmSize of Blower Hose Required 1 in. 25 mm

English Metric

Size of Air Hose Required (2) 1 in. 25 mmBrake Horsepower 3 at 90 psi 3 at 620 kPa

185 lb-ft 140 mm

100-150 rpm 100-150 rpm

Maximum Chuck Rotation 250 rpm 250 rpm

Torque at Chuck (at stall & 90 psi [620kPa])Rotation Speed at Chuck (norm. Oper. Speed)

English Metric

Net Weight 421 lbs 191 kgShipping Weight 451 lbs 205 kgCu contents 4-10 cu ft 0.14 cu m

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� 82 PSI at the drill inlet when running continous rotation wide open as in overburden

drilling. � 90 PSI at the drill inlet when running continous rotation throttled back as in average

rock formations. A 750 cfm (21.2 m³/min) air compressor must be used to maintain an air pressure of 100 PSI or more at the drill inlet, and in addition, provide the required volume of air for blow and rotation.

NOTE The air pressures indicated in above paragraphs are based on readings taken at sea level. The pressures will be 2,5 PSI (17 k Pa) lower for every 1000 ft (304m) altitude above sea level.

An air compressor having a capacity for 750 cfm (21.2 m³ / min) is required to provide the necessary volume of air at the most efficient pressure for the MW-140 Drill. For MW120 can be 600 cfm (17.0 m³ / min) air compressor. 3.1 AIR PRESSURE AND VOLUME Low or inadequate air pressure at the drill is costly and wasteful. In addition, an insufficient volume of air at the drill will not allow the machine to operate in the most officient manner. An air pressure of 100 PSI is recommended for maximum performance of the MW-140 or MW-120 Drill. This figure represents the air pressure at the drill and not at the compressor. There is always a certain amount of line drop between the compressor and the drill, and only the pressure and volume at the drill can be effective in doing work. If hoses are short and in relatively good condition, pressure drop between the compressor (or air receiver) and point of use should not exceed 15 percent of the initial pressure.

3.2 AIR HOUSE AND FITTINGS Quality hose designed especially for rock drill service should be used. It should be constructed with an outer covering which resists abrasive wear; it should have and oil resistant inner tube; and must be designed to with-stand the heat of the compresses air. The hose should be at least one size larger than the pipe thread on the drill. It should have a working pressure safety factor of at least 4 to 1 in relation to burst. The hose fitting should be kept as tight as possible and should be in good condition. Elimination of air leakage involves making the air system tight and ten keeping it tight. Air losses, through bad connections and worn hose, can often reach 10 to 20 percent of the total air compressed. 4. FUNCTIONAL DESCRIPTION The backhead is a compact cast steel unit with threaded inlet ports for the blower tube retainer and main air inlet connection. The inlet connection is a forged steel ell (90°) with screwed-in straight hose stem for a 1.1/2 in. (38 mm) main air hose. It is attached to the

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backhead by a cap and retaining ring so that it is free to swivel in the backhead. The MW-140 and MW-120 is a valveless drill: a simple air distributor (no moving parts) is installed in the rear bore of the cylinder in place of the valve chest assembly used in conventional drills. The internal bore of the air distributor is fitted with a pressed in replaceable bronze liner which relieves the distributor body of wear. Ports in the air distributor body (and liner) direct the main operating air throught the front and rear piston supply ports. The intermitent flow of air throught the front and rear main air supply ports is controlled by a piston extension that extendd into the distributor body, and opens and closes the air supply ports as the piston receiprocates. A long key is installed along the O.D. Of the distributor body to align the ports in the distributor with the connecting ports in the cylinder. The piston is designed with and integral piston extension that projects from the rear end of the piston head. It extends into the bore of the air distributor when the drill is assembled, and, as the piston reciprocates, open and closes the main air supply ports to the front and rear ends of the piston. Piston trale alone performs all valve functions. The piston bearing is designed with long bearing surfaces and with two pressed in sleeves; one to take wear from the piston stem and one to take wear from the chuck. The chuck is supported in both the fronthead and the counter bore in the piston stem bearing. Gear teeth on the O.D. Of the chuck mesh with chuck drive intermediate gear to rotate the chuck smoothly. The chuck engages the chuck jaw to transmit rotation to the shank piece. The rear end of the fronthead is counterbored to suport the chuck drive intermediate gear shaft and the pinion end of the motor drive gear. The front end of the fronthead is equipped with a replaceable bronze fronthead bushing that takes all wear and prolongs the service life of the chuck and fronthead. The MW-140 and MW-120 is designed with and air powered, integral rotation motor which includes a motor drive gear, and an enclosed housing assembly consisting of an air motor manifold and a motor gear housing. The motor drive gear and idler gear convert the operating air to rotation power. The rotation power developed by the drive gear is transmitted through a drive gear shaft, which extends through the center bore of the drive gear, to the chuck drive intermediate gear. The intermediate gear meshes with the chuck gear to transmit the motor rotation to the drill steel. The motor manifold encloses the rear end of the rotation motor, and includes two inlet ports for the forward and reverse control hoses. The forward rotation port includes a metering plug to cut down the rotation motor air consumption, and therefore, allow a greater volume of air to be directed to the drill hammer to improve drilling performance. 5. LUBRICATION REQUIREMENTS The first consideration in the operation of the MW-140 and MW-120 Drill is attention to lubrication. Intense heat is generated in the drill when run dry for even a few minutes. The heat destroy hardness of parts and often causes tiny cracks that speed the destruction of the drill. These small openings lead to progressively larger breaks. Adequate lubrication cannot be over-emphasized since most drill failures arise from faulty lubrication.

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Before operating the MW-140 or MW-120 for the first time, make sure the drill receives the proper type and amount of lubrication. 6. ROCK DRILL LUBRICATING OIL SPECIFICATIONS The rock Drill Oil used in the air line lubricator must be a well refined petroleum lubricating oil. It must be suitably compounded to provide the specified consistency and film strength, and be further compounded to provide the specified steam emulsion number. The latter is required to provide a satisfactory lubricant for such drukks where water or wet air is encountered. The oil must also be susdtantially non-corrosive to steel and bronze, and contain little or no sulphur. The composition of the “film strength” additive is not specified. The additive must be suitable for use with both steel and bronze, and be substantially non-corrosive to both metals. Except for consistency, all tests be conducted in accordance with the standard method (lastest edition) of the American Society for Testing Materials. In addition to meeting the above specifications, the Rock Drill Oil must perform satisfactorily in the drill. The responsability for meeting these specifications, the quality of the product and its performance in service must necessarily rest with the oil supplier.

NOTE Never use others oil, instead of Pneumatic Oil.

6.1 LIST OF OIL

CASTROL ESSO IPIRANGA PETROBRÁS

RDO 100 / MAGNA 220

AROX EP-150 IPIDRIL 100/220 LUBRAX FP 150/220

We recommend before start using the drifter take out the hose from the percussion, wait for the oil start getting out, then connect again and start drill. 6.2 AIR LINE LUBRICATOR The MW-140 and MW-120 Drill is designed without an internal oil reservoir. An air line lubricator must be used. When the MW-140 and MW-120 is mounted on a Crawlair Mounting, lubrication is supplied by a 2 gallon (7,6 liters) reservoir attached to the main frame. When the drill is used on a mounting not having a central oil reservoir, Air Line Lubricator is recommend.

� The oil level in the reservoir should be checked at the beginning of each hour shift and once during the shift – preferably after 3 hours of drilling time. (Refill the reservoir when the oil level has receded to 1/2 capacity. Smaller capacity lubricators must be checked frequently. Keep the lubricator well supplied with oil at all times)

� Rock Drill Oil conforming to Specifications as outlined must be used. The use of oil not conforming to our specifications will prove very harmful to the drill. Harmful

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effects will result when: • Oil with low flash point is used, which is conducive to “dieseling”. • Reclaimaed oil which is not of proper consistence and stringiness is used.

6.3 THREAD LUBRICATION It is very important that the threads of the drill rods, couplings, and bits are properly lubricated and cared for at all times. Proper lubrication will result in longer life and will simplify screwing and unscrewing drill rod joints. The following instructions apply to all drill rod threads.

� Clean all threads with cleaning solvent and a wire brush, and blow dry with compressed air

� Using a brush, coat all thread connections with a good molybdenun disulphide thread grease or equivalent.

6.4 CORRECT OIL CONSUMPTION Shop tests indicate that 5 to 6 quarts (4,7 to 5,7 liters) of lubricating oil per eight hour shift (six hours of which is drilling time) is the normal oil consumption of the MW-140 or MW-120 Drill. This figure may vary depending upon the ambient temperature. The following guide will assist in achieving the correct lubricator setting:

a) Check end of the striking bar. � Oil flow must be detected on the striking bar � No oil present on the striking bar is an indication that the drill is not receiving

adequate lubrication � Excessive oil on the striking bar is an indication that the drill is over lubricated

b) Check oil contenct of rotation motor exhaust air. If motor is receiving lubrication, a

film of oil will adhere to an object held in the exhaust flow. c) Evidence of “dieseling”. Lubricator setting must be decreased if “dieseling” occurs. d) Lubricator setting must be adjusted with temperature change.

� Early morning low temperatures require increased oil feed setting � Oil flow setting must be decreased as the temperature rises during the day

observe the striking bar. 6.5 DIESELING

a) “Dieseling” is the ignition of the air and oil mixture in the cylinder. b) Over-lubrication or flooding of the drill with oil will result in “dieseling” when the drill

is run on air cushion, eighter because of operational malpractice or adverse ground conditions.

c) “Dieseling” results in scored cylinders, pistons, abd pistons stem bearing. To avoid “dieseling”. � Avoid running on cushion � Avoid runing the drill in and out of the hole with the throttle wide open � keep the drill “feed-up” - this is difficult under adverse ground conditions but it is

important that an effort be made to “feed-up” as much as possible. � Use high-quality rock drill oil and maintain correct oil consumption.

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7. WATER REQUIREMENTS When the MW-140LS or MW-120LS Drill is used for wet drilling, the water pressure should be maintained at about 10 PSI (69 k Pa) less than the air pressure. If the water pressure exceeds the air pressure, water could be forced into the drill and will carry away the lubricant. Water pressure should never fall below 40 PSI ( 276k Pa). 8. OPTIONAL EQUIPMENT We have the version of MW-140 or MW-120 LS, that means Separately Flushing, in this case can be used with water, like water swivel. 8.1 STRIKING BAR The MW-140 and MW-120 Drill does not include a strking bar. The required striking bar must specially ordered. 9. BASIC OPERATING PRINCIPLES The operating of the MW-140 or MW-120 is based on two independent operating principles: (1) the principle governing piston reciprocation (hammer action) and (2) the principle governing the drill steel rotation. 10. DRILL PISTON RECIPROCATION The MW-140 and MW-120 is a valveless drill. An air distributor controlled by an extension on the piston head is used in place of the conventional double kicker port valve and parts. When the main operating air is directed into the drill, ports in the air distributor body direct the operating air through front and rear piston supply ports. The intermittent flow of air through the front and rear main air supply ports is controlled by the piston extension that extends into the distributor body and opens and closes the air supply ports as the piston reciprocated. Piston travel alone performs all valve functions. 11. DRILL STEEL ROTATION The MW-140 and MW-120 Drill is designed with independently controlled, air powered, gear type rotation motor that provides continous drill steel rotation – forward or reverse. The motor is controlled by a remore air control manifold that directs operating air to the manifold on the motor. The operator can switch from conventional forward, neutral, rotation, or reverse rotation.

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1. Motor Manifold 4. Chuck Drive Intermediate Gear 2. Motor Gear Housing 5. Geared Chuck 3. Drive Gear Assembly 6. Cover 12. OPERATING CONTROLS 12.1 REMOTE AIR CONTROL MANIFOLD A remote air control manifold must be used with the MW-140 or MW-120 Drill. The remote manifold is a standard component of our Crawlair Mountings; however, when the MW-140 or MW-120 is used on mountings not equiped with a remote control manifold, it must be specially ordered. 13. DRILLING PROCEDURES The following instructions covering drilling procedures are furnished as a general guide only. Detailed operating and drilling instructions are included in the Instruction Book covering the mounting on which the MW-140 or MW-120 is used. 13.1 CONNECTING THE SHANK PIECE TO THE DRILL

a) Loosen the chuck jaw retainer locking lug bolt and remove the chuck jaw retainer. b) Insert the shank end of the striking bar (not furnished with the drill) in the drill. c) Slide the chuck jaw retainer over the end of the strking bar. d) Retighten the chuck retainer locking lug bolt. 13.2 CONNECTING DRILL TO THE STRIKING BAR a) Clean and grease the threads on the striking bar and drill steel. b) Screw the drill steel coupling onto the striking bar. c) Screw the drill steel into the coupling joint.

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NOTE To prevent premature drill steel thread failure, it is very important that the threads be coated with a high pressure grease each time they are coupled or stored.

d) Screw the bit onto the drill steel. 13.3 DRILLING The MW-140 is designed to operate efficiently with a 750 cfm and MW-120 with 600 cfm air compressor. Hammer action and drill steel rotation are controlled separately and each must be regulated for optimum results in the drilling conditions encountered. No exact setting for the controls can be give due to varying rock formations, however, maximum penetratuion in hard rock can usually be achieved by setting the controls for maximum hammer action and minimum rotation. Conversely, this formations require minimum hammer action and maximum rotation. 13.4 ADDING EXTENSION RODS

a) Shut off the drill and raise the bit from the bottom of the hole. b) Move the rotation control to neutral position to stop rotation. c) “Feed” the drill down and hold the bit at the bottom of the hole under normal feed pressure. d) Move the drill control on and off in short bursts until the coupling is loose on the shank e) With the drill control off, move the continous rotation to the reverse position to fully uncouple the shank or rod. f) Run the drill to the top of the guide. g) Apply grease to the threads at both ends of the coupling. h) Screw a coupling on one end of the extension rod by hand. i) Align the extension rod and coupling with the striking bar and screw the other end into the coupling resting on the centralizer j) Screw the coupling onto the striking bar by hand until it is as tight as possible k) Move the continous rotation control to conventional forward (L.H.) rotation to screw up the extension rod at both ends.

CAUTION THE DRILL HAMMER CONTROL SHOULD NOT BE USED TIGHTENING THE COUPLING SINCE IT IS POSSIBLE TO CHIP THE THREADS ON THE SHANK PIECE AND EXTENSION ROD IF THESTRIKING BAR IS STRUCK WHEN THE THREADS ARE NOT IN FULL CONTACT

l) Perform from steps “a” to “k” for each extension rod used.

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13.5 REMOVING THE ROD SYSTEM FROM THE HOLE

a) Shut off the drill b) Feed the drill up the guide to raise the bit from the bottom of the role. c) Stop rotation. d) Feed the drill down and hold the bit at the bottom of the hole under normal feed pressure e) Move the drill control on and off in short bursts to loosen the coupling threads f) Shut off the drill g) Open the steel centralizer and feed te drill up the guide h) Stop the drill feed when the coupling clears the top side of the centralizer i) Close the centralizer and feed the drill down until the coupling rests on the centralizer j) Move the continous rotation control to reverse (R.H.) rotation and unscrew the drill steel from the coupling resting on the centralizer and cthe coupling on the striking bar. k) Stop rotation and feed the drill down the guide until the striking bar engages the coupling resting on the centralizer l) Move the continuous rotationcontrol to conventional (L.H.) rotation and screw the striking bar ino the coupling. Do not screw the joint tight m) Repeats steps “f” thru “m” as oulined above to remove successive sections of steel 13.6 DRILLING TIPS In order to assure maximum operating efficiency, the following suggestions should be observed. 13.6.1 SUGGESTION FOR DRILLERS a) Never pound on stuck steel. Nothing is accomplished thereby, and the drill and bit may be permanently damaged in the process. b) Never retract the drill at full throttle. Damage to the fronthead parts may result c) Never strike the drill with tools. The cylinder or other parts may be damaged. d) Never try to repair the drill on the job. Take it to a repair shop e) Never drag a drill along the ground, as the exhaust port and other opening will scoop up dirt f) Always blow out the air supply hose and flush out water hose before conecting them to the drill. This rids the lines of dirt. g) Always be sure the drill is well lubricated. Adjust the lubricanting oil reservoir or air line oiler, so that the striking bar always shows oil film yet does not cause fogging h) Always keep the assembly rods tight and at equal tension i) Always keep the drill aligned with the drill steel and hole. 13.6.2 CARE AND USE OF BITS a) Threads on drill steel and bit should be in good condition. Grease the threads

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before use. Be sure the bit bottoms on the steel. b) Never approach the rock with the drill running. Position carefully and collar the hole at reduced throttle. This prevents damage to inserts. c) Always keep the drill fed up to the work. Insufficient feed pressure will cause the bit to become loose on the steel and will damage the threads and cause inserts to tear loose. d) Always maintain alignment between the drill and the hole. e) Never allow the hole to become filled with loose cuttings. Blow the hole frequently. f) Never retract the drill at full throttle. Use part throttle. g) Never force or broach the bit into a hole. h) Don´t rough handle steels with bits on. i) Never run a dull bit j) Remove the bit frim the steel with a Stillson or bit wrench. Never use a hammer to loosen the bit 14. PREVENTIVE MAINTANCE

The MW-140 and MW-120 Drill should be included in a definite preventive maintenance schedule to assure top performance and to maintain long and efficient service life. The following check list should be observed :

a) Assembly rods must be tightened evenly and kept tight all times. If they are not tightened evenly, the excessicee part wear and damage. Torque the assembly rod nuts to 650 lb-ft (881 N.m).

b) Blow out the air hose to get rid of precipitation, rubber particles, and dirt before connecting it to the drill.

c) Air must be reasonbly dry. Condensation resulting from temperature changes causes emulsification of the drill lube oil.

d) Keep the air line lubricator supplied with a sufficient amount of rock drill lubricating oil

e) Keep lubricating oil free of dirt f) Drill must receive an adequate supply of lubrication. Over-lubrication is as

damaging as insufficient lubrication. To adjust lubricator for the first time, disconnect the main air hose from the drifter and tie it down so it won´t flip around. Run the compressor with the lubrication metering valve 1/2 to 3/4 of a turn out, until you can see (or feel) drops of oil spraying out of the hose.

g) Regardless of the method of lubrication, it is good practice to pour 1/2 cup of oil into the air hose before connecting it to the drill.

h) Schecule regular periods for checking lubrication. Do not wait for physical evidence of poor lubrication.

i) Use the proper size hose to get a sufficient volume of air to operate the tools efficiently.

j) When using new air supply hoses, the inside of the hose must be coated with oil before attaching to the drill. Blow lubricated air through the hose to atmosphere with the lubricator at its normal setting. It can take as long as 45 minutes to coat the inside of 50 ft of hose, the inside is coated.

k) Be sure all hose connections are tight. This is important. A loose hose connection not only causes leaks, but the hose may come coompletely off the tool, whip aroound and cause injury to the operator.

l) Be certain that the striking end of the striking bar is square, flat and free of all

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sharp edges. The striking bar should be repaired or discarded if peened, crowned, or upset.

m) Be sure that the hole in the drill steel is open. n) Excessively dull bits cause slow drilling and excessive pounding within the drill.

Always change bits when there is an appreciable drop-off in drilling speed, or any noticeable change in the action of the drill. Excessive dulling results in early failure.

o) If a drill is not operating properly, do not strike it with a hammer or steel. p) When drill is to remain idle, blow oil through machine to take moisture and

prevent rusting. q) The drill should be taken apart periodically, cleaned with kerosene or safety

solvent, and inspected for wear. 15. DISASSEMBLY AND REASSEMBLY INSTRUCTIONS 15.1 PRELIMINARY DISASSEMBLY INSTRUCTIONS Before beggining any disassembly instructions of the MW-140 or MW-120, the following precautions shoud be observed.

a) Never attempt majot work on the drilll in the field. The machine may be in worse condition after major maintenance was tried in the field than before. Send the drill to the shop.

b) Clean the exterior of the drill before tearing it down; do this in clean work area c) Use a babbit hammer for driving off the heavier exterior parts. d) Handle parts carefully. Hardened parts might chip or break if dropped on a hard

surface. e) Clean disassembled parts in a solvent. Proebe ports in the backhead, air

distributor, cylinder, etc. To loosen and remove foreign matter. Place the small parts in a clean container so they will not become lost.

15.2 DRILL DISASSEMBLY

a) Feed the drill down the guide until the chick jaw retainer (75)rests on the centralizer.

b) Remove the blower hose from the hose stem (3). c) Remove the main air hose, rotation motor hoses, and exhaust hose. d) Remove the eight drill mounting plate nuts and pull the drill off the drill mounting

plate. Take the drill to a clean work area to disassemble

WARNING THE MW-140 or MW-120 DRILL MUST BE PLACE IN A HORIZONTAL POSITION FOR DISASSEMBLING

e) Unscrew the hose stem (3) from the tube retainer (1) f) Unscrew the tube retainer (1) from the backhead (11) and pull the retainer,

blower tube (inner) (5), and tube support (outer) (4) completely oout of the drill. g) Remove the two assembly rods (9) and pull the backhead (11) away from the

cylinder (26) and remove the backhead adapter ring (12). h) Remove the air distributor key (24) from the cylinder (26).

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i) Flatten the tabs on the tab washer (30) and unscrew the swivel exhaust retainer (29) to remove the retainer, swivel exhaust (27), and retaining ring (28) from the cylinder (26).

j) Unscrew the chuck jaw retainer locking lug bolt (70) and remove the chuck jaw retainer (75).

k) Pull the shank piece out of the drill l) Remove thechick jaw (74) from the fronthead (62) m) Insert a 1 in. (25mm) diameter brass rod into the fronthead end of the drill until it

makes contact with this piston stem, and drive the piston stem, and drive the piston (32) and air distributor body (22) (with liner) out of the cylinder (26)

n) If worn, drive the air distributor body liner (23) out of the air distributor body (22) o) Remove the three drive gear cover bolts (57) and lockwashers (58) and lift the

rotation motor assembly off the gear cover (54) p) Carefully pull the fronthead (62) away from the drive gear cover (54) q) Pull the drive gear cover (54) away from the piston stem bearing (33). r) Insert a brass bar in the backhead end of the cylinder (26) and drive the piston

stem bearing (33) out of the cylinder s) Examine the piston stem sleeve (35), chuck wear sleeve (36), and chuck seat

(37) in the stem bearing (33). if parts are worn, drive the roll pin (34) out of the bearing (33); press the piston stem sleeve (35) out of the backhead end of the bearing; and press the chuck wear sleeve (36) and seat (37) out of the fronthead end of the bearing (33).

NOTE The chuck (72) and chuck drive intermediate gear (66) may come out at the same time the fronthead is removed. If they do not come out, remove them at this time. Be careful not to damage the gear teeth when removing the fronthead.

18

19

15.3 ROTATION MOTOR DISASSEMBLY

a) Remove the rotation motor assembly from the drive gear cover (54). Refer to paragraph 4.2.2, step 15.

b) Remove the five motor manifold bolts (40) and washers (41), and lift the air motor manifold (38) from the gear housing (43).

c) Lift the idler gear (51) and drive gear assembly, consisting of the drive gear (44) and drive gear shaft (49), out of the gear housing (43)

NOTE

Be careful not ot damage the teeth on the pinion end of the drive gear shaft (49) when removing the drive gear assembly

d) If necessary, remove the drive gear shaft (49) from the drive gear (44). e) Remove the thrust bearing (48) from the gear housing (43).

15.4 INSPECTION OF PARTS The operating performance of the MW-140 or MW-120 is directly dependent upon the condition in which the working parts are maintained. The drills must be inspected at frequent intervals for worn or damaged parts and replacement parts installed when necessary.

a) Piston and Cylinder � Replace the piston (32) and/or cylinder (26) when a 0,010 inch (0,254 mm)

feeler gauge can be inserted between these two parts � To determine wheter the piston or the cylinder is worn, install a new piston in

the cylinder and check the clearance. b) Piston and Piston Stem Bearing

Replace the piston stem bearing sleeve (35) when a 0,010 inch (0,254 mm) feeler gauge can be inserted between the stem of piston (32) and the sleeve (35).

c) Shank Aligner Replace the shank aligner (73) when the clearance a new shank and the shank aligner is more than 0,060 inch (1,5 mm).

d) Piston and Air Distributor Liner Replace the air distributor liner (23) when a 0,010 inch (0,254 mm) feeler gauge can be inserted between the extension on the piston (32) and the liner (23)

e) Motor Bearings Do not remove motor bearings for inspection. If after visul inspection, bearings are found to be worn or damaged, replace with new parts. 15.5 PRELIMINARY REASSEMBLY INSTRUCTIONS The following precautions should be observed before reassembling the MW-140 or MW-120

a) Keep hands and tool free of dirt b) Wipe a film of clean oil over all working parts as they are assembled

20

c) Do not allow dirt or chips from soft hammers to enter the drill d) Except for press fit sushing, parts should fit together easily. If force is required, a

part is out of alignment and must be corrected to prevent binding and damage. 15.6 ROTATION MOTOR REASSEMBLY

a) Install the thrust bearing (48) in the gear housing (43). b) Slide the idler gear (51) over the idler gear shaft (53), which is pressed in the

motor gear housing (43) c) With the drive gear shaft (49) assembled in the drive gear (44), align the teeth

on the drive gear (44) with the teeth on the idler gear (51) d) Slide the drive gear (44) into the gear housing (43) so that the pinion endof the

drive shaft (49) protudes through the bottom of the houosing. e) Insert the two motor manifold locating pins (42) in the 1/2 in. (13mm) holes

provided in the top side of the gear housing (43). f) Slide the air motor manifold (38) over the locating pins (42) in the gear housing

(43). g) Secure the manifold (38) ad housing (43) together with the five motor manifold

bolts (40) and tab washers (41).

NOTE Torque the five motor manifold bolts (40) to 80 lb-ft (109 N.m).

h) To attach the rotation motor to the drill, refer to paragraph 4.2.7, steps 5 and 6

15.7 DRILL REASSEMBLY

a) Place the fronthead (62) (front end down) on a clean working surface and insert the locating pin (56) in the 1/2 in. (13mm) hole provided in the fronthead.

b) Slide the chuck (72) with shank aligner (73) into the fronthead – shank aligner end first.

c) Align the chunck drive intermediate gear (66) with the chuck gear and seat the chuck drive intermediate gear shaft in the fronthead (62)

d) Align the pin hole in the drive gear cover (54) with the locating pin (56) previously inserted in the fronthead (62). Place cover on fronthead.

NOTE

When placing the rotation motor on the cover, make sure the pinion end of the motor drive gear shaft (49) meshes with the intermediate gear (66).

e) Place the assembled rotation motor on top of the drive gear cover (54) f) Secure the fronthead (62), drive gear cover (54), and rotation motor assembly

with the three bolts (57) and lock washers (58).

NOTE Torque the thre bolts (57) to 200 lb-ft (271 N.m)

21

g) Press the chuck seat (37) into the fronthead end of the piston stem bearing (33)

until bottomed. Press the chuck wear sleeve (36) into the fronthead endof the bearing (33) until bottomed against the chuck seat (37)

h) Press the piston stem bearing sleeve (35) into the backhead end of the piston stem bearing (33) until bottomed against its shoulder. Install the roll pin (34) in its groove in the piston stem bearing/piston stem bearing sleeve.

NOTE

Do not use the piston (32) to press the piston stem bearing sleeve (35) into the piston stem bearing (33). improper seating of replacement bearing sleeves in the bearing can result in piston and bearing sleeve breakage. An assembly tool should be used to seat the sleeve.

The preceding illustration provides dimensions for fabricating an assembly tool for installing the piston stem bearing sleeve (35) in the piston stem bearing (33). The following illustration shows the fabricated assembly tool seating the piston stem bearing sleeve (35) in the piston stem bearing (33).

22

NOTE

The “Must Pass” inside diamenter dimension of the bearing sleeve (35) must be checked after the sleeve has been installed. If sleeve is distorted during installation, and does not conform to dimension specified, the I.D. of the sleeve must be honed.

a) Install the piston stem bearing assembly in the assembled fronthead making

sure the word “Top”, which is stamped on the bearing (33), is facing the top of the drill (towards rotation motor).

b) Insert the piston (32) in the cylinder (26), and fit the cylinder to the piston stem bearing (33).

c) If removed, press the air distributor body liner (23) into the air distributor body (22)

d) Place the air distributor key (24) in its keyway in the air distributor body (22), and install the air distributor assembly in the cylinder (26) making sure the air distributor key (24) is aligned with its keyway in the cylinder.

e) Install the backhead adapter ring (12) and backhead (11) on the assembled cylinder

f) Slide the washer (7) and rubber (8) over the tube support (4) until they are approximately 1 in. (25mm) from the top, and slide the tube support (4) into the backhead (11).

g) Place the blower tube rubber (6) against the tube support collar and slide the inner tube (5) into the tube suport (4).

h) Screw the tube retainer (1) with assembled “O” ring (2) into the backhead (11), and screw the hose stem (3) into the tube retainer (1).

i) Insert hte two assembly rods (9) through the backhead (11), cylinder (26),drive gear cover (54), and fronthead (62) and secure the rods with the assembly rod nuts (10)

NOTE

Rods must be tight and under equal tension. Torque the assembly rod nuts to 650 lb-ft (881 N.m)

j) Lay the drill on its back to expose the front end of the fronthead (62).

23

k) Push the shank end of the shank piece into the drill until the lugs “butt” against the shank aligner (73)

l) Slide the chuck jaw (74) over the shank piece (tongue end first) and mate the chuck jaw tongues with the tongues on the chuck (72).

m) Screw the chuck jaw retainer (75) into the fronthead (62) n) Insert the chuck jaw retainer locking lug (71) in its boss in the fronthead (62),

and secure with the locking lug bolt (70) o) Slide the swivel exhaust retainer (29) and tab washer (30) onto the swivel

exhaust (27), and install the retaining ring (28) in its groove on the swivel exhaust (27).

p) Attach the swivel exhaust assembly to the exhaust port on the cylinder. 16. PERFORMANCE TESTING A recondionated drill should be tested before it is sent back to the job. Before connecting the air hose, check to see that the lubricating oil reservoir or the air line oiler is filled. Add a small amount of Rock Drill Oil directly iinto the air inlet afor initial lubrication. The Drill should start with less than 20 PSI (138 k Pa) air pressure, with the piston reciprocating smoothly. Let the drill run in slowly ar reduced pressure long enough to see that it is in good working order. If the drills stalls, turn off the air immediately. This indicates binding due to tight fits or unevenly tightened side rods. Check rod tension first, then start the drill again. After a short period of operation, a definte rythum should develop and an even exhaust note will be heard. The drill may become warm, but should not overheat. If erratic operation continues or stalling persists, disassemble the drill and check the binding of parts. After and initial period of low pressure operation, check the performance of a reconditionated drill with that if a new one by comparing its speed under similar conditions and with normal air pressure. Once testing is completed,place plastic plugs or caps in all ports to keep out of dirt until the drill is back in service. 17. TROUBLE SHOOTING The operating troubles outlined in the following table must not be construed as an indication of the operating difficulties to be expected. The MW-140 or MW-120 Drill is constructed of the finest materials available and if the drill is porperly installed and serviced, the onyl troubles that will develop will be due to normal wear associated with long, hard service.

24

TROUBLE PROBLEM CAUSE REMEDY

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