Utilicor Minicor 2 Operation Manual Download

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Table of Contents

minicor-2

™

at a Glance

Introduction

Suggested Operator Qualification and Training

Pre-Trip Procedure

Pre-Departure Checklist

Utilicor Process Pilot Bit and Integral Center Pilot Hole

Tips for a Successful Coring Operation

Step 1: Operating Instructions for Utilicor Rotary Cutter

Step 2: Coring Process

Step 3: Site Clean Up

Step 4: Detach Minicor-2

Tips for Successful Core Reinstatement

Core Reinstatement Procedure with Utilibond™

Core Reinstatement Equipment

Cold Weather Procedures

minicor-2

™

Equipment Maintenance

Drill Carriage Schematic

Pillow Block Assembly

Troubleshooting

minicor-2

™

Hydraulic Schematic

minicor-2

™

Electrical Schematic

Warranty

Utilibond™ MSDS

Utilibond™ WHIMIS.

Utilibond™ OSHA

Summary of Contents for Minicor 2

Page 1: ...ry Coring Attachment And Utilibond Permanent Pavement Bonding Compound Operations Manual 2010 Version MC2 1 1 Utilicor Technologies Inc 36 Densley Avenue Toronto Ontario Canada M6M 2R1 1 800 572 6666 www utilicor ca ...

Page 2: ... Instructions for Utilicor Rotary Cutter 13 Step 2 Coring Process 14 Step 3 Site Clean Up 17 Step 4 Detach Minicor 2 18 Tips for Successful Core Reinstatement 19 Core Reinstatement Procedure with Utilibond 21 Core Reinstatement Equipment 24 Cold Weather Procedures 25 minicor 2 Equipment Maintenance 28 Drill Carriage Schematic 30 Pillow Block Assembly 31 Troubleshooting 32 minicor 2 Hydraulic Schem...

Page 3: ...r 2 at a Glance Up Down Control Orbital Manual Valve Wash Pump Stabilizers E Stop Cutter Water Right Stabilizer Drum Motor Pillow Block Drive Adapter Core Drum Beacon Hydraulic Quick Connects Drum Speed Adjuster Water Petcock Water fill Port ...

Page 4: ...hnologies Inc 3 Minicor 2 at a Glance Left Stabilizer Winterizing Assembly Core Puller Holder Water Filter High Pressure Wash Pump Lockable Toolbox Drill Carriage Adjuster Door Bash Plate holder located on inside of door ...

Page 5: ...usands of keyhole excavations with ZERO failures Utilibond our proprietary core bonding compound is an integral part of the reinstatement process and has been independently tested and shown to create a bond in less than 30 minutes at 70ºF that is stronger than the original pavement and is capable of supporting the combined weight of five transit buses in under half an hour The Purpose of The Opera...

Page 6: ...facilitate any training needs you may require Please contact us directly for more information at 1 888 572 6666 toll free or via email to info utilicor ca For safety reasons this entire Operations Manual should be reviewed prior to operation of the Utilicor Rotary Coring Unit Failure to review the entire manual prior to commencing operations or to follow warnings and operating procedures outlined ...

Page 7: ...r s license for the appropriate class or level of motor vehicle or piece of equipment being operated Successful completion of a practical on site training program and operating examination for the Utilicor equipment administered by a qualified trainer First Aid and CPR training Traffic safety and awareness training for construction sites Safe excavation procedures training Underground electrical a...

Page 8: ...unit is safe to operate Pre Trip Inspection The following is a suggestion of some important elements of a pre trip procedure Consult your own company s procedures before continuing Before inspection ensure that the vehicle is positioned on a clean dry and level surface with wheels chocked both front and back 1 External Visually inspect the minicor 2 unit Check for hydraulic fluid and other leaks F...

Page 9: ... Are the pilot bit and coring drum in good condition Examine both for excess wear and replace if necessary Check to make sure the truck has spares of both items 7 Do you have all necessary personal protection equipment 8 Is the equipment secured to the trailer for transit 9 When loading the skid steer and minicor 2 on the trailer ensure that the minicor 2 is raised high enough to clear the trailer...

Page 10: ...ment and by which it is repositioned back into the pavement during reinstatement after completion of the repair Other coring processes which do not employ an integrated central pilot bit must either drill a separate bar hole in the core insert a separate lifting ring into the core or use some form of clamping mechanism or other device to lift the core out of the hole after cutting and to accuratel...

Page 11: ...an the coring drum it can provide the coring operator with an audible and sensory cue as to when the coring drum is about to core through the bottom of the pavement When the pilot bit breaks through the pavement into the sub grade there usually is a noticeable change in the sound and the feel of the coring process which can alert the operator to the fact that the coring drum is about to cut throug...

Page 12: ...work of cutting without excess pressure being applied Slow continuous turning of the orbital control wheel will allow the coring teeth to work and cut through the pavement without experiencing drum kick back or stalling of the hydraulic motor You are applying too much downward pressure if the drum stops turning or if the minicor 2 lifts off the ground 6 When cutting through asphalt after you have ...

Page 13: ...ntly rock the core back and forth 10 If the core should become stuck in the drum use the holes in the top of the coring drum to insert a push rod or spud bar to tap the top of stuck core remembering to rotate the drum a quarter turn after each tap Never tilt the drum to the horizontal position if a core is stuck in the drum or you could bend the shaft Keep the drum perpendicular and push the core ...

Page 14: ... on the hydraulic motors 3 If there is any back pressure in the hydraulic system on the minicor 2 or skid steer engaging the quick connect hydraulic couplers may be difficult Refer to the operation manual of your skid steer to determine how to de energize the hydraulic pressure in the auxiliary lines If the pressure was not released from the pressure hose before the unit was disconnected you will ...

Page 15: ...t i e DO NOT lift the skid steer wheels off the ground otherwise the settling of the hydraulics of the skid steer over time will result in an altered angle of approach of the core drum and cause the coring drum to bind or stick as you cut IMPORTANT Make sure that all 4 feet of the minicor 2 unit are in direct contact with the pavement and that the unit is resting firmly on the pavement 3 Engage hy...

Page 16: ... the coring operation 7 Turn the cutter on In the event of an emergency or hydraulic failure push the Estop in and all flow will be diverted back to the skid steer 8 You may have to adjust the flow control depending on the hydraulic flow of the skid steer The core drum should spin at approximately 12 Core Drum 200 to 225 RMP 18 Core Drum 175 to 200 RPM 24 Core Drum 100 to 130 RPM Cutter water petc...

Page 17: ...pavement 11 Raise Drum turning the control orbital counter clockwise until the drum is raised to its maximum height Using the Skid steer lift the minicor 2 off the ground to a safe transport height and move skid steer and the coring attachment away from cut core Lift the core out using core puller Relocate the core to safe place for reinstatement later CAUTION Some cores are VERY HEAVY Depending o...

Page 18: ...d connect the gun and wand Open the high pressure petcock 2 Turn water pump on 3 Detent the valve handle towards yourself to engage the high pressure pump 4 Wash down site and minicor 2 of all slurry and debris High Pressure Wash Petcock Water pump switch High Pressure Wash Pump ON Off ...

Page 19: ... 2 Relieve pressure in the skid steer s hydraulic system Consult skid steer operations manual The hydraulic hoses attached to the skid steer should go limp Failing to do this will make it virtually impossible to reconnect the couplings 3 Disconnect the couplers 4 Unlatch minicor 2 attachment ...

Page 20: ...tilibond powder DO NOT ALTER THE RATIO OF WATER TO UTILIBOND 6 Mix Utilibond using a portable drill powered mixing tool for at least 3 minutes until it reaches a creamy consistency 7 Gently pour Utilibond into the hole do not disturb base 8 Carefully lower the core into the hole Keep in mind that set times are dependent on temperature Utilibond achieves bond strength of 50 000 pounds five times th...

Page 21: ...ll be gently forced out through the kerf and pilot hole where it can be removed with a trowel and disposed of The core should be perfectly level with the road 11 When finishing the reinstatement keep the paved surfaces around the drying Utilibond wet and final clean up of the original paved surfaces will be easier 12 If you are reinstating a core on a hill or incline be patient while finishing the...

Page 22: ...ith a 1 2 bed of pea gravel Because the pea gravel is added fill that was not present before the backfill should be left approximately 1 to 2 lower than the base of the pavement Undercut the bottom of the existing pavement in the hole by about 1 all around to allow the pea gravel to fill under the pavement Utilibond will impregnate the pea gravel and create a solid base plug for the core to bond t...

Page 23: ... with water exactly to the bottom of the indicator line on the side of the pail 2 liters The proper proportion of water to Utilibond is critical to effective performance If necessary use a 2 litre jug to achieve exact water proportions DO NOT ALTER THE RATIO OF WATER TO UTILIBOND 5 Using a handheld drill and appropriate mixing tool we recommend the Mudslinger brand available at Home Depot mix the ...

Page 24: ...it with the surface of the core level with the surrounding pavement Do not apply too much pressure as you will not be able to raise the core if you push it below the level of the pavement 8 Carefully clean off the excess Utilibond from the surrounding pavement before it dries The bonding compound will begin to set up within approximately 15 minutes at 70 F Keep the paved surfaces around the drying...

Page 25: ... P E Core Puller Hand drill with mixing blade Shovel Broom Small pointing trowel 8 taping trowel Wire brush Grouting Sponge Utilibond Caution Tape Signs Hole Cover Traffic Control Devices Clean water Pea gravel Head Protection Hearing Protection Safety Boots Safety Glasses Gloves Traffic Vest Dust mask ...

Page 26: ...e coring equipment during colder months or if the equipment is to be stored outside To do this a Close the petcock on the water intake hose b Open the brass petcock on the winterizing tube c Insert winterizing tube in a jug of environmentally friendly antifreeze and turn on water pump open the core drum petcock run until the antifreeze fills the feed lines and the pillow block Close the petcock d ...

Page 27: ...ements In northern climates most of the roadwork involving pavement repair and reinstatement has been limited to the period between April and November when the ambient temperature is above 40ºF and there is no likelihood of frost Without some form of external heat source or cold weather chemical additives no water soluble cementitious product will set up and gain strength at temperatures below fre...

Page 28: ...libond s super fast strength gain formula the retained heat in the pre heated core and pavement eliminates the ice crystal problem for a sufficient time to allow the hydration reaction to kick in roughly 5 to 10 minutes That reaction generates additional internal heat that allows Utilibond to gain strength over the next 30 minutes or so Once this initial bonding reaction takes place freezing tempe...

Page 29: ...mber of cuts completed This will help you to better gauge the time when bits and drums will need to be replaced or refitted Excessively worn cutting teeth on the drum will result in an undersized narrower kerf and could cause the core or coupon to become stuck inside the drum NOTE Because of the enormous variability of working conditions there is no such thing as normal when it comes to assessing ...

Page 30: ...pect all water fittings control valves for condition Repair or replace as required 7 Keep the minicor 2 clean A clean piece of equipment is easier to maintain easier to inspect for overall condition will perform better and be safer to operate Contact Utilicor directly for any parts manuals for original equipment found on your truck or minicor 2 attachment that are not found in this manual ...

Page 31: ...arriage Adjustment The new igus drill carriage assembly requires NO GREASE AND NO ADJUSTMENTS The DryLinT are Self adjusting carriage automatic clearance adjustment Maintenance free dry operation Corrosion resistant Hard anodized aluminum rails ...

Page 32: ... 2010 Utilicor Technologies Inc 31 ...

Page 33: ...ndle Shaft 1 2 PB TB Tapered Bearing 2 3 PB BR Tapered Bearing Race 2 4 PB MS Pillow Block Shim 1 5 PB PB Pillow Block Casing 1 6 PB WS Pillow block Water Seal 2 7 PB EX Pillow block Key stock 1 8 PB SW Pillow Block Water Swivel 1 6 Part No Description Qty Pillow Block Assembly ...

Page 34: ...can be picked up while doing a walk around the truck during operation This may lead to the discovery of such things as oil leaks or overheating of parts FEEL The sense of feel usually applies when doing an inspection after the unit has been working for sometime In warmer climates it is good practice to feel certain hydraulic components or tanks for excessive heat If there is a problem of oil overh...

Page 35: ...220 B03F060P0151 THREE BANK CDS60 VALVE Set to 3 GPM Pressure Line from Skid Steer Return Line to Skid Steer MC 2 Hydraulic This drawing and the information contained herein are the sole property of Utilicor Technologies Inc No copies or transmittals of this information are permited without written consent of Utilicor Technologies Inc TECHNOLOGIES INC Date 01 05 2010 Revision MC2H D Created by SH ...

Page 36: ...his drawing and the information contained herein are the sole property of Utilicor Technologies Inc No copies or transmittals of this information are permited without written consent of Utilicor Technologies Inc TECHNOLOGIES INC Date 01 05 2010 Revision MC2E D Created by ST Approved by AP MINICOR 2 Project Scale NO SCALE Sheet 1 of 1 Electrical Schematic ...

Page 37: ...parts of said product found to the Vendor s satisfaction to be defective upon examination and provided that such part or parts shall be returned to the Vendor s facility at no cost to the Vendor Labor charges to install any replacement part will be allowed in accordance with the Vendor s schedule of applicable labor rates The Vendor shall not be liable for any freight travel costs or other similar...

Page 38: ...n water 10 Specific gravity 2 2 Coefficient of water oil distribution N Av Vapour pressure PSIG N Av Boiling point N Av Freezing point N Av pH 12 5 aqueous solution Vapour density Air 1 N Av Evaporation rate BuAe 1 N Av Volatiles by weight N Av SECTION IV FIRE AND EXPLOSION DATA Conditions of flammability Not considered flammable Flash point Method N Ap Auto ignition temperature N Av Upper flammab...

Page 39: ...ort term exposure to dry dusts may cause mild irritation Longer exposures or contact with wet product could cause severe irritation and or chemical burns Burns may be delayed Eyes Direct eye contact may cause mild to severe irritation Could cause chemical burns and eye damage if not promptly removed SECTION VI TOXICOLOGICAL PROPERTIES CONTINUED Ingestion May be harmful if swallowed May cause irrit...

Page 40: ...cording to recommendations listed below Dispose in accordance with all applicable government regulations PROTECTIVE EQUIPMENT Respiratory protection For prolonged exposure or if the TLV is exceeded wear NIOSH approved dust respirators Ventilation Use in well ventilated area Use general or local exhaust ventilation if the TLV is exceeded or is not known Protective gloves Effects on the skin may be ...

Page 41: ...ermissible Exposure Limit IARC International Agency for Research on Cancer NIOSH National Institute of Occupational Safety and Health CAS Chemical Abstract Services ACGIH American Conference of Governmental Industrial Hygienists OSHA Occupational Safety and Health Administration Reference 1 ACGIH Threshold Limit Values and Biological Exposure Indices for 2002 2 International Agency for Research on...

Page 42: ... conditions Keep away from acids and incompatibles Wash thoroughly after handling Keep container tightly closed when not in use Store in a cool dry well ventilated area away from incompatibles FIRST AID If inhaled remove victim to fresh air Obtain medical attention For skin contact immediately wash skin with soap and water Obtain medical attention If in contact with eyes immediately flush eyes wit...

Page 43: ... inhaled remove to fresh air If not breathing give artificial respiration If breathing is difficult give oxygen Get medical attention FIRE Use CO2 dry chemical or foam Water can only be used to cool exposed material Product becomes alkaline on contact with moisture SPILL OR LEAK Carefully shovel or sweep up spilled material and place in suitable container Avoid generating dust Use appropriate Pers...

Page 44: ... 2010 Utilicor Technologies Inc 43 ...

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