DM45, DM50, DML Instruction Manual - English - October 2011

Atlas Copco Drilling Solutions
Instruction Manual
MODEL: DM45,DM50,DML

Read the instruction manual before operating this equipment.
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Atlas Copco Drilling Solutions, LLC
2100 North First Street
Garland, Texas, 75040
(972)496-7400
Rev 006 Last Revision October 2011 toc - i
TABLE OF CONTENTS
DM45,DM50,DML Instruction Manual
TITLE PAGE
SECTION 1 - INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How this manual is organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Where to find information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Procedure When Receiving the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Identification Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Drill Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Instruction Manual Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Drill Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Standard on the DM45: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Standard on the DML: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Rotary Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Undercarriage and Propel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
J acks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Operators Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Identification of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
SECTION 2 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 - Safety and Health. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety and Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Health Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Emergencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 - Safety Precautions and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Drill Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Designated Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Non-Designated Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electrical Safety on Drilling Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Protection against Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Handling of Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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Handling of Failed Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Safety Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Qualify Your Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Equipment Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Operation Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Safety Instructions Governing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Setup and Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Electrical Power Line Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Operating Safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Drilling Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Propel (Tram) Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Stopping and Shutdown Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Wire Rope & Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Hot Oil and Components Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Cylinder Repairs or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Coolers and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Warning of Special Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Overhead Electric Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Grade Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Transporting and Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.3 - Safety Decals and Nameplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Safety Decals & Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
SECTION 3 - SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drill Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Non Designated Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Environment Rate Factor Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Duty: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Ambient Temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Altitude:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Service:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Application Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Operational Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Ambient Temperature Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
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Ground Pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Maximum Allowable Slope Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Operating Conditions for Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sound Pressure Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Vibration Exposure Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
DM45,50 DML Stability / Gradeability Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DM45,50 Drill Maximum Slope (Drill On J acks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
DML Drill Maximum Slope (Drill On J acks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Standard Equipment and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Standard on the DM45: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Standard on the DML: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Leveling J acks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Undercarriage and Propel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Tower, Carousel and Drill Pipe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
DRILL PIPE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
DM45,50 Rod Capacity Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
DML Rod Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Feed System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Power Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
DM45,50 Power Pack Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
DML Power Pack Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
DM45,50 Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
DML Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Electronic Air Regulation Control System (EARS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Cooler Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Hydraulic System Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Hydraulic Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Hydraulic System Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Hydraulic System Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
4000#Winch (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
8000#Winch (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Cab Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Proheat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Cab Sunshades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Cab Microwave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Rotary Head Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Cab Buddy Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Cab Tramming Inclinometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
DEI / Sprocket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Operators Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Tramming and J ack Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Drill Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Drill Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Air Regulation Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Ignition Console and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Engine Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Heating/AC Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
toc - iv Rev 006 Last Revision October 2011
TABLE OF CONTENTS
TITLE PAGE
Leveling Bubble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
DHD Lube Switch (HP Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Night Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Dust Collector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Water Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Angle Drill Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Strobe Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Electric Warning Horns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
High Intensity Discharge Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Fast Service Box and Hand Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Fire Extinguishers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Fire Suppression System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Fan Control (Cooler). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Remote Propel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Central Hydraulic Test Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Auto Thread Lube/Thread Greaser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Central Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Racor Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Tower Angle Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Timing Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Head up tram interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Engine Pre-lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Battery Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Arctic Articulating Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Cold Weather Package (Diesel Machine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
240 Volt Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Tow Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Dimensions and Weights DM45,50,DML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Dimensions and Weights DM45,50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Dimensions and Weights DML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Dimensions and Weights DML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
SECTION 4 - CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4 - Operating Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4 - Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operators Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Drill / Feed Function Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Gauges Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Engine Function Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Engine Diagnostic Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Compressor Functions Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Tram Functions Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Non-Cab Controls and Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Remote Propel System (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Hydraulic Hand Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Fan Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Rev 006 Last Revision October 2011 toc - v
TABLE OF CONTENTS
TITLE PAGE
Fire Suppression System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
SECTION 5 - OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5 - Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Safe Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Controls and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Drill / Feed Function Panel (Figure 5-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Breakout Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Carousel Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Carousel Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Chain Wrench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Rotation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Drill Feed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Drill Throttle Control (HP Drills). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Drill Feed Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Holdback Force (HP Drills). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Compressor Function Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Standard Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
EARS Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Tram Function Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Pre-Operation Controls Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Procedures and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Engine Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Verify Gauges & Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Stopping Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Propel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Stopping Drill Propel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Leveling The Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Raising/Lower The Tower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Tower Pinning (Vertical)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Tower Pinning (Angle Drilling Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Over Pressure Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Carousel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Setup for Carousel Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Carousel Operating Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Drill Rod Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Adding Drill Rod Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Add Drill Rod to Drill String. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Remove Drill Rod From Drill String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Rotary Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Rotary Drill String Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
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TITLE PAGE
Stabilizer Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Tricone Bit Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Rotary Drilling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Rotary Bit Changing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
DHD Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Downhole Drill String Tools and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
DHD Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
DHD Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
DHD Button Bit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Installing DHD Hammer to Drill Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Starting the Hole with a DHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
DHD Drilling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Bit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Removing Bit from DHD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Removing DHD from Drill String. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
General Drilling Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Transporting The Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Drill Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Loading Drill by Drive On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Loading Drill with Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Tie Down Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Towing The Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
General Towing Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Unlocking the Parking Brake (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Towing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Special Conditions of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Cold Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Hot Weather Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Water and Muddy Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
High Altitude Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Preservation & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
SECTION 6 - MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 - Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance Safety and Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fluid Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lines, Tubes and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fire or Explosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Crushing or Cutting Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Mounting and Dismounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
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Engine Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Handling Fluids and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.2 - Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Maintenance Schedule Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3 - Refill Capacities / Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Hazardous Substance Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Atlas Copco Recommended Oils and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Anti-Freeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Compressor Oil (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Compressor Oil (Arctic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Hydraulic Oil (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Hydraulic Oil (Arctic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Final Drive Oil (Tracks). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.4 - Maintenance As Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Service As Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Clean the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Loose Bolted Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Feed Cable & Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Replacement Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Feed Cable Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Winch Wire Rope Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
3600#Winch Wire Rope, Ball and Hook (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
8000#Winch Wire Rope, Ball and Hook (Option DML Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Feed Cable/Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Cable Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Grease Drum Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Change Grease Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Auto Thread Lube / Thread Greaser Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6.5 - Maintenance (8-10 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Overpressure Control System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Over Pressure System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Engine and Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Air Cleaner Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Connections and Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Empty Dust Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Engine Oil, Belts and Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Check Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Standard Fill Engine Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Engine Oil Quick Fill (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Engine Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Fuel Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
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Fuel Quick Fill (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Cooling System (Radiator & CAC) and (HOC & COC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Receiver Separator Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Drain Water from Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Receiver Tank Oil Quick Fill (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Drain Water from Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Check Hydraulic Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Hydraulic Tank Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Rotary Head Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Rotary Head Upper Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Clean the Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Dropout Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Suction Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Rod Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Manual Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Tower Central Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Frame Central Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Sheaves and Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Carousel and Cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Gearbox Driveshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
J ohn Bean Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
6.6 - Maintenance (50 Hours or Weekly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Battery Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Hoist (Winch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Hoist (Winch) Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Pump Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
FMC J ohn Bean (8 GPM) Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Change Initial Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
Undercarriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Oil Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Final Drive Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Final Drive Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Track Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
6.7- Maintenance (100 - 150 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88
Hoist (Winch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Hoist (Winch) Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Track Planetary Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Final Drive Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
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TABLE OF CONTENTS
TITLE PAGE
Change Initial Track Planetary Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6.8 - Maintenance (250 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Cat Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Cat Engine Oil and Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Drain Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Remove Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Quick Fill Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Cat Engine Fuel and Coolant Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Engine Valve Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
Cummins Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Cummins Engine Oil and Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Drain Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Remove Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Quick Fill Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Cummins Engine Fuel and Coolant Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
QSK19 (Tier 2) Fuel Filters Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Air Cleaners (Engine and Compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Primary and Safety Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122
Air Cleaner Pre-Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Air Cleaner Rain Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
Air Cleaner Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-124
Air Cleaner Service Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126
6.9 - Maintenance (500 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
Hydraulic Oil Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Hydraulic Fluid Condition Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129
Drain Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-130
Hydraulic Tank Breathers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
Pump Drive Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Change Initial Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135
Feed Cable and Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-137
Cable/Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-137
Victalic Air Hose and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
Air Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
Coupling Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139
Preparatory Steps for Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-139
Impact Wrench Usage Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-143
Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-144
Proper Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-144
Hoist (Winch) 8000#. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
Check Winch Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
Change Compressor Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-145
Tower Feed Cables and Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-147
toc - x Rev 006 Last Revision October 2011
TABLE OF CONTENTS
TITLE PAGE
Check Feed Cables and Chain Sag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-147
6.10 - Maintenance (1000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-148
Compressor Oil Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Change Receiver Tank Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Drain Receiver Tank Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-149
Hydraulic Oil Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-151
Main Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-153
Case Drain Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-154
Rotary Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-155
Rotary Head Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-156
Hoist (Winch) 8000 # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-157
Rod Changer Reducing Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-158
6.11 - Maintenance (1500-2000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-159
Receiver Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-160
Receiver Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-160
Compressor Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-162
Track Planetary Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-163
Change Planetary Gearbox Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-163
Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-164
Air Compressor Discharge Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-165
Compressor Discharge Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-165
6.12 - Maintenance (3000 Hours or 3 Years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166
Cat Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-167
Change Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-167
Drain Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-167
Flush Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-168
Filling Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169
6.13 - Maintenance (5000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-172
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-172
Change Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-172
6.13 - Maintenance (6000 Hours or 2 Years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-178
Cummins Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-179
Change Engine Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-179
Drain Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-179
Flush Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-180
Filling Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-181
6.14 - Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-184
Standard Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-184
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-184
Head Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-184
Recommended Torques in Foot Pounds (ft/lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-185
Recommended Torques in Nm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-186
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-187
Head Marking or Class. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-187
Recommended Torques in Foot Pounds (ft/lbs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-188
Recommended Torques in Newton-meters (Nm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-189
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SECTION 7 - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Fluid Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lines, Tubes and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fire or Explosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Crushing or Cutting Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Mounting and Dismounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Before Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.2 - Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Fluid Power Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Line Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Crossing Line Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
J oining Line Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Flexible Line Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Arrow Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Reservoir or Tank Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Fluid Container Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Accumulator Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Restrictor Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Activating Device Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Miscellaneous Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Pump and Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Pump Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Hydraulic Motor Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Instrument Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Sequence Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Directional Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Two Position Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Three Position Flow Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Valve Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Three Position 4-Way Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Forward Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Reverse Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Valve Centers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Series Parallel Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Pilot Operated Lock Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Overcenter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
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Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.3 - Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Main Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Propel Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Propel Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Motor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Diverter Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Propel/Drill Mode Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Drill/Propel Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Loop Filling/Replenishment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Loop Flushing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Oil Path Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Feed & Rotation Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Main Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Rotation Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Rotation Motor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Rotation Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Diverter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Drill/Propel Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Feed Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Remote Compensator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Over Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Over Pressure System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Regen Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Feed Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Load Holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
Rotation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Trouble Shooting Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Vent Feed Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Leak Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Down Feed Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
6 - Spool Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
9- Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Cooling Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Electric Over Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
General Concepts and Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Parker/Denison 9A Stroker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
EHC Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Dust Collector Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105
7.4 - Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
Electrical System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
Starting Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107
Electrical System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107
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TITLE PAGE
Cat Sensors and Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Cat Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
Cummins Engine Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120
7.5- Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Compressed Air System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Compressed Air System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Standard Compressor (Non-EARS) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
Operator Observed Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-128
Compressor Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130
Pneumatic System Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
Compressor Oil Lube System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132
Low Pressure Compressor (Non-EARS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132
Separation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137
Regulation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139
Regulation System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-140
Operation of Low Pressure Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-144
Compressor Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-149
High Pressure Compressor (Non-EARS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150
Separation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157
Regulation System - High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-159
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-174
Air Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-175
Electronic Air Regulation System (EARS) Compressor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-179
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-179
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-179
EAR-EFR Diagnostics (Flow Chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-188
3.1 Standard Test Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-199
3.2 Error Code Meaning and Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-199
3.3 Blown Fuse Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-202
3.4 Actuator Diagnostic Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-203
3.5 Actuator Test Using An Actuator Test Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-203
3.6 Potentiometer Testing Using A Multi-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-206
3.7 Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-207
3.8 Summed On/Off Inputs Decode Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-209
4.2 Connectors Of Sensor and Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-210
4.3 Female Control Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-212
7.6 - PowerView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-213
Murphy Link PowerView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-213
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-213
Faceplate Features and Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-214
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-215
Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-215
PowerView Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-216
Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-216
Engine Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-217
Stored Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-219
Faults and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-220
Auxiliary Gauge Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-220
Active Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-222
Shutdown Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-224
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TITLE PAGE
Back Light Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-226
Contrast Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-227
Select Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-229
Setup 1-Up Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-230
4-Up Display Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-235
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-238
7.7 - HNBR Hose / Victaulic Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-243
Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-244
Preparatory Steps for Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-244
Impact Wrench Usage Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-247
Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-248
Proper Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-248
7.8 - Dixon Boss Clamp Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-250
Torque Procedure For Dixon 4 Bolt Clamp With Atlas Copco Hose. . . . . . . . . . . . . . . . . . . . . . . . . 7-250
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-250
Process: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-250
Torque Procedure For Dixon 6 Bolt Clamp With Atlas Copco Hose. . . . . . . . . . . . . . . . . . . . . . . . . 7-252
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-252
Process: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-252
7.9 - IC Clamp Installation and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-254
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-254
7-10 Engine Heater (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-256
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-256
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-257
Principal of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258
1. Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258
2. Fuel Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258
3. Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258
4. Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259
5. Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259
6. PROHEAT Control Module (PMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259
7. Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259
8. Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259
9. Inspection Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
10. Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
11. Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
12. Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
13. Overheat Breaker Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
14. Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
15. On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260
16. Seven (7) Day Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-261
Normal Operating Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-261
Function and Component Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-262
Troubleshooting & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-263
On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264
Function Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264
(1) Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-264
(2) Flame Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-266
(3) Coolant Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-267
(4) Overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-268
(5) Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-269
(6) Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-271
(7) Temp Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-273
(8) Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-274
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(9) Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-276
(10) Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-278
(11) Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-280
(12) Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-282
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-283
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-284
Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-286
Fuel Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-287
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-288
Operational Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-289
Smoking Exhaust and Smelly Exhaust Fumes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-289
Low Heat Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290
Engine Temperature Gauge Reads Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290
Backfiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290
Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-290
Clean Heater Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-291
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-291
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-291
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-292
Clean Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-292
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-292
Engine Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-293
Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-293
Heater Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-294
Heater Wiring Diagram (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-295
Timer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-296
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-296
Heater Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-296
Wiring & Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-297
To Set Clock (Time & Day). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-298
To Set Single Timer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-298
To Set Dual Timer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-299
Manual & Timed Heater Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-300
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-301
7.11 Centro-matic Lube (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302
Fill Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302
Prime Feed Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-302
Failures without Alarm Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-304
Failures with Alarm Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-305
7.12 - Bean (FMC) Water Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-306
Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-306
Replacing Piston Cup Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-306
Replacing Suction and Discharge Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-309
Replacing the Power End Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-311
Servicing the Wrist Pin Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-315
Fastener Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-317
Trouble-Shooting Piston Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-317
toc - xvi Rev 006 Last Revision October 2011
TABLE OF CONTENTS
TITLE PAGE
SECTION 8 - GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 - Glossary Of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 - Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
DRILLING SOLUTIONS Rev 006 Last Revision October 2011 1-1
Section 1 - Introduction
DM45,DM50,DML Instruction Manual Section 1 - Introduction
1-2 Rev 006 Last Revision October 2011 DRILLING SOLUTIONS
1.1 - Introduction
General Information
This Safety, Operation and Maintenance Manual has been developed to present the safety,
operations and preventive maintenance requirements for safe, effective operation of the Atlas
Copco Drilling Solutions DM45,DM50,DML Blasthole Drills.
The purpose of this manual is to provide the operator and site maintenance personnel with the
knowledge of the fundamental rules and criteria to be followed for on-site use and
maintenance of a DM45,DM50,DML Blasthole Drill Rig.
The operator and site maintenance personnel must read and fully understand this Safety,
Operation and Maintenance Manual before operating or servicing the drill. This manual has
been organized to present the safety precautions, operation requirements and appropriate
information needed to:
1. Safely operate the DM45,DM50,DML Blasthole Drills while achieving optimum
production.
2. Understand the operating principal of each system associated with the
DM45,DM50,DML Blasthole Drills.
3. React effectively and safely to emergency and alarm conditions.
4. Perform the necessary pre-operational and post-operational checks on the drill.
Always keep the Instruction Manual on the drill and available to the operator and helper.
Section 1 - Introduction DM45,DM50,DML Instruction Manual
How this manual is organized
Although there is a substantial amount of information contained in the manual, it has been
organized so the reader can easily find the specific information needed. You are therefore
advised to follow the operation and maintenance instructions as specified in the drill instruction
manuals.
The manual is divided into sections by information based on answers to the following
questions:
1. What are the specific operator responsibilities? (See Section 2)
2. What are the specifications of the drill itself? (See Section 3)
3. What instruments and controls are used by the operator to operate and monitor
the drill? (See Section 4)
4. What are the operating capacities and limitations of the equipment? (See
Section 5)
5. What inspections are the responsibility of the operator, and when must they be
made? (See Section 6)
6. What should the operator do when problems arise. What are the types of
hydraulic, electrical and compressor systems? What is the correct operator
troubleshooting response? (See Section 7)
7. What do the various terms mean that are used in this manual? (See Section 8)
Where to find information
Each manual has a table of contents. If you are uncertain which section contains the
information or where the information is located within a particular section, the first step is to
consult the table of contents.
This instruction manual consists of the eight (8) sections shown below:
Section 1 - Introduction describing the drill
Section 2 - Safety
Section 3 - Technical Specifications
Section 4 - Operating Controls and Instruments
Section 5 - Operating Instructions
Section 6 - Maintenance Instructions
Section 7 - Systems/Troubleshooting
Section 8 - Glossary
If any part of this manual cannot be understood, contact your supervisor or local Drilling
Solutions Distributor. This is an essential condition for working safely with the drill.
The correct drill operation, use and regular maintenance are also essential elements
necessary to provide the highest performance and safety.
Note:
The present manual is accompanied with an engine instruction manual. You are therefore
advised to follow the operation and maintenance instructions as specified in both the engine
and drill instruction manuals.
Throughout the manual, Dangers, Cautions, Warnings, Notices and Notes are used to
provide the reader with special noteworthy information. In this manual, these terms have the
following significance:
DANGER
!
DANGER is used to indicate the presence of a hazard which will cause
severe personal injury, death or substantial property damage if the
warning is ignored.
WARNING
!
WARNING is used to indicate the presence of a hazard which can cause
severe personal injury, death or substantial property damage if the
warning is ignored.
CAUTION
!
CAUTION is used to indicates the presence of a hazard which will or can
cause minor personal injury or property damage if the warning is ignored.
NOTICE
NOTICE is used to notify people of installation, operation or maintenance
information which is important but is not hazard related. The hazard
warnings should never be included under the Notice signal word.
Procedure When Receiving the Drill
Your drill has been tested, accurately checked and prepared for shipment. Every part of the
drill, including the detached parts, has been accurately checked before being shipped from the
factory.
When you receive the drill, and before unpacking the equipment, check if damage has
occurred during transport and if any parts are missing. Check the equipment by consulting the
shipment documents.
If the goods are damaged, or if parts are missing, inform the freight agent as soon as possible.
He will inform you regarding how to proceed in order to make a complaint.
Identification Data
An exact description of the model type and the serial number of your drill will facilitate fast and
efficient response from our parts and service support operations.
Always provide the model of your drill and its serial number when you contact the local Drilling
Solutions service or parts office.
We advise you to enter your drill data on the following lines to maintain drill and engine
information necessary to facilitate fast and efficient response from our parts and service
support operations:
Model:____________________________________________________________________
Drill Serial Number:__________________________________________________________
Year of Manufacture:_________________________________________________________
Engine (Mfg. and Type of Engine):
_________________________________________________________________________
Engine Serial Number:
_________________________________________________________________________
Drill Identification
Engine Identification
The engine identification number can be found on the engine identification plate. The engine
data plate, as shown above, provides the model identification and other important data about
the engine. Refer to the engine operators instruction manual for further information on the
identification information. Have the following motor data available when communicating with
an Authorized Repair Location. The data on the data plate is mandatory when sourcing service
parts:
1. Engine Serial Number (ESN)
2. Control Parts List
3. Model
4. Advertised Horsepower and RPM
Instruction Manual Location
The instruction manuals are located within easy reach of the operator. A storage compartment
on the right side of the console control panel provides space for the drill manual. Also located
in the cab, is the Laminated Safety Manual.
General Information
All safety rules in section 2 must be observed.
If further information is required concerning recommended blasthole drilling applications,
contact your local Atlas Copco Drilling Solutions distributor.
Atlas Copco Drilling Solutions reserves the right to make any changes or modifications without
prior notice and without incurring any liability to retrofit machines previously shipped from the
factory.
Drill Description
DM45
The Atlas Copco DM45 is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling
rig specifically designed for production blasthole drilling; it is productive, tough, versatile, and
durable. The DM45 comes with a 30 (9.15 m) tower. Maximum drill depth (not available with
all rod sizes/thicknesses) is 175 (53.3 m).
Hole size range for rotary drilling applications is nominally 5-7/8 in. to 9 in. (149 mm to 229
mm). For DHD drilling with the high-pressure air option, nominal hole size range is 6 in. to 8
in. (152 mm to 203 mm). Feed pressure generates a weight on bit force of up to 45,000 lbf.
(200 kN). The DM45 utilizes a diesel engine to drive the air compressor and hydraulic system.
Operation of the drill is performed using electric over hydraulic controllers from an
ergonomically designed operator cab.
DML
The Atlas Copco DML is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling
durable. The DML comes standard with a 30 (9.15 m) tower, and there is also an optional 35
(10.7 m) tower. Maximum drill depth (not available with all rod sizes/thicknesses) with 35
tower is 205 (62.5 m), maximum depth with 30 tower is 175 (53.3 m).
Hole size range for rotary drilling applications is nominally 6 in. to 10-5/8 in. (152 mm to 270
mm). For DHD drilling with the high-pressure air option, nominal hole size range is 6 in. to 9-
7/8 in. (152 mm to 250 mm). Feed pressure generates a weight on bit force of up to 60,000 lbf.
(267 kN). The standard DML utilizes a diesel engine to drive the air compressor and hydraulic
system (optionally an electric motor is also available). Operation of the drill is performed using
electric over hydraulic controllers from an ergonomically designed operator cab.
Standard on the DM45:
Insulated, pressurized, air conditioned cab with tinted glass, and suspension
operator seat with seat belt.
900 CFM @ 110 psig air compressor (34 m3/min. @ 7.6 bar)
Caterpillar C15 diesel engine 440 HP (328 kW) @ 1800 RPM
Cummins QSX15 diesel engine 425 HP (317 kW) @ 1800 RPM
Cat 325L undercarriage with hydraulic track tensioners
Hydraulic cylinders driven cable feed system
4SV-2-10 two motor driven rotary head with lube pump for positive lubrication;
maximum torque 7,200 lbf-ft. (9,762 Nm) torque; speed range 0 161 RPM
Dust hood with curtains and hydraulically raising dust flap
Remote hydraulic tower pinning
Heavy duty engine silencer/muffler
Central lube system with manual points for grease application of entire rig
Ether Injection
No-bump rod changer
DHD lubricator (High Pressure units only)
Torque Limit Control (High Pressure units only)
Emergency shutdown button in cab
Battery isolation and jump start
Windshield wiper on front and rear tramming window of cab
Sliding hydraulically powered breakout wrench (fork chuck) for drill pipe breakout
4,000 lb. (3,629 kg) capacity auxiliary hoist
J ack up indicator lights
Three 48 (1.2 m) leveling jacks
Cooling package (hydraulic/compressor oil cooler, engine radiator, and engine
charge air cooler)
350 U.S. gallon (1,325 L) fuel tank
Independent air intake filters for engine and air compressor (with quick release dust
drop covers)
Reinforced rectangular steel track frame with oscillation yoke
9-light night lighting package
Tram alarm
30 foot drill pipe changer
4.5 OD by 3.5 API thread, 5 rod capacity carousel
Walkways and railings designed for maintenance access
Standard on the DML:
Caterpillar 330S undercarriage with hydraulic track tensioners
Ether Injection
No-bump rod changer
Sliding hydraulically powered breakout wrench (fork chuck) for drill rod breakout
charge air cooler)
drop covers)
Tram alarm
30 foot drill rod changer
Tower
The DM45,DM50,DML tower is constructed of welded rectangular steel tubing. Atlas Copco
has the tower welded by certified welders in a special rollover fixture that helps provide
optimum welds. The DML tower is a multi-pass tower, a carousel type drill rod changer is part
of the assembly and is located on the outside of the tower frame. The tower is raised and
lowered by two hydraulic cylinders. Raising the tower to the vertical positional with a full
complement of drill rod in the carousel and with the rotary head at the top of the tower, can be
accomplished in less than one minute. Tower pinning is remotely preformed from within the
operators cab. An angle drilling option is also available.
Rotary Head
Rotation on the DM45,DM50,DML is supplied by a rotary tophead powered by two hydraulic
motors. A gauge shows rotation pressure on the control panel for constant monitoring and
adjustment. A replaceable 29 spindle adapter between the spindle and the drill rod is
furnished as standard equipment, along with the nylatron head guides (which are
replaceable). Pulldown cables and pullback chains are attached to mounting plates, which are
attached to the rotary head case. A rotation tachometer is an option.
Feed System
The DM45,DM50,DML closed-loop hydrostatic feed system is powered by two hydraulic feed
cylinders that raise and lower the rotary head smoothly and positively. It is controlled by way
of cable for pulldown (utilizing 14 diameter sheaves and 1 diameter cable), and heavy-duty
chain for pullback. A gauge on the operators console indicates feed pressure. Single-lever
operation of feed speed and direction gives the operator greater ease of operation, along with
an adjustable feed force controller for smooth drilling.
Hydraulic System
The DM45,DM50,DML runs off of a reliable and efficient hydraulic system. A hydraulic oil
cooler is also standard to assure proper oil temperature in order to improve system efficiency,
and increase component life. The hydraulic pumps are mounted for convenient service access
on a single three-hole gearbox driven off the engine through a drive shaft.
The hydraulic system main pumps work through deverter valves to control feed/rotation and
propel. Since the system is a simple design It means fewer components to maintain and
replace for lower overall operating costs.
Main Frame
The DM45,DM50,DML main frame is a weld fabrication consisting of 10 x 14 (254 mm x 356
mm) structural steel tubing is used for both rails and crossbeams. The drill main frame consists
of a track frame which supports the power pack assembly (diesel engine, compressor,
hydraulic pumps), the cooler package (compressor oil cooler, hydraulic oil cooler, radiator
engine cooler), drill tower assembly, operators cab assembly and leveling jacks.
Undercarriage and Propel System
DM45/50
The DM45 utilizes an excavator-type undercarriage, built to Atlas Copco specifications. Tracks
are driven directly by a planetary gear system and two hydraulic motors rated at 111 Hp (83
Kw) each. Tram controllers are designed so that if the hand is removed from the controllers
they will return to neutral and cease rig movement.
A walking beam oscillation yoke allows the rig to propel over uneven ground while reducing
torsional stresses on the main frame. Both tracks are individually controlled, and act as an
independent unit. The tracks are hydraulically adjustable with a spring recoil system, and are
equipped with 23.6 (600 mm) wide replaceable triple bar grouser pads. Side frames on the
tracks have been designed by Atlas Copco and are designed specifically for the operation of
our drills.
Uses Atlas Copco ACGT2500 or optional Caterpillar 325L tracks.
DML
The DML utilizes an excavator-type undercarriage, built to Atlas Copco specifications. Tracks
they will return to neutral and cease rig movement.
A walking beam oscillation yoke allows the rig to propel over uneven ground while reducing
torsional stresses on the main frame. Both tracks are individually controlled, and act as an
independent unit. The tracks are hydraulically adjustable with a spring recoil system, and are
equipped with 33.5 (850 mm) wide replaceable triple bar grouser pads. Side frames on the
tracks have been designed by Atlas Copco and are designed specifically for the operation of
our drills.
Uses Atlas Copco ACGT 3000S or 3000L and the optional Caterpillar 330S or 330L tracks.
Power Pack
The power pack, which consists of a diesel engine directly coupled to an asymmetrical air
compressor on one end and a hydraulic pump drive on the other, is mounted on its own sub
base. The sub base is then mounted to the drill main frame. This in-line drive train
configuration maximizes mechanical efficiency. The separate sub base isolates components
from drilling and propel shock loads and maintains alignment between the components.
Heavy-duty engine silencer(s) is also provided to reduce power pack noise emission.
Independent air inlet cleaners with quick release dust drop covers are standard for both engine
and air compressor intake. Diesel motors come standard with 350 U.S. gallon (1325 liter) fuel
capacity with the option to upgrade to 650 U.S. gallon (2461 liter) fuel capacity.
Air Compressor
All air compressors used on the DM45,DM50,DML are manufactured by Ingersoll-Rand and
are the oil flooded asymmetrical rotary screw design. Tapered roller bearings are used on the
air end to handle thrust and radial loads.
Standard equipment for the air compressor includes a three-stage inlet air cleaner, full
instrumentation, and controls. The lubrication system includes an oil cooler, by-pass valve, oil
filter, oil pump, and combination air receiver and oil separator tank. A safety shut down system
is also provided for high discharge air temperature.
Regulation of the HR-2.5 high pressure compressor is accomplished by an On/Off system so
that when the drilling operation does not demand air, the compressor load can be removed.
This aids by conserving engine horsepower, extending compressor life, and providing easier
startup (particularly in cold weather operations).
An option available on the DM45,DM50,DML is Electronic Air Regulation Control System
(EARS).
Engines
The engines used on the DM45/50 drills use a water cooled engine manufactured by
Caterpillar or Cummins. The Caterpillar engine is a C-15 or C-18 type engine. The Cummins
engine is a QSX-15 type engine.
The engines used on the DML drills use a water cooled engine manufactured by Caterpillar or
Cummins. The Caterpillar engine is a C-15, C-18 or C-27 type engine. The Cummins engine
is a QSK-19 or QSX-15 type engine.
The DM45,DM50,DML drills are equipped with dual system air filtration. Dry type 3-stage air
cleaners, with optional pre-cleaners, provide clean air to the engine and the compressor.
Jacks
The DM45/50 drills incorporates three (3) leveling jacks to keep the drill level and stable while
drilling.
The DML drills incorporates three (3) leveling jacks to keep the drill level and stable while
drilling. Their is an option of four (4) leveling jacks.
Controls
All operational functions can be controlled from the driller's console within the cab of the
DM45,DM50,DML. Full details are provided in section 4.
Operators Cab
The cab is thermally insulated, heated, pressurized, equipped with tinted safety glass, has an
operator seat with seat belt, and can be entered by two hinged and lockable doors. The cab
has an ergonomically designed wrap around console and w.indshield wiper on drilling and rear
tramming window
The one-piece FOPS (Falling Object Protective Structure) cab is sound tested at 80 dBa and
certified (ISO 3449 Level 2). Full details are provided in section 4.
Seat Belts
Seat belts are included as a standard feature for the safety of the machine operator. Every
mine site is unique. It is the responsibility of the mine or machine operator to identify risks.
Where there is a risk that the operator can be ejected from the cab, the operator should wear
the seat belt provided. To increase visibility on the non-cab side and the non-drill end while
wearing the belt, the following alternatives should be considered:
1. a camera system, with a monitor in the cab
2. a remote propel system
3. another person, to assist in spotting the drill
Lighting
Nine External 70-watt Halogen lights are operated from a 24-volt electrical system. One
internal for cab interior lighting.
Gradeability
Refer to the DM45,DM50,DML Stability and Grade Limits with Drill on Tracks chart in Section
3-Specifications. Exceeding the slope or grade limitations of the drill and its configuration can
cause the drill to tip over. Prior to moving the drill, always determine the safe operating grade
of the drill with the tower (derrick) up or down.
Serviceability
The diesel engine, compressor and hydraulic pumps power pack is accessible from the walk
around decking. All daily checkpoints are positioned to encourage preventive maintenance.
DANGER
!
Your life may be endangered if the following is not complied with. DO
NOT add attachments to the machine that intrude into operators
protective area, reduce visibility, restrict emergency exits or add weight
exceeding certification weight. See the operators manual or contact your
dealer for complete inspection requirements and maintenance
instructions.
Identification of Major Components
VIEW OF DM45,50,DML DRILL LAYOUT
VIEW OF DM45,50,DML TOWER
Section 2 - Safety
DM45,DM50,DML Instruction Manual Section 2 - Safety
2.1 - Safety and Health
General Safety and Health
This manual has been published to alert operators, helpers and mechanics to the possible
physical dangers that are present in all phases of operation and maintenance of this drill.
Anyone working around this drill must read and thoroughly understand the precautions
outlined in this manual before attempting to operate or perform work on the drill. In addition,
SAFETY ALWAYS must always be the primary consideration of all personnel when working
around this drill under normal or unusual conditions.
Since this manual cannot cover every possible situation, all personnel are expected to
exercise good judgement and common sense when operating, servicing or working near this
drill.
If there is any doubt about the safe operating procedures of the drill, STOP! Review the
information supplied with the drill, ask your supervisor or contact your nearest Atlas Copco
Drilling Solutions representative for assistance.
Make sure all new employees read and understand the decals in the laminated Decal Safety
Manual that is mounted on the drill. Never remove the Decal Safety Manual. Replace the
manual if it becomes lost, damaged or illegible.
Safety and Health Statement
Every employer should have a safety and health philosophy based on the following
statements:
1. We are committed to providing a safe and healthy workplace for all our
employees.
2. We believe that injuries and accidents are preventable and that the well being
of all our employees can be protected in the work environment.
3. We believe that safety is number one. Safety will not be sacrificed for
production.
4. We believe that housekeeping is an integral part of our safety program and the
protection of our employees health.
5. We believe that all of our employees are responsible for the safety of their co-
workers. Each of us has the duty to listen, watch and act upon hazards that
might injure another.
6. We believe that good safety training is necessary to assist employees in
completing their assigned tasks in a safe manner.
7. We believe that safety is a team effort.
Safety is an integral part of every individuals job responsibility. Every employee must be
committed to these beliefs and must work in a manner that demonstrates that commitment.
Section 2 - Safety DM45,DM50,DML Instruction Manual
Emergencies
Emergencies are situations where there is personal injury or property damage, or when there
is imminent threat of personal injury or property damage. It is important for everyone to know
how to respond to emergency situations in order to minimize injury and damage. Each
operator must have a plan to be able to contact 911 or some other form of help, such as Fire
or Medical Emergency Services, immediately. These plans must be known to everyone
around the drill in case someone is injured.
Important Safety Instructions
Personal safety is of prime importance at all times when performing any operations or
maintenance on a drill. While we have no direct control over the way the drill is operated or
maintained, we wish to call your attention to those procedures which are potentially
hazardous. Knowing the guidelines shown in section 2.2 will help provide for your safety, for
the safety of those around you and for proper operation and maintenance of the drill.
2.2 - Safety Precautions and Guidelines
Overview
Before you operate, maintain, work around or in any other way use this drill: READ and
STUDY this manual. KNOW how to safely use the drill controls and what you must do for safe
maintenance. Failure to follow instructions or heed warnings could result in injury or death.
Ensure that the drill is in good operating condition before operating.
If you have ANY QUESTIONS about the safe use or maintenance of this drill, ask your
supervisor or contact your nearest Atlas Copco Drilling Solutions distributor for assistance.
NEVER GUESS-ALWAYS CHECK!
Safety must always be the most important concern. Do not operate the drill when conditions
are unsafe and consult your supervisor when safety is in doubt.
You must be alert, physically fit and free from the influences of alcohol, drugs or medications
that might affect your thinking ability, judgement, sight, hearing or reactions.
Signals must be given by the operator prior to starting or operating the drill.
Make sure all new employees read and understand the decals in the Decal Safety manual that
is mounted on the drill. Never remove the Decal Safety manual. Replace the Decal Safety
manual if it becomes lost, damaged or illegible.
IMPORTANT SAFETY INSTRUCTIONS
Personal safety is of prime importance at all times when performing any operations or
maintenance on a drill. While we have no direct control over the way the drill is operated or
maintained, we wish to call your attention to those procedures which are potentially
hazardous. Knowing the guidelines covered below will help provide for your safety, for the
safety of those around you, and for proper operation and maintenance of the drill.
Warnings
Throughout the manual, Notes, Notices, Cautions, Warnings and Danger symbols are used
to designate instructions of particular importance. Look for these symbols which point out
items of extreme importance to you and your co-workers safety. Read and understand
thoroughly. Heed the warning and follow the associated instructions. In this manual, these
terms have the following significance:
NOTE: Note is used for supplementary information not directly effecting
safety or damage to equipment. Note can also refer to special information
on the efficient use of the drill.
NOTICE
NOTICE: Notice is used to notify people of installation, operation or
maintenance information which is important but not hazard-related.
Hazard warnings should never be included under the NOTICE signal
word.
CAUTION
!
CAUTION: Caution is used to indicate the presence of a hazard which
WILL or CAN cause minor personal injury or property damage if the
warning is ignored.
WARNING
!
WARNING: Warning is used to indicate the presence of a hazard which
CAN cause severe personal injury, death or extensive property damage if
the warning is ignored.
DANGER
!
DANGER: Danger is used to indicate the presence of a hazard which WILL
cause SEVERE personal injury, death or substantial property damage if
the warning is ignored.
Drill Applications
The DM45,DM50,DML drills are built in accordance with state-of-the-art standards and
recognized safety rules. Nevertheless, misuse may constitute a risk to the life and limb of the
user or third parties, and may cause damage to the drill or other material property.
The DM45,DM50,DML drill must be used in accordance with its designated use as described
in the operating manual. The drill must only be operated by safety-conscious persons who are
fully aware of the risks involved in operating the drill. Any functional disorders, especially those
affecting the safety of the drill, must be corrected immediately.
Designated Applications
DM45,DM50
The DM45 is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling rig
specifically designed for production blasthole drilling; it is productive, tough, versatile, and
(200 kN).
DML
The DML is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling rig
specifically designed for production blasthole drilling; it is productive, tough, versatile, and
(267 kN).
Non-Designated Applications
The DM45,DM50,DML drills are not designed for pioneering or earth moving applications. The
DM45,DM50,DML drills are not designed for use on inclined surfaces greater than those
defined in the DM45,DM50,DML Stability and Grade Limits with Drill on Tracks chart and
DM45,DM50,DML Stability and Leveling Limits with Drill on J acks chart or on soft, unstable
ground surface without load bearing capacity to adequately support and maintain drill stability
while operating. Use of the drills for purposes other than that mentioned (such as for towing
other vehicles or equipment) is considered contrary to its designated use. The manufacturer
and/or supplier cannot be held liable for any damage resulting from such use. The risk of such
misuse lies entirely with the user / operator.
Operating the DM45,DM50,DML drill within the limits of its designated use also involves
compliance with the inspection and maintenance directives contained in the operating manual.
Set up the drill on a level surface. If this is not available, the site should be adequately
prepared prior to drill setup.
Electrical Safety on Drilling Machines
Installation, operation or service performed on this machine must be performed only by
competent and trained personnel who are familiar with the drill operators manual and
appropriate safety practices. This written instruction is for such personnel and is not intended
as a substitute for such training or appropriate operational experience in the safe operation of
this equipment. Always consult the operators manual and safety instructions.
Shock/Electrocution Hazard Hazardous voltage can cause severe injury or death. Do not
operate this equipment or work on this equipment unless you have read and understand the
instructions and warnings in the Operations Manual. Failure to follow the instructions or
warnings can result in severe injury or death.
Take these simple steps prior to performing any maintenance or electrical work:
1. Determine all the locations of the disconnecting means for the circuit receiving
maintenance.
2. Carefully de-energize the circuit.
3. Each employee working on the circuit must place his/her own lock and tag on
the disconnecting device.
4. Test the circuit receiving maintenance for voltage to ensure no electricity is
present.
5. Ground all the phase conductors to the equipment grounding conductor with a
jumper.
Shock/Electrocution Hazard Hazardous voltage can cause severe injury or death.
Disconnect all sources of power before servicing the machine. Perform Lockout/Tagout of the
machine. Test the circuit receiving maintenance for voltage to ensure that no electricity or
voltage is present. Failure to follow the instructions or warnings can result in severe injury or
death.
Protection against Shock
Disconnect Capacitors or equipment from power before doing any work. Check for an open
circuit to be certain that the capacitors are disconnected from the power source. Wait 5
minutes after de-energization and then short circuit and ground the capacitors before
handling.
Handling of Capacitors
Always discharge capacitors before handling. Use terminals with appropriate high voltage
shorting device to short out terminals. Ensure that any residual charge is absent from the
capacitor.
Handling of Failed Capacitors
Some failed capacitors may be found considerably bulged due to internal pressure from
gassing prior to circuit clearing. Such capacitors should be handled very carefully. A failed
capacitor should be short-circuited before handling (see Protection Against Shock). It is further
recommended that a bulged capacitor be permitted to cool before handling. This will lower the
internal pressure, reducing the possibility of case rupture. Consult the Material Safety Data
Sheet for information on further precautions in handling failed capacitors.
Safety Reminder
physical dangers that are present in all phases of the operation of this drill. Anyone working
around this drill must read and thoroughly understand the precautions outlined in this manual
before attempting to operate or perform work on the drill. In addition, SAFETY ALWAYS
must always be the primary consideration of all personnel when working around this drill under
normal or unusual conditions.
exercise good judgement and common sense when operating, servicing or working near the
drill. If there is any doubt about the safe operating procedure of the drill, STOP! and review the
information supplied with the drill or contact your nearest Atlas Copco Drilling Solutions
representative for assistance.
Qualify Your Personnel
Working on and with the drill must only be performed by qualified personnel. Statutory
minimum age limits must be observed.
Those who operate, maintain and work on Rotary Drill rigs must be competent:
Physically - To react correctly and quickly to avoid accidents.
Mentally - To understand and apply all established rules, regulations and safe practices. To
concentrate on the job to be done.
Emotionally - To withstand stress and prevent mistakes.
Those who operate, maintain and work on Rotary Drill rigs must be experienced:
Trained - In the operation and maintenance of the DM45,DM50,DML drills.
1. They should have read and understood the Manufacturers Instruction Manuals
and know the ratings and capabilities of the drill they are using.
2. They must understand hand signals.
3. They must understand the meaning of various symbols on instruments,
controls and specific parts of the drill.
Licensed - If required by law.
1. The individual responsibilities of the personnel responsible for operation, setup,
maintenance and repair of the drill should be stated clearly.
2. Define the drill operators responsibility with regard to observing site traffic
regulations.
3. The operator should have the authority to refuse instructions by third parties
that are contrary to safety.
4. Do not allow persons being trained or instructed in the operation or
maintenance of the drill to work without permanent supervision by an
experienced person.
5. Work on the electrical system and equipment of the drill must be done only by
a skilled electrician or by instructed persons under the supervision and
guidance of a skilled electrician and must be in accordance with electrical
engineering rules and regulations.
6. Work on the mainframe and drill tower (derrick), brake, air and hydraulic
systems must be performed by skilled personnel with special knowledge and
training for such work.
General Guidelines
1. STOW instruction manuals in the manual compartment provided in the
operators cab. Manuals must always be available at the site where the drill is
used. The operators instruction manual shall be within easy reach of the
operators station.
2. OBSERVE and INSTRUCT the user in all other generally applicable
mandatory and legal regulations relevant to accident prevention and
environmental protection. These compulsory regulations may also deal with the
handling of any hazardous substances, issuing and/or wearing personal
protective equipment, and traffic regulations.
3. SUPPLEMENT operating instructions with detailed working instructions
covering the methodology of the working sequences, all individual job
responsibilities and the overall supervisory responsibility.
4. ALWAYS be sure that persons entrusted with work on the drill have read the
operating instructions and in particular the chapter on safety before beginning
work. Reading the instructions after work has begun is too late. This is
especially important for persons who work only occasionally on the drill, e.g.
during setup or maintenance.
5. MAKE CERTAIN all personnel are working in compliance with the operating
instructions and are alert to risks and safety factors.
6. ALWAYS tie back or otherwise secure long hair. Wear close-fitting garments
and avoid wearing jewelry such as rings. Injury may result from clothing, hair or
jewelry being caught up in the machinery.
7. USE protective equipment wherever required by the circumstances or by the
law. Always wear approved safety equipment while working around the drill.
This includes an approved hard hat, safety glasses, protective footwear,
gloves, respirator and ear protection.
8. OBSERVE all safety instructions and warnings attached to the drill.
9. BE SURE all safety instructions and warnings attached to the drill are complete
and perfectly legible.
10. STOP the drill immediately in the event of safety relevant malfunctions or
change in drill behavior during operation. REPORT the malfunction to the
proper authority/person.
11. NEVER provide service or maintenance to the drill unless both tracks are on
firm, level ground.
12. DO NOT make any modifications to the drill which might affect safety without
having the manufacturers approval. This applies to the installation and
adjustment of safety devices and valves as well as to welding work on load
bearing elements.
13. ALWAYS ADHERE to the prescribed intervals and/or those specified in the
operating instructions for routine checks and inspections.
14. ENSURE that people, equipment and material not required for the correct
operation of the drill are removed and kept out of the work area. The operator
must never drill while people are around the drill platform. Alert people and
crew to stay clear of the hole while drilling is in process.
15. ALL PERSONNEL who work around the drill must ensure that any unsafe
conditions and practices are corrected or reported to the drill operator and
supervisor.
16. ALL PERSONNEL who are working around the drill, including support and
maintenance people, must obey all warning signs and must ensure their own
safety and the safety of others.
17. WITH careful planning, most accidents can be avoided.
A. Have a clear understanding of the work to be done.
B. Consider potential dangers or hazards.
C. Develop a plan to do the job safely.
D. Explain the plan to all personnel concerned.
Equipment Safety Rules
Before starting or working around the drill, read and understand the safety manual, decal
safety manual and labels located on the drill. Follow all directions on the labels. Do not remove
or deface the labels. Replace them if they become damaged or lost.
Do not operate or work on this drill unless the instructions in this training manual and the signs
on the equipment are understood. Failure to follow instructions or heed warnings could result
in injury or death. Ensure that the drill is in correct condition before operating.
Safety must always be the most important concern. Do not operate the drill when conditions
are unsafe and consult your supervisor when safety is in doubt. You must be alert, physically
fit, and free from the influences of alcohol, drugs, or medications that might affect your thinking
ability, judgement, sight, hearing, or reactions.
1. Anyone working around this drill must wear an approved safety equipment.
This includes approved hard hat, safety glasses, safety shoes and ear
protection. Do not wear loose clothing that can get caught in moving parts.
Wear gloves when handling heavy parts and tools or any objects that are sharp
or pointed. A respirator may be required in dusty conditions.
2. Keep cab, drill work areas and walk ways clean and free from grease, oil and
other items or tools that could cause a slip or fall.
3. Keep all warning and information labels clean and readable. Replace labels if
they become damaged, torn, painted over or removed.
4. Keep all controls and gauges in good working order. If they are broken or
damaged, replace them before operating the drill.
5. Make a complete walk-around inspection of the drill before starting drill. During
operation, make periodic checks to be sure the drill is operating properly.
6. Watch for leaking or broken hydraulic hoses or air hoses. Replace them before
they cause damage or a fire.
7. DO NOT operate the drill with excessively worn or broken parts.
8. Tighten or replace any loose or broken fittings, bolts or other connections
before operating drill.
9. Check the wires and connections before starting the drill. Loose wires can
cause fires and shocks. Spilled fluid can cause burns.
10. Use extreme caution when handling, cleaning, and wiring, or recharging
batteries. They can explode and spray acid. Keep battery covers in place all the
time.
11. Keep the operators cab clean. Mud, cans, bottles, tools and other debris can
jam controls and cause falls.
12. Make sure all controls are in neutral or off position before starting the drill.
13. Make sure all guards are in place on the drill. Replace the guards if they have
been removed for maintenance. DO NOT operate the drill if guards are not in
place.
14. Know where your helper or other personnel are at all times. DO NOT move the
drill if they are not in sight.
15. Signals must be given by the operator prior to starting or operating the drill.
16. Ensure that people, equipment and material not required for the correct
operation of the drill are removed and kept out of the work area. The operator
must never drill while people are around the drill platform. Alert people and
crew members to stay clear of the hole while drilling is in progress.
17. All members who work around the drill, including support and maintenance
people, must obey all warning signs and must ensure their own safety and the
safety of others.
18. Before moving drill, make sure there is nothing in the way of travel. Make sure
all the drill pipe is out of the ground and secured before moving.
19. Locate drill on level ground, if possible. Install cribbing (blocking) under each
jack to insure a stable lifting platform in case ground is broken or soft.
20. Before raising the tower (derrick), make sure it is clear of any tools or objects
that could fall. Check to see that all hydraulic and air hoses do not become
snagged during raising. Watch all hoist cables and keep them clear or
unspooled properly while raising the tower (derrick). Make sure any helpers or
visitors are away from drill while raising or lowering the tower (derrick).
21. When working on any air compressor hose or the receiver tank, relieve all
pressure in the system before removing any cap, plug or hose connection.
22. Never move the drill with the tower (derrick) partially raised, unless it is an angle
drill with the proper locking pins in place.
23. Never move the drill with tower (derrick) locking pins removed or unpinned. The
tower (derrick) is not designed to be held up by the tower (derrick) raising
cylinders alone.
24. Keep the work area clear of cuttings, tools and other objects.
25. Make sure all new employees read and understand the decals shown in the
Safety Manual, mounted in the operators cab. Never remove the Safety
Manual. Replace the manual if it becomes lost or illegible.
26. All personnel setting up drills or handling maintenance or repairs must know
and practice proper procedures, including lockout and tag out practices.
27. All personnel must watch for hazards during operations and alert the operator
of potentially dangerous situations, such as the presence of other personnel,
other equipment, unstable ground or overhanging obstacles.
28. To avoid accidents, factors such as the following must be considered.
a. Are there structures, power lines or other equipment which must be moved
or avoided during operation of the drill?
b. Is the surface firm enough to support the drill and auxiliary equipment?
c. What steps must be taken in order to keep all unnecessary people and
equipment at a safe distance from the drilling area?
29. Determine the load-bearing capacity of the ground or other surface on which
the drill will be operating. Be sure drill is adequately supported. Avoid soft or
unstable ground and areas with high water tables.
30. Prior to servicing or repairing the drill, follow lockout and tag out procedures.
Injury or death can occur if the drill is started before servicing is finished. Never
start drill or operate the equipment if lockouts or tag outs are on the controls.
Look inside and outside, underneath and all around the drill to be sure
everyone is clear.
31. Keep the drill clean and as dry as possible. Slippery surfaces can cause slips
and falls.
32. Wire rope running over drums and through sheaves creates pinch points. Do
not use hands or bars to guide wire rope onto drums; instead, use rope
guides. Keep clothing and all parts of the body away from running rope and
from the machinery that moves the rope.
33. During the drilling operation, keep all people away from the drilling platform,
tower (derrick) and drill string. Moving components and rotating drill string can
entangle clothing and may pinch, crush or strangle personnel.
34. Exceeding the slope or grade limitations of the drill and its configuration can
cause the drill to tip over. Prior to moving the drill into position, always
determine the safe operating grade of the drill with the tower (derrick) up and
down. Stay within the limits shown on DM45,DM50,DML Stability and Grade
Limits with Drill on Tracks and DM45,DM50,DML Stability and Leveling Limits
with Drill on J acks Charts (See Section 3). Do not move the drill with the tower
(derrick) up unless the ground is firm and level and no obstructions will cause
the drill to tip.
Contacting power lines with any part of the drill will cause death! Keep at
least 10 feet (3m) away from power lines. If there appears any danger of
wind or other obstruction closing the distance, do not drill in that area.
35. Personnel can be pinched, entangled or crushed by moving machinery while
the drill is in operation. Crew members must never place any part of their
bodies or clothing on or near any rotating machinery, gears, pinions, ropes,
cables, chains or wrenches.
36. The drilling process can produce flying debris and dust which can cause
serious respiratory difficulties for personnel working in or visiting the drilling
site. Always use water or foam to keep dust under control and keep the dust
curtains in place to prevent flying debris.
37. Always wear hard hats, safety glasses, ear protection, and steel-toed shoes
while working around the drill. Wear gloves when handling sharp objects or hot
items.
38. Wear respirators if there is any danger of blowing dust or cuttings.
39. Stow the hoist hook securely to the base of the machine when hoist is not in
use.
Pre-Start Inspection
1. INSPECT the drill daily. Ensure that the routine maintenance and lubrication
are being dutifully performed. Have any malfunctioning, broken or missing
parts repaired or replaced before use.
2. VERIFY that all instruction and safety labels are in place and readable. These
are as important as any other equipment on the drill.
3. NEVER fill the fuel tank with the engine running, while near an open flame, or
while smoking. Always wipe up any spilled fuel.
4. CHECK for WARNING or lockout tags placed on the drill. DO NOT operate the
drill until all of the repairs have been made and all the WARNING or lockout
tags have been removed by authorized personnel.
5. CLEAN any and all foreign material from the operators platform to reduce the
danger of a slipping or falling.
6. KNOW the location of the Emergency Shut Down Control if the drill is so
equipped.
7. ALWAYS know the capabilities and limitations of the drill: speed, gradeability,
steering and braking.
8. BE AWARE of the dimensions of the drills height, width and weight when
moving the drill.
9. CHECK for any conditions that could be dangerous: such as unstable ground
condition or an overhanging rock face.
Operation Safety
Safety Instructions Governing Operation
1. OBSERVE the location of fire extinguishers, if so equipped, and ensure that
they are fully charged and inspected regularly.
2. AVOID any operational mode that might sacrifice safety.
3. TAKE all necessary precautions to ensure that the drill is used only when in a
safe and reliable condition.
4. OPERATE the drill only if all protective and safety oriented devices, such as
removable safety devices, emergency shut off equipment, sound proofing
elements and exhausts are in place and fully functional.
5. START the drill from the operators cab seat only. If the drill is equipped with
an optional remote tramming control console, use the remote control unit from
a safe location when tramming over unstable ground conditions, loading the
drill on ramps for trailer transport or when there is a risk of a roll over condition.
6. WATCH all of the indicators during startup and shutdown procedures in
accordance with the operating instructions.
7. MAKE SURE no one is at danger or risk before starting up or setting the drill in
motion.
8. MAKE SURE no one is at danger or risk before starting up or setting the drill in
motion. Personnel can be pinched, entangled or crushed by moving machinery.
While the drill is in operation, crew members must never place any part of their
bodies or clothing on or near any rotating machinery, gears, pinions, ropes,
cables, chains or wrenches.
9. CHECK that the propel, steering, signaling and lighting systems are fully
functional before starting work or traveling with the drill.
10. CHECK that the accessories have been safely stowed away and that all
levelling jacks are retracted fully before moving the drill.
11. ALWAYS SWITCH ON the lighting system in conditions of poor visibility and
after dark.
12. MAKE SURE there is sufficient overhead clearance when crossing
underpasses, bridges and tunnels, or when operating under overhead lines.
13. ALWAYS KEEP at a safe distance from the edges of quarry face, pits and
slopes.
14. AVOID any operation that might be a risk to drill stability.
15. ALWAYS SECURE drill against any inadvertent movement and unauthorized
use before leaving the operators cab.
Setup and Start
1. ALWAYS USE handrails and steps to get on and off the drill. ALWAYS
MAINTAIN a three point contact when climbing onto or off the drill. Watch for
slippery surfaces when mounting.
2. READ and FOLLOW ALL instruction decals.
3. BEFORE starting the drill or propelling the drill, check inside, outside and
underneath drill for people or obstructions.
4. CHECK for Warning or Lockout tags on the controls. If there is a tag attached
to the key start switch, do not start the engine until the warning tag has been
removed by the person who installed it or by authorized personnel only.
5. BEFORE starting the engine, ENSURE the propel/drill mode selector is in the
Drill position and all tramming and drilling control levers are in the STOP or
neutral position.
6. BEFORE starting the engine, ENSURE that the track brakes are applied
(propel controllers are in STOP position).
7. CHECK all controls to be sure they are in STOP or NEUTRAL / OFF position
before starting the engine.
8. ALWAYS sound the horn before starting the drill to alert everyone in the area
(if the drill is so equipped).
9. START the engine from the operators position only.
10. CHECK touch screen, gauges and controls for correct operation. Stop the drill
immediately and replace any that are defective.
11. CHECK all safety devices. Report any defects immediately.
12. MAKE SURE the drill is stabilized and level before raising the tower (derrick).
Refer to DM45,DM50,DML Stability and Leveling Limits with Drill on J acks
chart. Use cribbing and/or blocking if you are not sure.
13. WHEN raising the tower (derrick), make certain there are no electrical power
lines or obstruction within the operating area of the drill.
14. LISTEN for unusual noises.
15. ENGAGE hydraulic controls slowly in cold weather to avoid shock loading.
Electrical Power Line Safety
DANGER
!
Do not raise the tower (derrick) or operate this drill in the vicinity of
electrical power lines. Operating too close or contacting a power line with
any part of the drill can result in electrocution.
Contacting power lines with any part of the drill will cause death! Keep at
least 10 feet (3 meters) away from power lines. If there appears any
danger of wind or other obstruction closing the distance, do not drill in
that area.
1. Place the drill as far as possible from electrical power lines and never work
inside the minimum specified distance set by local, state or federal regulations.
2. Treat all electrical lines as live power lines.
3. Clear the area. Slowly raise and lower the tower (derrick). If the distance to the
line has been misjudged, your reaction time might be too slow.
4. A signal person must be used to guide the drill in the vicinity of power lines. The
signal person and drill operator must be in direct visual contact at all times.
Operating Safely
1. ALWAYS make sure that no person or obstruction is in your line of travel before
you start tramming the drill.
2. NEVER CLIMB on or off the drill while it is in motion. If the drill is equipped with
an optional remote tramming control console, always use the remote control
unit from a safe location when tramming over unstable ground conditions,
loading the drill on ramps trailer transport or when there is a risk of a roll over
condition.
3. USE EXTREME CAUTION and be very observant when operating in close
quarters or congested areas.
4. NEVER carry passengers.
5. KNOW the area in which you are working. Familiarize yourself with any and all
work site obstructions and any other potential hazards in the area.
6. KNOW and USE the hand signals required for particular jobs and know who
has the responsibility for signaling.
7. DO NOT work in the vicinity of overhanging banks or on grades that could
cause the drill to slide or roll over.
8. AVOID side hill travel. ALWAYS operate up and down slopes. ALWAYS keep
the propel control lever in low speed close to STOP position when ascending
or descending hills.
9. NEVER allow bystanders, other than authorized persons, to stand within the
drill rig danger (working) area when the motor is running.
10. ALWAYS LOOK in all directions BEFORE changing your direction of travel
and sound the horn prior to moving.
11. DO NOT run the engine in a closed building for an extended length of time.
Exhaust Fumes Can Kill.
Drilling Safety
All Atlas Copco Drilling Solutions drills are equipped with an overpressure control system
which will vent feed pressure if the drill end leveling jacks are not supporting the weight of the
drill. To ensure someone has not disabled the system, each operator must perform the
overpressure control system operational check procedure daily as described in sections 6.5
of this manual.
1. Use the proper tools for the job. Do not attempt to lift drill pipe, subs, stabilizers
or bits without the proper lifting devices.
2. Use the proper technique in loading and unloading drill pipe. If a lifting bail is
used, make sure it can be detached by a helper while standing on the ground.
Use a pipe handling tool if the carousel needs to be filled. Make sure the safety
clip is in place.
3. Do not attempt any repairs to the drill while it is running. Stop the drill to make
repairs.
4. Do not allow anyone to climb the tower (derrick). If repairs must be made,
lower the tower (derrick) or use a manlift to reach the repair area.
5. Do not use the hoist cable as a manlift.
6. Do not ride the rotary head for any reason. It is not meant to be an elevator.
7. Do not operate the drill except from the operators console. Trying to operate
from any other position is a safety hazard and can cause serious injury.
8. If the drill is equipped with an optional remote tramming control console, always
use the remote control unit from a safe location when tramming over unstable
ground conditions, loading the drill on ramps for trailer transport or when there
is a risk of a roll over condition.
9. Do not hoist or brake too sharply. This can cause premature failure of
equipment and can be dangerous.
10. Dont retract the hoist so far that it slams into the crown block. Continuous pull
on the wire rope can break it and drop the load.
11. Know the limitations of your drill and dont exceed the design limits.
12. Know the operating intent of the sliding fork, list as follows:
Break joints with limited impact and minimal shock loads on the tower, carousel,
rotary head and feed components.
Capture the stabilizer bushing to promote accurate holes.
Secure stabilizers so that the rotary head can thread in.
Secure drill rod so that the rotary head can thread in.
Secure steel while lubing joints.
Secure steel when changing bits
WARNING
!
Operators and maintenance may never stand on the sliding fork or in the
path of the sliding fork while the machine is operating. If the sliding fork
rotates unintentionally, it could result in severe injury or death.
The optional tower access emergency button is located in the tower structure.
Propel (Tram) Safety
1. When moving the DM45,DM50,DML on long moves and flat level surfaces,
lower the tower and tram the drill in the direction of the cab first (drilling end). A
long move for the drill is considered to be any move other than moving from
hole to the adjacent hole in any given drilling pattern. Always refer to the
Stability / Gradeability charts for tramming direction and permissible slope
angles when tramming the drill (See Section 3 - Specifications).
2. Make sure all drill pipe is out of the hole before moving the drill.
3. Secure all drill pipe and tools before moving the drill.
4. Do not get on or off the drill when it is moving.
5. Know the drills height, width, weight and length before moving the drill.
6. Use the main pumps to control speed and direction. If a problem with tramming
arises and the pumps dont respond to controls, shift Drill/Propel Valve back to
DRILL. This will set the parking brakes and stop the drill.
7. Use caution when loading a drill onto a trailer. Make sure the ramp will hold the
weight of the drill.
8. If tramming with the tower (derrick) raised, make sure all locking pins are in
place and the ground is level and solid.
9. With the tower down, be careful cornering to allow for tower (derrick) overhang.
10. Know where your helpers are at all times. Do not move the drill if they are not
in view.
11. Know and use proper signals when moving the drill.
Stopping and Shutdown Safety
1. Move drill away from high wall or face before shutting the drill down for the day.
2. Dont park drill under an overhang or where a bank can cave in.
3. ALWAYS park the drill rig on solid, level ground. If this is not possible, always
park the drill at a right angle to the slope and chock the tracks.
4. If drill is left over a hole, lower jacks so tracks touch the ground.
5. Be sure to relieve all air pressure in the systems before leaving the drill.
6. Place all controls in neutral or park position before leaving the drill.
7. ALWAYS move the tram/drill mode selector to DRILL and make sure the
tramming and drill controllers are all in the STOP positions.
8. AVOID leaving the controls with the engine running. NEVER leave the
operators cab while the engine is running.
9. Before shutting the rig down allow about five (5) minutes to allow the
components to cool down before turning the key switch to OFF.
10. Lock the ignition and remove the keys before leaving the operators cab. Lock
all of the lockable compartments.
11. USE proper flags, barriers and warning devices, especially when parking in
areas of heavy traffic.
Maintenance Safety
In any work concerning the operation, conversion or adjustment of the drill and its safety
oriented devices or any work related to maintenance, inspection and repair, always observe
the startup and shutdown procedures set out in the operating instructions and the information
on maintenance work.
All personnel involved in setting up drills or handling maintenance and repairs must know and
practice proper procedures, including lockout and tagout practices.
1. Ensure that the maintenance area is adequately secured.
2. When the drill is completely shut down for maintenance and repair work, it must
be secured against inadvertent starting by:
a. Locking the principal control elements and removing the ignition key.
b. Attaching a warning sign to the main starter key switch.
3. Carry out maintenance and repair work only if the drill is positioned on stable
and level ground and has been secured against inadvertent movement.
4. USE CARE when attaching and securing lifting tackle to individual parts and to
other large assemblies being moved for replacement purposes to avoid the risk
of accidents. ALWAYS USE lifting gear that is in perfect condition and with
adequate lifting capacity. NEVER work or stand under suspended loads.
5. ALWAYS USE the correct tools and workshop equipment when performing
maintenance to the drill.
6. ALWAYS USE specially designed or otherwise safety oriented ladders and
working platforms when doing overhead assembly work. Never use drill parts
as a climbing aid and never climb the tower (derrick).
7. KEEP all handles, steps, handrails, platforms, landings and ladders free from
mud, dirt, snow and ice.
8. CLEAN the drill, especially connections and threaded unions, of any traces of
oil, grease or preservatives before carrying out maintenance or repair. NEVER
use aggressive detergents. Use lint free cleaning rags.
9. Before cleaning the drill with water, steam jet (high pressure cleaning) or
detergents, COVER or TAPE up all openings which, for safety and functional
reasons, must be protected against water, steam or detergent penetration.
Special care must be taken with electric motors, components and switch gear
cabinets.
10. ENSURE during cleaning of the drill that temperature sensors do not come into
contact with hot cleaning agents.
11. REMOVE all covers and tapes applied for that purpose after cleaning the drill.
12. After cleaning the drill, EXAMINE all fuel, lubricant and hydraulic fluid lines for
leaks, loose connections, chafe marks and damage. REPAIR or REPLACE
defective parts immediately.
13. Always TIGHTEN any and all screwed connections that have been loosened
during maintenance and repair.
14. Any safety devices that were removed for setup, maintenance or repair
purposes must be refitted and checked immediately upon completion of the
maintenance and repair work.
15. ENSURE that all the consumable and replaced parts are disposed of safely in
accordance with local regulations and with minimum environmental impact.
16. AVOID, whenever possible, the servicing, cleaning or examining the drill with
the engine running.
17. AVOID whenever possible; servicing or providing maintenance to the drill
unless the tracks are adequately chocked and the parking brake is applied.
18. DO NOT alter the engine settings from those indicated in the manual and the
engine option plate.
19. ALWAYS replace damaged or lost decals. Refer to the parts manual for proper
location and part number for all decals.
20. Use only original circuit breakers with the specified current rating. Shut down
the drill immediately if trouble occurs in the electrical system.
21. Work on the electrical system or on electrical equipment may only be carried
out by a skilled electrician or by specially instructed personnel under the direct
supervision and control of an electrician and in accordance with the applicable
electrical engineering.
22. If provided for in the regulations, power supply to parts of the drill on which
inspection, maintenance and repair work is to be carried out, must be cut off.
23. Before starting any work, check the de-energized parts for the presence of
power and ground or short circuit them in addition to insulating adjacent live
parts and elements.
24. The electrical equipment of the drill is to be inspected and checked at regular
intervals. Defects such as loose connections or scorched cables must be
rectified immediately.
25. Welding, flame cutting and grinding work on the drill should only be done if
expressly authorized, as there may be a risk of explosion and fire.
26. Before beginning any welding, flame cutting and grinding operations, clean the
drill and surrounding area from dust and other flammable substances. Make
sure that the premises are adequately ventilated (risk of explosion). Place fire
blankets on and around equipment where welding, flame cutting or grinding to
protect equipment from damage when welding, flame cutting or grinding. Have
a fully charged and inspected fire extinguisher immediately available.
27. Winches and ropes must be inspected frequently for unforeseen wear patterns
and discarded according to certain criteria (refer to ISO 4305).
28. Check all lines, hoses and screwed connections regularly for any leaks and for
obvious damage. Repair damage immediately. Splashed oil may cause injury
and fire.
29. Depressurize all system sections and pressure pipes (hydraulic, compressed
air) that are to be removed in accordance with the specific instructions before
carrying out any repair work.
30. Hydraulic lines must be laid and fitted properly and correctly. Ensure that there
are no connections that are interchanged. The fittings, lengths and quality of
the hoses must comply with the technical requirements.
31. Observe all of the product related safety regulations when handling oil, grease
and other chemical substances.
32. Be careful when handling hot consumables (risk of burning or scalding).
Fueling
1. NEVER fill the fuel tank with the engine running, while near an open flame or
while smoking. ALWAYS wipe up any spilled fuel.
2. Do not spill fuel on hot surfaces.
3. Refuel in a well ventilated area.
4. Keep open lights, lighted smoking materials, flames or spark producing devices
at a safe distance when refueling.
5. Keep fuel nozzle in contact with tank being filled, or provide a ground to prevent
static sparks from igniting fuel.
6. Turn off cab and fuel heaters.
7. Never mix any other fuel with diesel oil. An explosion can occur.
Batteries
1. DISCONNECT battery cables when working on the electrical system or when
welding on the drill. Disconnect the ground wire first when disconnecting
batteries.
2. BE SURE the battery area is well ventilated (clear of fumes) should it be
necessary to connect a jump battery or battery charger. Fumes from the battery
can ignite by a spark and explode.
3. BE SURE battery charger is OFF when making the connections if battery
charging is required.
4. ALWAYS wear safety glasses when servicing batteries.
5. Connect the ground cable last when installing a battery.
6. Battery acid will burn skin, eat holes in clothing and cause blindness if splashed
into the eyes.
7. Batteries generate a highly explosive mixture. A spark could ignite these gases.
8. Do not short across batteries. The spark could ignite the gases.
9. Keep battery covers in place at all times. Be sure there is no connection
between the battery terminals and the cover.
Wire Rope & Cable
Winches and ropes must be inspected frequently for unforeseen wear patterns, and discarded
according to certain criteria (refer ISO 4305).
1. Wire rope running over drums and through sheaves creates pinch points. Do
not use hands or bars to guide wire rope onto drums; instead, use rope guides.
Keep clothing and all parts of the body away from running rope and from
machinery that moves the rope.
2. Replace wire rope when it is worn to the following:
a. Six (6) randomly distributed broken wires are found in one lay.
b. Wear of one-third (1/3) of the original diameter of the outside wires.
c. Evidence of any heat damage from any cause.
d. Any kinking or cracking occurs.
3. Make sure all hooks are connected properly.
a. Saddle and nuts must be around lifting side of the cable.
b. Always use a thimble when installing a hook.
c. Always use the correct number of clamps for cable size.
d. All hooks must have lock type dogs to prevent cable from jumping out of the
hook throat.
4. Do not allow cable to backlash on hoist or drum.
a. Make sure the cable spools properly on hoist or drum.
b. Do not overload the hoist or wire rope.
Hot Oil and Components Safety
WARNING
!
The normal operating temperature of hydraulic oil is hot enough to cause
serious burns. Use precautions when working on any hot fluid lines or
changing filters.
WARNING
!
Hot oil or components can burn. Avoid contact with hot oil or
components.
WARNING
!
Do not allow used oil to drain into the ground. Dispose of used oil
properly and in accordance with local guidelines.
Cylinder Repairs or Replacement
1. When repairing cylinders, be sure to block them up to prevent dropping or
rolling off the drill.
2. After repairing or replacing cylinders, especially the feed or tower (derrick)
raising cylinders, purge all air out of each end of the cylinder before connecting
it to the drill. Air in one end can cause the derrick or rotary head to fall and
cause an accident.
3. Loosen feed cables or chains before trying to remove feed cylinders.
4. Plug all hoses as soon as they are removed from the cylinders to prevent oil
spills and slippery conditions.
5. Use a hoist to lift the larger cylinders.
Pumps and Motors
1. Make sure hoses are plugged when replacing pumps and motors.
2. Always replace pumps and motors with the same size and type.
3. Use the correct adapters when installing pumps or motors.
Valves
1. When working on valves, keep area clean to prevent contamination from
getting inside the valves.
2. Be sure the valve being installed is the same type as the one removed. Motor
and cylinder spools are interchangeable and may cause an accident or a failure
of a component if used incorrectly.
Hoses
1. Do not replace a hose with one of lesser strength or capacity. Breakage or
leakage could result.
2. Do not use a will-fit hose as it may fail and cause an accident before it can be
replaced by the correct type.
Coolers and Fans
1. Never remove the fan guard unless the drill is shut down and locked out.
2. When testing fan speed, do so with the guard in place.
3. Do not try to remove debris from inside the fan guard. Stop the drill and lockout
the key switch before removing.
4. Be careful while washing out coolers with pressure washers. Spray can injure
eyes or damage equipment.
5. Coolers are heavy. Obtain a suitable hoist capable of lifting and moving coolers
and/or radiator before replacing.
Guards
1. If any guards must be removed from the drill to perform service, always replace
them before the drill is started.
2. If a guard becomes damaged or lost, repair or replace it before starting drill.
3. Do not cut out or modify a guard. It was designed to protect people from getting
injured.
Tracks
1. Use the correct procedure for adjusting the track tension.
2. Never release all the pressure from the track tensioning spring. It can cause an
accident.
3. Always raise the drill on the jacks before replacing idlers or track pads.
Lubrication
1. Never attempt to lubricate the drill while it is running, unless the drill is fitted with
an automatic lube injection system. Stop the drill for all maintenance.
2. To lubricate fittings on the tower (derrick), lay the tower (derrick) down and use
a manlift to access hard to reach and inaccessible places. DO NOT climb the
tower (derrick) for ANY reason.
NOTE: If a lube point will not take grease, report it immediately. A bearing
can get hot and cause a fire if not lubricated properly.
Compressor
WARNING
!
The normal operating temperature of compressor oil is hot enough to
cause serious burns. Use precautions when working on any hot fluid
lines or changing filters.
Do not attempt to remove any plugs or open the drain valve before
making sure all air pressure has been relieved from the system.
1. Relieve all pressure in the receiver tank and lines before working on the
compressor system.
2. Do not allow tools or air powered equipment to be connected to the drill hoses.
They must be attached to the service regulator and the pressure adjusted to
the working capacity of the tool being used.
3. Do not remove any regulation or control hoses while the drill is running or when
pressure is still in the system. High pressure air can cause serious injuries.
4. Be careful when using service air to clean off the working area. High pressure
air can be dangerous.
5. Turn off drill air and exhaust the drill string before unscrewing drill pipe at the
table.
6. Do not turn on high pressure air too quickly when the air hoses are in the vicinity
of people. Hoses can jump and injure people, especially if there is water or oil
inside the hose.
Warning of Special Dangers
Overhead Electric Wires
When working with the drill, maintain a safe distance from overhead electric lines. If work is to
be carried out close to overhead electric lines, the working equipment must be kept well away
from them. CAUTION! DANGER! Check out the prescribed safety distances.
DANGER
!
If your Drill comes into contact with a live wire:
Do not leave the drill.
Warn others against approaching and touching the drill.
Have the live wire de-energized.
Tram the drill out of the hazard zone.
Do not leave the drill until the damaged line has been safely repaired or de-
energized.
Ventilation
Operate internal combustion engines and fuel operated heating systems only in adequately
ventilated premises. Before starting the drill in enclosed premises, make sure that there is
sufficient ventilation.
Grade Limitations
Refer to the DM45,DM50,DML Stability and Grade Limits with Drill on Tracks chart in
Section 3-Specifications. Exceeding the slope or grade limitations of the drill and its
configuration can cause the drill to tip over. Prior to moving the drill, always determine the safe
operating grade of the drill with the tower (derrick) up or down.
Seat Belts
Transporting and Towing
1. Drills must be towed, loaded and transported in accordance with the operating
instructions.
2. For towing the drill, observe the prescribed transport position, admissible
speed and itinerary.
3. Use only appropriate means of transport and lifting gear of adequate capacity.
4. Fastening of loads and the instructing of crane operators should be entrusted
to experienced persons only. The person giving the instructions must be within
sight or sound of the operator.
5. DO NOT attempt to load the drill rig on the transport vehicle without knowledge
and experience with the operation of the drill rig.
6. Always use a ramp when loading the drill on a transport vehicle. Be sure ramps
are of adequate strength, low angle, and proper height.
7. Use proper chock blocks in front and rear of the wheels of the transport vehicle
when loading the drill.
8. Be sure the trailer is on level ground and approach the transport vehicle loading
ramps squarely to make sure the drill rig does not drop off the side of the ramp.
9. Keep trailer deck clean of clay, oil, mud, ice, frost and other material that can
become slippery.
10. Use proper chock blocks in front and rear of the tracks once loaded on the
trailer.
11. Make sure the tramming and drill control levers are all in the STOP positions.
12. Position the engine speed control to LOW IDLE and turn key switch to OFF.
13. Lock all lockable compartments.
14. Always know the overall height, weight, width and length of the drill rig and
hauling vehicle. MAKE SURE there is sufficient clearance when crossing
underpasses, bridges and tunnels or when passing under overhead lines.
15. When moving the drill rig on public access roads, obey all traffic regulations and
be sure that proper clearance flags, lights and warning signs, including the
Slow Moving Vehicle emblem, are properly displayed. Know your
approximate stopping distance at any given speed. Never turn corners at
excessive speeds. Look in all directions before reversing your direction of
travel.
16. Position the drill rig on the transport vehicle centered from side to side and use
proper chock blocks in front and rear of the tracks.
17. Secure the drill rig to the deck of the transport vehicle with adequate chains or
cables and blocks to meet local regulations.
Towing
The towing procedure is for moving a disabled drill a short distance, only a few meters (feet)
at a low speed not faster than 2 km/h (1.2 mph), to a convenient repair location. This procedure
is for emergencies only. Always haul the drill on a transporter if long distance moving is
required.
Shielding must be provided on the towing machine to protect the operator if the tow line or bar
should break.
WARNING
!
Personal injury or death could result when towing a disabled drill
incorrectly. Follow the recommendations below to properly perform the
towing procedure.
1. Block the tracks to prevent any movement of the tracks before releasing the
track brakes or before disconnecting the final gear train. The drill can roll free if
it is not blocked.
2. Relieve the hydraulic tank and hydraulic line pressure before any disassembly.
3. Even after the drill has been turned off, the hydraulic oil can still be hot enough
to burn. Allow the hydraulic oil to cool before draining.
CAUTION
!
Use only draw bars for the towing requirement. Maximum towing speed =
2.0 km/h (1.2 mph). Maximum towing distance = 300 meters (984 feet).
NOTICE
To tow the drill, both final drives must be disengaged. Do not operate the
travel motors with the final drives disengaged. Damage could result.
Clean the final drive covers and the nearby areas before disengaging the
drives. Dirt can contaminate and damage the propel motors, reduce
propel performance and cause drill malfunctions.
2.3 - Safety Decals and Nameplates
Before you operate , maintain, work around or in any other way use this drill, read and
understand the safety decals and safety labels located on the drill. Follow all directions on the
labels. Do not remove or deface the labels. Replace them if they become damaged or lost.
Table 1: Safety Decals and Notices
REF. # NAME QTY.
DANGER
1. Hazardous Voltage 1 2657299562
WARNING
2. Rotating Blade 2 2657299455
3. Falling Derrick 2 2657299414
4. Rotating Parts 1 2657299430
5. Rotating Parts 2 2657299448
6. Pressurized Fluid 1 2657299463
7. Combustible Gas 1 2657299497
8. Fall or Crush Hazard 1 2657299505
9. High Pressure 1 2657299513
10. Power Head 2 2657299521
11. Falling Rod Carousel 1 2657299539
12. Falling Drill Pipe 1 2657299547
13. Combined Warning 1 2657299554
16. Dont Climb 1 2657318834
17. Fan Blades 1 2657338329
CAUTION
18. Excessive Hydraulic Oil 1 2657299422
NOTICE
19 Engine Failure 1 2657140444
20 Hydraulic Failure 1 2657156465
21 Dust Discharge 1 2657335200
22 Electrical Damage 1 2657345878
SAFETY MANUAL
23 DM45/50/DML Safety Manual 1 2657311151
REF. # NAME QTY.
Safety Decals & Nameplates
Section 3 - Specifications
DM45,DM50,DML Instruction Manual SECTION 3 - SPECIFICATIONS
3.1 - Specifications
General Description
The DM45, DM50 and DML drills are the Drilling Solution Mid-Range Drill Product Line.
DM45
The Atlas Copco DM45 is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling
(200 kN). The DM45 utilizes a diesel engine to drive the air compressor and hydraulic system.
Operation of the drill is performed using electric over hydraulic controllers from an
ergonomically designed operator cab.
DML
The Atlas Copco DML is a crawler mounted, hydraulic tophead drive, multi-pass rotary drilling
(267 kN). The standard DML utilizes a diesel engine to drive the air compressor and hydraulic
system (optionally an electric motor is also available). Operation of the drill is performed using
electric over hydraulic controllers from an ergonomically designed operator cab.
Drill Applications
The Mid-Range drills are built in accordance with state-of-the-art standards and recognized
safety rules. Nevertheless, their misuse may constitute a risk to the life and limb of the user or
third parties and may cause damage to the drills or other material property.
The Mid-Range drill must be used in accordance with its designated use as described in the
operating section of this manual (See Section 5). The Mid-Range drill must only be operated
by safety-conscious persons who are fully aware of the risks involved in operating the drill.Any
functional disorders, especially those affecting the safety of the drill, must be corrected
immediately.
SECTION 3 - SPECIFICATIONS DM45,DM50,DML Instruction Manual
WARNING
!
Set up the DM45, DM50 and DML drills on a firm level surface. If this is not
available, the site should be adequately prepared prior to drill setup.
Operating the drill within the limits of its designated use also involves
compliance with the inspection and maintenance directives contained in
the operating manual.
Non Designated Applications
The DM45,DM50,DML drills are not designed for pioneering or earth moving applications. The
DM45,DM50,DML drills are not designed for use on inclined surfaces or on soft and unstable
ground. Use of the drills for purposes other than that mentioned (such as for towing other
vehicles or equipment) is considered contrary to its designated use. The manufacturer and/or
supplier cannot be held liable for any damage resulting from such use. The risk of such misuse
lies entirely with the user.
Design Features
1. The DM45,DM50,DML blasthole drill is a crawler mounted, hydraulic tophead
drive, multipass drill rig designed specifically for production blasthole drilling in
mining applications by rotary / percussive action on prepared benches which
are flat and firm.
2. The DM45,DM50,DML utilize an excavator-type undercarriage driven directly
by a planetary gear system and two hydraulic motors (111 hp {82.8 Kw}on
DM45/50 and 151 hp {112.6 Kw}on DML). A walking beam oscillation yoke
allows the rig to propel over uneven ground without imposing excessive
torsional stresses on the main frame.
3. Drilling functions are hydraulically powered. Compressed air is used to clean
the hole. The hydraulic pumps and the air compressor are driven by a diesel
engine. The systems that support the drilling functions are controlled by
hydraulic and electrical components.
4. The DM45,DM50,DML drills are powered by a diesel engine. A heavy-duty
engine silencer/muffler is also provided to reduce power pack noise emission.
Separate air inlet cleaner(s) with quick release dust drop covers for the engine.
5. The DM45,DM50,DML drills utilize a diesel engine connected directly to a three
hole hydraulic pump drive gearbox on one end and the air compressor directly
connected to the other end. The pump drive gearbox, diesel engine and air
compressor are mounted on its own sub base, which in turn is mounted to the
main frame.
6. The DM45,DM50,DML drills are equipped with an oil flooded asymmetrical
rotary screw design compressor for high performance rotary drilling. Tapered
roller bearings are used on the air end to handle thrust and radial loads.
Separate air inlet cleaner with quick release dust drop cover for the
compressor.
7. The DM45,DM50,DML drills incorporate three (3) leveling jacks, as a standard
feature, to keep the drill level and stable while drilling.
8. The tower is constructed of welded rectangular steel tubing. The DM45,DM50
features a 30 foot (9.1 m) tower. The DML features a 30 foot (9.1 m) and a 35
foot (10.7 m) tower.The tower is raised and lowered by two hydraulic cylinders.
9. Drill rod changing is done by moving drill rod in and out of the carousel and
rotary head. The rotary head is used to move all drill rod in and out of the hole.
All the drilling functions are controlled from the operators cab adjacent to the
drill table. Drill pipe changing is accomplished from the operators console.
10. The DM45,DM50 drill has a Weight on Bit of 0 to 45,000 lb. [0 to 20,400 kg).
The DML drill has a Weight on Bit of 0 to 60,000 lb. [0 to 27,213 kg).
11. The DM45,DM50,DML drills have a rotary head which provides a Standard
Maximum Torque of 0-7,200 lbf-ft (9,762 N-m).
Environment Rate Factor Ranges
Duty:
1. Heavy - Hard Rock
2. Normal - Soft Rock
3. Light - Sand and Gravel
Ambient Temperature:
1. Hot - Above 125F (52C)
2. Nominal - Between limits of 125F (52C) Maximum and 15F (-9C) Minimum.
3. Cold - Between limits of 15F (-9C) and -40F (-40C)
4. Extreme Cold - Below -40F (-40C)
Altitude:
1. High - Above 6000 Feet (1828.8 Meters)
2. Nominal - Sea Level to 6000 Feet (1828.8 Meters)
Service:
1. Excellent - Well Prepared Benches, Scheduled Maintenance Program,
Advanced Training of Operators and Mechanics.
2. Nominal - Good Operating Conditions, Normal Maintenance, Basic Training
for Operators and Mechanics.
3. Poor - Bad Operating Conditions, Limited Maintenance, Limited Training for
Operators and Mechanics.
Application Type:
1. Construction - Nominal Application
2. Aggregates - Light Application
3. Gold - Heavy Application
4. Copper - Heavy Application
5. Coal - Nominal Application
6. Iron - Heavy Application
Operational Limitations
Ambient Temperature Range
The standard drill comes equipped for a nominal ambient temperature working range between
limits of 125F (52C) Maximum and 15F (-9C) Minimum.
Ground Pressure:
The DM45/50 utilizes an excavator type undercarriage with design ground pressure limit of
12.0 psi (82.7 kPa).
The DML utilizes an excavator type undercarriage with design ground pressure limit of 13.7
psi (94.5 kPa).
Maximum Allowable Slope Angle
The drills come equipped for operation on slopes not exceeding 20 degrees inclination.
Exceeding the slope or grade limitations of the drill and its configuration can cause the drill to
tip over. Always determine the safe operating grade of the drill with the tower up and down.
Stay within the limits shown on the DM45,DM50,DML Stability and Grade Limits with Drill on
Tracks chart.
Operating Conditions for Stability
Stability is affected by the tower position and orientation of the drill on the slope, the surface
stability (bearing strength), and wind conditions. Refer to the Blasthole Drill Stability/
Gradeability Chart for further guidance. Note: Drilling Solution does not authorize use on
slopes exceeding 20 degrees.
Sound Pressure Limitations
Operator Exposure to Noise Emission - In accordance with the requirements of clauses 1.75f
of Annex I of the Machinery Directive 89/392/EEC and Directive 91/368/EEC, EN791 Annex
A Cl. 4.1, the drill has been tested at normal engine operating speed at the following maximum
values: At Operators Station (in closed cab, seated/standing positions =less than 85 dBA.
Tests were conducted with machine running at operating engine speed. Machine was in an
open field with no structural objects reflecting sound.
Vibration Exposure Limitations
Operator Exposure to Vibration - In accordance with the requirements of clauses 22.2 of
Annex I of the Machinery Directive 89/392/EEC and Directive 91/368/EEC, EN791Annex ACl.
4.1, the drill has been tested and the weighted root mean square acceleration value to which
arms are subjected does not exceed 2.5 m/s. Weighted root mean square acceleration to
which body (feet and posterior) is subjected does not exceed 0.5 m/s. Tests were conducted
with machine running at operating engine speed. The drill was in an open field with no
structural objects reflecting sound.
DM45,50 DML Stability / Gradeability Chart
DM45,50 Drill Maximum Slope (Drill On Jacks)
DML Drill Maximum Slope (Drill On Jacks)
Standard Equipment and Specifications
DANGER
!
Your life may be endangered if the following is not complied with. DO
NOT add attachments to the machine that intrude into operators
protective area, reduce visibility, restrict emergency exits or add weight
exceeding certification weight. See the operators manual or contact your
dealer for complete inspection requirements and maintenance
instructions.
Standard on the DM45:
Cat 325L undercarriage with hydraulic track tensioners
Ether Injection
No-bump rod changer
Sliding hydraulically powered breakout wrench (fork chuck) for drill pipe breakout
charge air cooler)
drop covers)
Tram alarm
30 foot drill pipe changer
Standard on the DML:
Caterpillar 330S undercarriage with hydraulic track tensioners
Ether Injection
No-bump rod changer
Sliding hydraulically powered breakout wrench (fork chuck) for drill rod breakout
charge air cooler)
drop covers)
Tram alarm
30 foot drill rod changer
Main Frame
The Atlas Copco designed DM45/50 main frame is a weld fabrication consisting of both main
rails and crossbeams of 10 in. x 10 in. (254 mm x 254 mm) structural steel tubing.
The Atlas Copco designed DML main frame is a weld fabrication consisting of both main rails
and crossbeams of 10 in. x 14 in. (254 mm x 356 mm) structural steel tubing.
Leveling Jacks
The standard DM45,DM50,DML drills utilize a three point hydraulic leveling jack system to
keep the drill level and stable while drilling.
Table 1: DM45/50 Leveling Jack Specifications:
Leveling Jack Specifications
Type: Hydraulic cylinder with lock check
Number: Three (standard with drill:)
(Two) Drilling End: 5 bore x 4 rod diameter x 48 stroke (127 mm x 102
mm x 1,219 mm)
(One) Non-Drilling End: 5 bore x 4 rod diameter x 48 stroke (127 mm x 102
mm x 1,219 mm)
Lifting Capacity, each: 58,900 lbs (26,717 kg)
Jack Pad Diameter:
Drill End 30 in. Dia. (762 mm) Round with cut out
Non-Drill End 26 in. Dia. (660.4 mm)
Jack Pad Area:
Drill End
565 in.
2
(3,645 cm.
2
) each
Non-Drill End
531 in.
2
(3,426 cm.
2
) each
Jack Pad Bearing
Pressure (Approximate):
Drill End 68.9 psi (475 kPa)
Non-Drill End 66.7 psi (460 kPa)
Jack Indicator Lights: Three lights on the cab center gauge post illuminate
Green when the jacks are fully retracted.
Table 2: DML Leveling Jack Specifications:
Leveling Jack Specifications
Type: Hydraulic cylinder with lock check
Number: Three (standard with drill:) or Four (optional)
(Two) Drilling End: 5 bore x 4 rod diameter x 48 stroke (127 mm x 102
mm x 1,219 mm)
(One) Non-Drilling End:
Optional (Two)
5 bore x 4 rod diameter x 48 stroke (127 mm x 102
mm x 1,219 mm)
Lifting Capacity, each: 58,900 lbs (26,717 kg)
Jack Pad Diameter:
Drill End 30 in. Dia. (762 mm) Round with cut out
Non-Drill End 26 in. Dia. (660.4 mm)
Jack Pad Area:
Drill End
565 in.
2
(3,645 cm.
2
) each
Non-Drill End (same for 3
or 4 option)
531 in.
2
(3,426 cm.
2
) each
Jack Pad Bearing
Pressure (Approximate):
Drill End 68.9 psi (475 kPa)
Non-Drill End ( 3 jack) 66.7 psi (460 kPa)
Non-Drill End ( 4 jack) 59.9 psi (413 kPa)
Jack Indicator Lights: Three lights on the cab center gauge post illuminate
Green when the jacks are fully retracted.
Undercarriage and Propel System
The DM45/50 utilizes an excavator-type undercarriage, built to Atlas Copco specifications,
driven directly by a planetary gear system and two hydraulic motors rated at 111 hp (153 kW)
each. A walking beam oscillation yoke allows the rig to propel over uneven ground without
imposing excessive torsional stress on the main frame. Both tracks are individually controlled
with each track acting as an independent unit. The tracks are hydraulically adjustable with a
spring recoil system and are equipped with 23.6 in. (600 mm) wide replaceable triple bar
grouser pads.
Table 3: Undercarriage and Propel Specifications
Undercarriage DM45/50
Model: Atlas Copco ACGT 2500 Caterpillar 325L
Construction: Reinforced rectangular steel frame
Length: 15 ft.-3 in. (466 cm) 15 ft.-4 in. (468 cm)
Ground Contact 12 ft.-2 in.(379 cm) 12 ft.-5 in. (380 cm)
Mounting: Oscillating walking beam
Rated GVW: 88,185 lb. (40,000 kg) 110,000 lb. (38,555 kg) See
Note A.
Take Up
Adjustment:
Grease slack adjustment, spring recoil
Rollers Bearings: Sealed
Top Rollers: 2 per side, B6 class with sealed for life bearings
Bottom Rollers: 10 per side, B6 class with sealed for life bearings
Roller Location: Equally spaced between idler and sprocket
Towing Release: Track drive manually releases for towing
Track Final Drive: Hydraulic motor, axial piston, through planetary reduction
Final Drive Ratio 124:1 105.5:1
Propel Motors
Displacement:
Fixed 5.5 in
3
/rev (90 cm
3
/rev) Fixed 4.88 in
3
/rev (80 cm
3
/rev)
Rating: 111 hp (82.8 kW) each motor
Propel Speed: 0 to 1.0 mph (0 to 1.6 km/hr.) 0 to 1.3 mph (0 to 2.1 km/hr.)
Track Pads:Width: 23.6 inches (60 cm)
Track Pad Type: Triple bar grouser
Ground Pressure: 13.5 psi (93 kp)
The DML utilizes an excavator-type undercarriage, built to Atlas Copco specifications. Tracks
they will return to neutral and cease rig movement. A walking beam oscillation yoke allows
the rig to propel over uneven ground while reducing torsional stresses on the main frame. Both
tracks are individually controlled, and act as an independent unit. The tracks are hydraulically
adjustable with a spring recoil system, and are equipped with 33.5 (850 mm) wide replaceable
triple bar grouser pads. Side frames on the tracks have been designed by Atlas Copco and
are designed specifically for the operation of our drills.
Table 4: Cat Undercarriage and Propel Specifications
Brake: Plate type, spring applied, hydraulically released
Note A: Base on track roller capacity only. Improvements to track roller
frame strength &/or an increase in machine drawbar pull may
also be required to maintain expected performance & durability
Cat Undercarriage DML
Model: Caterpillar 330S Caterpillar 330L
Construction: Excavator-style lower with B7-class rollers, sprockets, and
tracks
Length: 15 ft.-0 in. (457 cm) 16 ft.-5 in. (502 cm)
Ground Contact: 11 ft.-8 in. (360 cm) 13 ft.-3 in. (404 cm)
Rated GVW: 120,000 lb. (54,431 kg) See
Note A.
130,000 lb. (58,967 kg) See
Note A.
Take Up
Adjustment:
Top Rollers: 2 per side 2 per side
Bottom Rollers: 7 per side 8 per side
Roller Location: Equally spaced between idler and sprocket
Towing Release: Track drive manually releases for emergency towing
Track Final Drive: Hydraulic motor, axial piston, through planetary reduction
Final Drive Ratio 99:1 99:1
Propel Motors
Displacement:
9.76 in.
3
/rev (160 cm
3
/rev) 9.76 in.
3
/rev (160 cm
3
/rev)
Undercarriage DM45/50
Table 5: ACGT Undercarriage and Propel Specifications
Rating: 151 hp (112.6 kW) each 151 hp (112.6 kW) each
Propel Speed: 0 to 1.3 mph (0 to 2.1 km/hr.) 0 to 1.3 mph (0 to 2.1 km/hr.)
Track Pads:Width: 33.5 in. (851 mm) 33.5 in. (851 mm)
Track Pad Type: Triple Bar Grouser
Ground Pressure: 13.7 psi (0.94 bar) 13.2 psi (0.91 bar)
Note A: Base on track roller capacity only. Improvements to track roller
frame strength &/or an increase in machine drawbar pull may
also be required to maintain expected performance & durability
Atlas Copco Undercarriage DML
Model: ACGT 3000S ACGT 3000L
Construction: Excavator-style lower rollers, sprockets, and tracks
Length: 15-0 (4.58 m) 16-6 (5.02 m)
Ground Contact: 11-9 (3.60 m) 13-2 (4.02 m)
Rated GVW: 143,300 lbs (65,000 kg) 143,300 lbs (65,000 kg)
Take Up
Adjustment:
Top Rollers: 2 per side, with sealed for life bearings
Bottom Rollers: 7 per side, with sealed for life
bearings
8 per side, with sealed for life
bearings
Roller Location: Strategically located for load distribution relative to the tower
position (vertical or horizontal)
Towing Release: Track drive manually releases for emergency towing
Track Final Drive: Hydraulic motors through planetary reduction
Final Drive Ratio 147:1
Propel Motors
Displacement:
7.63 in.3/rev. (125 cm3/rev.)
Rating: 151 hp (113 kW) each motor
Cat Undercarriage DML
Tower, Carousel and Drill Pipe Handling
The DM45,50,DML tower is constructed of welded rectangular steel tubing. Atlas Copco has
the tower welded by certified welders in a special rollover fixture that helps provide optimum
welds. The DM45,50,DML tower is a multi-pass tower, a carousel type drill rod changer is part
of the assembly and is located on the outside of the tower frame. The tower is raised and
lowered by two hydraulic cylinders. Raising the tower to the vertical positional with a full
complement of drill rod in the carousel and with the rotary head at the top of the tower, can be
accomplished in less than one minute. Tower pinning is remotely preformed from within the
operators cab.
Table 6: Tower
Propel Speed: 0 to 1.1 mph (0 to 1.8km/hr.)
Track Pads:Width: 33.5 in. (851 mm)
Track Pad Type: Triple Bar Grouser
Ground Pressure: 13.0 psi (0.89 bar) 12.1 psi (0.83 bar)
Drill Type DM45,50 DML
Tower 30 ft. (9.1 m) 30 ft. (9.1 m) 35 ft. (10.7 m)
Tower
Construction:
Four main member, open front, ASTM A500 GRB rectangular steel
tubing. All welded.
Tower
Raising
Cylinders:
Two (2) Hydraulic
Cylinders
Two (2) Hydraulic
Cylinders
Two (2) Hydraulic
Cylinders
Bore: 5 1/2 in. (140 mm) 5 1/2 in. (140 mm) 5 1/2 in. (140 mm)
Stroke: 48 in. (1,219 mm) 48 in. (1,219 mm) 48 in. (1,219 mm)
Physical
Tower
Length:
41 ft. 4 in. (12.6 m) 41 ft. 4 in. (12.6 m) 46 ft. 9 in. (14.2 m)
Rotary Travel: 35 ft. 7 in. (10.9 m) 35 ft. 7 in. (10.9 m) 40 ft. 6 in. (12.3 m)
Tubing Size:
Front Tube
Size:
5 in. x 3 in. x 3/8 in.
(127 mm x 76.2 mm x
9.5 mm)
5 in. x 3 in. x 3/8 in.
(127 mm x 76.2 mm x
9.5 mm)
5 in. x 3 in. x 3/8 in.
(127 mm x 76.2 mm x
9.5 mm)
Atlas Copco Undercarriage DML
DRILL PIPE CHANGE
Drill rod changing is accomplished from the operators console. A hydraulic positioned sliding
fork wrench is used to break the joint with limited impact that minimizes shock loads on the
tower, carousel, rotary head and feed components. Up to five drill pipe are stored in the
carousel (contingent upon rod size selection). Two hydraulic cylinders swing the carousel into
and out from the loading position under the rotary head. A hydraulic motor rotates the carousel
to index the rotary head for changing.
An exclusive key lock carousel design securely locks in the drill rod at both the bottom and
the top of the carousel to ensure maximum safety for drill rod storage and changing. An
auxiliary hoist is provided as standard for drill rod and accessory handling. A no-bump drill rod
change limits the feed force of the rotary head while the carousel is moved into the complete
out position, and prohibits the movement of the carousel if the head is not at the top of the
mast. This is provided as standard equipment on the DM45,50,DML.
Drill rods can be handled by a 4,000 pound (1814.4 kg) auxiliary hoist/winch that comes
standard on the rig, and is located at the top of the tower.
There is a 5,200 pound (2,359 kg) recommended total maximum weight capacity that the
carousel is able to handle. Chart on next page indicates number of drill rods to be used for
each rod configuration and the total depth that can be achieved at each length.
NOTE: Number of carousel cups is set up for use with .5 wall rod. Please conform to chart
guidelines on next page if not using .5 wall drill rod.
Rear Tube
Size:
3 in. x 3 in. x 5/16 in.
(76.2 mm x 76.2 mm
x 7.9 mm)
3 in. x 3 in. x 5/16 in.
(76.2 mm x 76.2 mm
x 7.9 mm)
3 in. x 3 in. x 5/16 in.
(76.2 mm x 76.2 mm
x 7.9 mm)
Diagonal
Cross
Members:
3 in. x 2 in. x 1/4 in.
(76.2 mm x 50.8 mm
x 6.4 mm)
3 in. x 2 in. x 1/4 in.
(76.2 mm x 50.8 mm
x 6.4 mm)
3 in. x 2 in. x 1/4 in.
(76.2 mm x 50.8 mm
x 6.4 mm)
Vertical Cross
Members:
3 in. x 2 in. x 1/4 in.
(76.2 mm x 50.8 mm
x 6.4 mm)
3 in. x 2 in. x 1/4 in.
(76.2 mm x 50.8 mm
x 6.4 mm)
3 in. x 2 in. x 1/4 in.
(76.2 mm x 50.8 mm
x 6.4 mm)
Drill Type DM45,50 DML
Tower 30 ft. (9.1 m) 30 ft. (9.1 m) 35 ft. (10.7 m)
DM45,50 Rod Capacity Chart
CAUTION
!
Carousel cup numbers are configured for use of .5 wall drill rod. Filling
the carousel with drill rods having a wall thickness greater than .5 wall
can potentially overload the tower. Use the guidelines listed below.
Table 7: DM45,50 Rod Capacity Chart
Rod Size
Rod Length
of Tower
Selection
Rod Wall
Thickness
Total
Number
On-Board
Hole Depth
4.5 OD x 3.5 API (144
mm OD x 89 mm API)
30 ft. (9.1 m) 0.5 (12.7 mm) 6 175 ft. (53.3 m)
30 ft. (9.1 m) 0.75 (19 mm) 5 145 ft. (44.2 m)
5 OD x 3.5 API (127
mm OD x 89 mm API)
or
5 OD x 3.5 BECO (127
mm OD x 89 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 6 175 ft. (53.3 m)
30 ft. (9.1 m) 0.75 (19 mm) 5 145 ft. (44.2 m)
5.5 OD x 3.5 BECO
(140 mm OD x 89 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 6 175 ft. (53.3 m)
30 ft. (9.1 m) 0.75 (19 mm) 4 115 ft. (35 m)
6.25 OD x 4 BECO
(160 mm OD x 102 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 5 145 ft. (44.2 m)
30 ft. (9.1 m) 0.75 (19 mm) 4 115 ft. (35 m)
7 OD x 4.5 BECO (178
mm OD x 114 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 5 145 ft. (44.2 m)
30 ft. (9.1 m) 0.75 (19 mm) 3 85 ft. (25.9 m)
*Rod Capacity includes one rod under the rotary head
DML Rod Capacity Chart
CAUTION
!
Carousel cup numbers are configured for use of .5 wall drill rod. Filling
the carousel with drill rods having a wall thickness greater than .5 wall
can potentially overload the tower. Use the guidelines listed below.
Table 8: DML Rod Capacity Chart
Rod Size
Rod Length
of Tower
Selection
Rod Wall
Thickness
Total
Number
On-Board
Hole Depth
4.5 OD x 3.5 API (144
mm OD x 89 mm API)
30 ft. (9.1 m) 0.5 (12.7 mm) 6 175 ft. (53.3 m)
30 ft. (9.1 m) 0.75 (19 mm) 5 145 ft. (44.2 m)
35 ft. (10.7 m) 0.5 (12.7 mm) 6 205 ft. (62.5 m)
35 ft. (10.7 m) 0.75 (19 mm) 4 135 ft. (41.1 m)
5 OD x 3.5 API (127
mm OD x 89 mm API)
or
5 OD x 3.5 BECO (127
mm OD x 89 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 6 175 ft. (53.3 m)
30 ft. (9.1 m) 0.75 (19 mm) 5 145 ft. (44.2 m)
35 ft. (10.7 m) 0.5 (12.7 mm) 6 205 ft. (62.5 m)
35 ft. (10.7 m) 0.75 (19 mm) 4 135 ft. (41.1 m)
5.5 OD x 3.5 BECO
(140 mm OD x 89 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 6 175 ft. (53.3 m)
30 ft. (9.1 m) 0.75 (19 mm) 4 115 ft. (35 m)
35 ft. (10.7 m) 0.5 (12.7 mm) 5 170 ft. (51.8 m)
35 ft. (10.7 m) 0.75 (19 mm) 3 100 ft. (30.5 m)
6.25 OD x 4 BECO
(160 mm OD x 102 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 5 145 ft. (44.2 m)
30 ft. (9.1 m) 0.75 (19 mm) 4 115 ft. (35 m)
35 ft. (10.7 m) 0.5 (12.7 mm) 5 135 ft. (41.1 m)
35 ft. (10.7 m) 0.75 (19 mm) 3 100 ft. (30.5 m)
7 OD x 4.5 BECO (178
mm OD x 114 mm
BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 5 145 ft. (44.2 m)
30 ft. (9.1 m) 0.75 (19 mm) 3 85 ft. (25.9 m)
35 ft. (10.7 m) 0.5 (12.7 mm) 4 135 ft. (41.1 m)
35 ft. (10.7 m) 0.75 (19 mm) 3 100 ft. (30.5 m)
The rod support extends to support the lower end of the drill rod while adding rods, this assists
with aliening the added rod currently in the deck fork and deck bushing.
7.625 OD x 5.25
BECO (194 mm OD x
133 mm BECO)
30 ft. (9.1 m) 0.5 (12.7 mm) 4 115 ft. (35 m)
30 ft. (9.1 m) 0.75 (19 mm) 3 85 ft. (25.9 m)
35 ft. (10.7 m) 0.5 (12.7 mm) 3 100 ft. (30.5 m)
35 ft. (10.7 m) 0.75 (19 mm) 2 65 ft. (19.8 m)
*Rod Capacity includes one rod under the rotary head
Rod Size
Rod Length
of Tower
Selection
Rod Wall
Thickness
Total
Number
On-Board
Hole Depth
Rotary Head
Rotation on the DM45,50,DML is supplied by a rotary Power Head (also called Tophead)
powered by two hydraulic motors. A gauge shows rotation pressure on the control panel for
constant monitoring and adjustment. A replaceable 29 spindle adapter between the spindle
and the drill rod is furnished as standard equipment, along with the nylatron head guides
(which are replaceable). Pulldown cables and pullback chains are attached to mounting
plates, which are attached to the rotary head case. A rotation tachometer is an option.
On the DM45,50,DML, a rotary head with lube flush for motor positive lubrication is standard.
Table 9: DM45,50,DML Rotary Head Specifications
Rotary Head Specifications
Model: 4SV-2-10.0
Speed Range: Variable, 0 to 161 RPM
Torque: Variable, 0 to 7,200 lbf-ft (9,762 Nm)
Number of Motors Two (2)
Type of Motor: One (1) variable displacement and one (1) fixed.
Head Guides: Replaceable Nylatron
Rotary Head Weight: Approximately 2600 lbs. (1,179 kg)
Reduction: 15:1
Feed System
The DM45,50,DML closed-loop hydrostatic feed system is powered by two hydraulic feed
cylinders that raise and lower the rotary head smoothly and positively. It is controlled by way
of cable for pulldown (utilizing 14 diameter sheaves and 1 diameter cable), and heavy-duty
chain for pullback. A gauge on the operators console indicates feed pressure. Single-lever
operation of feed speed and direction gives the operator greater ease of operation, along with
an adjustable feed force controller for smooth drilling.
Table 10: DM45/50 Feed System Specifications
Table 11: DML Feed System Specifications
30 ft. Tower
Weight on Bit: Variable, 0 to 45,000 lb. (0 to 20,412 kg)
Mechanism Type: Two hydraulic cylinders with cable feed
Cylinder Bore: 4 1/4 in. (108 mm)
Rod Diameter: 3 1/4 in. (83 mm)
Stroke: 196 in. (4,978 mm)
Pulldown Cable Diameter: 1 in. (25.4 mm)
Pullback Chain: 160 H
Feed Speed: 146 ft./min. (44.5m/min.)
Retract Speed: 205 ft./min. (62.5m/min.)
Pullback Capacity: 0 to 22,000 lbf. (0 to 98 kN)
Tower 30 ft. (Standard) 35 ft. (Optional)
Weight on Bit: Variable, 0 to 60,000 lb. (0 to 27,216 kg)
Mechanism Type: Two hydraulic cylinders with cable feed
Cylinder Bore: 4 1/4 in. (108 mm) 4 3/4 in. (121 mm)
Rod Diameter: 3 1/4 in. (83 mm) 3 3/4 in. (95 mm)
Stroke: 196 in. (4,978 mm) 226 in. (5,740 mm)
Pulldown Cable Diameter: 1 in. (25.4 mm)
Pullback Chain: 160 H
Feed Speed: 146 ft./min. (44.5m/min.) 109 ft./min. (33.2m/min.)
Retract Speed: 205 ft./min. (62.5m/min.) 181 ft./min. (55.2m/min.)
Pullback Capacity: 0 to 22,000 lbf. (0 to 98 kN)
Single-lever operation of feed speed and direction gives the operator greater ease of
operation. This simplified control also provides faster down feed. The system operates more
efficiently than other designs due to lower flows and the resulting reduced pressure drop. This
enables the pumps to operate in the more efficient portion of their performance curves.
NOTE: The Feed Holdback Pressure Gauge Option for HP drills only, located on the control
console. Shows the hydraulic pressure in the feed cylinders when drill holdback pressure is
applied to prevent excessive down pressure on the drill bit.
Power Pack
The DM45,50,DML power pack (or power train) consists of a diesel engine directly coupled to
an Ingersoll-Rand air compressor on one end and a hydraulic pump drive on the other end.
This complete power pack assembly is mounted on its own sub base, which in turn is mounted
to the rig main frame. The in-line drive train configuration maximizes mechanical efficiency,
and the separate floating sub base isolates the components from drilling and propel shock
loads and helps to maintain alignment between them.
A heavy-duty engine silencer/muffler is also provided to reduce power pack noise emission.
Separate air inlet cleaners with quick release dust drop covers are standard for both engine
and air compressor intake.
Diesel motors come standard with 350 U.S. gallon (1325 liter) fuel capacity with the option to
upgrade to 650 U.S. gallon (2461 liter) fuel capacity.
DM45,50 Power Pack Selection
Table 12: DM45,50 Selections
DM45,50 Engine Type:
Compressor CFM @psi
(M
3
/Min @kPa)
Engine
Manufacture
Engine/
Motor Model
HP (kW) @ RPM
XL 900 @ 110 (@ 758) Caterpillar C15 440 (328) @ 1800
Cummins QSX15 425 (317) @ 1800
XL 1050 @ 110 (@ 758) Caterpillar C15 475 (354) @ 1800
Cummins QSX15 475 (354) @ 1800
XL 1200 @ 110 (@ 758) Caterpillar C15 540 (403) @ 1800
Cummins QSX15 530 (395) @ 1800
HP 900 @ 350 (@ 2413) Caterpillar C15 540 (403) @ 1800
Cummins QSX15 530 (395) @ 1800
HP 1070 @ 350 (@ 2413) Caterpillar C18 630 (470) @ 1800
Cummins QSX15 600 (447) @ 1800
DML Power Pack Selection
Table 13: DML Selections
DML Engine Type:
Compressor CFM @psi
(M
3
/Min @kPa)
Engine
Manufacture
Engine/
Motor Model
HP (kW) @ RPM
XL 1900 @ 110 (54 @ 758) Caterpillar C27 800 (597) @ 1800
Cummins QSK19 755 (563) @ 1800
XL 1600 @ 110 (45 @ 758) Caterpillar C18 630 (470) @ 1800
Cummins QSX15 600 (447) @ 1800
XL 1200 @ 110 (34 @ 758) Caterpillar C15 540 (403) @ 1800
Cummins QSX15 530 (395) @ 1800
HP 1250 @ 350 (35 @ 2413) Caterpillar C27 800 (597) @ 1800
Cummins QSK19 755 (563) @ 1800
HP 1450 @ 350 (41 @ 2413) Caterpillar C27 800 (597) @ 2100
Cummins QSK19 760 (567) @ 2100
Air Compressor
DM45,50 Compressors
Air compressors used on the DM45,50 are manufactured by Ingersoll-Rand and are of the oil
flooded asymmetrical rotary screw design. Tapered roller bearings are used to handle thrust
and radial loads. Standard equipment for the air compressor includes a separate three-stage
inlet air cleaner and full instrumentation and controls. The lubrication system includes an oil
cooler, by-pass valve, oil filter, oil pump, and combination air receiver and oil separator tank.
A safety shut down system is also provided for high discharge air temperature.
Table 14: DM45,50 Air Compressor Specifications
Make: Ingersoll-Rand
Type (Low Pressure): Single stage oil flooded asymmetrical rotary screw
Type (High Pressure): Two-stage over and under oil flooded asymmetrical
rotary screw
Bearing Type: Tapered roller
Air End Lubrication: Positive, gear oil pump
Filtration System: 10 micron element filter (XL900/XL1050/XL1200)
20 micron element filter (HP900/HP1070)
Capacities and Pressure
Available:
900 CFM @ 110 psi (25.5 m3/min. @ 7.6 bar)
1050 CFM @ 110 psi (29.7 m3/min. @ 7.6 bar)
1200 CFM @ 110 psi (34.0 m3/min. @ 7.6 bar)
900 CFM @ 350 psi (25.5 m3/min. @ 24.1 bar)
1070 CFM @ 350 psi (30.3 m3/min. @ 24.1 bar)
DM45,50 Compressor Type:
DML Compressors
Air compressors used on the DML are manufactured by Ingersoll-Rand and are of the oil
flooded asymmetrical rotary screw design. Tapered roller bearings are used to handle thrust
and radial loads. Standard equipment for the air compressor includes a separate three-stage
inlet air cleaner and full instrumentation and controls. The lubrication system includes an oil
cooler, by-pass valve, oil filter, oil pump, and combination air receiver and oil separator tank.
A safety shut down system is also provided for high discharge air temperature.
Regulation of the HR-2.5 high pressure compressor is accomplished by an on-off system so
that when the drilling operation does not demand air, the compressor load can be removed.
This aids by conserving engine horsepower, extending compressor life, and providing easier
startup (particularly in cold weather operations).
Table 15: DML Air Compressor Specifications
Make: Ingersoll-Rand
Type (Low Pressure): Single stage oil flooded asymmetrical rotary screw
Type (High Pressure): Two-stage over and under oil flooded asymmetrical
rotary screw
Bearing Type: Tapered roller
Air End Lubrication: Positive, gear oil pump
DML Compressor Type:
Filtration System: 12 micron element filter (XL1200/XL1600/XL1900)
20 micron element filter (HP1250/HP1450)
Capacities and Pressure
Available:
1200 CFM @ 110 psi (34.0 m3/min. @ 7.6 bar)
1600 CFM @ 110 psi (45.3 m3/min. @ 7.6 bar)
1900 CFM @ 110 psi (53.8 m3/min. @ 7.6 bar)
1250 CFM @ 350 psi (35.4 m3/min. @ 24.1 bar)
1450 CFM @ 350 psi (41.1 m3/min. @ 24.1 bar)
Electronic Air Regulation Control System (EARS)
An option available on the DM45,50,DML is Electronic Air Regulation Control System (EARS).
This system is designed to deliver variable air volume control (within system capacity), while
still maintaining constant air pressure. The air pressure adjustment allows the operator to
optimize productivity by using the flow knob to control the butterfly valve which allows for a
reduction in air flow back to the compressor while maintaining the air pressure setting. This
allows for a reduction in power needed, giving higher fuel efficiency levels.
The electronic valve control system eliminates the use of the small air hoses which could
possibly freeze in extreme cold weather applications (the only air hoses in the EARS system
are the two main air hoses which are large enough in diameter that they are not susceptible
to freezing over).
The EARS system is comprised of very few components, which provides easy startups as only
a small number of adjustments are required. On the EARS system the butterfly valve set up is
a swing through design (with full 360 deg movement) which eliminates sticking at the inlet.
Cooler Package
Coolers for the hydraulic oil, compressor oil, and diesel engine coolant are attached to the
main frame. Operational ambient temperature rating for the DM45,50,DML is up to 125
degrees F (52 degrees C).
DM45,50 Cooler Sections:
DML Cooler Sections:
Table 16: Cooling System
Cooling System Specifications
Type: Side by side radiator, hydraulic oil, compressor oil, cac cooler
Fan: Hydraulically driven, 54 in. (1372 mm) diameter, 8-blade
Cooler Motor:
Fixed displacement, 6.0 in
.3
/rev (98 cm
3
/rev)
Rating: 125F (52C) ambient at sea level
Function: Cools hydraulic oil, compressor oil and diesel engine coolant.
Table 17: Charge Air Cooler (CAC) System
Hydraulic System
All drilling and propel functions are hydraulically powered. The hydraulic system consists of a
82 gallon (310 Liter) hydraulic reservoir with 5 micron filtration, hydraulic pumps mounted on
a three hole pump drive gearbox and various motors, valves, cylinders, pipes, hoses, filters
and gauges. A hydraulic oil cooler assures cool oil temperatures to maximize system efficiency
and component life.
The three hydraulic pumps are mounted for convenient service access on a single three hole
pump drive gear box driven off the diesel engine through a drive shaft.
The two main pumps supply hydraulic power to either drilling functions (Drill Feed and
Rotation) or Tram (Propel) functions. The auxiliary circuits triple pump supplies oil for all other
functions other than tramming, drill feed/rotation.
CAC System Spec
Type: Side by side cooler
Fan: Hydraulically driven, 30 in. (762 mm) diameter, 9-blade
CAC Fan Motor:
Fixed displacement, 0.67 in.
3
/rev (11 cm
3
/rev)
Main Cooler Fan
Motor:
Fixed displacement, 8.0 in.
3
/rev (131 cm
3
/rev)
Temp Rating: Continuous 32F to 176F (0C to 80C)
Function: Cools Charge Air
Hydraulic System
Table 18: Hydraulic System Specifications
Hydraulic System Pumps
Table 19: Feed Pump Specifications
Table 20: Rotation Pump Specifications
Hydraulic System Pressures
Feed System:
25 ft. (7.6 m) 4,500 psi (310 bar) Pulldown
4,000 psi (276 bar) Pullback
Rotation System: 4,500 psi (310 bar)
Auxiliary System: 3,000 psi (207 bar)
Number: One (1)
Type: Pressure compensated, variable displacement, axial piston
Capacity: 0 to 62 GPM (0 to 234.7 L/m)
Displacement:
7.25 in.
3
/rev (119 cm
3
/rev)
Function: Feed system and Cab side Propel system
Number: One (1)
Type: Pressure compensated, variable displacement, axial piston
Capacity: 0 to 62 GPM (0 to 234.7 L/m)
Displacement:
7.25 in.
3
/rev (119 cm
3
/rev)
Function: Rotation system and Non-Cab side Propel system
Table 21: Triple Pump Specifications
Hydraulic Motors
Table 22: Cooler Fan Motor Package Specifications
Number: One (1)
Type: Hydraulic, Vane pump
Capacity:
P1 0 to 41.44 GPM (0 to 156.9 L/m)
P2 0 to 23.8 GPM (0 to 90.1 L/m)
P3 0 to 11.6 GPM (0 to 43.9 L/m)
Displacement (Fixed):
P1
4.84 in.
3
/rev (79 cm
3
/rev)
P2
2.75 in.
3
/rev (45 cm
3
/rev)
P3
1.34 in.
3
/rev (22 cm
3
/rev)
Function:
P1 Cooler package fan motor
P2 6 and 9 Spool valve
P3 Cooler package fan motor
Standard Fan
Motor
Main Fan Motor
(HP1250,HP1450,
XL1900 ONLY)
CAC Fan Motor
(HP1250,HP1450,
XL1900 ONLY)
Number of
Motors:
One (1) One (1) One (1)
Displacement:
6.0 in.
3
/rev (98 cm
3
/
rev)
8.0 in.
3
/rev (131.1
cm
3
/rev)
0.69 in.
3
/rev (11.3
cm
3
/rev)
Function: Cool the engine, hydraulic oil, compressor oil and charged air.
Table 23: Hoist Motor Specifications
Table 24: Dust Collector Fan Specifications
Table 25: Water Injection Pump Motor Specifications
Table 26: Carousel Index Motor Specifications
Hydraulic System Reservoir
Table 27: Hydraulic Reservoir Specification
Number: One (1)
Displacement:
11.9 in.
3
/rev (195.0 cm
3
/rev)
Function: Facilitates Drill Pipe Handling
Number: One (1)
Displacement:
1.5 in.
3
/rev (24.6 cm
3
/rev)
Function: Drives Dust Collector Fan
Number: One (1)
Displacement:
9.6 in.
3
/rev (157.3 cm
3
/rev)
Flow: 8 GPM (30.3 L/m)
Function: Drives Water Injection Pump
Number: One (1)
Displacement:
1.54 in.
3
/rev (25.2 cm
3
/rev)
Function: Drives Carousel
Capacity: 82 gallons (310 L)
Location: Within Tower Support Structure
Standard Equipment: Oil Level Indicator and Oil Temperature Gauge
Hydraulic System Cylinders
Table 28: Leveling Jack Cylinders
Leveling Jack Cylinder Specification
Type: Hydraulic Cylinder with double holding valve. Set at 4500
psi (310.3 bar)
Quantity: Three (3)
(Two) Drill Side: 5 in. bore x 48 in. stroke / 4 in. rod diameter
(127 mm x 1,219 mm / 102 mm)
(One) Non Drill End: 5 in. bore x 48 in. stroke / 4 in. rod diameter
(127 mm x 1,219 mm / 102 mm)
Optional - (Two) Non
Drill End (DML ONLY):
5 in. bore x 48 in. stroke / 4 in. rod diameter
(127 mm x 1,219 mm / 102 mm)
Cylinder Bore: 5.00 inch (127.0 mm)
Cylinder Rod Diameter: 5.00 inch (127.0 mm)
Cylinder Stroke: 5.00 inch (127.0 mm)
Jack Pad Diameter: 26 in. (660 mm) drilling end (side jacks)
Jack Pad Diameter: 30 in. (762 mm) non-drilling end
Function: Raise, level and lower the drill
Table 29: Tower Raising / Lowering Cylinders
Table 30: Rod Changer Cylinders
Table 31: Rod Support Cylinders
Tower Raising / Lowering Specification
Type: Hydraulic Cylinder
Quantity: Two (2)
Tower 30 ft. (DM45,50,DML) and 35 ft. (DML)
Cylinder Bore: 5.5 in. (139.7 mm)
Cylinder Rod Diameter: 3 in. (76.2 mm)
Cylinder Stroke: 48 in. (1,219.2 mm)
Function: Raise and lower the tower
Rod Changer Specification
Quantity: Two (2)
Cylinder Rod Diameter: 1.75 in. (44.5 mm)
Cylinder Stroke: 10 in. (254 mm)
Function: Open (out) and close (in) carousel
Rod Support Specification
Quantity: One (1)
Cylinder Stroke: 2 in. (50.8 mm)
Function: Extend and retract rod support
Table 32: Chain Wrench Cylinders
Table 33: Tower Pinning Cylinders
Table 34: Telescopic Cylinders (Option)
Chain Wrench Specification
Quantity: One (1)
Cylinder Rod Diameter: 1.5 in. (38.1mm)
Function: The chain wrench is used to clamped around the box end
of the drill pipe above the table. By operating the chain
wrench cylinder, the pipe joint can be broken and the drill
rod set in the carousel.
Tower Pinning Specification
Quantity: One (1)
Function: Lock tower in horizontal position and angle drill positions .
Telescopic Specification
Quantity: Two (2)
Cylinder Bore: 2 in. (50.8 mm)
Function: Raise and lower the telescopic dust curtain
Table 35: Air Throttle Cylinders (High Pressure Only)
Table 36: Dust Curtain Cylinders (Option)
Table 37: Sliding Break Out Cylinders
Air Throttle Specification
Quantity: One (1)
Function: Used for opening and closing the air throttle.
Dust Curtain Specification
Quantity: One (1)
Function: Raise and lower the dust flap
Sliding Break Out Specification
Quantity: One (1)
Function: Holds drill rod at table level for breakout procedure
Table 38: Feed Cylinders
Winch
4000# Winch (Standard)
The 4000 lb winch can be used on the DM45,50,DML drill.
The following information is on the Ramsey SCH-3600 winch. Do not exceed 3,600 lbs (1,630
kgs) load. Recommended Wire Diameter is 3/8 in. (9.5 mm).
NOTE: Specifications in chart are based on 3/8 in. (9.5 mm) EIPS wire rope.
NOTE: The rated line pulls shown in chart are for the winch only. Consult the wire rope
manufacturer for wire rope rating.
Table 39: Winch Load and Speed Recommendations
Feed Specification
30 ft. Tower
(DM45,50,DML)
35 ft. Tower (DML ONLY)
Type: Hydraulic Cylinder Hydraulic Cylinder
Quantity: Two (2) Two (2)
Cylinder Bore: 4.25 in. (108 mm) 4.75 in. (120.7 mm)
Cylinder Rod Diameter: 3.25 in. (82.6 mm) 3.75 in. (95.3 mm)
Cylinder Stroke: 196 in. (4978.4 mm) 226 in. (5740.4 mm)
Function: Move drill string up and down during drilling operations
Layer of Cable 1 2 3 4
Line Pull lbs 3600 3200 2900 2700
kgs 1630 1450 1310 1220
Line Speed fpm 48 52 56 60
mpm 14 15.8 17 18.2
Cable
Capacity
ft. 25 55 85 120
m 7 16 25 36
4000# Winch Specification
1. Gear Reduction Ratio: 5.1:1
2. Hydraulic pressure required for Rated Line Pull: 1,800 psi (124 bar).
3. Hydraulic flow required for Rated Line Speed: 8 GPM (30.28 L/min).
8000# Winch (Option)
The 8000 lb winch can only be used on the DML drill.
The following information is on the Braden (BG8A) winch. Do not exceed 8,000 lbs (3,629
kgs) load. Recommended Wire Diameter is 7/16 in. or 1/2 in. (11.1 mm or 12.7 mm).
NOTE: The rated line pulls shown in chart are for the winch only. Consult the wire rope
manufacturer for wire rope rating.
Table 40: Winch Load and Speed Recommendations
8000# Winch Specification
1. Gear Reduction Ratio: 59.06:1
2. Hydraulic pressure for Rated Line Pull: 2,000 psi (138 bar).
Rope Size Layer Line Pull Line Speed
7/16 in. (.438 in.)
[11.1 mm]
1 8,000 lbs. (3629 kgs) 140 ft./min (42.7 meter/min)
6* 5,370 lbs. (2436 kgs) 208 ft./min (63.4 meter/min)
1/2 in. (.500 in.)
[12.7 mm)
6* 5,140 lbs. (2331 kgs) 219 ft./min (66.8 meter/min)
*This layer does not comply with ANSI Spec. 5-132a2c for 1/2 exposed flange.
Operators Cab
All operational functions can be controlled from the driller's console within the cab of the
DM45,50,DML. The cab is thermally insulated, pressurized, equipped with tinted safety glass,
has an operator seat with seat belt, and can be entered by two hinged and lockable doors.
Table 41: Cab Specifications
Seat Belts
the seat belt provided. To increase visibility on the non-cabside and the non-drill end while
Thermal/Sound Insulation: Quiet (tested at 80 dBA)
Mechanical Design: 1-piece construction and FOPS certified (ISO 3449 Level
2)
Mounted: Isolation mounted
Dimension: Width: 66.85 in. (1698 mm)
Length: 88.84 in. (2257 mm)
Height: 89.37 in (2270 mm)
Number of Doors: Two (2)
One hinged on drill deck side
One hinged on outboard side
Control Console
Serviceability:
All controls are electric over hydraulic. The console is
hinged for simplified access to the controllers. A wiring
harness leads from the controllers to the spool valves
and main pump controllers.
Heater: 42,000 BTU/HR
Air Conditioner: 36,000 BTU/HR; three-stage inlet filter
Ventilators: Adjustable vents for climate control
Coolant: R-134A
Operator Seat: One swivel type, adjustable, high back with arm rests.
Cab Glass: Tinted Safety Glass
Windshield Wipers: Drilling and rear tramming window (optional on non-
drilling window)
Cab Optional Equipment
Proheat
Proheat is a diesel fueled engine preheat solution for quick and reliable cold weather starting.
An integrated system that circulates heated coolant, warming the engine block to make
starting easier while reducing start-up engine wear.
Cab Sunshades
Optional pull down, fabric cab sunshades are available on the DM45,50,DML. Sunshades are
located on all windows (including the cab door windows)
Cab Microwave
Optional 24V microwave, mounted in the DM45,50,DML cab is available. The microwave runs
off of the same 24V power supply supporting the cab functions (no external power supply or
gen-set is required).
Rotary Head Tachometer
A rotary head tachometer mounted in the cab on the console is another option available on
the DM45,50,DML.
Cab Buddy Seat
Optional fold-up buddy seat is also available for purchase on the DM45,50,DML.
Cab Tramming Inclinometers
Optional tramming inclinometers show the angle of the DM45,50,DML drill while tramming
(and utilizes color to indicate when the rig is operating in the green zone).
DEI / Sprocket Installation
Another option available on the DM45,50,DML is the Thunderbird DEI (Drill Efficiency
Indicator) plus, for depth indication. Note that this DEI does not have on board data storage.
DEI display is installed in the cab, and data collection point is mounted on the tower.
If a data storage system is desired, but the DEI plus is not the system of choice, another option
is a sprocket encoder installation. Sprocket installation allows the rig to easily be fitted up with
any third party drill monitoring system of choice.
Operators Controls
Tramming and Jack Controls
J oystick for dust curtain flap and curtains. Switch selecting propel or drill mode. Control for
tower raising cylinders. Optional water injection flow control knob. Two (2) independent propel
controls for left and right track operation. Three (3) independent jack leveling controls. Three
indicator lights for jacks stowed.
Drill Controls
Top row controls are Hoist, Break-out fork, Carousel index, Carousel swing and chain wrench.
Middle row controls are Torque limit, Rotation, Feed and Drill air throttle. Bottom row controls
are Drill feed force, Rod support and holdback force.
Drill Gauges
There are two Bit Air gauges used, low pressure drill reads 0 to 160 psi (0 to 11 bar) and high
pressure drill reads 0 to 400 psi (0 to 27.6 bar).
The Supercharge gauge reads 0 to 400 psi (0 to 2758 kPa).
The Rotation gauge reads 0 to 7500 psi.
The Pulldown gauge reads 0 to 7500 psi.
The Rotation Speed (option) gauge reads 0 to 30 x 100 RPM.
Air Regulation Controls
Standard Compressor Panel:
The panel above supports different air end configurations. Low pressure drill will have just a
control lever On/Off.
High pressure (HR2) drill will have the air pressure regulator, compressor volume control, on/
off switch and no control lever.
High pressure (HR2.5) drill will have the air pressure regulator, compressor volume control,
on/off switch and control lever.
EARS Compressor Panel:
The panel above is the optional configuration EARS (Electronic Air Control System).
Diagnostic light at the top left on the panel.
Second row is Air Flow control knob and to the right is Maximum Pressure knob.
Bottom is Compressor On/Off switch.
Ignition Console and Gauges
Top row controls from left to right are Emergency Stop, Engine Throttle, Compressor
Discharge Temperature, Fuel Quantity Gauge, Engine Tachometer, and Key On Hourmeter.
Bottom row controls from left to right are Diagnostic Powerview, Drill lights switch, Tram lights
switch, Oil Pressure gauge, Water Temperature gauge, and Circuit Breakers switches.
Ignition Console and Gauges (continued)
Top row controls from left to right are Key On/Off switch, Primer button, Start button and Alert
Horn button.
Second row controls from left to right are Ether button and Windshield Wiper knobs (front, rear
and auxiliary).
Bottom row controls from left to right are Tower Pinning switch, Tower Un-pinned light and
Datalink 9 Pin Connector.
Engine Diagnostic
Engine Diagnostic lights and switches. Stop Engine light (Red), Engine Warning light (Amber),
Maintenance Indicator light (Blue) and Engine Diagnostic toggle switches (Increase /
Decrease switch and On / Off switch).
Heating/AC Controls
The Heating and Air Conditioning controls are Fan speed knob, Temperature control knob,
Heat / Air Conditioning switch and Heat pull knob.
Leveling Bubble
Leveling Bubble used to level drill when on jacks, for drilling operations.
DHD Lube Switch (HP Units Only)
The DHD Lubricator switch and light. The light is on top and flashes when system is working.
The On / Off switch is below the light.
Night Lights
A nine-light halogen night lighting system is provided as standard for operator visibility under
low light operating conditions.
One (1)-Hole Collar Area Illumination
One (1)-Power Pack Illumination
Two (2)-Tower Illumination
Five (5)-Tramming Illumination
One (1)-Internal 40 watt for cab interior illumination
Optional Equipment
Dust Collector
A no visible emission. dry dust collector is optional equipment on the DM45,50,DML. It is a
pleated paper element-type fan/filter unit. Interval flushing is controlled by an electronic timer.
A vacuum hose allows the fan/filter unit to draw the dust out of the collection area. The dust is
removed from the air stream as the air flows through the filters. Heavy cuttings are contained
around the hole.
Table 42: Dust Collectors
Table 43: Dust Collector Specifications
Dust Collector 3600 4500 7SB
Capacity 3600 CFM
(102 m
3
/min.)
4500 CFM
(127 m
3
/min.)
7,000 CFM
(198 m
3
/min.)
Mounting Fender (non-cab
side)
Fender (non-cab
side)
Top of non-cab side
jack
Dimensions
Length 52 in. (1,321 mm) 72 in. (1,829 mm) 61 in. (1,549 mm)
Height 88.5 in (2,248 mm) 72 in. (1,829 mm) 138 in. (3505.2 mm)
Width or Diameter 25 in. (635 mm) 24 in. (610 mm) 53.5 in. (1,359 mm)
Number of Filter
Elements
4 6 9
Inlet Diameter 8 in. (203 mm) 10 in. (254 mm) 12 in. (305 mm)
Configuration Rectangular Rectangular Cyclone
Type: No visible emission pleated paper element with
pneumatic flushing
Model: Model and capacity are dependent on size of air
compressor.
Fan Motor: Hydraulic driven
Fan Motor Operating
Pressure:
2,750 psi (189.6 bar)
Internal Baffle between
Collector Intake Duct and
Filters:
Yes
Dust collector type.
Dust Hood: Rectangular with split curtains and hydraulically
retractable front curtain
Water Injection
The Water Injection System injects a regulated quantity of water into the air flow going to the
drill rod. The water content suppresses the dust created by the drilling operation. The Water
Injection system has a hydraulic motor drive, and is operated from the cab control system.
There are several sizes of water injection systems available. The water injection tanks are
mounted in several locations to ensure the drilling water requirements are met (details shown
in charts below).
Table 44: Water Injection Tanks for DM45,50
Table 45: Water Injection Tanks for DML
Water Injection
Tank Size:
300 Gallon 400 Gallon 500 Gallon
(1135 Liters) (1514 Liters) (1893 Liters)
Water Tank
Location:
300 gallon belly
tank.
400 gallon tank on
deck.
300 gallon belly
tank, and 200
gallon tank on
deck.
Option
Constraints:
Not available with
680 gallon fuel.
Not available with
dust collector
option.
Not available with
dust collector
option and /or 680
gallon fuel.
Water
Injection
Tank Size:
300 Gallon 400 Gallon 500 Gallon 700 Gallon
(1135 Liters) (1514 Liters) (1893 Liters) (2650 Liters)
Water Tank
Location:
300 gallon
belly tank.
400 gallon
tank on deck.
300 gallon
belly tank, and
200 gallon
tank on deck.
300 gallon
belly tank, and
400 gallon
tank on deck.
Option
Constraints:
Not available
with 680 gallon
fuel.
Not available
with 3600,
4500, or 7SB
dust collector
option.
Not available
with 3600 or
7SB dust
collector
option and/or
680 gallon
fuel.
Not available
with 3600,
4500, or 7SB
dust collector
option and/or
680 gallon
fuel.
Table 46: Water Injection System
Optional Water Tank Outside of Track Frame:
On DM45,50,DML drill with the water injection option, another option available is to have a ball
valve which allows the water tank to drain outside of the track frame.
Angle Drill Package
There are two optional angle drilling packages available on the DM45,50,DML. Both packages
allow the tower to be positioned from the vertical in 5 degree increments. All controls are
located at the operators control console inside the cab. The optional angle drill package
includes drill rod support, and an angle drill tie bar.
1. Allows the tower to be positioned 0 to 20 degree angle drill.
2. Allows the tower to be positioned 0 to 30 degree angle drill.
An optional angle telescoping dust curtain (only for 0 to 20 degrees), allows for ease of dust
curtain operation with the angle drill package. Angle telescoping for the last 20 to 30 degrees
is not available due to interference issues on the dust hood. The angle telescoping dust curtain
can also be used with the standard vertical drill, if a telescoping dust curtain is desired.
Water Injection System Specification
Type: FMC (J ohn Bean)
Size: 8 GPM (30.28 L/min.)
Capacity: 0 to 8 GPM (0 to 30.28 L/min.)
Pressure: 550 psi (37.92 bar) max
Hydraulic Motor
Drive:
Fixed Displacement 9.6 in.
3
/rev (101.6 cm.
3
/rev)
Function: Dust Suppression
Strobe Lights
Strobe lights are available on the DM45,50,DML, these lights can be mounted on the cab and/
or on the crown of the tower. Blue or amber strobe color options are available. The tower
strobe light is flashing at all times when the ignition key switch is on, the cab strobe light is
flashing whenever the ignition key switch is on and the cab is in propel mode.
Electric Warning Horns
Option available, is to have 2 warning horns activated by one button in the DM45,50,DML cab.
These 2 horns are 24V electrically operated and mounted on the top of the cab. They are
mounted facing opposite directions so that the horns can be heard on both sides of the rig.
High Intensity Discharge Lights
High Intensity Discharge (HID) lights are available, the Nordic/HID night light option consists
of upgrading the standard halogen lights to 9 Xenon 24V, 35 Watt lamps (this upgrade keeps
the lights in the standard light location).
These lamps have great luminous intensity and a color mimicking natural daylight. They are
designed specifically for forestry/mining/earth moving use, and are designed to have low
power consumption. Lights can be turned on when engine is on or off.
Fast Service Box and Hand Pump
Fast Fill Service box at ground level, quick connect fittings for fill and evacuation of fuel [item
1 in photo], hydraulic oil [item 2 in photo], engine coolant [item 3 in photo] receiver tank oil [item
4 in photo], and crankcase oil [item 5 in photo] is an available for the DM45,50,DML.
An option for fuel only quick fill, is also available on the DM45,50,DML.
When the quick fill for fuel only or no fast service option is selected, there is a hand pump for
the hydraulic oil fill included on the rig.
Fire Extinguishers
Available on the DM45,50,DML is two 20 pound manual fire extinguishers mounted onto the
rig. One extinguisher is mounted on the hand railing next to the cooler, and the other is
mounted on the hand railing on the cab side of the non-drill end of the rig.
If more than two fire extinguishers is desired, additional extinguishers can also be mounted by
special request.
Fire Suppression System
Fire Suppression kit with manual activation is also available on the DM45,50,DML. The fire
suppression kit includes one canister mounted on the non drill end side of the rig (near the air
cleaners), and two manual activation buttons (on mounted in cab, and one mounted for ground
access).
The fire suppression canister contains Foray
TM
dry chemical fire suppressant which utilizes a
nitrogen cartridge for the pneumatic actuator. This fire extinguisher agent is rated for
extinguishing Type A (trash/wood), Type B (liquids) and Type C (electrical equipment)
fires. The fire suppression canister can be recharged as needed.
Fan Control (Cooler)
The DM45,50,DML is available to be equipped with a 2 speed or variable speed fan control.
The 2 speed fan control system consists of two speeds (slow and fast). Slow fan speed is to
be used in ambient temperatures below 95 degrees F (35 degrees C)
The variable speed fan control option, is controlled by a knob in the cab offering speed
selections over the entire range of fan speed from off to max/high. Variable fan speed is
typically used for cold weather start ups.
Remote Propel System
The remote propel system is available as an option for the DM45,50,DML. The remote propel
system allows the operator the ability to move the drill rig remotely from a drive pendant which
can be worn on the operators shoulders. The remote propel pendant, is connected to the rig
by a cord, and is operated by joysticks (exactly like those used in the cab).
Emergency Shutdown
NOTE: All drills come standard with an emergency shutdown button mounted in the cab (even
when ground level shutdown option is not selected).
Ground level shutdown (GLS) buttons are located outside of the cab on the DM45,50,DML. By
pressing the ground level shutdown, electrical power to the engine is disconnected.
The one button option, has the shutdown switch mounted on the side of the drill near the
receiver tank. For the two button option, one shutdown switch is mounted near the receiver
tank and the second is mounted on the opposing side of the drill near the cooler.
The tower mounted emergency shutdown switch is located where personnel standing on the
drill table could easily reach it.
Additional switches, and additional locations for ground level shutdown buttons are also
available.
Central Hydraulic Test Station
The central hydraulic test station allows for testing of component pressures. You can use a
standard test fitting gauge and plug it into the desired port to read the system pressure. The
test station is mounted on a bracket next to the cooler.
Auto Thread Lube/Thread Greaser
Pneumatic thread lube for lubrication of rod threads through a spray nozzle located near the
sliding fork wrench.
Central Lubrication
The DM45,50,DML comes standard with a central lube system consisting of grease points that
can be used to lube the components on the drill. One set of grease zerts is located on the non-
cab side of the tower, and another on the frame (drill end, non-cab side) near the tower
support.
There are two additional options to this system, one of which is an automatic lube system with
a hand pump (hand pump is located on the cab side, non drill end of the rig), and the other is
a completely automated lubrication system with an air pump that is activated by an electronic
timer.
Racor Fuel Filter
The Racor fuel filter is specifically designed to separate out any water that may be in the fuel
lines. The Racor filter is a 10 micron rated filter.
A Racor fuel filter with 24 Volt heater is another option available. The Racor fuel filter is
specifically designed to separate out any water that may be in the fuel lines. The Racor filter
with heater is a 2 micron rated filter.
Tower Angle Indicator
A tower angle indicator dial is also available. This dial is mounted on the tower and visually
displays the angle at which the tower is sitting. The tower angle indicator is easily viewed from
inside the cab.
Timing Shaft
Timing shaft is installed on the tower. The timing shaft keeps the power head pullback chains
synchronized, so that the rotary head sits level to facilitate making drill joints quickly.
Head up tram interlock
The head up tram interlock is an option that wont allow the operator to tram the drill while the
head is not all the way at the top.
Engine Pre-lube
Optional engine pre-lube assembly is also available for both the Cummins and Cat diesel
engines. The engine pre-lube, lubes the valve zone prior to engine startup, giving the benefit
of less wear and tear on the engine over time.
Battery Equalizer
The battery equalizer allows the 24V batteries to deliver 12V DC/20 amp power. The 12V
connector for the battery equalizer is located outside the glove box inside the cab.
Arctic Articulating Hoses
Operating in extremely cold temperatures is to have the articulating hoses replaced with arctic
rated hoses. Selecting this option will have all of the hoses which move on the machine base,
tower, dust curtain, and drill package replaced with the arctic rated hoses.
Cold Weather Package (Diesel Machine)
The cold weather package allows for warm start-up, and drill operation while operating in
extremely cold ambient conditions (when determining if cold weather options are needed you
should take into account the lowest ambient operating temperatures).
Many of the heaters are to be powered by a 240 Volt power source which can be the optional
generator installed on the drill or by another external power source. All the 240V heaters are
wired into a 240V breaker box which in turn can be plugged into the power source of choice.
With the selection of any 240 Volt heater, the hydraulic fluid supplied will be SHC525 oil (for
optimized cold weather operation) instead of the standard ISO32 oil.
In addition to the cold weather package there are also several heater options which can be
ordered.
Cold Weather Package includes (diesel machine):
Breaker Box Installation for 240 V heaters
Fuel tank heater [240 V powered]
Water tank heater [240 V powered]
Hydraulic tank heater [240 V powered]
Engine oil Pan heater [240 V powered]
Additional forced air cab heater [240 V powered]
Diesel fired engine pre-heater for heating engine coolant [24V powered]
Additional Cold Weather Package:
DHD tank heater [240 V powered]
Radiator Heater (for engine coolant) [240 V powered]
Receiver tank Heater [240 V powered]
Additional 240V outlet in cab [240 V powered]
Additional 110V outlet in cab [240 V powered]
Racor Fuel Filter Heater [24 Volts standard cab voltage powered]
Insulated Battery Box [insulation only/includes no heat source]
Diesel fired pre-heater for heating engine coolant [diesel powered]
Water injection pump heater with arctic fox manifolds. This heater is installed with an
insulated box that surrounds both the pump and the heater.
Arctic fox manifolds for water tank. This option also adds arctic fox piping to run warm
water through the DHD tank (on HP machines only).
240 Volt Generator
The generators are diesel-driven and provide 30 KW of power at 110/220/380 Y 50 Hz or 110/
240/415 VAC 60 Hz. It is a self-contained package that can be run independently of the deck
engine. All AC wiring required for the cold weather package is independent of the DC wiring.
Tow Hooks
2 tow hooks on the non drill end of the drill.
Standard Tools
Chain wrench (with wrench rest)
Centralizer Bushing (Static Deck Bushing)
Sliding Fork Wrench
Spindle sub
Lifting bail
Socket for feed chain adjustment on tower
Manuals:
3 sets of parts and operations manuals are provided standard with each drill. The language of
the manuals is selected to be the same as the nameplates and decals, unless specifically
requested to be done differently. Additional sets of manuals, and link one manuals are also
options available.
Keys:
2 sets of keys come standard with each drill. Additional sets of keys are also available.
Dimensions and Weights DM45,50,DML
Dimensions and Weights DM45,50
Dimensions shown in table below are for a standard 30 ft. (9.1 m) tower, excluding drill pipe
and accessories.
Table 47: Dimensions and Weights 30 ft. Tower
Dimensions
and Weights
DM45 / DM50 DML
Tower Up Tower Down Tower Up Tower Down
Length: 32 ft.-3 in. 43 ft.-7 in. 32 ft.-3 in. 43 ft.-6 in.
(9.83 m) (13.28 m) (9.83 m) (13.26 m)
Working
Height:
43 ft.-7 in. 18 ft.-0 in. 44 ft. 1 in. 18 ft.-5 in.
(13.28 m) (5.49 m) (13.44 m) (5.61 m)
Width
Between
Track Pads:
6 ft.-9 in. (2.06 m)
Distance
Between Jack
Center at Drill
End:
9 ft.-1 in. (2.77 m) 9 ft.-8 in. (2.95 m)
Distance
Between Jack
Centers Front
to Rear:
20 ft. (6.17 m)
Working
Weight:
77,000 -85,000 lb. 80,000 - 110,000 lb.
(34,927 - 39,916 kg) 36,287 - 49,895 kg)
Dimensions shown are for the DM45,50 frame and frame with 30 ft. tower.
Dimensions and Weights DML
Table 48: Dimensions and Weights 30 ft. Tower
Dimensions
and Weights
DM45 / DM50 DML
Tower Up Tower Down Tower Up Tower Down
Length: 32 ft.-3 in. 43 ft.-7 in. 32 ft.-3 in. 43 ft.-6 in.
(9.83 m) (13.28 m) (9.83 m) (13.26 m)
Working
Height:
43 ft.-7 in. 18 ft.-0 in. 44 ft. 1 in. 18 ft.-5 in.
(13.28 m) (5.49 m) (13.44 m) (5.61 m)
Width
Between
Track Pads:
6 ft.-9 in. (2.06 m)
Distance
Between Jack
Center at Drill
End:
9 ft.-1 in. (2.77 m) 9 ft.-8 in. (2.95 m)
Distance
Between Jack
Centers Front
to Rear:
20 ft. (6.17 m)
Working
Weight:
77,000 -85,000 lb. 80,000 - 110,000 lb.
(34,927 - 39,916 kg) 36,287 - 49,895 kg)
Dimensions shown are for the DML frame and frame with 30 ft. tower.
Dimensions and Weights DML
Dimensions shown are for the DML frame with 35 ft. tower.
Section 4 - Controls
DM45,DM50,DML Instruction Manual Section 4 - Controls
4 - Operating Controls and Instruments
Safety
WARNING
!
Read and understand Section 2 - Safety Precautions and Guidelines
before you operate or perform any maintenance, service or repairs on the
drill.
Safety should be the main concern for anyone working on or around the drill. Do not perform
any function that could put someone in danger.
WARNING
!
If you are not experienced with the drills controls and instruments, read
and understand Section 4 - Operating Controls & Instruments.
Unexpected drill motion or moving parts can cut or crush. Shut down
motor before working on the drill.
Section 4 - Controls DM45,DM50,DML Instruction Manual
General Information
The following operational hints should be observed:
1. Always perform safety checks prior to starting and using the drill.
2. After starting the engine, wait until the engine, hydraulics and the airend are up
to normal operating temperatures before operating the drill.
3. Always chock the tracks if there is a possibility of uncontrolled movement.
4. Do not lubricate the drill while the engine is running.
5. Always operate the drill at full power when drilling and tramming.
6. If drill is equipped with the remote control system option, always use it from a
safe location when propelling on unstable surfaces where there may be a risk
of overturning and when loading onto a transporter where there is a risk of
overturning.
7. Never propel or stop the drill on a slope or surface that is liable to collapse.
8. Never stop the drill against a high wall that is liable to collapse or cause a
crushing risk.
9. Always sound the horn (option) before moving the drill in either direction to alert
personnel and allow sufficient time before putting the drill in motion.
4 - Operating Controls
Operators Console
The operating controls section provides basic information about the operating controls,
instruments and indicators located on the control panel and the drill, that are used when
operating the drill.
All operating functions can be controlled from the drillers console within the cab of the drill.
Operation of the drill is performed using electric over hydraulic controllers ergonomically
located so that the operator faces the drill centralizer while drilling. The controls on the console
are arranged in operating function panels.
Drill / Feed Function Panel
Figure 4-1
(1) Controller - Hoist
The Hoist Controller (see figure 4-1) controls the hoists direction and speed when raising
or lowering drill pipe during loading into or unloading from the carousel.
To operate the hoist, pull up or lift the controller lock on the controller and slowly move the
controller in the required direction. After the control has moved past Stop or neutral position,
the controller lock can be released. Controller lock must be pulled or lifted to move controller
through Stop or neutral position to move in the other direction. Controller is spring loaded to
Stop position.
To slow and stop the hoist, move the control slowly to the STOP position and release the
handle. A spring applied brake on the hoist will automatically apply when the control is
released in the STOP position.
(2) Controller - Breakout Wrench
To operate the Sliding Breakout Wrench Controller (see figure 4-1) , pull up or lift the
controller lock on the controller and slowly move the controller to engaged position and the
sliding breakout wrench will slide forward and engage the flats on the drill rod or DHD. After
the control has moved past Stop or neutral position, the controller lock can be released.
Moving the controller to the disengaged position will retract the sliding breakout fork wrench.
Controller lock must be pulled or lifted to move controller through Stop or neutral position to
move in the other direction. Controller is spring loaded to Stop position.
(3) Controller - Carousel Index
The Carousel Index Controller (see figure 4-1) controls the rotation of the carousel between
indexing positions when multipass drilling is required.
Placing the controller into forward position will rotate the carousel clockwise to the next
indexing position. Placing the controller into reverse position will rotate the carousel
counterclockwise to the next indexing position. To operate the Carousel Index Controller,
pull up or lift the controller lock on the controller and slowly move the controller to engaged
position. After the control has moved past Stop or neutral position, the controller lock can
be released. Controller lock must be pulled or lifted to move controller through Stop or
neutral position to move in the other direction. Controller is spring loaded to Stop position.
Figure 4-2
By controlling the rotation of the carousel, the index projections A can be aligned with the
indexing pointer B (see figure 4-2). When correctly aligned, the drill rod will have been
positioned with its axis aligned to the axis of the rotary head spindle. The loading or
unloading process can then be completed.
(4) Controller - Carousel Swing
The Carousel Swing Controller (see figure 4-1) controls the two carousel swing cylinders,
causing the carousel swing to move between the stowed and drill rod load positions.
Pushing the controller will move the carousel to the stowed position, while pulling the
controller will move the carousel under the rotary head to add or remove drill pipe. To
operate the Carousel Swing Controller, pull up or lift the controller lock on the controller and
slowly move the controller to engaged position. After the control has moved past Stop or
neutral position, the controller lock can be released. Controller lock must be pulled or lifted
to move controller through Stop or neutral position to move in the other direction. Controller
is spring loaded to Stop position.
(5) Controller - Chain Wrench
The Chain Wrench Controller (see figure 4-1) controls the hydraulic cylinder used with the
chain wrench when loosening the threaded joints between the drill rod and the down hole
drill, and also during bit replacement.
Placing the controller in the extend position will extend the cylinder. Placing the controller
into the retract position will retract the cylinder. To operate the Chain Wrench Controller, pull
up or lift the controller lock on the controller and slowly move the controller to engaged
position. After the control has moved past Stop or neutral position, the controller lock can
be released. Controller lock must be pulled or lifted to move controller through Stop or
neutral position to move in the other direction. Controller is spring loaded to Stop position.
(6) Control - Torque Limit
The rotation torque limit control rotary switch (see figure 4-1) controls the amount of
pressure being applied to the rotary head rotation motors. It can be adjusted to limit torque
on the bit during difficult drilling conditions. Turning the control clockwise will increase
pressure. Turning the control counterclockwise will reduce the pressure.
This is an option for low pressure drills and standard on high pressure drills only.
(7) Controller - Rotation
The Drill Rotation Controller (see figure 4-1) controls the direction and speed of drill rotation.
To rotate the drill in either the clockwise or counterclockwise direction, gradually move the
controller in the required direction and speed of rotation will progressively increase. To stop
rotation, move the controller into the STOP position where the indent should click into place.
Controller will stay in the position placed.
To operate the Rotation Controller, pull up or lift the controller lock on the controller and
slowly move the controller to engaged position. After the control has moved past Stop or
neutral position, the controller lock can be released. Controller lock must be pulled or lifted
to move controller through Stop or neutral position to move in the other direction.
Note: Rotation is only possible when the Mode Selector valve is in the Drill mode position.
(8) Controller - Drill Feed
The Drill Feed Controller (see figure 4-1) controls the direction and rate of drill feed.
Controller will stay in the position placed.
To feed the drill in either the UP or Down direction, gradually move the controller in the
required direction. The feed rate will progressively increase. To stop feed, move the
controller into the STOP position. The lock should click into place.
Note: Feed is only possible when the Mode Selector valve is in the Drill mode position.
(9) Controller - Drill Air Throttle
The Drill Air Throttle Controller (see figure 4-1) controls the air flow to the drill string and
allows air flow down the hole to operate the DHD (Down Hole Drill) and clean the hole. It is
used to turn ON/OFF the drilling air during drill rod or hammer changes. It can be adjusted
to a lower setting while collaring the hole. Controller is spring loaded to the Stop position.
This is an option for high pressure drills only.
(10) Rotary Switch - Drill Feed Force Control
The Drill Feed Pressure Control Rotary Switch (see figure 4-1) controls the down feed
pressure to the feed cylinders while doing actual drilling.
Turning the control clockwise will increase feed pressure. Turning the control
counterclockwise will reduce the feed pressure.
Rotational torque limit control is standard on high pressure machines, and is an option
available on low pressure machines.
Torque limit control is used to limit the horsepower on the rotary head by reducing the
torque. As the torque on the rotary head is reduced the overall horsepower of the rotary
head is reduced while you maintain the same rotational speed).
Note: When using down hole hammer drilling, use only sufficient feed pressure to match the
rate of penetration.
(11) Toggle Switch - Rod Support
The Rod Support device is used when using the Angle Drilling Option.
Move the Rod Support Manual Override Switch (see figure 4-1) into EXTEND position to
extend the rod support. Moving the Rod Support Manual Override Switch into RETRACT
position will retract the rod support.
(12) Rotary Switch - Holdback Force
The Drill Holdback Pressure Control Rotary Switch (see figure 4-1) is provided to avoid
excessive down feed pressure on the drill bit. This is an option for high pressure drills
only.
On deep holes, the weight of the drill string may become excessive and overload the drilling
system. To avoid this problem, drill holdback pressure can be varied so that the down hole
drill bit is not overloaded.
Turning the control clockwise will increase and counterclockwise will reduce the holdback
pressure.
Gauges Panel
Figure 4-2
(13) Gauge - Bit Air Pressure
The (Drilling) Bit Air Pressure Gauge (figure 4-2) monitors the air pressure available for
drilling.
The Bit Air Pressure gauge has two (2) types, depending on the air end on the drill.
1. Low pressure drill, gauge will read from 0-160 psi with operating pressure 110
psi.
2. High pressure drill, gauge will read from 0-400 psi with operating pressure 350
psi.
Note: Ensure that the pressure is adjusted to the type of downhole hammer being used.
(14) Gauge - Supercharge Pressure
The Supercharge Pressure Gauge (figure 4-2) monitors the main pump supercharge
pressure. It shows the operator how much pressure is being delivered to the main pump
inlet.
Note: It is essential that the supercharge pressure gauge reads not less than 65 psi during
normal operation. Shutdown the machine to avoid serious damage to the main hydraulic
system components. Call for service assistance to detect cause of the low pressure reading.
(15) Gauge - Rotation Pump Pressure
The Rotation Pressure Gauge (figure 4-2) shows the amount of hydraulic pressure being
applied to the rotary head motor(s). It corresponds to the amount of torque developed by the
rotary head during operation.
The Rotation Torque Limit Control Option (figure 4-1, item 6) can restrict the torque value.
(16) Gauge - Pulldown Pressure
The Pulldown Pressure Gauge (figure 4-2) shows the amount of hydraulic down pressure
being exerted on the bit by the feed (cylinder) system.
Pressure can be increased or decreased by turning the Drill Feed Force Control (figure 4-1,
item 10).
(17) Gauge - Holdback Pressure
The Feed Holdback Pressure Gauge (figure 4-2) shows the hydraulic pressure in the feed
cylinder when drill holdback pressure is applied to prevent excessive down pressure on the
drill bit. This is an option for high pressure drills only.
Pressure can be increased or decreased by turning the Feed Holdback Pressure Rotary
Switch Option (figure 4-1, item 12).
Engine Function Panel
Figure 4-3
(18) Button Switch - Emergency Stop
The RED emergency stop button switch (figure 4-3) shuts off power to the fuel valve and
stops the engine when it is pushed.
After depressing the switch, it is necessary to reset the switch before the machine can be
restarted. To reset, pull the switch out into its active position.
Note: This switch has the same effect as turning the ON/OFF key switch fully to the STOP
position. Do not use the E-Stop as an On/Off switch. Use only in emergencies.
(19) Control Knob - Engine Throttle
Engine Throttle control knob (figure 4-3) increases or decreases engine speed (RPM).
To increase engine speed, turn the control knob clockwise until the desired RPM is reached.
To decrease engine speed, turn the control knob counter-clockwise. Lock the control knob
in place by tightening the tension nut. Turning the tension nut clockwise will tighten the
control knob shaft. Turning the tension nut counter-clockwise will loosen the nut allowing the
control knob to turn freely for increasing or decreasing engine speed.
NOTE: Do not over turn control knob, stop to stop is 2.25 turns.
(20) Display - Powerview
The PowerView display (figure 4-3) is a multifunction tool which enables equipment
operators to view many standard engine parameters as well as active and stored trouble
codes. The display can show either a single parameter or a quadrant display showing four
parameters simultaneously. Diagnostic capabilities include codes with text translation for
most common fault conditions.
Fault finding is done directly on the Power view screen. The system will show information
about what is wrong.
(21) Toggle Switch - Drill Lights
The Drill Lights Control Switch (figure 4-3) is an ON/OFF switch that controls all the work
lights. Move the switch to the ON position to turn on the lights and illuminate the working
area.
(22) Toggle Switch - Tram Lights
The Tram (Propel) Lights Control Switch (figure 4-3) is an ON/OFF switch that controls all
the tramming lights. Move the switch to the ON position to turn on the lights and illuminate
the area of the direction of travel.
(23) Gauge - Discharge Temperature
The Compressor Discharge Air Temperature Gauge (figure 4-3) shows the temperature of
the oil and air leaving the air end.
Normal operating temperatures are 180-230F (82-110C). This gauge also contains a
switch that will stop the engine if the oil temperature in the compressor exceeds 248F
(120C).
(24) Gauge - Fuel
The fuel gauge (figure 4-3) monitors the level of fuel in the fuel tank. The tank should be
refilled when the indicator needle moves to or below 1/4 tank.
(25) Gauge - Tachometer
The Tachometer Gauge (figure 4-3) shows the RPM of the engine while the engine is
running. The tachometer is calibrated in RPM x 100 with a range of 0 to 30.
The tachometer is driven by the magnetic pickup which receives its signal from the engine
flywheel. The pickup is a solid state device that counts teeth on the flywheel and sends a
signal to the tachometer. The wires between the pickup and tachometer are specially
shielded wires to prevent interference from outside signals.
(26) Gauge - Oil Pressure
The engine oil pressure gauge (figure 4-3) indicates the engine oil pressure. This gauge
should not read less than 10 psi on LOW idle nor less than 27 psi on HIGH idle rpm.
The pressure gauge reads from 0 to 100 psi (0 to 700 kPa). The increments are in 5 psi
markings.
(27) Gauge - Water Temperature
The Engine Coolant Temperature Gauge (figure 4-3) shows the temperature of the engine
coolant system. Normal operating temperature is from 150-208F (65-98C). The system
will shut down if the temperature exceeds 210F (99C).
The temperature gauge reads from 100F to 250F (40C to 120C).
(28) Circuit Breakers
The bank of seven (7) Circuit Breakers (figure 4-3) protect the drills electrical circuits. The
Circuit Breakers are mounted between the current producer, batteries or alternator and the
devices they are protecting. In the event of an overload of a circuit, press in the tripped
circuit breaker.
NOTE: If there is a reoccurrence, call for service assistance to correct the
cause of the overload in the circuit.
The Circuit Breaker identification is as follows:
1. 5 Amp ---Engine Shutdown
2. 15 Amp - Windshield Wiper System
3. 20 Amp - Power Distribution for OEM Controllers
4. 20 Amp - Heater/AC System
5. 15 Amp - Power Distribution for Engine
6. 15 Amp - Drill Working Lights
7. 20 Amp - Tram (Propel) Lights
8. 15 Amp - Water Dump (Option)
(29) Hourmeter
THe Hourmeter (figure 4-3) shows the number of hours and partial hours, that the key switch
has been in the On position.
(30) Key Switch - Electrical System ON/OFF
The electrical system ON/OFF Key Switch (figure 4-3) turns on all electrical power to the
engine and controls stopping and run operations.
NOTE: Always stop the engine and remove the key when leaving the drill
unattended and/or performing certain maintenance procedures.
(31) Button Switch - Engine Fuel Primer
The Engine Fuel Primer Button Switch (figure 4-3) permits the priming of the engine fuel
system after the drill has been standing idle for an extended period of time or after fuel filter
replacement.
(32) Button Switch - Engine Start
The Engine Starter Button Switch (figure 4-3) energizes the starter motor and engages the
starter motor solenoid to crank the engine for startup. Once the engine starts, release the
Engine Starter Button Switch immediately.
If the engine does not start, WAIT 2 minutes to allow the starter to cool before trying again.
Do not engage the starter motor solenoid longer than 30 seconds at a time or it will overheat
and burn up the starter motor.
(33) Button Switch - Horn (Option)
Pressing the Horn push button (figure 4-3) will sound the horn and is used for a number of
warnings.
The Horn push button activates the horn to alert anyone near the drill that the engine is
about to be started.
The Horn push button activates the horn to alert personnel in the work zone that the drill is
about to be moved.
(34)Button Switch - Thread Greaser (Option)
The Thread Greaser push button (figure 4-3) engages grease for spraying grease to the
pipe threads.
(35) Button Switch - Ether (Option)
The Engine Ether Cold Start Button Switch (figure 4-3) controls the cold starting aid system.
WARNING
!
Starting aids are extremely flammable and can explode. Avoid
overloading the engine when starting
While cranking the engine with the Engine Starter Button Switch, press the Engine Ether
Cold Start Button to inject ether into the engine intake. Releasing pressure on the switch will
automatically cut off the starting aid operation.
NOTE: Starting aid may be required when temperature is below 32F (0
C) and will be required when temperature is below 10F (-12C).
(36) Switch - Front Windshield Wiper Selector (Option)
The Front Windshield Wiper Switch (figure 4-3) activates the front windshield wiper and has
three positions: High Speed, Low Speed and Off.
(37) Switch - Rear Windshield Wiper Selector (Option)
The Rear Windshield Wiper Switch (figure 4-3) activates the rear windshield wiper and has
three positions: High Speed, Low Speed and Off.
(38) Switch - Auxiliary Windshield Wiper Selector (Option)
The Auxiliary Windshield Wiper Switch (figure 4-3) activates the side windshield wiper on
the drilling deck side and has three positions: High Speed, Low Speed and Off.
(39) Toggle Switch - Tower Locking Pin
The Tower Locking Pin Switch (figure 4-3) activates the hydraulic tower pinning cylinder and
controls the locked or unlocked position of the tower locking pin.
(40) Indicator Light - Tower Unpinned Warning
The Tower Unpinned warning light (figure 4-3) will illuminate Red anytime the tower
pinning is not fully pinned.
(41) Data Link Socket Connector
The Data Link Socket (figure 4-3) provides attachment of computerized engine test
equipment when troubleshooting engine problems. Provided for use by engine service
personnel. Diagnostic Lights and Toggle Switches will be explained further in the Electrical
Section of TROUBLESHOOTING Section 7.
Engine Diagnostic Panel
Figure 4-4
The Engine Diagnostic Panel monitors the engine anytime the engine is running. Should a
fault occur, these lights will come on to alert the operator of a problem that needs to be
corrected. There are three different colored lights on the operators console. Each light has
its own function. The light colors indicate how critical the problem is.
When the key switch is turned to on position, all three indicator lights will come on
momentarily to test the lights and then go out.
(42) Indicator Light (RED) - Engine Stop
The Red light signals problems in the Engine Protection System. The Red light will come on
when an out of range condition occurs. These include:
1. High Coolant Temperature
2. Low Coolant Level
3. High Oil Temperature
4. Low or Very Low Oil Pressure
(43) Indicator Light (AMBER) - Engine Warning
The Amber Indicator Light signals In-Range Failures of the Engine Protection System.
(44) Indicator Light (BLUE) - Maintenance Indicator
The Blue Indicator Light signals a maintenance issue that needs corrected such as a filter
is dirty.
(45) Toggle Switch - Increase / Decrease
The diagnostics Incremental/Decremental selector switch is used to detect the type of
engine fault. The Incremental/Decremental switch is a spring centered switch that moves
the ECM UP one fault code every time it is toggled upward and it moves the ECM DOWN
one fault code every time it is pushed downward. When it is released, it moves back to the
neutral position.
(46) Toggle Switch - On / Off
The Engine Diagnostic Selector Switch is used to turn on the engine diagnostic system and
start the sequence of fault code lights flashing. The Diagnostic Switch must be in the OFF
position for normal operation. It will not show fault codes if it is left in the ON position.
Compressor Functions Panel
NOTE: Standard Drill Compressor Function Panel
Figure 4-5
(47) Regulator - Air Pressure (HP Only)
The Compressor Air Pressure Regulator (figure 4-5) regulates the pressure to the
compressor receiver/separator tank. This is for high pressure drills only.
Rotate the adjustment knob clockwise to increase the operating air pressure to the pressure
required for the particular model of downhole drill being used. Refer to the Bit Air Pressure
Gauge (see figure 4-2, item 13) while adjusting pressure.
(48) Regulator - Compressor Volume Control (HP Only)
The Compressor Volume Control (figure 4-5) is used to change the angle of the butterfly
valve to decrease the volume (cfm) of air being allowed into the air end. It can be adjusted
to match the volume being used by various downhole drills. Clockwise rotation increases
compressor volume. Counterclockwise rotation decreases compressor volume. It should be
screwed in clockwise for normal drilling. This is for high pressure drills only.
(49) Toggle Switch - Compressor ON/OFF (HP Only)
The Compressor ON/OFF Switch (figure 4-5) opens and closes the inlet valve to allow the
compressor to build pressure or shut off. It makes air when it is in the ON position and
closes the air inlet when it is in the OFF position. This is for high pressure drills only.
(50) Control Lever - Compressor Cold Start (HP Only)
The Compressor Cold Start Control Lever (figure 4-5) is used to close the air inlet to the
compressor when starting a cold engine. Closing the air intake prevents build up of pressure
within the compressor rotors and there by reduces startup torque load on the cold engine
allowing the starter motor to spin the engine at a higher rpm. This is for high pressure
drills only.
(50) Control Lever - Low Pressure Compressor (LP Only)
On Low Pressure drills, the Compressor Control Lever (figure 4-5) is used as an Air Throttle
that turns on the compressed air to power the Downhole Drill (DHD) and cleans the cuttings
out of the hole for both rotary and Downhole drilling. This is for low pressure drills only.
NOTE: EARS (Electronic Air Regulation System) Compressor Function
Panel
Figure 4-6
(47) Light - Diagnostic
The RED Diagnostic Light (figure 4-6) is normally off but will flash out an error code if the
controller detects an error.
The diagnostic light flashes error codes in 1 sec. flashes 1 sec. apart with a 2 sec. delay
before reascending the error code. A 2 sec. flash at start up signals that the controller has
power and is programmed.
If this light is blinking turn off the engine and fix the issue.
(48) Control Knob - Air Flow
The Flow control knob (figure 4-6) is a variable voltage input into the MC2 controller (.5 VDC
to 4.5 VDC ). When the compressor on/off switch is in the on position it regulates the flow
into the compressor between the minimum flow (required to prevent damage to the
compressor) and maximum flow. (Full open position on the butterfly valve). The Flow can
be turned down to provide less flow for collaring a hole.
(49) Control Knob - Maximum Pressure
The Pressure control knob (figure 4-6) is a variable voltage input into the MC2 controller (.5
VDC to 4.5 VDC ). When the compressor on/off switch is on it regulates the maximum
pressure in the receiver tank between the minimum holding tank pressure and the maximum
working pressure of the compressor system. During normal drilling the Max pressure knob
should be full open for quickest response times and the bit orifice should be sized to provide
the correct back pressure for drilling.
(50) Switch - Compressor On/Off
The on/off switch (figure 4-6) commands the controller to minimum in the off position.
The Compressor on/off switch energizes the operator flow and pressure control commands.
When the switch is in the on position the Flow and Pressure control knobs are active and
their combined inputs to the MC2 controller regulate the desired compressor output. When
the switch is in the off position the flow knob and max pressure knob is overwritten and flow
is set to the minimum flow required to prevent damage to the compressor (similar to anti
rumble) and the Maximum pressure is set to the minimum holding tank pressure.
Tram Functions Panel
Figure 4-7
(51) Controller - Dust Curtain UP/DOWN
The Dust Curtain Controller (figure 4-7) energizes the hydraulic cylinder that raises or
lowers the dust curtain to ensure maximum collection of ejected dust.
NOTE: Always check that the dust curtain is clear of the ground when
tramming the drill to avoid damage to the components.
(52) Rotary Switch - Water Injection Flow Control (Option)
The Water Injection Flow Control Rotary Switch (figure 4-7) adjusts the flow rate of water
into the air stream to keep down dust and prevent collaring in the hole when the water
injection pump is running. Rotate the switch clockwise to increase or counterclockwise to
decrease the water flow rate. This is an option.
(53) Rotary Switch - Water Injection/Dust Collector Selector
The three (3) position Water Injection/Dust Collector Selector Switch (figure 4-7) is used to
select Water Injection operation, OFF (neither operation) or Dust Collector operation.
The Water Injection operation mode activates the hydraulic motor that engages the water
injection pump which injects a regulated quantity of water into the drill air stream to suppress
dust created by the drilling operation.
The Center position disengages both systems.
The Dust Collector operation mode activates the hydraulic motor that engages the dust
collector fan, causing a vacuum around the hole inside the dust curtain. Small cuttings and
dust ejected from the hole are deposited in the hopper or against the filters.
(54) Rotary Switch - Propel/Drill Mode Selector
The Propel or Drill Selector Switch (figure 4-7) is a rotary switch used to select either Propel
(Tram) Mode or Drill mode operations.
WARNING
!
Moving the Propel/Drill Selector Switch from propel to drill position when
tramming may cause loss of drill control, lurching, equipment damage or
serious injury. Move the Propel/Drill Selector Switch only when the drill is
stopped.
In the Propel position, the main pump flow is diverted to the Propel (Tram) controls (see
items 55 and 56). The drill may be moved and the brakes are released through a drill propel
valve and deverter valve as hydraulic flow to the propel motors increases.
In the Drill position, the main pump flow is diverted to the Drill Feed (figure 4-1, item 8) and
Drill Rotation (figure 4-1, item 7) controls and the parking brakes are automatically applied
in this position.
(55) Controller - Left Track Propel (Tram)
WARNING
!
LOSS OF MACHINE CONTROL
Moving the tram (propel) controller (F-STOP-R) quickly may cause loss of
drill control, lurching or serious injury. Move the tram (propel) controller
slowly.
The Left Track Propel Controller (figure 4-7) regulates the left hand side track direction and
speed of travel. To propel the drill in either Forward or Reverse direction, pull up or lift the
controller lock on the controller and slowly move the controller in the desired direction until
the required propel speed and direction are desired. After the controller has moved past
Stop or neutral position, the controller lock can be released. Controller lock must be pulled
up or lifted to move controller through Stop or neutral position to move in the other direction.
To slow and stop drill propel, move controller slowly towards the STOP position. Positioning
the controller in the STOP position will halt drill propel movement.
(56) Controller - Right Track Propel (Tram)
WARNING
!
slowly.
The Right Track Propel Controller (figure 4-7) regulates the right hand side track direction
and speed of travel. To propel the drill in either Forward or Reverse direction, pull up or lift
the controller lock on the controller and slowly move the controller in the desired direction
until the required propel speed and direction are desired. After the controller has moved past
To slow and stop drill propel, move controller slowly towards the STOP position. Positioning
the controller in the STOP position will halt drill propel movement.
(57) Controller - Tower Raise/Lower
The Tower Raise/Lower Controller (figure 4-7) moves the tower raising cylinders which
extend or retract for raising and lowering of the tower during drill setup.
To move the tower, pull up or lift the controller lock on the controller and slowly move the
controller in the desired direction. After the controller has moved past Stop or neutral
position, the controller lock can be released. Controller lock must be pulled up or lifted to
move controller through Stop or neutral position to move in the other direction.
NOTE: When raising or lowering the tower, always control the movement
to avoid impact as the tower is brought into final vertical or horizontal
positions.
CAUTION
!
Tower structure can be damaged by hard contact between the tower base
and the tower support structure.
(58) Controller - Rear Leveling Jack
The Rear J ack Controller (figure 4-7) extends and retracts the leveling jack cylinder on the
non-drilling end of the drill to raise or lower the drill.
To move the jack, pull up or lift the controller lock on the controller and slowly move the
When operating the leveling jack controls, observe the Bubble Level (item 65)
(59) Controller - Non-Cab Side Leveling Jack
The Non-Cab Side J ack Controller (figure 4-7) extends and retracts the leveling jack
cylinder on the non-drilling end of the drill to raise or lower the drill.
(60) Controller - Cab Side Leveling Jack
The Cab Side J ack Controller (figure 4-7) extends and retracts the leveling jack cylinder on
the non-drilling end of the drill to raise or lower the drill.
(61) Indicator Light - Leveling Jacks Retracted Rear
The Leveling J ack UP Indicator Light (figure 4-7) illuminates when the rear leveling jack is
up (retracted) and fully stowed.
(62) Indicator Light - Leveling Jacks Retracted Non-Cab Side
The Leveling J ack UP Indicator Light (figure 4-7) illuminates when the non- cab side
leveling jack is up (retracted) and fully stowed.
(63) Indicator Light - Leveling Jacks Retracted Cab Side
The Leveling J ack UP Indicator Light (figure 4-7) illuminates when the cab side leveling
jack is up (retracted) and fully stowed.
Console
Figure 4-8
(64) Control - Heat/Air Conditioning
The Heat/Air Conditioner Control (figure 4-8) includes the temperature regulator control
knob, fan regulator control knob, heat /cool switch and pull knob for heat.
(65) Bubble Level
The Air Bubble Level Gauge (figure 4-8) is used when leveling the drill in all directions. The
tower is designed to be vertical when the bubble is centered. The bubble must be centered
before raising the tower, after tower is vertical and before drilling begins.
(66) Toggle Switch - DHD Lubricator (HP Only)
The DHD Lubricator Switch (figure 4-8) is an ON/OFF switch and function light for the DHD
lubrication system. This is for high pressure drills only.
(67) Compartment - Instruction Manual Storage
The Instruction Manual Storage Compartment (figure 4-8) provides a secure, dry location
within easy reach of the operator. Safety and operator instruction manuals must be available
to the operator at all times.
(68) Inclinometers (Option)
The Inclinometers (figure 4-8), one measuring the transverse angle (cross gradient) and one
measuring the longitudinal angle, are provided to guide the operator when tramming on
inclines where excessive gradients may create an overturning hazard. This is an option.
The longitudinal angle inclinometer registers the inclination in direction of travel while the
other transverse angle inclinometer measures the inclination at 90 degrees to the direction
of travel. Lower the tower when tramming over unstable surfaces.
NOTE: Always refer to the Stability / Gradeability charts for tramming direction and
permissible slope angles when tramming the drill (See Section 3 - Specifications).
Non-Cab Controls and Instruments
Remote Propel System (Option)
Figure 4-9
(69) Connection - Remote Control Cable
Remote Propel Control Cable connection point on the remote control unit.
(70) Light - Remote Propel Indicator
When the Light is illuminated, indicates the controls are active.
(71)Switch - Emergency Stop
The RED emergency stop button switch (figure 4-9) shuts off power to the fuel valve and
stops the engine when it is pushed.
After depressing the switch, it is necessary to reset the switch before the machine can be
restarted. To reset, pull the switch out into its active position.
Note: This switch has the same effect as turning the ON/OFF key switch fully to the STOP
position. Do not use the E-Stop as an On/Off switch. Use only in emergencies.
(72) Controller - Remote Left Track Propel
WARNING
!
slowly.
The Remote Left Track Propel Controller (figure 4-9) regulates the left hand side track
direction and speed of travel. To propel the drill in either Forward or Reverse direction, pull
up or lift the controller lock on the controller and slowly move the controller in the desired
direction until the required propel speed and direction are desired. After the controller has
moved past Stop or neutral position, the controller lock can be released. Controller lock must
be pulled up or lifted to move controller through Stop or neutral position to move in the other
direction. To slow and stop drill propel, move controller slowly towards the STOP position.
Positioning the controller in the STOP position will halt drill propel movement.
(73) Controller - Remote Right Track Propel
WARNING
!
slowly.
The Remote Right Track Propel Controller (figure 4-9) regulates the right hand side track
direction and speed of travel. To propel the drill in either Forward or Reverse direction, pull
direction. To slow and stop drill propel, move controller slowly towards the STOP position.
Positioning the controller in the STOP position will halt drill propel movement.
(74) Control - Remote Control Unit with Shoulder Harness
The Remote Tram (Propel) Control Unit (figure 4-9) permits the operator to tram the drill
from a remote place of safety on occasions where there could be a risk of overturning due
to unstable ground surface conditions or loading onto a trailer. This is an option.
Make ready the drill to be propelled remotely;
All jacks stowed.
Tower locked in vertical position or tower in horizontal position.
Equipment and personnel removed from around the drill to a safe location.
To use the Remote Tram (Propel) Control Unit:
1. All personnel off the drill and located at a safe distance from the drill.
2. Place all controls in the stop or neutral position.
3. Engine running at 1800 rpm or high idle (see figure 4-3, item 25).
4. Turn Drill/Propel (Tram) selector switch (see figure 4-7, item 54) from Drill
Mode to Propel (Tram) Mode.
5. Connect the remote control cable to the drill remote plug, straighten the control
cable out to the Safe Zone (away from high wall and out of the line of travel)
and connect control cable to the Remote Control Unit. The Green Indicator
Light should illuminate when the remote control cable is connected to the drill
remote plug and remote control unit.
6. Place shoulder straps on your shoulders and place the Remote Control Unit in
front of you (see figure 4-9, item 74).
Use the Remote Control Unit to tram the drill or load the drill onto a trailer. When the risk of
overturning no longer exists, remove the Remote Control Cable and resume control from the
main control console.
Hydraulic Hand Pump
Figure 4-10
The Hydraulic hand pump is used to fill the hydraulic tank reservoir.
1. Prepare the drill to fill hydraulic tank:
a. Power Head at top of tower.
b. Tower in horizontal position.
c. All jacks fully retracted.
d. Drill on flat level surface.
e. Key On/Off switch in the OFF position (Engine Stopped).
2. Clean the hose fitting and quick-connection, connect hose to the fitting on the
hydraulic hand pump.
3. Ensure the breathers on top of the hydraulic tank are clean and will allow the
tank to breathe.
4. Fill hydraulic tank with new and clean oil.
5. Move handle back and forth to pump oil from oil container to hydraulic tank.
6. Stop pumping oil when the oil level on the hydraulic tank is at the full mark on
the sight gauge.
7. Disconnect hose from hydraulic hand pump and move oil container to a safe
zone.
Fan Control
A 2 speed or variable speed fan control options are available on the drill.
2 speed fan control
2 speed fan control system consists of two speeds (slow and fast). Drawing of the controller
(which is mounted on the side of the cooler) is pictured below. Slow fan speed is to be used in
ambient temperatures below 95 degrees F (35 degrees C)
Variable Speed Fan Control
The variable speed fan control option, is controlled by a knob in the cab offering speed
selections over the entire range of fan speed from off to max/high. Variable fan speed is
typically used for cold weather start ups.
Fire Suppression System
The fire suppression system is a manual activated by two (2) activation buttons, one (1)
mounted in the cab and one (1) mounted for ground access.
In case of Fire follow the decal instruction:
1. Shut Off Power
2. Pull Ring Pin
3. Strick Button
This fire extinguisher agent is rated for extinguishing type A (trash/wood), type B (liquids) and
type C (electrical equipment) fires. The fire suppression canister can be recharged as needed.
WARNING
!
Do not Ingest, breath, get it in eyes or on skin. Avoid all unnecessary
exposure to the chemical substance and ensure prompt removal from
skin, eyes, and clothing. Wear protective equipment at all times when
working with chemical substance. Seek medical advice. Can cause
severe personal injury or death.
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Section 5 - OPERATING
DM45,DM50,DML Instruction Manual Section 5 - Operating Instructions
5 - Operating Safety
Safe Operations
Introduction
WARNING
!
drill.
WARNING
!
Always wear the correct safety gear while working on or around the drill.
This includes an approved hard hat, safety glasses, steel toe shoes,
gloves, respirator and ear protection. Do not wear loose fitting clothing
that can become caught in rotating components.
WARNING
!
and understand Section 4 - Operating Controls and instruments before
you operate or perform any maintenance, service or repairs on the drill.
WARNING
!
Unexpected drill motion or moving parts can cut or crush. Shut down the
engine before working on the drill.
Section 5 - Operating Instructions DM45,DM50,DML Instruction Manual
General Information
overturning.
crushing risk.
7. Before starting engine on drill, always check to see that the drill/propel selector
is in the drill mode and both joystick control levers are in Stop or neutral
position.
8. After starting the engine, wait until the hydraulics and the air end are up to
normal operating temperatures before operating the drill.
10. Always operate the drill at full engine power when drilling or tramming the drill.
Seat Belts
Controls and Functions
Figure 5-1
Drill / Feed Function Panel (Figure 5-1)
Hoist
1. Before attempting to operate the jib hoist, verify J ib Boom arm is in the
operating position (jib boom arm extended out from the tower crown) and
securely bolted down. The J ib Boom is positioned with the pulley on the Boom
in line with the opening on the carousel top cover plate.
2. To operate the Hoist, pull up or lift the controller lock on the controller and
slowly move the controller in the desired direction (controller away from
operator, Hoist up and controller towards operator, Hoist down) until the
required hoist speed and direction are desired. After the controller has moved
past Stop or neutral position, the controller lock can be released. The controller
is spring loaded to the Stop position when released. Controller lock must be
pulled up or lifted to move controller through Stop or neutral position to move
in the other direction.
3. Speed of hoist is proportional to the controller movement. To slow or stop hoist,
move controller slowly towards the Stop position. Positioning the controller in
the Stop position will halt hoist movement.
4. The hoist function can be operated in drill mode or in propel mode.
Breakout Fork
1. To operate the Breakout Fork, pull up or lift the controller lock on the controller
and move the controller in the desired direction (controller away from operator,
breakout fork engaged and controller towards operator, breakout fork
retracted). After the controller has moved past Stop or neutral position, the
controller lock can be released. The controller is spring loaded to the Stop
position when released. Controller lock must be pulled up or lifted to move
controller through Stop or neutral position to move in the other direction.
Carousel Index
1. To operate the Carousel Index, pull up or lift the controller lock on the controller
Carousel Index counter-clockwise and controller towards operator, Carousel
Index clockwise). After the controller has moved past Stop or neutral position,
the controller lock can be released. The controller is spring loaded to the Stop
2. Speed of carousel index is proportional to the controller movement. To slow or
stop carousel index, move controller slowly towards the Stop position.
Positioning the controller in the Stop position will halt carousel index
movement.
Carousel Swing
1. To operate the Carousel Swing, pull up or lift the controller lock on the controller
Carousel Swing Out and controller towards operator, Carousel Swing In).
After the controller has moved past Stop or neutral position, the controller lock
can be released. The controller is spring loaded to the Stop position when
released. Controller lock must be pulled up or lifted to move controller through
Stop or neutral position to move in the other direction.
2. Speed of carousel swing is proportional to the controller movement. To slow or
stop carousel swing, move controller slowly towards the Stop position.
Positioning the controller in the Stop position will halt carousel swing
movement.
Chain Wrench
1. To operate the Chain Wrench, pull up or lift the controller lock on the controller
Chain Wrench extend and controller towards operator, Chain Wrench retract).
After the controller has moved past Stop or neutral position, the controller lock
can be released. The controller is spring loaded to the Stop position when
released. Controller lock must be pulled up or lifted to move controller through
Stop or neutral position to move in the other direction.
2. Speed of chain wrench is proportional to the controller movement. To slow or
stop chain wrench, move controller slowly towards the Stop position.
Positioning the controller in the Stop position will halt chain wrench movement.
Torque Limit
Torque Limit function is standard on high pressure drills and option available on low pressure
drills.
1. Torque Limit is a rotary knob switch that controls minimum torque to maximum
torque on the rotary head.
2. To operate the torque limit, turn the control knob to the right (clockwise) to
increase the torque pressure.
3. Turn the control knob to the left (counter-clockwise) to decrease the torque
pressure.
Rotation Control
1. in Drill Mode to operate the Rotation, pull up or lift the controller lock on the
controller and move the controller in the desired direction (controller away from
operator, the Rotation is breakout and controller towards operator, the Rotation
is drill). After the controller has moved past Stop or neutral position, the
controller lock can be released. The controller is not spring loaded to the Stop
position when released, the controller stays in the position placed. Controller
lock must be pulled up or lifted to move controller through Stop or neutral
position to move in the other direction.
2. Speed of rotation is proportional to the controller movement. To slow or stop
chain wrench, move controller slowly towards the Stop position. Positioning the
controller in the Stop position will halt rotation movement.
Drill Feed Control
1. in Drill Mode to operate the Drill Feed, pull up or lift the controller lock on the
controller and move the controller in the desired direction (controller away from
operator, the Drill Feed is up and controller towards operator, the Drill Feed is
down). After the controller has moved past Stop or neutral position, the
controller lock can be released. The controller is not spring loaded to the Stop
position when released, the controller stays in the position placed. Controller
lock must be pulled up or lifted to move controller through Stop or neutral
position to move in the other direction.
2. Speed of drill feed is proportional to the controller movement. To slow or stop
drill feed, move controller slowly towards the Stop position. Positioning the
controller in the Stop position will halt drill feed movement.
Air Drill Throttle Control (HP Drills)
1. To operate the Air Drill Throttle Controller, pull up or lift the controller lock on
the controller and move the controller in the desired direction (controller away
from operator, Air Drill Throttle opens and controller towards operator, Air Drill
Throttle closes). After the controller has moved past Stop or neutral position,
the controller lock can be released. The controller is spring loaded to the Stop
2. Speed of Air Drill Throttle is proportional to the controller movement. To slow
or stop Air Drill Throttle, move controller slowly towards the Stop position.
Positioning the controller in the Stop position will halt Air Drill Throttle
movement.
3. Placing controller in the Stop position does not stop the air. To completely stop
air going through the Air Throttle, Controller has to be moved to the fully closed
position until the 9-spool has shut ball valve Off. To allow full air going through
the Air Throttle, Controller has to be moved to the fully open position until the
9-spool has fully open ball valve.
Drill Feed Force
1. Drill Feed Force is a rotary knob switch that controls minimum feed force to
maximum feed force on the pulldown system.
2. To operate the feed force, turn the control knob to the right (clockwise) to
increase the feed force pressure.
3. Turn the control knob to the left (counter-clockwise) to decrease the feed force
pressure.
Rod Support
1. Rotary head at the top of the tower, the rod support cylinder should extend and
retract. Switch moved away from the operator, Rod Support extends. Switch
moved towards the operator, Rod Support retracts.
2. Extending the rod support cylinder and then moving the rotary head down away
from the top of the tower. The rotary head should stop after moving a few feet
away from the upper stops.
3. The rotary head a few feet away from the upper stops, the rod support cylinder
should retract.
4. The rotary head a few feet away from the upper stops, the rod support cylinder
should not extend.
Holdback Force (HP Drills)
1. The Drill Holdback Force is a rotary knob switch that controls excessive down
feed pressure on the drill bit. This feed system balances the pressures within
the feed cylinders to counteract gravity, string weight and pulldown force. This
is an option for high pressure drills only.
2. On deep holes, the weight of the drill string may become excessive and
overload the drilling system. To avoid this problem, drill holdback pressure can
be varied so that the downhole drill bit is not overloaded.
3. Turning the control clockwise will increase and counter-clockwise will reduce
the holdback pressure.
Compressor Function Panels
Standard Compressor
Standard Compressor Function Panel
Figure 5-2
Regulator - Air Pressure (HP Only)
The Compressor Air Pressure Regulator (figure 5-2) regulates the pressure to the
compressor receiver/separator tank. This is for high pressure drills only.
Rotate the adjustment knob clockwise to increase the operating air pressure to the pressure
required for the particular model of downhole drill being used. Refer to the Bit Air Pressure
Gauge (see figure 4-2, item 13) while adjusting pressure.
Regulator - Compressor Volume Control (HP Only)
The Compressor Volume Control (figure 5-2) is used to change the angle of the butterfly
valve to decrease the volume (cfm) of air being allowed into the air end. It can be adjusted
to match the volume being used by various downhole drills. Clockwise rotation increases
compressor volume. Counter-clockwise rotation decreases compressor volume. It should
be screwed in clockwise for normal drilling. This is for high pressure drills only.
Toggle Switch - Compressor ON/OFF (HP Only)
The Compressor ON/OFF Switch (figure 5-2) opens and closes the inlet valve to allow the
compressor to build pressure or shut off. It makes air when it is in the ON position and
closes the air inlet when it is in the OFF position. This is for high pressure drills only.
Control Lever - Compressor Cold Start (HP Only)
The Compressor Cold Start Control Lever (figure 5-2) is used to close the air inlet to the
compressor when starting a cold engine. Closing the air intake prevents build up of pressure
within the compressor rotors and there by reduces startup torque load on the cold engine
allowing the starter motor to spin the engine at a higher rpm. This is for high pressure
drills only.
Control Lever - Low Pressure Compressor (LP Only)
On Low Pressure drills, the Compressor Control Lever (figure 5-2) is used as an Air Throttle
that turns on the compressed air to power the Downhole Drill (DHD) and cleans the cuttings
out of the hole for both rotary and Downhole drilling. This is for low pressure drills only.
EARS Compressor
EARS (Electronic Air Regulation System) Compressor Function Panel
Figure 5-3
Light - Diagnostic
The RED Diagnostic Light (figure 5-3) is normally off but will flash out an error code if the
controller detects an error.
The diagnostic light flashes error codes in 1 sec. flashes 1 sec. apart with a 2 sec. delay
before re-sending the error code. A 2 sec. flash at start up signals that the controller has
power and is programmed.
If this light is blinking turn off the engine and fix the issue.
Control Knob - Air Flow
The Flow control knob (figure 5-3) is a variable voltage input into the MC2 controller (.5 VDC
to 4.5 VDC ). When the compressor on/off switch is in the on position it regulates the flow
into the compressor between the minimum flow (required to prevent damage to the
compressor) and maximum flow. (Full open position on the butterfly valve). The Flow can
be turned down to provide less flow for collaring a hole.
Control Knob - Maximum Pressure
The Pressure control knob (figure 5-3) is a variable voltage input into the MC2 controller (.5
VDC to 4.5 VDC ). When the compressor on/off switch is on it regulates the maximum
pressure in the receiver tank between the minimum holding tank pressure and the maximum
working pressure of the compressor system. During normal drilling the Max pressure knob
should be full open for quickest response times and the bit orifice should be sized to provide
the correct back pressure for drilling.
Switch - Compressor On/Off
The on/off switch (figure 5-3) commands the controller to minimum in the off position.
The Compressor on/off switch energizes the operator flow and pressure control commands.
When the switch is in the on position the Flow and Pressure control knobs are active and
their combined inputs to the MC2 controller regulate the desired compressor output. When
the switch is in the off position the flow knob and max pressure knob is overwritten and flow
is set to the minimum flow required to prevent damage to the compressor (similar to anti
rumble) and the Maximum pressure is set to the minimum holding tank pressure.
Tram Function Panel
Figure 5-4
Controller - Dust Curtain UP/DOWN
The Dust Curtain Controller (figure 5-4) energizes the hydraulic cylinders. To raises dust
curtain move controller to the right and move controller to the left to lower dust curtain to
ensure maximum collection of ejected dust.
To raises dust flap move controller up or away from operator and move controller down or
towards operator to lower dust flap.
NOTE: Always check that the dust curtains and dust flap is clear of the
ground when tramming the drill to avoid damage to the components.
Rotary Switch - Water Injection Flow Control (Option)
The Water Injection Flow Control Rotary Switch (figure 5-4) adjusts the flow rate of water
into the air stream to keep down dust and prevent collaring in the hole when the water
injection pump is running. This is an option.
For this function to work, the rotary switch operating the Water Injection/Off/Dust Collector
must be selected to water injection position. With water injection On select desired water
flow by rotating the switch clockwise to increase or counter-clockwise to decrease the water
flow rate.
Rotary Switch - Water Injection/Dust Collector Selector
The three (3) position Water Injection/Dust Collector Selector Switch (figure 5-4) is used to
select Water Injection operation, OFF (neither operation) or Dust Collector operation.
The Water Injection operation mode activates the hydraulic motor that engages the water
injection pump which injects a regulated quantity of water, assisted by the water injection
flow control into the drill air stream to suppress dust created by the drilling operation.
The Center position Off disengages both systems.
The Dust Collector operation mode activates the hydraulic motor that engages the dust
collector fan, causing a vacuum around the hole inside the dust curtain. Small cuttings and
dust ejected from the hole are deposited in the hopper or against the filters.
Rotary Switch - Propel/Drill Mode Selector
The Propel or Drill Selector Switch (figure 5-4) is a two position rotary switch used to select
either Propel (Tram) Mode or Drill mode operations. Turn the selector counter-clockwise,
the drill is in Propel Mode and turn the selector clockwise, the drill is in Drill Mode
operation.
WARNING
!
Moving the Propel/Drill Selector Switch from propel to drill position when
tramming may cause loss of drill control, lurching, equipment damage or
serious injury. Move the Propel/Drill Selector Switch only when the drill is
stopped.
In the Propel position, the main pump flow is diverted to the Propel (Tram) controls. The drill
may be moved and the brakes are released through a drill propel valve and diverter valve
as hydraulic flow to the propel motors increases.
In the Drill position, the main pump flow is diverted to the Drill Feed and Drill Rotation
controls and the parking brakes are automatically applied in this position.
Controller - Left Track Propel (Tram)
WARNING
!
slowly.
The Left Track Propel Controller (figure 5-4) regulates the left hand side track direction and
speed of travel. To propel the drill, turn the Propel/Drill Mode Selector Switch to Propel
mode position. Move propel controller in either Forward or Reverse direction, pull up or lift
the controller lock on the controller and slowly move the controller in the desired direction
until the required propel speed and direction are desired. After the controller has moved past
To slow or stop drill propel, move controller slowly towards the Stop position. Positioning the
controller in the Stop position will halt drill propel movement. Controller is spring loaded to
the Stop or neutral position.
Speed of the track is proportional to the controller movement.
Controller - Right Track Propel (Tram)
WARNING
!
slowly.
The Right Track Propel Controller (figure 5-4) regulates the right hand side track direction
and speed of travel. To propel the drill, turn the Propel/Drill Mode Selector Switch to
Propel mode position. Move propel controller in either Forward or Reverse direction, pull
direction. To slow or stop drill propel, move controller slowly towards the Stop position.
Positioning the controller in the Stop position will halt drill propel movement. Controller is
spring loaded to the Stop or neutral position.
Speed of the track is proportional to the controller movement.
Controller - Tower Raise/Lower
The Tower Raise/Lower Controller (figure 5-4) moves the tower raising cylinders which
extend or retract for raising and lowering of the tower during drill setup.
To raise the tower, increase the engine speed to High idle rpm. Pull up or lift the controller
lock on the controller and slowly move the controller in the direction away from the operator.
To lower the tower, pull up or lift the controller lock on the controller and slowly move the
controller in the direction toward the operator. After the controller has moved past Stop or
neutral position, the controller lock can be released. Controller lock must be pulled up or
lifted to move controller through Stop or neutral position to move in the other direction.
Controller is spring loaded to the Stop or neutral position.
Speed of the tower is proportional to the controller movement.
NOTE: When raising or lowering the tower, always control the movement
to avoid impact as the tower is brought into final vertical or horizontal
positions.
CAUTION
!
Controller - Rear Leveling Jack
The Rear J ack Controller (figure 5-4) extends and retracts the leveling jack cylinder on the
non-drilling end of the drill to raise or lower the drill.
To raise the drill up, pull up or lift the controller lock on the controller and slowly move the
controller in the direction away from the operator. To lower the drill, pull up or lift the
controller lock on the controller and slowly move the controller in the direction toward the
operator. After the controller has moved past Stop or neutral position, the controller lock can
be released. Controller lock must be pulled up or lifted to move controller through Stop or
neutral position to move in the other direction. Controller is spring loaded to the Stop or
neutral position.
Speed of the jack is proportional to the controller movement.
When operating the leveling jack controls, observe the Bubble Level
Controller - Non-Cab Side Leveling Jack
The Non-Cab Side J ack Controller (figure 5-4) extends and retracts the leveling jack
cylinder on the non-drilling end of the drill to raise or lower the drill.
neutral position.
Controller - Cab Side Leveling Jack
The Cab Side J ack Controller (figure 5-4) extends and retracts the leveling jack cylinder on
the non-drilling end of the drill to raise or lower the drill.
neutral position.
Indicator Light - Leveling Jacks Retracted Rear
The Leveling J ack UP Indicator Light (figure 5-4) illuminates when the rear leveling jack is
up (retracted) and fully stowed.
Indicator Light - Leveling Jacks Retracted Non-Cab Side
The Leveling J ack UP Indicator Light (figure 5-4) illuminates when the non- cab side
leveling jack is up (retracted) and fully stowed.
Indicator Light - Leveling Jacks Retracted Cab Side
The Leveling J ack UP Indicator Light (figure 5-4) illuminates when the cab side leveling
jack is up (retracted) and fully stowed.
Operating Procedures
General Information
overturning.
crushing risk.
7. Before starting engine on drill, always check to see that the drill/propel selector
is in the drill mode and both joystick control levers are in Stop or neutral
position.
8. After starting the engine, wait until the hydraulics and the air end are up to
normal operating temperatures before operating the drill.
10. Always operate the drill at full engine power when drilling or tramming the drill.
Walk Around Inspection
Before every shift and prior to starting the drill, a walk around inspection of the overall drill
should be performed. This is in addition to the 8-10 hour daily routine maintenance
procedures. Performance of this inspection can result in longer life and maximum productivity
from the drill.
Hydraulic System
A careful inspection of all hydraulic components (pumps, motors, valves, hoses, etc.) should
be made to detect possible leaks or any irregularities. This is particularly important when the
drill is new. Drills have been equipped at the factory with a hydraulic oil containing a blue
colored dye which will aid in early detection of leaks.
WARNING
!
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
Compressor System
A careful inspection of all compressor components (air end, air end pump, valves, hoses,
fittings and filters) should be made to insure there are no compressor oil leaks or any
irregularities. This is particularly important when the drill is new.
WARNING
!
High Pressure can cause severe injury or death. Completely relieve
pressure before removing filler plug, fittings or receiver cover.
Coolant System
The engine radiator should be checked for leaks daily. Failure to cool the engine properly can
result in engine failure or severely reduce engine life
WARNING
!
Injury can occur when removing the radiator cap. Steam or fluid escaping
from the radiator can burn. Inhibitor contains alkali. Avoid contact with
skin and eyes.
Always shut down the engine and allow it to cool down before removing
the radiator cap. Remove the radiator cap slowly to relieve pressure.
Avoid contact with steam or escaping fluid.
Fuel Systems
The fuel systems should be checked on a daily basis for possible leaks. Maintain the fuel tanks
at a high level to minimize water condensation inside the tanks. This is best accomplished by
filling the fuel tanks at the end of each day. Check fuel tanks and fuel lines for possible leaks.
Because of the potential fire hazard, leaks must be corrected as soon as they are spotted.
Select the proper grade of fuel oil in accordance with the information in the 6.3 Refill
Capacities/Lubricants/Fuel section of this manual.
WARNING
!
Fuel is flammable. May cause serious injury or death. Shut down the
engine, extinguish all open flames and do not smoke while filling fuel
tanks or draining fuel filters. Always wipe up any spilled fuel.
General Checks
Other general checks should be made at this time for any wear and tear on the drill. Check for
broken or cracked welds, loose or missing bolts, broken or inoperative gauges, or any other
irregularities which could lead to more costly breakdowns.
Check all bolted assemblies for tightness. Inspect the entire drill for any loose, worn or missing
parts and replace them as needed. Inspect fluid lines, hoses, filler openings, drain plugs,
pressure caps, tower cables, hoist wire cables, muffler, engine, safety shrouds and the area
under the drill for signs of leakage.
Frequently walk around the drill and inspect for leaks, loose or missing parts, damaged parts
or parts out of adjustment. Perform all recommended daily maintenance.
Operators Areas
1. Keep operators area clean! Clean windshields and all lights. Check that all
lights function.
2. Make sure the operators areas, steps and grab rails are clean. Oil, grease,
snow, ice or mud in these areas can cause you to slip and fall. Clean your boots
of excess mud before getting on the drill.
3. Remove all personal items or other objects from the operators cab and the
operators platform area. Secure these items in the tool box, tool cabinet or
remove them from the drill.
Pre-Start Inspection
Before starting the drill, a pre-operation inspection of the overall drill is very important. This
inspection should be performed before each shift and at every startup. These checks and
verifications are in addition to the 8-10 hour daily routine maintenance. Performance of this
inspection can result in longer life and maximum productivity from the drill.
The following are checks and verifications of the overall drill that should be performed prior to
starting. Refer to the instructions given in Section 6 Maintenance for the correct maintenance
procedures and oil specifications.
Engine Lubricating Oil Level
Check the engine oil level by viewing the dipstick. The drill must be level when checking the
oil level to be sure the measurement is correct. Wait at least 5 minutes after shutting off the
engine to check the oil level. This allows time for the oil to drain into the oil pan. If oil level is
low, refer to the instructions given in the Maintenance Procedures section of Section 6
Maintenance.
WARNING
!
oil or hot components to contact the skin.
Engine Coolant Level
Check engine coolant level, at the radiator sight glass. The level should be maintained so fluid
can be seen in the sight glass. If the coolant level is low, refer to the instructions given in the
Maintenance Procedures section of Section 6 Maintenance.
WARNING
!
Injury can occur when removing the radiator cap. Steam or fluid escaping
from the radiator can burn. Inhibitor contains alkali. Avoid contact with
skin and eyes.
Always shut down the engine and allow to cool before removing the
radiator cap. Remove cap slowly to relieve pressure. Avoid contact with
steam or escaping fluid.
Check Fuel Level
Check fuel level gauge. The tank should be refilled when the indicator needle moves to below
1/4 tank. Refer to the Maintenance Procedures section of Section 6 Maintenance. Select the
proper grade of fuel oil in accordance with the instructions given in the Fuel Specifications
section of Section 6 Maintenance.
WARNING
!
Fuel is flammable. May cause serious injury or death. Shut down engine,
extinguish all open flames, and do not smoke while filling tank. Always
wipe up any spilled fuel.
Drain Fuel Filter / Water Separator
The fuel filter / water separator should be monitored daily for signs of water and sediment. If
water is present, drain the water and sediment from the filters / separators. Refer to the
instructions given in the Maintenance Procedures section of Section 6 Maintenance.
WARNING
!
Fuel is flammable. May cause serious injury or death. Shut down engine,
extinguish all open flames, and do not smoke while filling tank. Always
wipe up any spilled fuel.
Compressor Oil Level
Check the compressor oil level. With the drill in a level position, the oil level should be in the
middle of the sight gauge. If oil is required, follow the instructions in the Maintenance
Procedures section of Section 6 Maintenance.
WARNING
!
pressure before removing filler plug, fittings or receiver cover. Hot oil or
components can burn. Avoid contact with hot oil or components.
Drain Water from Receiver Tank
When compressing air, water will condense in the receiver tank and mix with the compressor
oil. If allowed to accumulate, the water will significantly reduce bearing life. Follow the
instructions in the Maintenance Procedures section of Section 6 Maintenance and relieve
water from the system.
WARNING
!
High Pressure can cause severe injury or death. Do not attempt to remove
any plugs or open the drain valve before making sure all air pressure has
been relieved from the system. Hot oil or components can burn. Avoid
contact with hot oil or components.
Batteries
Check the battery posts and cables for corrosion. Check and keep the electrolyte levels above
the battery plates or to the bottom of the fill holes. Refer to the Maintenance Procedures
WARNING
!
Batteries contain an acid and can cause injury. Battery fumes can ignite
and explode. Do not smoke when observing battery fluid level. Skin and
eye contact with battery fluid can cause injury. Avoid skin and eye
contact with battery fluid. If contact occurs, flush area immediately with
water.
Pump Drive Gearbox Oil Level
Check the oil level in the Pump Drive Gearbox and maintain it to the FULL level indicated on
the dipstick. Refer to the Maintenance Procedures section of Section 6 Maintenance.
WARNING
!
Rotating Shaft can cause severe injury or death. Do not operate with
guard removed. Hot oil or components can burn. Avoid contact with hot
oil or components.
Hydraulic Oil Level
The hydraulic oil level should be checked by the sight gauge on the hydraulic tank.
1. The oil level must be checked with all hydraulic cylinders retracted, tower down
(horizontal), jacks up and rotary head at the top of the tower should be between
the FULL mark and the MINIMUM mark on the sight gauge.
2. The top of the oil level MUST be visible when the engine is running and when
the engine is stopped. There must be oil showing on the gauge at all times.
Add oil to bring to levels defined above by following directions in the Maintenance Procedures
CAUTION
!
Excessive hydraulic oil can rupture the sealed hydraulic tank and cause
injury or property damage. Do not fill hydraulic tank with hydraulic
cylinders extended. Retract all cylinders and fill tank to indicated level.
NOTICE
Dirt in the hydraulic system will lead to premature component failure. A
clean, contaminant free system is extremely important to the drills
proper function. Take extra care when working around or on the hydraulic
system to ensure its complete cleanliness.
Complete the pre-start inspection as prescribed below.
1. Inspect for loose, damaged or bent items on tower.
2. Inspect for hydraulic leaks in tower.
3. Inspect undercarriage for missing, loose, broken or bent parts.
4. Inspect fuel and water tanks for damage or leaks.
5. Inspect drive motors, hosing, and final drive for leaks and loose, damaged or
missing parts.
6. Inspect coolers for damage or leaks.
7. Inspect drill deck area for leaks and damaged or missing parts.
8. Inspect cable tensioning system for damage.
9. Inspect cables for tension, wear, or damage.
10. Inspect chains for tension, wear, or damage.
11. Inspect pump drive, pumps, valves and hosing for leaks, damaged or missing
components.
12. Inspect driveline for any signs of failure, damage or leaks.
13. Inspect the hydraulic reservoir tank for damage, leaks or apparent missing
components.
14. Inspect engine for leaks and for damaged or missing parts.
15. Inspect compressor assembly for loose, missing or damaged parts.
16. Inspect compressor assembly for oil leaks.
17. Inspect compressor receiver tank safety valves for leaks, loose parts or
damage.
18. Inspect compressor and engine air inlet system for damage, air leaks, missing
parts, loose mountings, etc.
19. Ensure the main batteries are switched on to supply the 24 volt electrical
system.
20. Inspect the fire suppression system for readiness, leaks, and damaged or
missing components.
21. Inspect the cab for broken windows, broken or damaged door hinges, latches,
knobs and torn seals.
22. Inspect seat for visible damage, chair damage, and looseness.
23. Check the area around the drill for any unauthorized vehicles, people, power
line obstructions, or any other obstructions in the immediate drill area.
24. Report any damage, leaks, broken or missing components, as well as any
obvious malfunctions or safety hazards to your immediate supervisor.
Keep Operators Areas Clean
Clean windshields, mirrors and all lights. Check that all lights function.
Make sure the operators areas, steps and grab rails are clean. Oil, grease, snow, ice or mud
in these areas can cause you to slip and fall. Clean your boots of excess mud before getting
on the drill.
Remove all personal items or other objects from the floor of the operators area. Secure these
items in a tool box or remove them from the drill.
Pre-Operation Controls Inspection
Before starting the drill, a check to verify that the Warning Lights, Tram Alarm, Horn (Option)
and Emergency Stop controls are functioning properly is very important. This inspection
should be performed before each shift and at every startup.
CAUTION
!
Any drill defects should be reported to the proper personnel. Defects
must be corrected before starting and operating the drill.
The following are checks and verifications of the drill controls that should be performed prior
to starting. Refer to Section 4 Operating Controls.
Figure 5-5
Control Checks
1. Key switch in the Off position (figure 5-5).
2. Make sure the Drill / Propel selector switch (figure 5-5) is in the Drill mode
position.
3. Make sure both the Left Track controller and Right Track controller (figure 5-5)
are in the Stop positions. The controllers are spring loaded to the Stop position
when released.
NOTE: If the levers do not return to STOP when released, have the defect
corrected immediately.
4. Place both the Drill Rotation controller and the Drill Feed controller (figure 5-5)
in their Stop positions. The controllers are not spring loaded to the Stop
position, they remain in the position they are placed.
5. Turn the On/Off key switch (figure 5-5) to the ON position. Watch the Engine
Diagnostic Panel Illumination Lights to come on momentarily and go out. Three
color lights are Red (top), Amber (middle) and Blue (bottom).
NOTE: Engine Diagnostic On/Off switch Off. If the lights dont come On
or they do not go out after Testing , have the defect corrected
immediately.
6. With the key switch in the ON position. Turn the Drill / Propel selector switch
to Propel Mode. The Tram Alarm should emit an intermittent beeping sound
when the Drill / Propel selector switch is in the Propel mode. Turn Drill / Propel
selector switch to Drill mode and the Tram Alarm should stop.
NOTE: If the tram alarm does not function as described above, have the
defect corrected immediately.
7. Turn the On/Off key switch to OFF position.
8. Press the HORN (Option) button to confirm that the horn is functioning properly.
9. Place the Drill / Propel selector switch into Propel mode position. Move the
Right Track controller in either direction away from Stop position. Turn the On/
Off key switch to the ON position and press the STARTER BUTTON. The
engine should not start.
Move the Right Track controller to the Stop position.
10. Place the Drill / Propel selector switch into Drill mode position. Move the Left
Track controller in either direction away from Stop position. Turn the On/Off key
switch to the ON position and press the STARTER BUTTON. The engine
should not start.
Move the Left Track controller to the Stop position.
11. With the Drill / Propel selector switch in Drill mode position. Move the Drill Feed
controller in either direction away from Stop position. Turn the On/Off key
should not start.
Move the Drill Feed controller to the Stop position.
12. With Drill / Propel selector switch in Drill mode position, move Drill Rotation
controller in either direction away from Stop position. Turn the On/Off key
should not start.
Move the Drill Rotation controller to the Stop position.
13. Check the Tower Pinning Light by starting the engine (See the Instructions for
Starting Engine). Move the tower pinning switch to un-pinned position and the
tower pinning light should illuminate Red. Move the tower pinning switch to
pinned position and the tower pinning light should go out.
NOTE: If light do not illuminate, notify service personnel to rectify the
defect.
14. Check the EMERGENCY Stop will the engine is running. Push IN on the
Emergency Stop Switch. The engine must immediately STOP. After engine
has stopped turn the On/Off key switch to the OFF position and reset the
Emergency Stop Switch, pull OUT.
CAUTION
!
If any controls, instruments or devices do not function correctly, report
any drill defects to the proper personnel. Defects must be corrected
before starting and operating the drill.
Procedures and Functions
WARNING
!
Read and understand Section 2.2 Safety Precautions and Guidelines
drill.
Do not attempt to drill or operate the drill if you are not experienced with
the drill operating system, system instruments or controls.
1. Before starting the engine and moving the drill, check inside, outside and
underneath the drill for people or obstructions.
2. Check for Warnings or Lockout Tags on the controls. If there is a tag attached
to the switch, do not start the engine until the warning tag has been removed
by the person who installed it.
3. Start the engine from the operators position only.
4. Avoid leaving the controls with the engine running. Never leave the operators
drill platform while the engine is running.
CAUTION
!
If any controls, instruments or devices do not function correctly, look for
fault warnings and report any drill defects to the proper personnel.
Defects must be corrected before starting and operating the drill.
After all pre-operational inspection items are complete and any needed services or corrections
have been completed, you may proceed to the start sequence.
Engine Starting Procedure
1. Turn battery jump start select switch (figure 5-6) to the 1 position (Option).
Figure 5-6
2. Ensure all emergency stop buttons are in the OUT position.
3. Make sure all controls are in neutral or OFF positions.
4. Make sure the DRILL / PROPEL selector switch is in the DRILL mode position.
5. Make sure the LEFT TRACK controller and RIGHT TRACK controller are in the
Stop positions.
6. Make sure that the DRILL ROTATION controller and the DRILL FEED
controller are at the Stop positions.
7. MAKE SURE no one is at danger or risk before starting the engine.
Start Engine
1. Depress the Attention Horn Button (Option) to alert personnel that the engine
is about to be started (figure 5-7).
2. Turn the On/Off key switch to the ON position. Watch the Engine Diagnostic
Panel Illumination Lights to come on momentarily and go out. Three color lights
are Red (top), Amber (middle) and Blue (bottom).
NOTE: Engine Diagnostic On/Off switch Off. If the lights dont come On
or they do not go out after Testing , have the defect corrected
immediately.
3. Press and hold in the Fuel Primer button switch (figure 5-7) and listen. Primer
pumping action will slow down as fuel pressure builds up. Release the button
when the pump slows down.
4. Move the Compressor Control Lever (figure 5-7) to closed position. Below is a
list of air ends and control lever operations. (See Compressor Operation)
a. Low pressure air end - Control lever to closed position (control lever will
stay in this position when released).
b. High pressure (HR2) air end - Control lever to closed position (control lever
will stay in this position when released).
c. High pressure (HR2.5) air end - Control lever to closed position ( control
lever must be held during start, after engine is at low idle slowly ease the
control lever forward and release the control lever).
d. EARS system (High or Low pressure) air end - Compressor on/off switch
turned to Off position.
Figure 5-7
5. Hold the start button (figure 5-7) in the start position until the engine has
started, then release the start button.
CAUTION
!
To prevent damage to the starter motors, do not engage the starting
motors for more than thirty seconds. Wait 2 minutes between each
attempt to start.
6. If the engine does not start within 30 seconds, release the starter button. To
avoid overtaxing the starter motors or the batteries, do not use the starter for
more than 30 seconds. Let the starter motors cool and the batteries recover for
two minutes before trying again. If the engine still will not start after a couple of
tries, check the fuel lines for possible fuel starvation or air leaks. Starting failure
may mean fuel is not reaching the injectors. The absence of blue or white
exhaust smoke during cranking indicates no fuel is being delivered.
7. Allow the engine to run at low idle speed.
8. Listen for unusual noises from the engine, compressor, and power pack area.
9. Ensure the cooler fans are turning.
10. Observe the hydraulic system for any obvious leaks.
WARNING
!
In event of unusual noise, leaks, cooling fan non-operation, or any other
non-listed problem, IMMEDIATELY SHUT THE DRILL DOWN to prevent
damage to the drill. Notify your immediate supervisor of the problem and
do not run the drill until the problem is corrected.
11. Continue running the engine at idle speed to allow the engine and hydraulic
systems to warm to the minimum prescribed operating temperature of 75F
(23.9C) for hydraulics and 150F (65.5C) for the engine.
12. When minimum operating temperatures have been reached, you are ready to
begin propelling or drilling operations.
Ether Cold Start Option
The Ether Cold Starting (Option) is available for starting engine when ambient temperature is
below 50F (10C).
To use this option for starting, press and release the ETHER Injection button (figure 5-7)
while pressing the starter button switch (Ether is only injected when the starter button is
operated).
WARNING
!
Starting aids are extremely flammable and can explode.
Overloading the engine air intake system could result in an explosion.
Avoid overloading the engine air intake system with starting aids.
Verify Gauges & Controls
After starting the drill, a check to verify that the Gauges and Engine Diagnostic Lights are
functioning properly. This inspection should be performed before each shift and at every
startup.
Figure 5-8
With the engine running, verify that:
1. The Supercharge Pressure Gauge (figure 5-8) must be above 65 psi min. to
110 max. psi.
CAUTION
!
Do not operate the Drill when Supercharge pressure is beyond the limits.
Operating the drill beyond the limits can cause severe damage to the drill
and equipment. Do not run the drill until the problem is corrected.
2. The Engine Oil Pressure Gauge (figure 5-8) must be above 10 psi at LOW idle
nor less than 27 psi on High idle rpm.
CAUTION
!
Do not operate the Drill when Engine Oil pressure is beyond the limits.
Operating the drill beyond the limits can cause severe damage to the
Engine. Do not run the drill until the problem is corrected.
3. The Engine Tachometer (figure 5-8) should read 1200 rpm on LOW idle.
4. The Engine Water Temperature Gauge (figure 5-8) indicator shows a reading
as the engine warms up. Normal operating temperature is from 150-208F (65-
98C). The system will shut down if the temperature exceeds 210F (99C).
5. Make sure Engine Diagnostic Lights (figure 5-8) are not indicating a fault code.
6. With the air compressor turned off, the Air Pressure Gauge (figure 5-8) should
read air psi.
a. Low Pressure air end - 0 psi.
b. High Pressure air end - 125-140 psi.
c. EARS Low Pressure air end - 45-50 psi.
d. EARS High Pressure air end - 105-110 psi.
7. The Hydraulic Oil Temperature Gauge, located on the back of the hydraulic
tank, should indicate 100F (38C) before starting any operation of the drill.
Stopping Engine
Normal Stopping
1. Make sure Propel/Drill selector is in the Drill Mode position.
2. Turn off the compressor and allow the receiver to blow down to minimum
pressure.
Low Pressure Drills (Standard) - On low pressure drills, the compressor is
turned off with the use of a manual inlet control. This is a lever and cable
arrangement. Pull the lever towards the operator to close the inlet.
Low Pressure Drills (EARS) - On low pressure EARS drill, the compressor is
turned off with the On/Off toggle switch. Move the toggle switch towards the
operator, this will close the butterfly valve and open the vent valve.
High Pressure Drills (Standard) - On high pressure drills, the Compressor
On/Off Switch is used to turn the compressor off. This is a two position,
pneumatic switch. It is used to open and close the compressor inlet valve. Move
the toggle switch away from the operator, this will close the butterfly valve.
High Pressure Drills (EARS) - On high pressure EARS drill, the compressor
is turned off with the On/Off toggle switch. Move the toggle switch towards the
3. Turn the Engine Throttle (speed selector) to LOW idle position for about 5
minutes to allow the engine and fluids to cool down.
4. Make sure all controllers are in the Stop or neutral position.
5. Turn the key switch to the OFF position.
6. After the engine has stopped, make sure the compressor blowdown valve
opens and blows all the air out of the receiver tank.
Emergency Stopping
The emergency stopping procedure for the drill may be very abrupt. This abrupt stop may
damage the drill due to potentially high stress loading on its components. There are two types
of emergency shutdowns; one is by the operator pushing the emergency stop button and the
other is when one of the shutdown devices on the drill has registered an out of limit condition.
If the operator or other personnel are in immediate danger, or if an emergency arises that is
not under control of the shutdown devices, such as a fire or other outside caused problem,
initiate an emergency stop with the following procedure:
1. Push in the Emergency Stop Button and exit the drill.
a. When one of the emergency stops or shutdown devices is energized, it
immediately shuts off fuel to the engine. All engines are energize to run
which means there must be power to the fuel valve to allow fuel to flow. If
power is lost, the fuel valve closes and stops the engine.
b. Every attempt should be made by the operator to shut the drill down under
a Normal Shutdown, if possible, to prevent damage to the drill.
c. All of the drill shutdown devices have gauges that show the operating
temperature or pressure of the system they monitor. The operator should
be able to avoid a shutdown condition if he checks the gauges frequently.
Propel
1. Before propelling the drill the following items must be done to propel:
a. Make sure that all the controls are in the neutral, stop or OFF position. The
Drill/Propel Selector should be in the drill mode position.
b. When the engine, hydraulic and compressor oils have all reached 100F
(38C), the drill can be propelled (trammed).
c. Power Head at the top of the tower.
d. Tower fully pinned and locked vertical (short distance), visually check pins
locked or tower fully horizontal (long distances).
e. All jacks must be fully retracted (stowed).
Note: On the Tram Function Panel below jack controllers, 3 green lights will
illuminate when jacks are fully retracted (stowed).
f. Check travel and work area for personnel and obstructions.
g. Increase the Engine Throttle (figure 5-9) speed to High idle rpm position.
Note: Never use engine speed control to control the speed of travel.
2. Move Drill/Propel Selector switch to Propel Mode.
Figure 5-9
3. The Track Propel Controllers (figure 5-9) regulates the track direction and
speed of travel. To propel the drill in either Forward or Reverse direction, pull
up or lift the controller locks on the controller and slowly move the controllers in
the desired direction until the required propel speed and direction are desired.
After the controllers has moved past Stop or neutral position, the controller
locks can be released. Controller locks must be pulled up or lifted to move
controller through Stop or neutral position to move in the other direction. To
slow or stop drill propel, move controllers slowly towards the Stop position.
Positioning the controllers in the Stop position will halt drill propel movement.
The controllers are spring loaded to the Stop position when released.
WARNING
!
slowly.
4. Each Propel Track motor is operated independent from the other. Steer the drill
by moving the Propel Controllers (figure 5-9) and control the direction of track
rotation of the respective Left Hand (non-cab side) and Right Hand track (cab
side). This way, the drill can be counter rotated when operating in a close area.
WARNING
!
If the drill is moving and something causes the drill to start to run away,
immediately move the Drill/Propel Selector to DRILL mode. This will shift
the diverter valves to Drill and stop any more oil from passing through the
propel motors. It will stop the drill.
Unexpected drill motion or sudden stop can cause loss of drill control,
lurching or serious personnel injury.
NOTICE
Propel speed is proportional to the amount of controller movement.
5. During tramming, monitor the inclinometers (option) to ensure that drill does not
exceed slopes limitations in either direction of travel or at 90 to the line of travel.
Refer to Stability/Gradeability Chart in Section 3 Specification.
Stopping Drill Propel
1. For normal stopping, move Track Propel Controllers (figure 5-9) towards the
Stop or neutral position.
2. To completely stop drill movement, position the Track Propel Controllers in the
Stop or neutral position.
3. Unless you are intending to move the drill immediately, move Drill/Propel mode
selector switch to Drill Mode position. This action sets the brakes on the propel
motors and keeps the tracks from moving.
Leveling The Drill
WARNING
!
Be sure the ground is level and solid before lowering jacks. Never stop
the drill against a high wall that is liable to collapse or cause a crushing
risk.
Figure 5-10
1. On arrival at the hole location, position the drill with the centralizer on the
location of the hole.
2. Always check to see that the drill/propel mode selector (figure 5-10) is in the
drill mode position and both propel controllers are in the Stop or neutral
position. Make sure the drill feed and drill rotation controllers are in the Stop or
neutral position.
3. Increase engine speed to High idle rpm with the Engine Throttle Selector (see
figure 5-7).
4. When leveling the drill, first lower all jacks until all jacks are on the ground. Then
raise the lowest point of the drill.
a. Evenly extend the three leveling jacks. Keep the drill level as indicated by
the bubble in the bubble level gauge (figure 5-10).
b. Level the drill until the level bubble (figure 5-10) is centered. Both propel
tracks (cab side and non-cab side) should not be touching the ground.
NOTICE
Drilling operations require the tracks to be completely clear of the ground
when the drill is leveled. The height must be sufficient to provide total
clearance of the tracks to prevent excess drive system wear during
drilling operations.
WARNING
!
Use adequate cribbing (blocking) under each jack to prevent the jacks
from sinking into the ground and causing the drill to tip over.
It is the Sole responsibility of the operator to ensure the drill does not turn
over.
Raising/Lower The Tower
CAUTION
!
Structural damage is possible If the tower is raised without the drill being
leveled.
1. The drill must be leveled and supported by the leveling jacks before the tower
is moved. Use the Tower Raise/Lower Controller (figure 5-10) to raise the
tower.
2. Before tower is full vertical, slowly move the controller to Stop or neutral
position so not to slam the tower into vertical position.
3. To lower the tower reverse the procedure above (See Tower Pinning).
NOTICE
Tower speed is proportional to the amount of Controller movement.
CAUTION
!
and the tower support structure. Never slam the tower into the Vertical or
Horizontal position.
Tower Pinning (Vertical))
1. After the tower has been raised vertical, lock the tower vertical locking pins.
2. Position the Tower Pinning switch (figure 5-10) into the locked position and
check that the tower Unpinned Warning Light is not illuminated Red. When
the pin is fully engaged, the light should extinguish.
3. Ensure that the tower vertical locking pins are locked in place after raising the
tower by visual inspection of the tower pin.
4. Check the level bubble (figure 5-10) and adjust leveling jacks as necessary to
center the bubble. The tower is vertical when the bubble is centered.
WARNING
!
Tower locking pin must be in the locked position during drilling
operations. Severe damage can occur when drilling is done with vertical
locking pin disengaged.
Tower Pinning (Angle Drilling Option)
There are two optional angle drilling packages available. The 0 - 20 degree angle drill
package, and the 0 - 30 degree angle drill package. Both packages allow the tower to be
positioned from the vertical position to angle position in 5 degree increments.
NOTE: When the drill is being used with the Angle Drilling option, it is still necessary to level
the drill in vertical position before moving the tower to the required angle.
1. Position the Tower Pinning switch (figure 5-10) into the un-locked position and
check that the tower Unpinned Warning Light is illuminated Red.
2. Physically verify locking pin for the tower is unlocked.
3. Moving the tower (up/down) controller toward the operator will enable tower
movement and lower tower to the angle desired from five (5) to twenty (20) or
from five (5) to thirty (30) in increments of five (5).
4. If the pin is stuck between the lock or unlock position, use the tower wiggle
feature.
a. Make sure the tower pinning switch is in the un-lock position.
b. Move the tower (up/down) controller in one direction slowly.
c. If the pin is not free, move the tower (up/down) controller in the other
direction slowly.
5. After ensuring the correct tower drilling angle (0 to 30) has been reached, lock
the tower locking pin by moving the Tower Pinning switch (figure 5-10) into the
locked position and check that the Tower Unpinned Warning Light is not
illuminated Red. When the pin is fully engaged, the light should extinguish.
6. Due to the possibility of slight differences in manufacturing tolerances, wear or
slight damage, you may find it necessary to gently wiggle the tower (up/down)
controller to fully lock tower pin.
7. Ensure that the tower locking pin is locked in place after raising the tower by
visual inspection.
8. The rod support must support the drill rod when tower is in angle drilling.
9. To go return to the vertical position with the tower just reverse the procedures.
NOTICE
Before moving tower from angle drilling to vertical position, the optional
angle telescoping dust curtain must be raised up fully. Ground
conditions and/or uneven bench could damage the dust curtain if not
fully raise before the tower is positioned vertical.
Over Pressure Control System
Figure 5-11
Every drill is equipped with an Over Pressure Control System to help prevent tipping of the drill
by over feeding during the drilling process. A pilot valve (figure 5-11), mounted under each
drilling end jack cylinder nipple, is closed as long as the jack is extended with the jack pad
firmly on the ground. If the jack pad is raised off the ground, or the ground gives way under the
pad, the nipple will push the pilot valve plunger down and open the compensator vent line on
the main feed pump. This action reduces the feed pressure to zero (0) psi and prevents the
drill rod from extending further. Both jack pads must be firmly on the ground so the pilot valve
plungers extend and close. Pressure is then returned to the feed system.
This Test Must Be Performed At The Start Of Each Shift.
1. Raise the drill on all jacks until the tracks are about one (1) inch off the ground.
2. Level the drill using bubble level gauge in the cab.
3. Raise the tower to vertical (figure 5-12) position by following instructions in
Raising The Tower Procedure.
4. Pin (lock) tower pinning by following instructions in Tower Pinning (Vertical)
Procedure.
5. Stall maximum pulldown (figure 5-12) with the power head at the bottom of the
tower.
6. Lift (retract) the Cab Side J ack (figure 5-12) off the ground and verify the feed
pressure drops below 500 psi on the feed pressure gauge on the gauge panel
in the cab, if not re-extend jack and fix the problem.
7. Slowly lower (extend) the Cab Side J ack on to the ground, re-level drill and
verify the feed pressure returns to maximum pulldown pressure (figure 5-12).
8. Lift (retract) the Non-Cab Side J ack (figure 5-12) off the ground and verify the
feed pressure drops below 500 psi on the feed pressure gauge on the gauge
panel in the cab, if not re-extend jack and fix the problem.
9. Slowly lower (extend) the Non-Cab Side J ack on to the ground, re-level drill and
verify the feed pressure returns to maximum pulldown pressure (figure 5-12).
Figure 5-12
Carousel
The Carousel (or Rod Holder) is used to transfer drill rods from the ground or another vehicle
to the rotary head when adding or removing drill rod from the drill string.
After the carousel has been initially loaded with drill rod, it becomes a rod holder and is used
to add and remove drill rod from the drill string.
The carousel is mounted on the Rod Changer and can be hydraulically positioned under the
rotary head for loading drill rod from the carousel to the rotary head or unloading drill rod from
the rotary head to the carousel.
The drill may be delivered to the work site with or without drill rods loaded into the Rod
Changer Carousel. Before tramming the drill to the hole location work site, it is recommended
that the carousel be loaded with a quantity of drill rods required up to a maximum of six (1 drill
rod attached to the rotary head and 5 drill rods in the carousel). Refer to Drill Pipe Change in
Section 3 - SPECIFICATIONS for more detailed information on the Rod Capacity Chart.
Figure 5-13
Setup for Carousel Loading
1. Position the drill on a level, firm surface.
2. Move the propel/drill mode selector to Drill Mode.
3. Increase engine speed to High idle rpm.
4. Extend the three leveling jacks to ground and level the drill as indicated by the
bubble in the level gauge.
a. Adjust the drilling end jacks until the bubble is centered.
b. Adjust the non-drilling end jack until the bubble is centered.
5. Use the tower raise/lower controller to raise the tower. As the tower approaches
a vertical position, slowly move the controller to Stop or neutral position to allow
the tower to position without impact.
6. Move the drill tower locking pin switch into the locked position and check that
the drill tower locking pin disengaged warning light is not illuminated. When pin
is fully engaged the light should extinguish.
7. Check the level bubble and adjust leveling jacks as necessary to center the
bubble. The tower is vertical when the bubble is centered.
Carousel Operating Procedure
Instructions for operating the carousel prior to loading drill rods.
1. With the tower in the vertical position, use the Carousel Swing Controller to
swing the carousel open all the way (figure 5-14).
2. With the Carousel Index Controller, rotate the carousel so an empty drill pipe
holding slot is in line with the opening on the carousel top cover (figure 5-14).
Figure 5-14
3. The Carousel Rod Holder is in position to accept the loading of drill rod from an
external source.
Drill Rod Loading
WARNING
!
Drill rods are extremely heavy. All lifting equipment must be adequately
sized for lifting and be in good condition. Extreme care must be exercised
in handling drill rod safely. Death or serious injury can occur if safe work
practices are not followed.
Drill rod can be loaded onto the drill from the ground or from a truck. Both methods are
acceptable when safe work practice is followed.
NOTICE
Minimum safe manpower requirements for this task = 3 persons.
1. Lay out the drill rods in a parallel direction to the undercarriage with the pin end
about three feet (0.914 m) from the drilling end dust curtain door.
Note: The dust curtain door must be down or closed position.
2. Screw the supplied lifting bail on the pin end carefully as far as it will go. (Hand
tight is normally satisfactory.)
3. After tightening the lifting bail, inspect it to ensure it is completely screwed on
the pin thread.
4. Remove the plastic thread protector plug installed in the box end of the drill rod.
5. Swing the handrail out of the way or remove the handrail to access the drill
deck.
6. Ensure the rotary head is parked against the top stops in the tower.
7. Extend or lower the hoist cable and attach the lifting bail to the drill rod to be
picked up.
WARNING
!
Drill rod being pulled from a vehicle or the ground can become dangerous
if not handled properly. Keep drill rod under control at all times.
8. If the drill rod is on a trailer or flatbed truck, a tag line should be employed to
restrain the box end as the drill rod is lifted by the hoist. The drill rod must be
prevented from sliding off the trailer or stack and causing harm and/or damage.
9. While in the Drill mode, raise the non-drilling end to its maximum height
(machine up position).
10. Place the drilling end to its minimum height (machine down position).
11. The drill will now be in a position of maximum height on the non-drilling end and
minimum height on the drilling end. This position allows the drill rod to be safely
lifted without damaging the drills dust door, deck, kick plate, or items on the drill
table.
12. Extend the rod support out.
13. Gently begin picking up the drill rod using the hoist.
WARNING
!
Do not stand or work under a suspended load. Failure of lifting equipment
or sudden unforeseen movement can cause death or serious injury.
14. When the drill rod is raised to a level that will allow the box end to clear the drill
deck, lower the non-drilling end of the drill slowly to allow the drill rod to swing
across the deck and rest against the drill table.
15. When the drill rod is resting against the drill table, gently raise the drill rod to a
height that will clear the drill table.
16. Looking at the bubble level in the cab, level the drill with the jacks.
17. Using the hoist, raise the drill rod so the box end clears the carousel cup by
about two inches (50.8 mm).
18. With rod changer open, index the carousel (using the controller, move left or
right) to line up the pointers on the carousel (figure 5-15) to the load position.
Figure 5-15
19. When the carousel is in the correct position, stand beside the drill rod and
maneuver into the carousel and seat it in the upper section of the carousel.
WARNING
!
Do not stand directly under the drill rod or put hands and fingers in pinch
points. Serious injury can occur if sudden uncontrolled movement
occurs.
20. When the drill rod is correctly positioned in the top carousel section, the bottom
should be lined up to lower into the carousel cup.
21. Carefully align the wrench flats on the drill rod with the cup flats and lower the
drill rod into the carousel cup.
22. When the rod is loaded into the carousel, release the tension on the winch line.
23. Lower the winch line to leave one foot (25.4mm) or so of slack.
24. Lowering the tower to the horizontal position.
a. While in Drill mode, unlock the vertical tower locking pin by move the drill
tower locking pin switch into the un-locked position and check that the drill
tower locking pin disengaged warning light is illuminated. When pin is
disengaged the light should be illuminated Red.
b. While in Drill mode, lower the tower by moving the tower controller towards
the operator to enable tower down movement. When tower is almost
horizontal, feather or slow the tower movement as not to slam tower into
the resting support.
CAUTION
!
Tower structure can be damaged by hard contact between the tower and
the tower rest support.
25. When the tower is lowered horizontal, climb into the tower via ladder or man lift.
CAUTION
!
Must use correct personal fall protection gear in case of a fall or slip to
prevent injury.
26. Access the upper end of the carousel and remove the lifting bail.
27. Leave the lifting bail on the winch hook and exit the tower access area and
return to the cab area or safe zone.
28. Raise the tower to the vertical position, lock the tower and repeat the process
until the carousel is full.
a. The drill must be leveled and supported by the leveling jacks before the
tower is raised.
b. Use the tower raise/lower controller to raise the tower. As the tower
approaches a vertical position, slowly move the controller to Stop or neutral
position to allow the tower to position without impact.
CAUTION
!
c. Move the drill tower locking pin switch into the locked position and check
that the drill tower locking pin disengaged warning light is not illuminated.
When pin is fully engaged the light should extinguish.
d. Check the level bubble and adjust leveling jacks as necessary to center the
bubble. The tower is vertical when the bubble is centered
WARNING
!
Tower locking pin must be in the locked position during drilling
operations and during drill rod loading/unloading/replacing procedures.
29. This completes the loading of the drill rods.
Adding Drill Rod Procedure
Drill rods are stored in the carousel rod holder and is indexed (rotated) into position to connect
to the rotary head. The following procedure applies to DM45,50,DML drills. Follow the
operating instructions previously mentioned and:
1. Position the drill on a level, firm surface.
2. Move the propel/drill mode selector to Drill Mode.
3. Increase engine speed to High idle rpm.
4. Extend the three leveling jacks to ground and level the drill as indicated by the
bubble in the level gauge.
a. Adjust the drilling end jacks until the bubble is centered.
b. Adjust the non-drilling end jack until the bubble is centered.
5. Use the tower raise/lower controller to raise the tower. As the tower approaches
a vertical position, slowly move the controller to Stop or neutral position to allow
the tower to position without impact.
6. Move the drill tower locking pin switch into the locked position and check that
the drill tower locking pin disengaged warning light is not illuminated. When pin
is fully engaged the light should extinguish.
7. Check the level bubble and adjust leveling jacks as necessary to center the
bubble. The tower is vertical when the bubble is centered.
8. Raise rotary head to top of tower.
9. Make sure drill rod is in the correct position on the carousel.
10. Swing the carousel into loading position with drill rod under rotary head.
11. Engage clockwise rotation slowly.
12. Using the drill feed, lower the rotary head slowly until the threads are engaged.
Watch the carousel for an indication of extra loading and listen to the threads
making contact.
13. Continue rotating until drill rod revolves in the bottom cup against stop on
carousel. Stop rotation.
14. If drill rod rotation is forcing cup against the stop, move the drill rod in a counter
clockwise rotation slightly to free the rod.
WARNING
!
Be sure a good joint has been made by looking up at the connection
between the spindle adapter and the upper pipe joint before moving the
drill rod.
15. Raise drill rod out of carousel cup and swing the carousel all the way into the
open (stowed) position.
16. Using drill feed, lower the drill rod onto the next joint after lubricating the threads
properly.
17. Engage clockwise rotation slowly.
18. Tighten joint securely. Raise drill string slightly to allow removal of the sliding
fork wrench or J -Wrench if it was used.
Add Drill Rod to Drill String
Follow the procedure below to add drill rod to the drill string. Follow the operating instructions
previously mentioned and:
1. Using proper drilling technique, drill down until the flats on the pin end of the
drill rod pass below the drill table. Reverse feed and bring flats on drill rod
above the table.
2. Stop rotation. Switch off lubricator if it is being used. Turn off the water injection
pump if it is being used. Turn off drill air.
3. Low Pressure Drills (Standard) - On low pressure drills, the compressor is
turned off with the use of a manual inlet control. This is a lever and cable
arrangement. Pull the lever towards the operator to close the inlet.
Low Pressure Drills (EARS) - On low pressure EARS drill, the compressor is
turned off with the On/Off toggle switch. Move the toggle switch towards the
High Pressure Drills (Standard) - On high pressure drills, the Compressor
On/Off Switch is used to turn the compressor off. This is a two position,
pneumatic switch. It is used to open and close the compressor inlet valve. Move
the toggle switch away from the operator, this will close the butterfly valve.
High Pressure Drills (EARS) - On high pressure EARS drill, the compressor
is turned off with the On/Off toggle switch. Move the toggle switch towards the
4. Engage the sliding fork wrench (drill rod retainer) controller and insert sliding
breakout wrench on to the flats of the drill rod.
5. Use full counter-clockwise rotation power to break the joint. As threads
disengage, use drill feed UP position to allow threads to separate. When joints
are separated, stop rotation. Stop Feed.
6. Use fast feed to raise rotary head to top of tower.
7. Index the next drill rod in carousel. Swing carousel in under the rotary head.
Using drill feed, slowly lower the rotary head.
8. Start slow clockwise rotation. Continue to lower the rotary head until the spindle
adapter makes contact with the pin end of the drill rod.
9. Tighten joint threads until the drill rod cup at the bottom of the carousel rotates.
WARNING
!
Be sure a good joint has been made by looking up at the connection
between the spindle adapter and the upper pipe joint before moving the
drill rod.
10. Stop rotation. Raise drill rod out of the carousel.
11. Swing the carousel to the open (stowed) position.
12. Lubricate the drill rod threads.
13. Use drill feed to lower the drill rod onto threads of the drill rod in the table.
14. Start slow rotation until joint is tight.
15. Stop feed and rotation.
16. Raise the drill string with drill feed only high enough to relieve pressure on the
sliding fork wrench (drill rod retainer). Disengage the sliding fork wrench (drill
rod retainer) from the drill string. Resume drilling.
17. Continue to repeat adding drill rod procedure.
Remove Drill Rod From Drill String
1. Raise the rotary head, with drill string, to top of tower until the upper flats on the
bottom drill rod line up with the sliding fork wrench on the drill table.
2. Stop feed and rotation. Engage the sliding fork wrench on the upper flats of
bottom drill rod.
3. Use counter-clockwise rotation to break the joint at the table. Watch upper joint
between the drill rod and spindle sub when breaking the joint.
WARNING
!
If upper joint comes loose instead of lower one, stop rotation
immediately. The drill rod can come loose and fall.
4. If the upper joint breaks loose first, tighten the joint up with clockwise rotation.
5. Use the chain wrench on side of tower to break the lower joint. Retract and
extend the chain wrench cylinder back and forth until the joint breaks.
6. Remove and move chain (breakout) wrench and cylinder out of the way.
7. Use reverse rotation and feed to finish unscrewing the drill rod.
8. Raise the rotary head and drill rod to the top of the tower.
9. Make sure the carousel is indexed properly (See Carousel Operating
Procedure in the CAROUSEL Section) . Swing the carousel in line with the drill
rod.
10. Feed the rotary head down until the hex area on box end of the drill rod is in the
lower carousel cup. The upper pin end of drill rod must be seated in the upper
carousel holding slot. Refer to Carousel Operating Procedure in CAROUSEL
Section.
11. Use full counter-clockwise rotation to break the joint between the spindle
adapter and the drill rod. Use drill feed up position to detach threads.
12. Index the carousel into position to accept the next drill rod and swing the
carousel out of the way into the open (stowed) position.
13. Use fast feed to move rotary head to the bottom of the tower until the spindle
is just above the threads of the drill rod in the table. Stop the rotary head.
14. Lubricate the threads on the drill rod.
15. Slowly feed down the rotary head until the spindle threads contact the drill rod
threads.
16. Start slow forward rotation until the connection is tight. Stop feed and rotation.
17. Raise drill string slightly to remove pressure on the sliding fork wrench.
18. Disengage the sliding fork wrench.
19. Start forward rotation and drill feed. Raise the rotary head, and one drill rod, to
the top of tower until the upper flats on the bottom drill rod line up with the
sliding fork wrench on the drill table.
20. Repeat the process for each drill rod in hole.
Rotary Drilling
Rotary drilling methods use the combination of raw weight and rotation to chip and carve rock
from a hole. The rotary method works fine in formations where adequate weight and stress
can be applied to the rock to initiate fracture and chipping.
Rotary drilling is done by rotating a tricone bit against the rock while using down pressure to
crush the rock. A stabilizer is normally used to keep the hole straight and to prevent the bit
from becoming stuck.
After the drill has been set up for drilling, there are a number of operations which involve
handling heavy drill rods, drill bits and other components used for various drill rod and drill bit
changing procedures.
WARNING
!
Heavy components must be handled with care using appropriate lifting
aids provided to facilitate heavy component lifting operations.
Rotary Drill String Tools and Accessories
The following are drill string tools and accessories used in rotary drilling for installing or
changing the tricone drill bit and breaking tight threaded joints between drill rods, rotary head,
spindle or drill bits (Figure 5-16).
Figure 5-16
1. Rotary Head
2. Hoist (Tower Mounted)
3. Lifting Bail
4. Chain Wrench
5. Drill Pipe
6. Drill Pipe Centralizer Bushing
7. Drill Split Bushing
8. Optional Stabilizer
9. Tricone Bit
10. Rotary Head Spindle
11. Hoist Cable
12. Spindle Sub
13. J -Wrench
14. Angle Drill Support (Option)
15. Table Centralizer Bushing
16. Drill Bit Sub
17. Sliding Fork Wrench (Drill Rod Retainer)
18. Bit Basket
Stabilizer Installation Procedure
The procedure is for installing the Stabilizer (option) or Starter Rod. Before starting, be sure
the rotary head is at the top of the tower and the rod changer/carousel is in the open (stowed)
position.
Figure 5-17
1. Install the correct lifting bail on the pin end of the stabilizer. Use the hoist to
raise the stabilizer and line it up over the table.
WARNING
!
Be sure a good joint has been made by looking at the connection between
the lifting bail and the stabilizer pin end threads before moving the
stabilizer.
2. Put a block of wood or metal on the ground under the drill table so the stabilizer
can rest on the ground while making connections. For short stabilizers, secure
upper section in sliding fork wrench so rotary head can be threaded to it.
3. Lower stabilizer through table and onto the block of wood or plate on ground.
4. Remove lifting bail and move the hoist cable out of the way and secure.
5. Lubricate thread joints properly.
6. Install stabilizer bushings around the stabilizer.
7. Feed rotary head down to engage threads on pin end of stabilizer. Using slow
forward rotation, tighten the stabilizer securely.
8. Raise stabilizer above table.
Tricone Bit Installation Procedure
The procedure below is for installing the Tricone drill bit on the stabilizer (option) or Starter
Rod. Note that the procedure is the same if you are installing the Tricone bit directly onto the
drill rod.
WARNING
!
aids to facilitate heavy component lifting operations.
1. Raise the centralizer bushing above stabilizer.
2. Move the stabilizer above table.
3. Install the rotary (Tricone) bit basket and the appropriate insert in the drill table.
4. Insert the Tricone bit into the insert in the bit basket.
5. Lubricate the threads on tricone bit.
6. Using the rotary head feed controller, lower the stabilizer (or drill rod) down onto
the threads on the bit and tighten securely by using slow forward rotation.
WARNING
!
Be sure a good joint has been made by looking at the connection between
the stabilizer and the tricone bit pin end threads before moving the
stabilizer.
7. Raise rotary head up until the Tricone bit clears the bit basket.
8. Remove the bit basket and store it out of the way.
9. Lower the stabilizer until the bit is below the table.
10. Install centralizer bushing.
11. Turn compressor on.
12. Turn on the drill air throttle (HP Only).
13. Turn on forward rotation and adjust speed.
14. Use drill feed control in the down position to start drilling. Adjust feed down
pressure with the drill feed force rotary control switch.
15. Adjust rotation speed as required.
Rotary Drilling Procedure
1. Make sure the stabilizer or bit sub, rotary bit and drill rod are installed correctly.
2. The engine speed should be High idle rpm.
3. Turn on the drill air throttle (Standard HP drills only), Compressor on (EARS HP
drills), Compressor lever ON (Standard LP drills only) and Compressor on
(EARS LP drills). Refer to the instructions in the Compressor Operation
Section.
4. Move drill rotation controller to drill (clockwise direction) position. With the
controller, adjust to slow rotation speed for starting the hole.
Note: Rotation is only possible when the Drill / Propel Mode Selector is in the
DRILL mode position.
5. Turn on the dust collector if necessary, or turn on the water pump if water
injection is required at startup.
6. Use drill feed controller in the DOWN position until the bit contacts the ground.
7. The first several feet or meters of drilling is called overburden. It usually
consists of soft soil, broken rock, gravel or clay. When drilling through this
mixture, care must be taken to prevent excessive cuttings from being blown out
of the hole and causing a washout.
8. Adjust the rotation and feed speed to fit the type of overburden being drilled.
9. Use the drill feed controller in the DOWN position to start drilling. Adjust feed
down pressure with the drill feed force rotary control switch.
10. Adjust the rotation and the feed speed (down pressure) as required by checking
the rotation and pulldown gauges.
11. Watch the cuttings coming from the hole to determine what type formation you
are drilling through.
12. Using proper drilling technique, drill down until the flats on the pin end of the
drill rod pass below the drill table. Reverse feed and bring flats on drill rod
above the table.
13. Stop rotation. Switch off dust collector if it is being used. Turn off water injection
pump if it is being used. Turn off drill air.
14. Follow the procedures in Adding Drill Rod to Drill String and resume drilling.
15. Follow the procedures in Removing Drill Rod from Drill String as needed.
Rotary Bit Changing Procedure
The procedure below is used when changing or replacing a rotary bit during the rotary drilling
process.
WARNING
!
1. Feed the drill rod up until the rotary bit is just below the table and raise the
centralizer bushing.
2. Feed the drill rod up until the bit is above the table.
3. Install the bit basket.
4. Lower the bit into the bit basket.
5. Install the chain wrench onto the chain wrench hydraulic cylinder.
6. Connect the chain wrench onto the drill rod.
7. Extend the chain wrench.
8. Retract the chain wrench to break the bit loose from the drill rod.
9. When the bit is loose, remove and move the chain wrench out of the way.
10. Use reverse rotation to unscrew the bit from the drill rod.
11. Use slow feed up to allow the bit threads to unscrew. Raise the drill rod above
the bit.
12. Remove the old bit from the bit basket and replace it with the new bit.
13. Lubricate the threads on the new bit.
14. Lower drill rod onto bit.
15. Use slow forward rotation to tighten bit into drill rod.
16. Tighten securely.
17. Raise drill rod assembly above table.
18. Remove bit basket.
19. Lower drill rod until bit is below table.
20. Install centralizer bushing.
21. Turn on the drill air throttle (Standard HP drills only), Compressor on (EARS HP
drills), Compressor lever ON (Standard LP drills only) and Compressor on
(EARS LP drills). Refer to the instructions in the Compressor Operation
Section.
22. Engage drill rotation controller in the forward (clockwise) position and adjust
rotation speed.
23. Use the drill feed controller in the DOWN position to start drilling. Adjust feed
down pressure with the drill feed force rotary control switch.
24. Adjust rotation speed as required.
DHD Drilling
Description
DHDs achieve high productivity in hard rock applications by adding percussion to the drilling
process. In harder rock, the rotary method cannot supply sufficient load on the bit inserts to
crack the rock and produce a chip.
Percussion drills overcome the rotary bit load limitation by producing a very high load during
impact on the hammer. This load is sufficient to drive the cutting inserts into the rock to
produce chips.
DHDs operate by using the position of a piston to direct supply and exhaust air to and from
drive and return volumes. The drive volume drives the piston toward impact and the return
volume returns the piston in preparation for another impact stroke.
Refer to Atlas Copco Technical Manual for Quantum Leap Downhole Drills , Part Number
52117397 for detailed information on Model QL Series Downhole Drills (Ref. to PMI Article #
9852 1864 01).
After the drill has been set up for drilling, there are a number of operations which involve
handling heavy drill rods, downhole hammers, drill bits and other components used for various
drill rod and drill bit changing procedures.
WARNING
!
Downhole Drill String Tools and Accessories
The following are drill string tools, accessories and items involved with respect to loading the
carousel, changing drill rod, installing and removing the DHD hammer, bit changing and
releasing tight threaded joints between drill rods, DHD, DHD chuck, and rotary head spindle
(Figure 5-18).
1. Rotary Head
2. Hoist (Tower Mounted)
3. Lifting Bail
4. Chain Wrench
5. Drill Pipe
6. Drill Pipe Centralizer Bushing
7. DHD Hammer
8. Starter Rod
9. Bit Basket
10. Rotary Head Spindle
11. Hoist Cable
12. Spindle Sub
13. J -Wrench
14. Angle Drill Support (Option)
15. DHD Centralizer Half Bushings
16. Button Bit
17. Sliding Fork Wrench (Drill Rod Retainer)
18. Bit Detaching Chuck (to fit button bit)
Figure 5-18
DHD Processes
Downhole drilling with a DHD consists of several processes. There is an order that should be
followed to maximize performance. To downhole drill, an operator must: Install a DHD hammer
to Starter Rod , Button Bit on the DHD hammer, Starting the hole with the DHD hammer, Add
Drill Rod to the Drill String, Follow DHD Drilling Procedures, Remove the Drill Rod, Remove
the DHD hammer from Drill String, Remove the Bit from DHD and follow some General Hints.
DHD Installation
1. Remove the Drill Bushing from the table (tower bottom).
2. Attach the lifting bail to the backhead of the DHD.
3. Lower hoist cable until the cable hook can be installed into lifting bail.
4. Lift the DHD above the table and lower it through the hole in the drill table until
the wear sleeve is about halfway below the table.
5. Install DHD centralizer half bushings around the DHD to secure it. Lower the
DHD until the flats on the backhead are just above the split bushings. Stop
lowering.
Figure 5-19
6. Install J -Wrench over flats on the backhead with long handle wrench against
the derrick.
7. Lower the cable until the DHD hangs on the J -Wrench.
8. Remove lifting bail and secure the hoist cable.
9. Use the fast drill feed control to lower the rotary head until the spindle is just
above the DHD backhead threads and stop.
10. Lubricate the threads on the backhead of the DHD with the correct thread
grease. Select the proper grade of grease in accordance with instructions given
in the Lubricant Specifications section of Section 6 Maintenance.
11. Lower the rotary head until the spindle threads contact the threads on the DHD.
12. Start slow forward (clockwise) rotation and lower the rotary head until the
connection is tight and the J -Wrench starts to move.
13. Stop rotation. Move rotary head up slowly to free the DHD from the J -Wrench.
If the wrench is dragging against the tower, reverse rotation slightly until the
wrench is free.
14. Remove the J -Wrench.
15. Using the Drill Feed Controller to regulate the speed, raise the DHD up out of
the table.
DHD Button Bit Installation
The Button Bit must be installed on the Downhole Hammer Drill.
Figure 5-20
1. Remove the Drill Bushings from table and install the correct size Bit Basket and
Bit Detaching Chuck for the size bit to be used into the drilling platform recess.
2. To prevent rotation of the Bit Basket, slide the Sliding Fork Wrench forward to
engage the flats of the bit basket.
3. Manually insert the Button Bit into Bit Basket, being careful not to damage
inserts.
NOTE: The Button inserts on a DHD bit are made to take a large force in one
direction only and that is straight up. If a button receives a blow from any other
direction, it may break. Handle bits with care.
4. Feed rotary head down until DHD is about 10 inches (25 cm) from the top of the
bit. Stop feed.
5. Remove DHD bit chuck and retainers from DHD by unscrewing them.
6. Install DHD BIT chuck and retainers on button bit and lubricate threads on
chuck.
NOTE: Bit Splines should be well lubricated with Rock Drill Oil or thread grease
before the chuck is installed over the splines. Additionally, the threads on the
chuck should be well coated with thread grease before threading the chuck into
the DHD. Remember to install the bit retaining ring halves before threading the
chuck into the DHD.
NOTE: Follow Actual Manufacturers Lubrication Instructions when using
DHD Hammers. Rock Drill Oil is only used on Atlas Copco DHDs.
7. Slowly feed the rotary head down until the DHD is over the top of the bit. Stop
feed.
8. Slide the chuck and retainers up to make contact with the threads on the DHD.
9. Engage forward rotation slowly and hold the chuck in position so it threads up
on the DHD. Tighten securely.
10. Stop rotation. Feed DHD with bit up to clear the bit basket and remove the
basket.
11. Feed the DHD and bit down through the table until the bit and bit chuck are
below the table top.
12. Install DHD split bushings
NOTE: The table may be close enough to the ground to prevent hanging the
DHD and bit on the backhead. If this is the case, a shallow hole can be drilled,
with the DHD connected to the rotary head, to allow it to be left in the table while
loading a piece of drill pipe in the rotary head.
Installing DHD Hammer to Drill Rod
The drill rod (or starter rod) must be connected to the DHD and the rotary head.
1. Connect DHD and Bit assembly to the rotary head and drill down until DHD can
be removed at the table.
2. Remove DHD from rotary head by inserting the J -Wrench on backhead flats of
the DHD and using reverse rotary head rotation.
Figure 5-21
3. After DHD is unthreaded, use reverse rotary head rotation and raise the rotary
head to the top of the tower. The DHD will be hanging off of the J -Wrench.
4. Install a drill rod from the carousel onto the rotary head. (See Adding Drill Rod
Procedure).
5. Lower rotary head and drill rod, stopping to place the drill rod centralizer
bushing on the drill rod.
grease. Select the proper grade of grease in accordance with instructions given
in the Lubricant Specifications section of Section 6 Maintenance.
7. Slowly lower rotary head and drill rod, which should be slowly rotating
clockwise, and tighten on to the DHD.
8. Stop feed and rotation when drill rod is tightened on to the DHD.
9. Raise the rotary head until the DHD is high enough above the table to allow
removal of the J -Wrench and remove the J -Wrench.
10. Down feed, allowing the drill rod centralizer bushing to seat in the table
centralizer.
11. Turn on the compressor (Follow the instructions in the High Pressure
Compressor section of Section 3-Specification).
12. Using the compressor and DHD, drill a hole the length of the drill pipe (See
DHD Drilling Procedures).
13. Raise the rotary head and drill rod to top of tower.
14. Stop feed and rotation. Shut off the drill air throttle. Turn off the lubricator.
15. Remove the DHD from the drill rod using the J -Wrench. (See Removing DHD
from the Drill String Procedure).
16. Remove the drill rod and load it into the carousel (See Removing Drill Rod from
Drill String Procedure).
17. Use the lifting bail and the hoist cable to lift the starter rod and hang it over the
DHD.
18. Install the drill rod centralizer over the starter rod before manually connecting
the starter rod to the DHD. It will hang on top of the DHD backhead.
grease.
20. Slowly lower the starter rod until the threads make contact with the DHD.
Manually tighten the connection.
Figure 5-22
21. Using the hoist, raise the DHD and starter rod until the J -Wrench can be
removed.
22. Lower the DHD and the starter rod into the hole until the fork wrench can be
installed on the flats of the starter rod.
23. Remove the lifting bail and secure the hoist cable out of the way.
24. Bring the rotary head down close to the pin end of the starter rod. Stop feed.
25. Lubricate the threads of the starter rod.
26. Slowly lower the rotary head, which should be slowly rotating clockwise, to
tighten on to the starter rod.
Note: An alternative method is to use the lifting bail to pick up the starter rod
until the DHD can be attached manually. Raise the DHD and starter rod and
then carefully lower through the centralizer in the table and set it on the ground.
A man lift must be used to remove the lifting bail and guide the rotary head on
to the pin end of the rod.
Starting the Hole with a DHD
Figure 5-23
When using the Atlas Copco DHD for the first time, pour one cup (8 oz./230ml) of Rock Drill
Oil into the drill backhead to lubricate it before starting the DHD.
Note: Follow Actual Manufacturers Lubrication Instructions when using DHD
Hammers. Rock Drill Oil is only used on Atlas Copco DHDs.
1. The DHD should be connected to the drill rod or (starter rod) to drill the hole.
2. The engine speed should be High Idle RPM.
3. Turn on the compressor. Adjust the pressure regulator to the desired setting.
Refer to High Pressure Operation instructions in the Compressor Operation
section.
4. Turn on the DHD lubricator switch on the console (Figure 5-23).
5. The DHD lubricator indicator light will light up to confirm the lubrication system
is in service.
6. Regulate the flow if necessary. Read the instructions on the side of the
lubricator to regulate for the compressor size of the drill.
7. Start the forward (clockwise) rotation using the Drill Rotation Controller.
Regulate speed as needed with the Drill Rotation Controller.
Note: Rotation is only possible when the Drill / Propel Mode Selector is in the
Drill Mode position.
8. Make sure the dust aprons are in place.
9. Open the Drill Air Throttle slowly and allow air flow to operate the DHD.
10. Move the Drill Feed Controller to the DOWN position and adjust the feed speed
for drilling conditions.
11. The first several feet or meters of drilling is called overburden. It usually
consists of soft soil, broken rock, gravel or clay. When drilling through this
mixture, care must be taken to prevent excessive cuttings from being blown out
of the hole and causing a washout.
12. When the DHD has drilled below the drill table, it should be with drawn from the
hole. Move the Drill Feed controller to UP position and raise the DHD up out of
the table until the split DHD bushings can be removed.
13. Stop Rotation. Shut off Drill Air Throttle. Turn off oiler.
14. Slowly lower the drill string down until the drill rod centralizer bushing can be
inserted into the drill table. This bushing should be sitting on the backhead of
the DHD around the drill rod. Drilling can now be resumed (See DHD Drilling
Procedures).
DHD Drilling Procedures
1. Make sure the DHD, button bit and drill rod are installed correctly.
2. The engine speed should be High Idle RPM. Turn on the drill air throttle
controller slowly. Turn on the DHD lubricator. Turn on the water pump or dust
collector if necessary.
3. Push the drill rotation controller to clockwise (forward) position. Adjust rotation
speed with controller.
Note: Rotation is only possible when the Drill/Propel Mode Selector is in the
Drill Mode position.
4. Use drill feed controller in the DOWN position while starting a hole.
5. Regulate the drill feed by using the feed pressure control on the console.
Figure 5-24
6. Adjust the rotation and feed speed (down pressure) by checking the rotation
and pulldown gauges. Pulldown pressure can be turned to holdback pressure
when there is enough weight on the drill string to pull the drill string downward
(Figure 5-24).
7. Watch the cuttings coming from the hole to determine what type formation you
are drilling through.
Bit Removal
Bit removal can be one of the most dangerous and frustrating tasks associated with the drilling
operation. However, with the proper tools and techniques it should require no more than a few
minutes to remove a bit. The following lists pointers which will be beneficial in helping you
remove a bit quickly, safely and with reduced risk to damaging DHD parts and components:
1. Use sharp tong jaws. Worn or rolled over tong jaws increase the jaw pressure
and make the wrench more prone to damaging the hammer case. Many
hammer cases are case hardened which means sharp jaws are needed to grip
through the hardened case.
2. Grip the casing in the proper location. Gripping over threads can make thread
loosening extremely difficult. Example; as the wrench tightens it exerts an
inward force which can pinch the threads if they are under the wrench jaw. This
only increases the torque that is needed to uncouple the thread. Also, do not
grip the casing in an area where the bore is not supported by either the piston
or bearing. Gripping over an unsupported area can distort the bore.
3. Insure the bit fits properly within the bit basket. An improper fit may result in the
bit slipping from the basket.
4. Never weld or hammer on the casing to loosen it. All casings except the QL200
are case hardened for extended service life. The hard casing surface can be
cracked by welding or impacting with a sledge hammer.
DANGER
!
Be sure chain wrenches or tongs are rated for the torque applied. The
flying parts of chain wrenches can cause injury or death when they break.
Removing Bit from DHD
1. With the DHD hanging off of the J -Wrench, lower and connect rotary head to
DHD.
2. Using drill feed, raise the rotary head until the DHD is high enough above the
table to allow removal of the J -Wrench and remove the J -Wrench.
3. Using drill feed, raise DHD up until the bit basket can be installed into table
recess.
4. Insert bit basket and bit detaching chuck into table recess and lower the bit into
basket.
5. Attach chain wrench to lower section of DHD. Do not allow chain wrench to
contact DHD chuck.
6. Use the Chain Wrench Controller to extend and retract the chain wrench
cylinder. Loosen the bit chuck from DHD wear sleeve.
7. Remove the chain wrench and feed the rotary head up slowly. Simultaneously
reverse the rotary head rotation and unscrew the bit chuck completely from the
DHD wear sleeve. Stop feed and rotation.
8. Lift the bit chuck and retainers from the drill bit and remove the drill bit from bit
basket.
9. Replace the old bit with new one and manually install bit chuck and retainers
on new bit or manually install bit chuck and retainers back on DHD for storage.
Removing DHD from Drill String
1. Using drill feed, move the drill string so the backhead on the DHD is slightly
above the table.
2. The centralizer bushing must be held up out of the way so the J -Wrench can
be inserted on the backhead.
3. Install the split bushings around the DHD. Lower the DHD until the flats on the
backhead are just above the table.
4. Use the J -Wrench to secure the backhead on the table. Use drill feed to move
DHD down until J -Wrench rests on table.
5. Slowly reverse rotation until the J - Wrench is almost touching a vertical tower
member.
Figure 5-25
6. Using full rotation speed with drill rotation controller, reverse rotation and
impact the J -Wrench against the tower member.
7. When the joint is loose, reduce speed on the drill rotation controller and slowly
raise the rotary head until connection is separated.
8. Remove the drill rod from rotary head and store in the carousel.
9. If you are not going to remove the bit from the DHD, connect the lifting bail to
backhead and lift the DHD out of the table. Store the split bushings.
General Drilling Hints
1. The DHD lubricator must always be used whenever the DHD is being operated.
Use the correct oil for the DHD and the season.
The amount of oil required varies with the size of the air compressor, not the
DHD. Select the compressor size on the three position Lubricator Air Flow
Selector. On 1050 cfm compressors, the setting is 900 cfm.
Figure 5-26
Note: Follow Actual Manufacturers Lubrication Instructions when using DHD
Hammers. Rock Drill Oil is only used on Atlas Copco DHDs.
2. The Water Injection Option should be used to contain dust and must be used
whenever water is encountered in the hole to prevent collaring.
3. Do not operate the water pump if no circulation is being observed (i.e. bit is
stuck in the hole). Water will fill up the air supply lines and flow back into the
receiver tank of the compressor.
4. Do not open the drill air throttle flow control suddenly. It may cause a collapse
of the separator element over a period of time.
Transporting The Drill
Safety Precautions
The Downhole Hammer Drill must be connected to the rotary head and be lifted so the Button
Bit can be installed.
1. When towing the drill, observe the prescribed transport position, admissible
speed and the itinerary.
2. DO NOT attempt to load the drill rig on the transport vehicle without the
knowledge and the experience with the operation of the drill rig.
3. Keep the trailer deck clean of clay, oil, mud, ice, frost and other material that
can become slippery.
4. Always know the overall height, weight, width and length of the drill rig the and
hauling vehicle. MAKE SURE there is sufficient clearance when crossing
underpasses, bridges and tunnels or when passing under overhead lines.
5. When moving the drill rig on public access roads, obey all traffic regulations and
be sure that proper clearance flags, lights and warning signs, including the
Slow Moving Vehicle emblem, are properly displayed. Know your
approximate stopping distance at any given speed. Never turn corners at
excessive speeds and look in all directions before reversing your direction of
travel.
Drill Preparation
1. Remove all loose tools, material and accessories from the drill.
2. Raise the rotary head to the top of the tower.
3. Rotate the carousel so the empty area is in line with the drill rod in the head.
Swing the carousel into the closed position.
4. Lower the tower. Feather the controller as the tower approaches the tower rest
so it doesnt impact with excessive force.
5. Retract leveling jacks, starting with the non-drilling end leveling jack(s). Retract
the drilling end leveling jacks.
6. Make sure all controls are in neutral and any water lines and other connections
are removed and stored.
7. Idle the engine at LOW idle (1200 rpm) position for five (5)minutes to cool all
fluids down. Stop the engine and be sure the compressor blows down.
WARNING
!
Transferring the drill and equipment between work sites is potentially
hazardous.
Before transporting the drill on public roads, check with your supervisor for instructions and
information in respect to traffic regulations regarding construction machinery.
Note: For more information on transporting, refer to the Transporting and Towing section of
Section 2 - Safety Precautions and Guidelines.
Loading Drill by Drive On
The following information is for loading the drill under its own power (drive on) for transporting.
1. Choose level ground which will solidly support the vehicle.
2. Always use a ramp when loading the drill rig on a transport vehicle. Be sure the
ramps are of adequate strength, low angle, and proper height.
3. Clean the trailer surface and loading ramps.
4. Use the proper chock blocks in the front and rear of the wheels of the transport
vehicle when loading the drill rig.
5. A signal man must assist the operator with any necessary warnings.
6. Use the Remote Propel (Option) Control Unit during loading the drill and control
the loading procedure from a safe vantage point.
NOTE: For more information on the Remote Propel Control Unit Option, refer
to Section 4 Operating Controls.
7. Approach the transporter loading ramps squarely to make sure the drill does
not drop off side of ramp.
8. Propel the Drill onto the transporter vehicle trailer.
proper chock blocks in front and rear of the tracks .
10. Move the propel/drill mode selector to the DRILL mode position and make
sure the propel and drill controllers are all in the Stop positions.
11. Idle the engine at LOW idle (1200 rpm) position for five (5) minutes to cool all
fluids down.
12. Shut engine down, apply the parking brake switch (option) and be sure the
compressor blows down.
13. Lock all lockable compartments and vandal protection devices on the drill.
Loading Drill with Lifting Equipment
Figure 5-27
The following information is for loading the drill, by lifting equipment, for transporting.
1. Use only appropriate means of transport and lifting gear of adequate capacity.
2. The fastening of loads and instructing of crane operators should be entrusted
to experienced personnel only. The personnel giving the instructions must be
within the sight or sound of the operator.
3. Always use the four lift points and proper lifting tackle. Refer to weight
distribution in Section 3 Specifications.
4. Attach the lifting frame to drill using the four lift points marked with lift symbol
as reference (figure 5-27).
5. Ensure that the appropriate lifting equipment is rated to the drills weight before
lifting.
proper chock blocks in front and rear of the tracks .
Tie Down Drill
1. After loading the drill on the transporter, ensure that all pivoting assemblies are
in the locked positions and there are no unsecured or loose items which could
dislodge during transport.
2. Ensure that the propel/drill mode selector is in the Drill Mode position and
make sure the propel and drill controllers are all in the Stop positions.
3. If the engine has been running, idle the engine at LOW idle (1200 rpm) position
for five (5) minutes to cool all fluids down.
4. Shut down engine and remove ON/OFF switch key.
5. Lock all lockable compartments and vandal protection devices on the drill.
Figure 5-28
6. Use proper chock blocks in front and rear of the tracks once loaded on the
trailer.
7. Secure the drill rig to the deck of the transport vehicle with adequate chains,
cables, tensioning devices, blocks or other appropriate equipment to the four
tie down points in accordance with local regulations.
8. The driver of the transport vehicle must be aware of the total weight load on the
axles and the overall dimensions of the drill. For further information, refer to the
Dimensions and Weights in Section 3 - Specifications.
Towing The Drill
WARNING
!
Personal injury or death could result when towing a disabled drill
incorrectly. Follow the recommendations below to properly perform the
towing procedure.
1. You MUST block the tracks to prevent any movement before releasing the
brakes or before disconnecting the final gear train. The drill can roll free if it is
not blocked.
2. Relieve hydraulic tank and hydraulic line pressure before any disassembly.
Operate the track propel controllers in both directions, with engine stopped, to
relieve pressure.
3. Even after the drill has been turned off, the hydraulic oil can still be hot enough
to burn. Allow the hydraulic oil to cool before draining.
NOTICE
To tow the drill, both final drives must be disengaged. Do not operate the
travel motors with the final drives disengaged. Damage could result.
Clean the final drive covers and the nearby areas before disengaging the
drives. Dirt can contaminate and damage the propel motors, reduce
propel performance and cause drill malfunctions.
CAUTION
!
Use only draw bars for the towing requirement.
Maximum towing speed = 2.0 km/h (1.2 mph).
Do Not let the track rollers get hot during towing. Check periodically
during towing.
General Towing Information
These towing instructions are for moving a disabled drill a short distance, only a few meters
(feet) at a low speed not faster than 1.2 mph (2 km/h), to a convenient repair location. These
instructions are for emergencies only. Always haul the drill on a transporter if long distance
moving is required.
Shielding must be provided on the towing machine to protect the operator if the tow line or bar
should break.
Do not allow the operator, or any other personnel, on the drill when it is being towed.
Before towing, make sure the tow line or bar is in good condition and has sufficient strength
for the towing situation involved. Use a towing line or bar with a strength of at least 1.5 times
the gross weight of the towing machine for towing a disabled drill stuck in mud or when towing
on a grade.
Attach cable to front end (cab end) tie down points if pulling forward, or attach to the rear end
tie down points if pulling in reverse.
Do not used a chain for towing. A chain link can break, causing possible personal injury. Use
a wire rope cable with loop or ring ends. Use an observer in a safe position to stop the towing
procedure if the cable starts to break or unravel. Stop towing whenever the pulling machine
moves without moving the towed drill.
Keep the tow line angle to a minimum. Do not exceed 30 angle from the straight ahead line of
travel.
Sudden machine movement could overload the tow line or bar and cause premature
breakage. Gradual and smooth acceleration will minimize breakages of towing components.
Normally, the towing machine should be as large as the disabled drill and have sufficient
braking capacity, weight and power to control both the machine and the disabled drill for the
grade and distance involved. To provide sufficient control and braking when moving the
disabled drill downhill, a larger towing machine or additional tandem connected machines
could be required. This will prevent a runaway or uncontrolled towing operation.
All the different situation requirements cannot be given here. Capacities range from minimal
towing machine capacity required on smooth, level surfaces and increases to maximum
capacity required on inclines and poor surface conditions.
Unlocking the Parking Brake (Option)
The transmission is fitted with a disengaging gear. The disengaging gear is used to change
the transmission into neutral, i.e. the motor and transmission are disengaged without releasing
the brake. This neutral position is of special importance when the machine is to be towed:
at higher speeds
over longer distances
without actuating the hydraulics.
The transmission must be protected from undue heating during traveling.
Undercarriages with drive units that are fitted with parking brakes cannot be moved when the
hydraulic system is not functioning. For this reason, it is possible to fit the undercarriage with
an unlocking mechanism.
Towing Procedure
To tow the drill, use the following procedure:
1. Attach the drill to an appropriate towing vehicle using appropriate cable and
draw bar which can be secured in position at the selected tie-down points on
the drill. Remove the chocks.
2. Locate the final drive engagement mechanism.
WARNING
!
Only disengage final drives when machine is NOT moving.
Figure 5-29
3. Thoroughly clean the area around the disconnect cover.
4. The disengagement flange (A) is secured with 2 bolts (tightening torque 53
Nm).
5. To disengage, both bolts have to be removed. The disengagement flange can
now be moved to the distance of 16mm, as shown in the drawing, by means of
two bolts screwed into the withdrawal hole (C). To avoid further movement, the
flange must be secured with 2 bolts.
6. Repeat procedure for the other track drive.
7. When required, reverse the procedure to re-engage the input shaft.
8. Before removing the drill from the towing vehicle and draw bar, Make sure the
final drive engagement mechanism is engaged properly or install chocks at
each end of both tracks to keep the drill from moving after removing draw bar.
WARNING
!
To avoid damage of gear teeth, it is absolutely necessary that
disengagement and re-engagement is carried out with the machine at a
standstill.
NOTICE
Do not allow oil temperature to exceed 194F (90C) while towing.
WARNING
!
The brakes are ineffective when the input shaft is disengaged. Provide
other methods to control movement of the drill.
Special Conditions of Use
Cold Weather Conditions
1. Refer to 6-3 Refill Capacities / Lubricants / Fuel in the maintenance section for
information regarding cold weather lubricants, hydraulic fluids, coolants. fuel
etc.
2. Use winter grade diesel fuel for operation at subzero temperatures.
3. Be extremely careful when using cold weather starting aids. Starting aids are
very flammable and should only be used if needed.
4. Remove batteries and store in a warm area to about 68F (20C).
5. Perform and follow warm-up procedures upon start-up before operating the
drill.
Hot Weather Conditions
1. Monitor temperature gauges.
2. Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
Water and Muddy Conditions
1. Clean the drill of accumulated material and thoroughly grease all lubrication
points. Refer to 6-3 Refill Capacities / Lubricants / Fuel in the maintenance
section for information regarding lubricants, hydraulic fluids, coolants, fuel, etc.
Dusty Conditions
1. Keep air cleaner elements clean and free of accumulation of dirt.
2. Wear a protective mask.
High Altitude Conditions
1. Be aware that engine power will be reduced.
2. Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.
Preservation & Storage
Observe the following when storing the drill for short periods of time:
1. Replace and secure all weatherproof covers.
2. Change all lubricants and fluids that may have deteriorated with use. Refer to
6-3 Refill Capacities / Lubricants / Fuel in the maintenance section for
information regarding lubricants, hydraulic fluids, coolants, fuel, etc.
3. Check that the storage site is not subject to flooding or other natural hazards.
4. Wherever practical, run the engine and operate all the drill functions at regular
intervals.
Section 6 - Maintenance
DM45,DM50,DML Instruction Manual Section 6- MAINTENANCE
6.1 - Maintenance Safety
Maintenance Safety and Health
physical dangers that are present in all phases of operation and maintenance of this drill.
WARNING
!
Improper maintenance can cause severe injury or death. Read and
understand the SAFETY PRECAUTIONS AND GUIDELINES section of this
manual before you operate or perform any maintenance, service or
repairs.
Anyone working around this drill must read and thoroughly understand the precautions
outlined in this manual before attempting to operate or perform work on the drill. In addition,
SAFETY ALWAYS must always be the primary consideration of all personnel when working
around this drill under normal or unusual conditions.
exercise good judgement and common sense when operating, servicing or working near this
drill.
WARNING
!
and understand the OPERATING CONTROLS & INSTRUMENTS section of
this manual.
Section 6 - MAINTENANCE DM45,DM50,DML Instruction Manual
If there is any doubt about the safe operating procedure of the drill, Stop !! Review the
information supplied with the drill, ask your supervisor or contact your nearest Drilling
Solutions representative for assistance.
Make sure all new employees read and understand the decals in the Decal Safety Manual
mounted on the drill. Never remove the Decal Safety Manual. Replace the manual if it
becomes lost or illegible.
WARNING
!
SAFETY PRECAUTIONS
Most accidents involving product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially dangerous situations before trouble occurs. Some of the potential problems and
ways to prevent them are shown below.
Fluid Penetration
1. Always use a wooden board or cardboard when checking for leaks.
2. Leaking fluid under pressure can cause serious injury or death.
3. If fluid is injected into the skin, see a physician immediately.
Lines, Tubes and Hoses
1. Repair any loose or damaged oil lines, tubes and hoses. Leaks can cause fires.
2. Inspect all lines, tubes and hoses carefully. Do not use your bare hands to
check for leaks.
3. Tighten all connections to the recommended torque.
4. Make sure that all clamps, guards and heat shields are installed correctly to
prevent vibration, rubbing against other parts and excessive heat during
operation.
5. Check for the following:
a. End fittings damaged, leaking or displaced.
b. Outer covering chafed or cut and wire reinforcing exposed.
c. Outer covering ballooning locally.
d. Evidence of kinking or crushing of the flexible part of the hose.
e. Armoring embedded in the outer cover.
Burn Prevention
1. Do not touch any part of an operating engine or its components.
2. Allow the engine or its components to cool before any repair or maintenance is
performed.
3. Relieve all pressure in air, oil, or cooling systems before any lines, fittings or
related items are disconnected or removed.
Coolant
1. Use caution when removing filler cap, grease fittings, pressure taps, breathers
or drain plugs.
At engine operating temperature, engine coolant is hot and under pressure.
The radiator and all lines to heaters or the engine contain hot water. When
pressure is relieved rapidly, this hot water can turn into steam. Always allow the
hot cooling system components to cool before draining. Any contact with hot
water or steam can cause severe burns. Check the coolant level only after the
engine has been stopped and the filler cap is cool enough to remove with your
bare hand.
2. Hold a rag over the cap or the plug to prevent being sprayed or splashed by
liquids under pressure.
3. Remove the cooling system filler cap slowly to relieve pressure.
4. Cooling system additive (conditioner) contains alkali. To prevent personal
injury, avoid contact with the skin and eyes and do not drink.
Oils
1. Hot oil and components can cause personal injury. Do not allow hot oil or any
components to contact the skin.
2. Keep all shields in place to protect from oil spray in case of a line, tube or seal
failure.
Batteries
1. Battery electrolyte contains acid and can cause injury. Avoid contact with skin
and eyes. Wash hands after touching batteries and connectors. The use of
gloves is recommended. Batteries give off flammable fumes, which can
explode. Ensure there is proper ventilation for batteries, which are located in an
enclosure.
2. Always thaw a frozen battery before jump starting. Frozen batteries can
explode.
3. Do not smoke when observing the battery electrolyte levels.
4. Always wear protective glasses when working with batteries.
5. Never disconnect any charging unit circuit or battery circuit cable from the
battery when charging unit is operating. A spark can cause the flammable
vapor mixture of hydrogen and oxygen to explode.
Fire or Explosion Prevention
1. Fire may result from lubricating oil sprayed on hot surfaces causing personal
injury and property damage. Inspect all lines and tubes for wear or
deterioration. They must be routed, supported or clamped securely. Tighten all
connections to the recommended torque. Leaks can cause fires.
2. Determine whether engine will be operated in an environment in which
combustible gases could be drawn through the air inlet system. These gases
could cause the engine to overspeed, which in turn could seriously damage the
engine and result in bodily injury or property damage.
3. All fuels, most lubricants and some coolant mixtures are flammable.
4. Diesel fuel is flammable. Gasoline is flammable. The mixtures of diesel and
gasoline fumes are extremely explosive.
5. Do not smoke while refueling or in a refueling area. Do not smoke in areas
where batteries are charged, or where flammable materials are stored.
6. Batteries give off flammable fumes which can explode. Keep all fuels and
lubricants stored in properly marked containers and away from all unauthorized
persons. Store all oily rags or other flammable material in a protective
container, in a safe place.
7. Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean
them thoroughly with a nonflammable solvent before welding or flame cutting
on them. Remove all flammable materials such as fuel, oil and other debris
before they accumulate. Do not expose the engine to flames, burning brush,
etc., if possible.
8. Shields (if equipped), which protect components from oil spray in the event of
a line, tube or seal failure, must be installed correctly.
9. Provide adequate and proper waste oil disposal. Oil filters must be properly
installed and housing covers tightened to proper
when being changed.
10. Clean and tighten all electrical connections. Check regularly for loose or frayed
electrical wires. Refer to maintenance schedules for intervals. Have all loose or
frayed electrical wires tightened, repaired or replaced before operating the
drilling rig.
11. All of the wiring must be kept in good condition, properly routed and firmly
attached. Routinely inspect wiring for wear or deterioration. Loose, unattached,
extra or unnecessary wiring must be eliminated All wires and cables must
conform to the recommended gauge and be fused if necessary. Do not use
smaller gauge wire or bypass fuses. Tight connections, recommended wiring
and cables properly cared for will help prevent arcing or sparking which could
cause a fire.
12. All Batteries must be kept clean with covers kept on all cells, recommended
cables and connections used and battery box covers kept in place when
operating.
13. When starting from an external source, always connect the positive (+) jumper
cable to the POSITIVE (+) terminal of the battery of the engine to be started.
To prevent potential sparks from igniting combustible gases produced by some
batteries, attach the negative () boost ground cable last, to the starter
NEGATIVE () terminal (if equipped) or to the engine block. See the Operation
Section of this manual for specific starting instructions.
Fire Extinguisher
1. Have a fire extinguisher available and know how to use it.
2. Inspect the fire extinguisher at the beginning of each shift and have it serviced
as recommended on its instruction plate.
Crushing or Cutting Prevention
1. Support equipment and attachments properly when working beneath them.
2. Never attempt adjustments while the engine is running unless otherwise
specified in this manual.
3. Stay clear of all rotating and moving parts. Guards should be in place whenever
maintenance is not being performed.
4. Keep objects away from moving fan blades. They will throw or cut any object
or tool that falls or is pushed into them.
5. Wear protective glasses when striking objects to avoid injury to your eyes.
6. Chips or other debris can fly off objects when struck. Make sure no one can be
injured by flying debris before striking any object.
Mounting and Dismounting
1. Clean steps, handholds and areas of the drill you will be working on or around.
2. Always use the steps and handholds when mounting and dismounting with a
three point stance.
3. Do not climb on or jump off the drill. Do not stand on components that cannot
support your weight. Use an adequate ladder.
Before Starting the Engine
1. Inspect the drill for potential hazards.
2. Be sure all protective guards and covers are installed if a drill must be started
to make adjustments or checks. To help prevent an accident caused by rotating
parts, work carefully around them.
3. Do not disable or bypass automatic shutoff circuits. They are provided to
prevent personal injury and drill damage.
4. Never start an engine with the governor linkage disconnected.
5. Make provisions for shutting off air or fuel supply to stop engine if there is an
overspeed condition on start-up after performing repair or maintenance to the
engine.
Engine Starting
1. DO NOT start the engine or move any of the controls if there is a warning tag
attached to the controls. Check with the person who attached the tag before
starting.
2. Make sure no one is working on, or close to the engine or the engine driven
components before starting the engine. Always inspect the engine before and
after starting.
3. Start the engine only from the operators station. Never short across the starter
terminals or the batteries as this could by-pass the engine neutral start system
as well as damage the electrical system.
4. Always start the engine according to the required Engine Starting Procedure
described in this manual to prevent major engine component damage and
personal injury.
5. Stop the engine according to the Engine Stopping instructions in the Operation
Section to avoid overheating and accelerated wear of the engine components.
6. Only use the Emergency Stop button in an emergency. DO NOT start the
engine until the problem causing the emergency stop has been located and
corrected.
7. On initial startup or overhaul, be prepared to STOP the drill should an
overspeed condition occur. This may be accomplished by cutting the fuel and
air supply to the engine.
8. Check the compressor oil temperature gauge frequently during the operation of
lube oil heaters to ensure proper operation.
9. The diesel engine exhaust contains products of combustion that may be
harmful to your health. Always start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust to the outside.
Starting Aids
1. Ether and other starting aids are poisonous and flammable. Do not smoke while
changing ether cylinders.
2. Use ether only in well ventilated places.
3. Keep ether cylinders out of the reach of unauthorized persons.
4. Do not store replacement ether cylinders in living areas, the storage
compartment or the cab.
5. Do not store ether cylinders in the direct sunlight or at temperatures above
102F (39 C). Discard cylinders in a safe place. Do not puncture or burn
cylinders.
Engine Stopping
1. Stop the engine according to the Engine Stopping Instructions in the Operation
2. Use the emergency stop button only in an emergency. DO NOT start drill until
the problem is resolved.
3. Be prepared to stop the engine should an emergency condition occur.
Maintenance Information
To prevent minor irregularities from developing into serious conditions, several other services
or checks are recommended for the same intervals as the periodic lubrication. The purpose of
these services or checks is to ensure the uninterrupted and safe operation of the drill by
revealing the need for adjustment caused by normal wear.
Prior to conducting any maintenance work, ensure that the following instructions are
observed:
1. The drill should be parked on a firm, level surface.
2. Ensure the engine is shut down and fluids allowed to cool.
3. Stop the engine and allow the hydraulic oil pressure to fall before working on
the hydraulic hose installations or connections.
4. Stop the engine and allow compressor air pressure to completely relieve from
the receiver tank before working on the compressor, receiver tank and hose
installations or connections.
5. Disconnect the electrical power or (Battery Cables) and cover exposed
terminals before working on the drills electrical system.
6. Thoroughly wash all fittings, caps, plugs, etc. with nonflammable, nontoxic
cleaning solution before servicing to prevent dirt from entering while performing
the service.
When there is a need for service personnel to work on the drill in the working area or
danger zone and this involves activation of one or several drill functions, such work
shall only be done under the following conditions:
1. There shall always be two people present: both being fully instructed on the
safety issues. One of them, from the main operators station, shall supervise
the safety of the service man doing the work.
2. The supervisor shall have immediate access to the emergency stop in all
situations.
3. The area where the service work is to be performed shall be properly
illuminated.
4. Communication between the service man and the supervisor at the main
operators station shall be established in a reliable manner.
5. Only when the drill is shut down completely and the means of starting are
isolated, is a person allowed to perform repair and maintenance work alone on
the drill.
Handling Fluids and Oil
1. When draining fluids, ensure that adequate sealable containers are available
and that every care is taken to prevent spillage.
2. Always ensure waste fluids are disposed of in an environmentally safe manner.
3. Always ensure that used filters are stored in secure containers and disposed of
in an environmentally safe manner.
The maintenance schedule in this section shows those items requiring regular
service and the interval at which they should be performed. A regular service
program should be geared to the items listed under each interval. These intervals
are based on average operating conditions. In the event of extremely severe, dusty
or wet operating conditions, more frequent maintenance than specified may be
necessary.
NOTE:
Refer to the Actual Manufacturers Operation and Maintenance Manual for the
Maintenance Schedules and procedures for the Engine on the drill.
NOTE:
Refer to the Actual Manufacturers Service Maintenance Manual for Maintenance
Schedule and procedures for the Engine on the drill.
6.2 - Maintenance Schedule
Maintenance Schedule Information
Before each consecutive interval is performed, all of the maintenance requirements from the
previous interval must also be performed. Note: If the drill is operating under very severe
conditions (such as very dusty air), the scheduled maintenance intervals should be reduced.
Table 1: Maintenance as Required
Description Action Lubrication
Housekeeping Clean the Drill
Loose Bolted Connections Check - Tighten to proper
torque
See Torque Specifications
Hoist (Winch 3600#) Check - Drum Bushings
and Seals for grease
seepage.
SHC 007 grease
Winch Wire Rope (3600#
and 8000#)
Check - Wear, Stretch
conditions and clamps
Tower Feed Cables and
Chains
Check - Sag Distance,
Wear and Stretch
conditions
Grease Drum Option Change - Grease Drum See Parts Book
Thread Greaser Option Change - Grease Drum See Parts Book
Table 2: Maintenance at 8-10 Hours or Daily
Overpressure Control Test - System
Engine and Compressor
Air Cleaner
Check - Air Cleaner
Service Indicator
See Parts Manual
Check - Connections and
Ducts for leaks
Empty - Dust Cup
Engine Check - Crankcase Oil
Level. Add if low
SAE 15W40 Engine Oil
(Refer to OEM Manual)
Check - Engine Belts &
Tensioner
Engine Fuel Filter Drain - Water from Fuel/
Water Separator
Fuel Tank Check - Fuel Level #1 and #2-D S15 ULSD
Cooling System ( HOC and
COC) & (Rad and CAC)
Clean - Cooling Fins
Check - Radiator Coolant
Level
50/50 - Water & Coolant
Receiver Separator Tank Check - Compressor Oil
Level
LP-150 (Low Pressure)
HP-350 (High Pressure)
Drain - Water from
Receiver Tank
Hydraulic Reservoir Check - Oil Level on Tank
Sight Gauge
ISO AW32 Hydraulic Oil
Drain - Water from
Hydraulic Reservoir
Hydraulic Oil Filters Check - Main Return Oil
Filter Restriction Indicators
See Filter Elements and
Kits Chart for
replacements
Check - Case Drain Oil
Filter Restriction Indicator
Rotary Head Check - Rotary Head Oil
Level
SAE 90W Gear Oil
Grease Upper Bearing Extra Heavy Duty Moly 2
Multi-Purpose Grease
Housekeeping Clean the Drill
Table 3: Maintenance at 50 Hours
Dust Collector Check - Dropout and
Suction Hoses, Rod Seal
and Blower Discharge
See Parts Manual
Check - Impulse Air and
Filters
Manual Lubrication Points
Tower Central Bank 5 shots of grease into each
fitting
MPG - EP-O Grease
Frame Central Bank 5 shots of grease into each
fitting
MPG - EP-O Grease
Sheaves and Sprockets 5 shots of grease into each
fitting
MPG - EP-O Grease
Carousel and Cups 5 shots of grease into each
fitting
MPG - EP-O Grease
Gearbox Driveshaft 5 shots of grease into each
fitting
MPG - EP-O Grease
J ohn Bean Water Injection
Pump
Check - Complete Pump SAE 30 Non-Detergent Oil
Batteries Check - Electrolyte Level Distilled Water
Check - Keep Terminals
cleaned and tight
Hoist (Winch) Periodic Inspection
Hoist (Winch) Wire Rope Periodic Inspection of wire
rope condition
Pump Drive Gearbox Inspect for Oil Leaks.
Clean Breather
Check - Oil Level 80W90 Gear Oil
Pump
Change the Initial Oil.
Clean the magnetic plug.
SAE 30 Non-Detergent Oil
Table 4: Maintenance at 100 to 150 Hours
Undercarriage Check - Final Drive
Mounting Bolts
Check for Final Drive Oil
Leaks
Check - Final Drive Oil
Level
Cat - SAE 50W / AC -
80W90 Gear Oil
Check - Track Tension Refer To Manufactures
Service Manual.
Track Adjustment
Hoist (Winch) Tighten Hoist (Winch)
Mounting Bolts
Track Planetary Gearbox Check - Final Drive
Mounting Bolts
Change - Planetary Final
Drive Initial Oil
80W90 Gear Oil
Engine Change - Engine Oil SAE 15W40 Engine Oil
Change - Engine Oil
Filter(s)
Kits Chart
Replace - Fuel Filter(s)
Replace - Coolant Filter(s) Refer to Engine Manual
(OEM Manual)
Check - Engine DCA/SCA
Level
Cat Engine Valve Lash -
Inspection and Adjustment
Refer to Engine Manual
(OEM Manual)
Engine Air Cleaners Replace Primary and
Safety Elements
Kits Chart
Compressor Air Cleaners Replace Primary and
Safety Elements
Kits Chart
Hydraulic Reservoir Change - Hydraulic Tank
Breather
Kits Chart
Hydraulic Oil Analysis ISO AW32
Pump Drive Gearbox Change - Oil 80W90 Gear Oil
Feed Cable & Wire Rope Clean and Lubricate Cable
and Rope
See Instructions Section 6
Compressor Air Hose/
Clamps
Inspect Air Hose,
Retighten Clamp Bolts
See Section 6
Hoist (Winch 8000#) Check - gear oil level 80W90 Gear Oil
Compressor Change - Compressor Oil
Filters
Kits Chart
Compressor Oil Analysis
Tower Feed Cables and
Chains
Check - Sag Distance
Receiver Tank Change Compressor Oil LP-150 (Low Pressure)
HP- 350 (High Pressure)
Hydraulics Replace Main Return Oil
Filter
Kits Chart
Replace Case Drain Oil
Filter
Rotary Head Change - Rotary Head Oil SAE 90W Gear Oil
Hoist (Winch) 8000 # Change - Oil 80W90 Gear Oil
Rod Changer Reducing
Gear
Change - Oil 80W90 Gear Oil
Table 8: Maintenance at 1500 - 2000 Hours
Table 9: Maintenance at 3000 Hours or 3 Years
Table 11: Maintenance at 6000 Hours or 2 Years
Receiver Tank Change Receiver
Separator Elements
Kits Chart
Compressor Air Discharge
Hose
Change - Discharge Hose
Track Planetary Gearbox Check - Final Drive
Mounting Bolts
80W90 Gear Oil
Change - Planetary Final
Drive Oil
Pump
Change - Oil. Clean the
magnetic plug.
SAE 30 Non-Detergent Oil
Coolant System Cat
Engines
Flush and Change See Actual Manufactures
Operation and
Maintenance Manual
Hydraulics Change Hydraulic Oil ISO AW32
Coolant System Cummins
Engines
Flush and Change See Actual Manufactures
Operation and
Maintenance Manual
6.3 - Refill Capacities / Lubricants
Hazardous Substance Precaution
The following information is provided to assist the owners and operators of Atlas Copco Drilling
Solutions Equipment. Further information may be obtained by contacting your Atlas Copco
Drilling Solutions Distributor.
The following substances are used in the manufacturing and operation of this drill and may be
hazardous to health if used incorrectly.
Table 12: Substance Hazards
Substance Precaution
Hydraulic Oil Avoid ingestion, skin contact and breathing fumes
Compressor Oil Avoid ingestion, skin contact and breathing fumes
Preservative Grease Avoid ingestion, skin contact and breathing fumes
Rust Preventive Avoid ingestion, skin contact and breathing fumes
SAE Gear Oil Avoid ingestion, skin contact and breathing fumes
Rock Drill Oil Avoid ingestion, skin contact and breathing fumes
Anti-Freeze Avoid ingestion, skin contact and breathing fumes
Engine Lubricating Oil Avoid ingestion, skin contact and breathing fumes
Engine Fuel Avoid ingestion, skin contact and breathing fumes
Battery(s) Avoid ingestion, skin contact and breathing fumes
Engine Exhaust Fumes Avoid breathing fumes.
Engine Exhaust Fumes Avoid buildup of fumes in confined spaces.
General Information
Lubrication is an essential part of preventive maintenance, affecting to a great extent the
useful life of the unit. Periodic lubrication of the moving parts reduces to a minimum the
possibility of mechanical failures.
Different lubricants are needed and some components in the unit require more frequent
lubricant than others. Therefore, it is important that the instructions regarding types of
frequency of the application be explicitly followed.
The lubrication chart that follows in this section shows those items requiring regular service
and the interval at which they should be performed. Details concerning oil and other lubricants
follow the lube chart. A regular service program should be geared to the items listed under
each interval. These intervals are based on average operating conditions. In the event of
extremely severe, dusty or wet operating conditions, more frequent lubrication than specified
may be necessary.
1. Specific recommendations of the brand and grade of lubricants are not made
here due to regional availability, operating conditions and also the continual
development of improved products. Where questions arise, refer to component
manufacturers manual and a reliable supplier.
2. All oil levels are to be checked with the drill parked on a level surface and while
the oil is cold, unless otherwise specified.
3. On plug type check points, the oil levels are to be at the bottom edge of the
check port.
4. All grease fittings are SAE Standard unless otherwise indicated. Grease the
non sealed fittings until grease is seen extruding from the fitting. One ounce (28
grams) of EP-MPG equals one pump on a standard one pound (0.45 kg)
grease gun.
5. Over lubrication on non sealed fittings will not harm the fittings or components,
but under lubrication will definitely lead to a shorter lifetime.
6. Unless otherwise indicated, items not equipped with grease fittings (linkages,
pins, levers, etc.) should be lubricated with oil once a week. Motor oil, applied
sparingly, will provide the necessary lubrication and help prevent the formation
of rust. An anti-seize compound may be used if rust has not formed. Otherwise,
the component must be cleaned first.
7. Grease fittings that are worn and will not hold the grease gun, or those that
have a stuck check ball, must be replaced.
To prevent minor irregularities from developing into serious conditions, several other
services or checks are recommended for the same intervals as the periodic lubrication.
1. Thoroughly wash all fittings, caps, plugs, etc. with a non-flammable, non-toxic
the service.
2. Lubricants must be at operating temperature when draining.
3. During regular lubrication service, visually check the entire unit with regard to
capscrews, nuts and bolts being properly secured.
4. Spot check several capscrews and nuts for proper torque. If any are found
loose, a more thorough investigation must be made.
5. If a defect is detected which requires special maintenance service, stop the drill
operation until the defect has been corrected. If necessary, contact the local
Atlas Copco Drilling Solutions distributor for assistance.
Lubrication Table
Periodic lubrication requirements are listed in the following Lubrication Chart. These
requirements include lubricant checks and greasing designated areas of the drill.
Table 13: Lubrication Chart
SERVICE
INTERVAL
DESCRIPTION SERVICE REMARKS QUANTITY
10 HOURS
OR DAILY
COMPRESSOR OIL ADD AS
NEEDED
LP-150 (Low Pressure) FILL TO MIDDLE OF
SIGHT GLASS
HP-350 (High
Pressure)
ENGINE OIL ADD AS
NEEDED
SAE 15W40 (Refer to
OEM Engine Manual)
FILL TO FULL MARK
GEARBOX
DRIVESHAFT
GREASE MPG - EP-O Grease 5 Shots Of Grease Into
Each Fitting
HYDRAULIC OIL ADD AS
NEEDED
ISO AW32 FILL TO FULL MARK
ROTARY HEAD OIL ADD AS
NEEDED
SAE 90W GEAR OIL FILL TO MIDDLE OF
SIGHT GLASS
ROTARY HEAD
GREASE
GREASE Extra HD Moly 2 Multi-
Purpose
ADD UNTIL RELIEF
POPS OUT
COOLING SYSTEM
(RAD & CAC)
ADD AS
NEEDED
50/50 - Water& Coolant
(Refer to OEM Engine
Manual)
FILL TO TOP OF THE
SIGHT GLASS
MANUAL LUBRICATION
POINTS (TOWER &
FRAME)
GREASE MPG - EP-O Grease 5 Shots Of Grease Into
Each Fitting
WATER INJ ECTION
PUMP (J OHN BEAN)
ADD AS
NEEDED
SAE 30W NON-
DETERGENT OIL
FILL TO BOTTOM OF
PLUG HOLE
50 HOURS PUMP DRIVE GEARBOX ADD AS
NEEDED
80W90 GEAR OIL FILL TO FULL MARK
ON DIPSTICK
TRACK PLANETARY
GEARBOX
CHECK CAT TRACKS-SAE
50W, AC TRACKS-
80W90 GEAR OIL
(REQUIRED
LUBRICANT)
FILL TO LEVEL HOLE
BATTERIES CHECK DISTILLED WATER FILL TO FULL MARK
WATER INJ ECTION
PUMP (J OHN BEAN)
CHANGE SAE 30W NON-
DETERGENT OIL
FILL TO BOTTOM OF
PLUG HOLE (1 QUART
or .95 LITERS)
150
HOURS
TRACK PLANETARY
GEARBOX
CHANGE CAT TRACKS-SAE
50W, AC TRACKS-
80W90 GEAR OIL
(REQUIRED
LUBRICANT)
APPROX. 2.1 GAL. (8.0
LITERS) PER FINAL
DRIVE
250
HOURS
ENGINE OIL AND
FILTERS
CHANGE SAE 15W40 (Refer to
OEM Engine Manual)
FILL TO FULL MARK
ON DIPSTICK
500
HOURS
PUMP DRIVE GEARBOX CHANGE 80W90 GEAR OIL 6.0 QUARTS (5.68
LITERS)
COMPRESSOR OIL
FILTERS
CHANGE LP-150 (Low Pressure) FILL TO MIDDLE OF
SIGHT GLASS
COMPRESSOR COMP.
OIL
ANLYSIS
LP-150 (Low Pressure) FILL TO MIDDLE OF
SIGHT GLASS
HYDRAULIC OIL HYD. OIL
ANLYSIS
ISO AW32 FULL MARK ON
HYDRAULIC TANK
(ALL CYLINDERS
RETRACTED)
HOIST (WINCH) 8000 # CHECK 80W90 GEAR OIL
FILL TO BOTTOM OF
FILL HOLE
1000
HOURS
RECEIVER TANK OIL CHANGE LP-150 (Low Pressure) FILL TO MIDDLE OF
SIGHT GLASS
HYDRAULIC FILTERS CHANGE ISO AW32 APPROX. 110 GALLON
(416 LITER) FULL
MARK ON HYDRAULIC
TANK (ALL
CYLINDERS
RETRACTED)
ROTARY HEAD OIL CHANGE SAE 90W GEAR OIL FILL TO MIDDLE OF
SIGHT GLASS 7.5 - 8
GALLON (28 - 30
LITERS)
SERVICE
INTERVAL
Refill Capacities
The following fluid capacities are provided for servicing personnel who must perform drill
maintenance in remote locations where complete shop facilities and resources are not
available. These capacities will give the servicing personnel an approximation of the fluid
capacities of the components to be serviced. Always ensure that the specified method of
checking for accurate fluid levels is used.
Table 14: Capacities
1000
HOURS
HOIST (WINCH) 8000 # CHANGE 80W90 GEAR OIL FILL TO BOTTOM OF
FILL HOLE
ROD CHANGER
REDICING GEAR
CHANGE
80W90 GEAR OIL FILL TO BOTTOM OF
FILL HOLE
1500-2000
HOURS
TRACK PLANETARY
GEARBOX
CHANGE CAT TRACKS-SAE
50W, AC TRACKS-
80W90 GEAR OIL
(REQUIRED
LUBRICANT)
325 L / 330 S / 330 L
2.1 GAL. (8.0 LITERS),
ACGT 2500 / 3000 S/
3000 L 2.1 GAL (8.0
LITERS) PER FINAL
DRIVE
COMPRESSOR OIL CHANGE LP-150 (Low Pressure) FILL TO MIDDLE OF
SIGHT GLASS
RECEIVER TANK
ELEMENT
CHANGE LP-150 (Low Pressure) FILL TO MIDDLE OF
SIGHT GLASS
J OHN BEAN WATER
INJ ECTION PUMP OIL
CHANGE SAE 30 NON-
DETERGENT
BOTTOM OF PLUG
HOLE (1 QUART or .95
LITERS)
3000
HOURS
COOLANT SYSTEM
FLUID (CAT ENGINE)
FLUSH /
CHANGE
CAT ELC OR CAT
DEAC
TOP OF SIGHT GLASS
5000
HOURS
HYDRAULIC OIL CHANGE ISO AW32 110 GALLON (567
LITER)
6000
HOURS
COOLANT SYSTEM
FLUID (CUMMINS
ENGINE)
FLUSH /
CHANGE
50 / 50 MIX
(DEIONIZED WATER /
ANTIFREEZE)
TOP OF SIGHT GLASS
APPROXIMATE CAPACITIES
COMPONENT APPROXIMATE QUANTITY
SYSTEMS
Engine Manufacture and Type:
SERVICE
INTERVAL
Cat C-15 (SAE 15w40 Refer to OEM
Engine Manual)
40 qts. (38 liters)
Cat C18 (SAE 15w40 Refer to OEM
Engine Manual)
40 qts. (38 liters)
Cat C-27 (SAE 15w40 Refer to OEM
Engine Manual)
58 qts. (55 liters)
Cummins QSK-19 (SAE 15w40 Refer to
OEM Engine Manual)
72 qts. (68 liters)
Cummins QSX-15 (SAE 15w40 Refer to
OEM Engine Manual)
48 qts. (45 liters)
Radiator - Engine Coolant 44 gallon (166.55 liters)
Fuel Tank (#1 and #2-D S15 ULSD) 350 gallon (1,325 liters)
Hydraulic Tank (ISO AW32): 82 gallon (310 Liter)
Receiver Tank Oil:
LP-150 - Low Pressure
HP-350 - High Pressure
Low Pressure Tank 32.5 gallon (123
liters)
High Pressure Tank 20 gallon (72 liters)
Rotary Head Oil (SAE 90W Gear Oil): 7.5 - 8 gallon (28-30 liters)
Pump Drive Gearbox (80W90 Gear Oil): 6.0 quarts (5.68 liters)
Water Injection Pump (SAE 30W Non-
Detergent Oil):
1.0 quart (0.95 liters)
Hoist (Winch) 8000#(80W90 Gear Oil) 4.0 pints (1.9 liter)
Rod Changer Reducing Gear (80W90
Gear Oil)
Track Final Drive (CAT TRACKS- SAE 50W, AC TRACKS- 80W90 GEAR OIL)
CAT 325 L Final Drive Gearbox
2.1 gallon (8.0 liters) per drive
CAT 330 S Final Drive Gearbox
CAT 330 L Final Drive Gearbox
ACGT 2500 Final Drive Gearbox
2.1 gallon (8.0 liters) per drive
ACGT 3000 S Final Drive Gearbox
ACGT 3000 L Final Drive Gearbox
APPROXIMATE CAPACITIES
Atlas Copco Recommended Oils and Lubricants
NOTICE
Use Atlas Copco Branded Oils and Lubricants where Applicable.
Anti-Freeze
Anti-Freeze is a permanent type Ethylene Glycol base with rust inhibitor and pump lubricant.
Coolant is normally composed of three elements: water, additives and glycol.
Water
Water is used in the cooling system to transfer heat. Distilled or deionized water is
recommended for use in the engine cooling systems. DO NOT use the following types of water
in cooling systems: hard water, softened water that has been conditioned with salt, and sea
water. If distilled water or deionized water is not available, use water with the properties that
are listed in the following table.
Table 15: Water Requirements
Additive
Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives
or insufficient amounts of additives enable the following conditions to occur: corrosion,
formation of mineral deposits, rust, scale, pitting and erosion from cavitation of the cylinder
liner and foaming of the coolant. Additives must be added at the proper concentration.
Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits
can enable the following problems to occur:
Formation of gel compounds
Reduction of heat transfer
Leakage of the water pump seal
Plugging of radiators, coolers and small passages
Minimum Acceptable Water Requirements
Property Maximum Limit
Chloride (Cl): 40 mg/L (2.4 grains/US gallon)
Sulfate (SO): 100 mg/L (5.9 grains/US gallon)
Total Hardness: 170 mg/L (10 grains/US gallon)
Total Solids: 340 mg/L (20 grain/US gallon)
Acidity: pH of 5.5 to 9.0
Glycol
Glycol in the coolant helps to provide protection against the following conditions: Boiling,
Freezing and Cavitation of the water pump and the cylinder liner. For optimum performance,
use a 1:1 mixture of a water/glycol solution.
CATERPILLAR ENGINES;
Refer to Cat Operation and Maintenance Manual, Refill Capacities and Recommendations.
There are two primary coolants used in Caterpillar Engines:
Preferred - Cat ELC (Extended Life Coolant) or a commercial extended life coolant
that meets the Caterpillar EC-1 specifications.
Acceptable - Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-
duty coolant/antifreeze that meets ASTM D4985 or ASTM D5345 specifications.
NOTE: Cat DEAC DOES NOT require a treatment with SCA at the initial fill. Commercial
heavy-duty coolant/antifreeze that meets ASTM D4985 or ASTM D5345 specifications
MAY require a treatment with an SCA at the initial fill. Read the label or the instructions that
are provided by the OEM of the product.
Caterpillar recommends a 1:1 mixture of water and glycol. This mixture will provide optimum
heavy-duty performance as a coolant/antifreeze.
CUMMINS ENGINES;
Refer to Cummins Operation and Maintenance Manual, Refill Capacities and
Recommendations. There are two primary coolants used in Cummins Engines:
A 50/50 mixture of good-quality water and fully formulated anti-freeze.
Fully formulated coolant.
NOTE: The coolant or fully formulated anti-freeze must meet TMC RP 329 or TMC RP 330
specifications.
Compressor Oil (Standard)
Low Pressure (LP-150) Compressor Oil
Table 16: Low Pressure Compressor Oil Ranges
Compressor Operating Pressure Range PSI 100-300
Ambient Temperature Range, Upper Limit Degrees F (C ) 125 (52)
Ambient Temperature Range, Lower Limit Degrees F (C ) -10 (-23)
Table 17: Low Pressure Compressor Oil Properties
High Pressure (HP-350) Compressor Oil
Table 18: High Pressure Compressor Oil Ranges
Table 19: High Pressure Compressor Oil Properties
Viscosity
cSt @ 40 C (104 F) 35.3
cSt @ 40 C (104 F) 7.4
cSt @ -40 C (-40 F) 16.67
Viscosity Index 183
Flash point, C (F) 180 (356)
Gravity, API 32
Colour RED
ISO Viscosity Grade 46
Compressor Operating Pressure Range PSI 300-400
Ambient Temperature Range, Upper Limit Degrees F (C ) 125 (52)
Ambient Temperature Range, Lower Limit Degrees F (C ) -10 (-23)
ISO Grade ASTM 68
Product Number 259138
API Gravity D 287 35.9
Viscosity, Kinematic D 445
cSt at 40C (104F) 64.6
cSt at 100C (212F) 10.4
Viscosity, Saybolt D 445
SUS at 100F (38C) 330
SUS at 210F (99C) 61.7
Viscosity Index D 2270 150
Flash Point, C (F) D 92 254 (489)
Pour Point, C (F) D 97 -42 (-44)
Compressor Oil (Arctic)
This Arctic compressor oil is used in both Low Pressure (LP) and High Pressure (HP)
DM45,50,DML drills. The oil is a high performance synthetic universal ATF oil used in cold
temperature.
Table 20: Arctic Compressor Oil Properties
Color, ASTM D 1500 L 0.5
Copper Corrosion 3 h at 121C (250F) D 130 1B
Water Separability, D 1401 15
Minutes to 0 mL emulsion
Foam Tendency / Stability, mL/mL D 892 10/0
Sequence I
Oxidation Stability
Hours to 2.0 mg KOH/g acid number
a
D 943 18,000+
Minutes to 25 psi pressure drop D 2272 1800
Physical Characteristics
Product Number 52470-2
Gravity, API 37.3
Specific Gravity 0.838
Pour Point, C (F) -54 (-65)
Flash Point, min.,C (F) 216 (420)
Viscosity
cP at -40F (-40C) 7,380
cP at -10F (-24C) 1210
cP at 0F (-18C) 740
SUS at 100F (38C) 144
SUS at 210F (99C) 45
cSt at 40C (104F) 29.4
cSt at 100C (212F) 5.7
ISO Grade ASTM 68
Hydraulic Oil (Standard)
The quality of the hydraulic oil is important to the satisfactory performance of any hydraulic
system. The oil serves as the power transmission medium, system coolant and lubricant.
Selection of the proper oil is essential to ensure proper system performance and life.
Grade AW32 is a general specification. Grade ISO AW32 is a general specification.
NOTICE
Hydraulic oil must conform to Parker Hydraulic Pump Division HF-O
Standards (4-11-78) and ISO Viscosity Grade 32.
Table 21: Hydraulic Oil Specification
Hydraulic Oil (Arctic)
Table 22: Arctic Hydraulic Oil Specification
Viscosity Index 136
Color RED
AW32 HYDRAULIC OIL
ISO
Viscosity
Grade
Flash C
(F),(D92)
Pour C
(F)
Viscosity Viscosity
Index
SAE
Grade
(Approx.)
cSt at
40C
(104F)
cSt at
100C
(212F)
32 225 (437) -37 (-35) 36.5 7.1 162 5W-20
SYNTHETIC HYDRAULIC OIL 524 525
ISO Viscosity Grade 32 46
Viscosity, ASTM D 445
cSt @ 40C (104F) 32 46
cSt at 100C (212F) 6.4 8.54
Brookfield Viscosity @ -18C (0F), ASTM D 2983, cP 923 1376
Viscosity Index, ASTM D 2270 144 154
Density 15C, ASTM D 4052, kg/L 0.852 08514
Engine Oil
For latest applicable engine lubricating oil specifications, Refer to Engine Operation and
Maintenance Manual, contact the engine manufacturer, your distributor or your local Drilling
Solutions distributor. Drills leave the factory with SAE 15W40 OIL.
Engine oil must meet or exceed the following performance requirements: SAE Viscosity 15W-
40, API Service Class CD, MIL-L-2104C.
Table 23: Engine Oil Specifications
Copper Strip Corrosion, ASTM D 130, 3 hours @ 100C 1B 1B
Rust Characteristics, ASTM D 665B Pass Pass
FZG Gear Test, Din 51534, Fail Stage II II
Pour Point, C, ASTM D 97 -54 -54
Flash Point, C, ASTM D 92 234 238
Foam Sequence I, II, III, ASTM D 893 ml 50/0 50/0
Viscosity SAE Grade 15W-40
Gravity
Specific @ 60F (15.6C) 0.881
API 29.1
Flash Point, C (F) Min. 205 (400)
Pour Point, C (F) -33 (-27)
Color 4.0
Viscosity
cSt @ 40C 118
cSt at 100C 15.8
Viscosity Index 136
High Temperature/High Shear Vis., cP 4.3
Low Temperature Viscosity
Vis (cP) at Temperature (C) 6,400 @ -20
Low Temperature Pumping, cP.(C) 23,000 @ -25
Sulfated Ash Content, % wt. 1.3
Shear Stability, % Vis Loss <4.0
Gear Oil
Table 24: Gear Oil Specifications
Unless otherwise specified, SAE-80W-90 gear oil viscosity may be used for year round
service. Low temperature usage is restricted as follows:
Table 25: PUMP DRIVE GEAR OIL
Final Drive Oil (Tracks)
Cat tracks use SAE 50w oil and Atlas Copco tracks use 80W-90 Gear Oil.
Normal Operating Conditions
The actual manufacturer recommends only using lubricants that fulfill necessary viscosity
requirements for lubricating the final drives.
The viscosity rating on the rating plate on the final drive and the following requirements must
be observed: Use only lubricants with viscosity ratings for ISO VG150 and ISO VG220 for
normal operating conditions from 50F to 86F (+10C to +30C).
SAE Grade 80W-90
Viscosity, ASTM D 445
cSt @ 40C 136
cSt @ 100C 14.5
Viscosity Index, ASTM D 2270 105
Pour Point, C, ASTM D 97 -30
Flash Point, C, ASTM D 92 202
Density @ 15C kg/l, ASTM D 4052 0.897
PUMP DRIVE EXTREME PRESSURE GEAR OIL
SAE Viscosity Number Minimum Ambient Temp.F (C)
75W -40F (-40C)
80W -15F (-26C)
85W +10F (-12C)
90W +20F (-7C)
140W +40F (+5C)
250W +50F (+10C)
Severe Operating Conditions
Under severe operating conditions, e.g. in an ambient temperature range between -22F and
122F (-30C and +50C), the actual manufacturer recommends using transmission oil with
appropriate viscosity or a fully synthetic lubricant.
For lower operating temperatures, use oil with a lower viscosity (SAE 80W-90) and
for higher temperatures, use oil with a higher viscosity (SAE 85-140).
Grease
EP-O Grease
The recommended operating temperature range is from -20C to 130C but they may be used
at higher temperatures if the lubrication frequency is increased accordingly.
Table 26: EP Grease Specifications
Multi-Purpose Grease
This grease has a high level of chemical stability and offer excellent protection against rust and
corrosion. This grease feature is a high dropping points and maximum recommended
operating temperature of 140 C (284F). Multi-purpose grease is formulated with an ISO VG
460 base oil viscosity.
NLGI Grade O
Soap Type Lithium
Color Med. Brown
Structure Smooth
Penetration, Worked 370
Dropping Point, C 180
Viscosity of Oil
cSt at 40C 150
Timken OK Load, Kg 18
4-Ball Weld, Kg 250
4-Ball Wear, Scar mm 0.4
Emcor Distilled Water
Washout Test 0-0
Table 27: Multi-Purpose Grease Specifications
Diesel Fuel
Cat Engines
Caterpillar recommends that all distillate diesel fuel, including ULSD fuel (fuel less than or
equal to 15 ppm sulfur using ASTM D 2622 or DIN 51400) meet the requirements of the
Caterpillar Specifications for Distillate Diesel Fuel.
In North America, diesel fuel that is identified as No. 1-D or No. 2-D in ASTM D975 generally
meet the specifications. Caterpillar recommends diesel fuels that are distilled from crude oil.
Diesel fuels from other sources could exhibit detrimental properties that are not defined or
controlled by this specification.
S15 (ULSD) is defined by the U.S. Environmental Protection Agency (EPA) as U.S. diesel fuel
with a sulfur content not to exceed 15 ppm (parts per million). S15 and S500 are designations
for diesel fuels that meet 15 ppm and 500 ppm maximum sulfur content, respectively, as
defined in the American Society for Testing and Materials (ASTM standard D975 Table 1). In
different regions of the world ULSD may refer to different maximum sulfur content values, but
ULSD and S15 are often used interchangeably in North America (U.S. and Canada). The S15
and S500 designations also apply to the Canadian diesel market.
NLGI Grade 2
Thickener Type Li-Complex
Color, Visual Dark Blue
Penetration, Worked, 25 C, ASTM D 217 280
Dropping Point, C, ASTM D 2265 280
Viscosity of Oil, ASTM D 445
cSt @ 40 C 460
4-Ball Wear Test, ASTM D 2266, scar, mm 0.50
4-Ball Weld Load, ASTM D 2509, Kg 315
Timken OK Load, ASTM D 2509, lb. 50
Bomb Oxidation, ASTM D 942, Pressure drop at
100 hrs, kPa (psig)
13.8 (2)
Corrosion Prevention, ASTM D 1743 Pass
Rust Protection (EMCOR), IP 220-mod/ASTM D
6138., Distilled Water
0,0
Copper Strip Corrosion, ASTM D 4048 1a
Notice: Operating with fuels that do not meet Caterpillars recommendations can cause the
following effects: starting difficulty, poor combustion, deposits in the fuel injectors, reduced
service life of the fuel system, deposits in the combustion chamber and reduced service life of
the engine.
Table 28: Requirements for Diesel Fuel (ASTM D975-97)
Cummins Engines
Cummins Engine Company recommends the use of ASTM No. 2D fuel. The use of No. 2
diesel fuel will result in optimum engine performance. At operating temperatures below 32F
(0C), acceptable performance can be obtained by using blends of No. 2D and No. 1D. The
use of lighter fuels can reduce fuel economy.
Grade Grade Grade Grade
Property LS #1 LS #2 No. 1-D No. 2-D
Flash Point C, min. 38 52 38 52
Water and sediment,% vol, max. 0.05 0.05 0.05 0.05
Distillation temp., C, 90% (Min.) - 282 - 282
Distillation temp., C, 90% (Max.) 288 338 288 338
Kinematic Viscosity, mm2/s at 40C (Min.) 1.3 1.9 1.3 1.9
Kinematic Viscosity, mm2/s at 40C
(Max.)
2.4 4.1 2.4 4.1
Ramsbottom carbon residue, on 10%,%
mass, max.
0.15 0.35 0.15 0.35
Ash,% mass, max. 0.01 0.01 0.01 0.01
0.10
Sulfur,% mass, max 0.05 0.05 0.05 0.50
2.00
Copper Strip Corrosion. Max 3 hours at
50C.
No. 3 No. 3 No. 3 No. 3
Cetane Number, min. 40 40 40 40
One of the following properties must be met:
Property LS #1 LS #2 No. 1-D No. 2-D
(1) Cetane index 40 40 - -
(2) Aromaticity,% vol, max 35 35 - -
The viscosity of the fuel must be kept above 1.3 cSt at 212F (100C) to provide adequate fuel
system lubrication.
Cummins diesel engines have been developed to take advantage of the high energy content
and generally lower cost of No. 2 Diesel Fuels. Experience has shown that a Cummins diesel
engine will also operate satisfactorily on No. 1 fuels or other fuels within the specifications
shown in the following table.
Table 29: Cummins Specification for Distillate Diesel Fuel
Specifications Requirements ASTM Test
Viscosity 1.3 TO 4.1 Centistokes per second at
104F (1.3 to 4.1 mm per second at 40C)
D-445
Cetane Number 40 minimum above 0C (32F) (exception:
in cold weather or in service with prolonged
idle, a higher cetane number is desirable)
D-613
Sulfur Content Not to exceed 0.05 mass percent for
engines without after treatment devices.
For engines with after treatment devices,
sulfur content can not exceed 0.0015 (15
ppm) mass percent.
ASTDMD129
or 1552
Active Sulfur Copper Strip Corrosion not to exceed
Number 3 rating after three hours at 50C
(122F)
ASTM D130
Water and Sediment Not to exceed 0.05 percent by volume ASTM D1796
Carbon Residue Not to exceed 0.35 mass percent on 10
volume percent residuum.
Rams bottom
ASTM D524 or
Conradson
ASTM D189
Density 42 to 30 API gravity at 0.816 to 0.876 g/
cc at 15C (60F)
ASTM D287
Cloud Point 10F (6C) below lowest ambient temp at
which the fuel is expected to operate
ASTM D97
Ash Not to exceed 0.02 mass percent (0.05
mass percent with lubricating oil
blending). Oil blending is prohibited on
engines with after treatment devices.
ASTM D482
Distillation The distillation curve must be smooth and
continuous.
ASTM D86
Acid Number Not to exceed 0.1 mg KOA per 100 ml. ASTM D664
6.4 - Maintenance As Required
General Information
WARNING
!
before you operate or perform any maintenance, service or repair on the
drill.
and understand Section 4 - Operating Controls.
Safety should be the main concern for anyone working on or around the
drill. Do not perform any function that could put someone in danger.
Always wear correct safety gear while working on or around the drill. This
includes an approved hard hat, safety glasses, steel toe shoes/boots,
that can become caught on rotating components.
4. If drill is equipped with a remote control system option, always use it from a safe
location when propelling on unstable surfaces where there may be a risk of
overturning, or when loading onto a transporter where there is a risk of
overturning.
crushing risk.
7. Before starting the engine on the drill, always check to see that the drill/propel
mode selector is in the drill position and both joystick control levers are in
neutral position and that the track brakes are applied.
8. Always sound the horn before moving the drill in either direction to alert
Service As Required
The following maintenance in this MAINTENANCE AS REQUIRED section requires attention
on an as needed basis before, during and after the drill operation shift. This is in addition to
the 8-10 hour daily routine maintenance procedures. Performance of this inspection can result
in longer life and maximum productivity from the drill.
Clean the Drill
The complete drill must be given a weekly cleaning. Daily cleaning will be required if material
is adhering to the tower or track working parts.
1. Make sure that the inside of the operators cab, decking, steps and grab rails
are clean. Oil, grease, snow, ice or mud in these areas can cause you to slip
and fall. Clean your boots of excess mud before getting on the drill.
2. Check that no material or debris is jammed between track sprockets and track
tensioners.
3. Check the tower feed installation for debris buildup around the sheaves.
4. Thoroughly wash all fittings, caps, plugs, etc. with a nonflammable, non-toxic
the service.
NOTICE
Protect all electric components and control panels against entry of water
or steam when using high pressure cleaning methods. Cover the
hydraulic fill cap breathers located on top of tank.
5. After cleaning, check for defects in the air cleaner ducts.
a. Check intake for accumulation of debris that could restrict air flow.
b. Check air cleaner mounting hardware for security.
c. Check all hoses for cracks, chafing or deterioration and replace at the first
sign of probable failure.
Loose Bolted Connections
If any loose nuts or bolts are found during the frequent walk-around and the daily inspections,
ensure they are properly torqued. Refer to Torque Specifications for the required torque
for all bolt sizes and grades. Always replace self-locking nuts if they have been loosened.
Feed Cable & Wire Rope
The wire rope industry recognizes the ASME (American Society for Mechanical Engineers)
standards for the criteria to set the end of the service life of wire ropes on cranes and towers,
based on visible indicators of wire rope deterioration.
Replacement Guideline
The standards for cranes and towers allow six (6) broken wires in a wire rope lay length, or
three (3) broken wires in one strand, in a wire rope lay. The lay length is 5.5 times the wire
rope diameter (B30.4-B30.8).
The overhead hoist standard criteria is twelve (12) broken wires in a wire rope lay length, or
four (4) broken wires in one strand per lay length (B30.2 and B30.16).
There is no industry wide recognized standard for wire rope on drills, but the above standards
can be used as a guide to determine a safe practical point for wire rope replacement. Cable
feed on the pullback side on a drilling derrick, as the cables support the drill pipe string and
the rotary transmission devise. The cable feed on the pulldown side of the drill does not reflect
any of the ASME standard conditions. The only load these cables see is the hydraulically
applied loads. There is no dead weight being supported and no component free fall will occur
due to complete failure of the rope. However, a tension rope failure is possible, so replacement
should not be delayed beyond the above determined replacement point.
Also, note that any broken wires protruding from the wire rope create a snagging hazard.
These wires should be trimmed flush to the wire rope diameter. These trimmed broken wires
need to be recorded and logged as to their exact locations as part of the broken wire count
criteria for determining wire rope replacement.
Figure 6-1
Figure 6-1 shows the wire rope broken down. The wire rope is made up of strands woven
around a core. Each strand is made up of individual wires. If a rope breaks four (4) wires from
the same strand within the lay length, it should be replaced according to ASME standards.
One lay length is the distance along the wire rope that it takes one strand to make one
revolution. The diameter of a wire rope is taken at the highest points. It is NOT taken across
the flats of the strands.
Feed Cable Replacement
Refer to the parts manual for your specific drill serial number to ensure the correct feed cables,
anchors, clamps and hardware are used. Do not substitute. Do not reuse cable anchors or
clamps.
Replace wire rope when any of the following conditions are met:
1. Six randomly distributed broken wires are found in one lay
2. The outside wires are worn more than one third (1/3) of their original diameter
3. There is evidence of heat damage of any kind
4. The wire rope is kinked or damaged.
Wire Rope
Winch ropes, including their anchorage and other load carrying components of the winch
system, e.g. sheave bearings, rope sheaves and drill hooks, shall be checked at least once a
week.
Wire ropes shall be examined and discarded in accordance with 3.5 of ISO 4309:1990. In table
3.5 of ISO 4309:1990, classification groups M1 and M2 shall be used. On drill rigs with normal
hook load of more than 1000KN, the winch rope shall be regularly paid out and shortened
according to a plan laid down by the manufacturer on basis of experience.
Wire rope used in drilling operations becomes unusable because of wear and wire breakage
and should be discarded according to certain criteria.
1. Replace when four (4) randomly distributed broken wires are found in one lay.
2. Replace when wire rope shows wear of one third (1/3) of the original diameter
of the outside wire.
3. Replace when evidence of any heat damage from any cause is found.
4. Replace when any kinking or cracking occurs.
Winch Wire Rope Installation
WARNING
!
The cable clamp is not designed to hold the full load alone. NEVER
attempt to lift a load with less than five (5) wraps of cable on the drum.
Unless a revolving stand is available, we recommend unwinding the cable coil prior to
installing on winch drum. This prevents the cable from becoming twisted during the winding
operation.
Figure 6-2
Take the free end of the wire rope and insert it through the small opening of the anchor pocket.
Loop the wire rope and push the free end about 3/4 of the way back through the pocket. Install
the wedge, then pull the slack out of the wire rope. The wedge will slip into the pocket and
secure the wire rope into the drum. The anchor is designed to accommodate several sizes of
wire rope. You may anchor 3/8 inch and 7/16 inch (10mm and 11mm) wire rope by inserting
the wedge large end first. You may anchor 1/2 inch and 9/16 inch (13mm and 14mm) wire rope
by inserting the wedge small end first (See Figure 6-2).
1. Wind cable onto the drum.
a. Leather gloves should be used when handling winch cable.
b. The cable winds in on TOP of the winch drum. Care should be taken to wind
the cable on the winch drum as evenly and as tight as possible.
2. Always use two persons when winding the cable onto the winch drum; one
person to operate the controls and the other to guide the cable from a safe
distance to obtain as level a winding job as possible.
3. When winding the winch cable on the winch drum, never attempt to maintain
tension by allowing winch cable to slip through hands. Always use hand-over-
hand technique.
3600# Winch Wire Rope, Ball and Hook (Standard)
The cable is a one (1) piece cable, their is no cable clamps, it has a crimped sleeve. There is
a permanently attached ID tag between ball and hook which contains mfg. date, serial #,
length, size, material, maximum working load and CE mark information (See Figure 6-3).
Information on the ball, wire rope and hook;
1. 8 mm (5/16) Wire rope, 35 x 7 compacted strand, right lay, galvanized rotation
resistant, 2160 grade.
2. McKissick SHB 20 split ball.
3. 3/8 Galvanized, heavy duty thimble.
4. Swivel safety hook, CE
5. Stainless steel one (1) piece duplex sleeve.
Figure 6-3
8000# Winch Wire Rope, Ball and Hook (Option DML Only)
Information on the cable clamp, wire rope and hook;
1. 1/2 (12.7 mm) Wire rope, 19 x 19 classification, normal breaking strength 14.6
tons.
2. 1/2 Galvanized, heavy duty thimble.
3. Swivel safety hook
4. Cable (wire rope) clamps, 1/2 forged steel base hot dip galvanized finish.
Wire Rope Clamps
Incorrect installation of the rope clamps can cause premature rope failure and/or possible
bodily injury (See Figure 6-4).
Nuts should always be retightened after the initial load has been applied.
Figure 6-11
A termination made in accordance with the following instructions and using the number of clips
shown has an approximate 80% efficiency rating. This rating is based upon the catalog
breaking strength of wire rope. If a pulley is used in place of a thimble for turning back the rope,
add one additional clip.
The number of clips shown is based upon using right regular or Lang lay wire rope, 6 X 19
Class or 6 X 37 Class, fibre core or IWRC, IPS or XIPS.
The number of clips shown also applies to right lay wire rope, 8 X 19 Class, fibre core, IPS,
sizes 1-1/2 inch and smaller; and right regular lay wire rope, 18 X 7 Class, fibre core, IPS and
XIPS, sizes 1-3/4 inch and smaller.
The important things are using proper thimble size, number of clamps and size, and installing
them properly. Refer to drawing Figure 6-4 and Wire Rope Clamp Torque Specification.
Table 30: Wire Rope Clamp Torque Specifications
Correct Usage of Wire Rope Clips
Dimensions are in inches and approximate
Clip Size Inches
Minimum Number
of Clips
Amount of Rope
to Turn Back in
Inches
Torque in Foot
Pounds
1/8 2 3-1/4 -
3/16 2 3-3/4 -
1/4 2 4-3/4 15
5/16 2 5-1/2 30
3/8 2 6-1/2 45
7/16 2 7 65
1/2 3 11-1/2 65
9/16 3 12 95
5/8 3 12 95
3/4 3 18 130
7/8 4 19 225
1 5 26 225
1-1/8 6 34 225
1-1/4 6 37 360
1-3/8 7 44 360
1-1/2 7 48 360
1-5/8 7 51 430
1-3/4 7 53 590
2 8 71 750
2-1/4 8 73 750
2-1/2 9 84 750
2-3/4 10 100 750
3 10 106 1200
Correct Usage of Wire Rope Clips
Dimensions are in inches and approximate
Clip Size Inches
Minimum Number
of Clips
Amount of Rope
to Turn Back in
Inches
Torque in Foot
Pounds
Feed Cable/Chain Adjustment
To prevent cables from unwinding while the cable is being adjusted, install a 1-1/2 open end
wrench on the stud end of the cable to prevent it from turning. If the cable is allowed to unwind,
it will require frequent adjustments that will use up all the adjusting threads. Holding the cable
while tightening will insure proper adjustment and a longer cable life.
Figure 6-5
1. Move the rotary head to the top of the tower.
2. There are two lock nuts on the front end of the stud and one lock nut on the
rear. The proper procedure for adjusting the cable is to loosen the front lock nut
several turns to allow the cable to be tightened. Next, loosen the outside rear
lock nut to allow the adjusting nut to be able to rotate. Holding the stud end with
a wrench, tighten the adjusting nut against the support. This action pulls the
cable and shortens its length. When the sag in the center of the cable is about
1/2, move the rear locking nut up behind the adjusting nut and tighten them
together. Next, move the front locking nut up until it is touching the support and
tighten securely (See Figure 6-5).
Figure 6-6
3. With the tower horizontal, verify cable slack adjustment. It should be 1-3/4 to
1-7/8 Per Engineering Drawing, from the center of the cable to the bottom of
the main chord (5 x 3 guide tube), at the center of the tower with the rotary head
at the top stop (See Figure 6-6).
4. The cable should NOT rotate as the rotary head travels up and down the tower.
When the adjustment threads are all used up, the cable needs to be replaced.
Cable Lubrication
Lubrication of the feed cables should be included in the maintenance schedule. Cables should
be cleaned with a wire brush and solvent and lubricated approximately every 500 hours. The
lubricant can be applied with either a spray or a brush and is recommended for protection
against corrosion only.
Grease Drum Option
On drills equipped with a automatic lubrication system option, changing the 120 lb. (54.4 kg )
grease drum is an As Required maintenance item. The type of grease required is MPG - EP-
O grease (See Figure 6-7). The Timer/Controller is located inside the cab, on the wall by the
tower side door (See Figure 6-8). A flashing light will signal when the grease drum is empty
and needs to be replaced.
Figure 6-7
Change Grease Drum
WARNING
!
Do not attempt to service the lubrication system when the drill is running.
Shut off the engine and relieve air pressure.
1. Undo the drum tie downs.
2. Remove the pump, cover and follower.
3. Replace the used grease drum with a new grease drum. (Use a man-lift to
place new grease drum on to the deck or platform.) Dispose of the used grease
drum in accordance with local guidelines and regulations.
4. Reattach the follower, drum cover and pump.
5. Start the engine. When the compressor is turned on, the lube cycle will begin.
NOTE: Drill running, supply air to the system has to be grease purged. Air supply at the air
regulator assembly is adjusted to 80 PSI.
WARNING
!
Electrical shock hazard. Turn off and lock out power before opening
Timer/Controller enclosure.
Figure 6-8
Auto Thread Lube / Thread Greaser Option
WARNING
!
Do not attempt to service the Thread Grease system when the drill is
running. Shut off the engine and relieve air pressure.
On drills equipped with a automatic thread lube/thread greaser system option, changing the
35 lb. (15.9 kg ) grease bucket is an As Required maintenance item. The type of grease
required is Zinc 50 (NLGI Grade 15-2) grease (See Figure 6-9).
Figure 6-9
1. Remove the pump and cover by loosening the three thumb screws.
2. Replace the used grease bucket with a new grease bucket. (Use a man-lift to
place new grease bucket on to the deck or platform.) Dispose of the used
grease bucket in accordance with local guidelines and regulations.
3. Reattach the cover and pump.
4. Start the engine. When the compressor is turned on, the lube cycle will begin.
6.5 - Maintenance (8-10 Hours)
General Information
WARNING
!
drill.
Safety should be the main concern for anyone working on or around the
drill. Do not perform any function that could put someone in danger.
Always wear correct safety gear while working on or around the drill. This
includes an approved hard hat, safety glasses, steel toe shoes/boots,
that can become caught on rotating components.
overturning.
crushing risk.
7. Before starting engine on the drill, always check to see that the drill/propel
Overpressure Control System Test
WARNING
!
The Over Pressure Control DOES NOT relieve the operator from the
responsibility of having control of the drill at all times. While the Over
Pressure Control reduces the chance of a tip over, the operator must see
that he does not over feed the drill to this extent.
NOTICE
The operator must ensure the jacks are located on firm ground. Nothing
can prevent the drill from upsetting if the ground or shoring under the
jacks gives way.
NOTICE
LIABILITY FOR TIPPING A UNIT OVER LIES SOLELY WITH THE DRILLER.
Over Pressure System Test
Do not test the Overpressure Control System with a drill pipe in the rotary head. Only test the
system with the rotary head against the lower tower stops.
Step One:
Level the drill with the tracks about 1-2 inches (25.4 - 50.8 mm) off the ground. The
drill weight must be fully supported by the leveling jacks.
Step Two:
Raise the tower and pin it in the vertical position.
Step Three:
Feed the rotary head down against the bottom stops of the tower.
Step Four:
Slowly increase pulldown pressure to maximum pulldown pressure.
Step Five:
Slowly lift the cab side leveling jack off the ground. Feed pressure must drop
immediately below 500 psi when the jack pad is lifted. The rotary head will normally
travel upwards slightly when pressure vents. If pressure vents immediately, go on to
step six.
If feed pressure does not drop below 500 psi, reduce system pressure with the feed
controls, fix the problem or contact your supervisor for system repairs immediately.
Step Six:
Repeat steps 4 and 5, this time raising the dust collector side jack slightly. If pressure
drop immediately below 500 psi when the jack pad is lifted slightly off the ground, the
system is working.
If feed pressure does not drop below 500 psi, reduce system pressure with the feed
controls, fix the problem or contact your supervisor for system repairs immediately.
Engine and Compressor Air Cleaner
Air Cleaners must be checked daily as part of the 8-10 hour routine maintenance procedure.
Check the air cleaner service indicator, connections and ducts, and empty dust cup daily.
When restriction indicates that element servicing is required, follow the instructions shown in
6-5 Maintenance. For further information about the Air Cleaner, See Section 6-5, 250 hour
Maintenance.
Figure 6-10
WARNING
!
Air born dust may be hazardous. Wear proper personal protective
equipment while handling air cleaners and elements.
CAUTION
!
Raw, unfiltered air can cause compressor damage. Never service the air
cleaner while the drill is running.
Air Cleaner Indicators
Figure 6-11
1. Check the engine and compressor air cleaner visual restriction indicators
(Figure 6-11) before every shift during every shift and after every shift.
2. Clean and inspect compressor air cleaner visual restriction indicators. They
should be GREEN. If the indicators are RED, indicating a plugged air cleaner,
clean or replace the filter elements.
3. After servicing the element, reset the restriction indicator to GREEN when the
element is replaced in the air cleaner housing.
4. The compressor air cleaner must be checked to verify the restriction indicators
are not sticking. Check by pressing in the rubber boot on bottom of indicator.
The internal green and red indicator should move freely.
Connections and Ducts
Engine and Compressor
Figure 6-12
Check air cleaners connections and ducts for leaks before every shift, during every shift and
after every shift. Ensure all connections between the compressor air cleaner and air
compressor are tight and sealed. Ensure all connections between the engine air cleaner and
engine are tight and sealed. (See Figure 6-12)
NOTE: Dust that gets by the air cleaner system can often be detected by
looking for dust streaks on the air transfer tubing or just inside the intake
manifold inlet.
Empty Dust Cups
As daily routine maintenance, and as required in extremely dusty conditions, the dust cup on
the air cleaner must be emptied of accumulations.
Figure 6-13
On air cleaners equipped with dust cups, the cup must be emptied when it becomes 2/3 full.
The frequency of dust cup servicing varies with the operating conditions. It may be necessary
to empty the dust cup daily (See Figure 6-13).
1. Loosen the dust cup clamps and remove the dust cups on the compressor air
cleaner.
2. Empty any accumulations of dust and dirt and replace the dust cup. Secure the
dust cup clamps.
3. When reinstalling the dust cup, make sure it seals all the way around the air
cleaner body.
4. Inspect the o-ring between the dust cup and the air cleaner body. If it is
damaged in any way, it must be replaced.
5. On filters equipped with a quick release dust cup, simply release the latch on
the dust cup and allow it to swing down and empty. When it is empty, close the
dust cup and lock it in place with the latch.
6. On filters equipped with vacuator valves, the dust cup service is cut to a
minimum. A quick check to see that the vacuator valve is not inverted,
damaged or plugged is all that is necessary.
Engine Oil, Belts and Tensioner
Check Engine
WARNING
!
components.
Check the engine oil level with the engine not running and on level surface. Allow time for the
oil to return to the crankcase before checking level. Remove the dip stick and wipe with clean
rag. Place dip stick back in and remove, check oil level. Oil level should be at full mark on dip
stick. If oil is low, add oil to engine and recheck oil level until the oil is at the full mark on dip
stick. Do Not Over Fill Engine Oil. Refer to the Engine Operation and Maintenance Manual for
the correct type of oil.
Check the engine belt. Inspect the belt for wear and for cracking. Replace the belt if the belt
is not in good condition. The belt should be tight but not too tight. Refer to the Engine Operation
and Maintenance Manual for more information.
Check the belt tensioner in accordance with the Engine Operation and Maintenance Manual.
Standard Fill Engine Crankcase
1. The drill must be level and the engine must not be running.
2. Locate the oil filler cap on the engine.
3. Clean oil filler cap and area of debris. Remove oil filler cap.
CAUTION
!
Any contamination entering the engine during filling will seriously risk
damage to the engine. The system uses filtration only on the return oil
and therefore oil in the engine must be free of contamination.
4. Fill with new, clean engine oil SAE 15W40 oil. (Refer to OEM Engine Manual)
Refer to 6.3 Refill Capacities and Lubricants Specifications, under Capacities
for more detailed information.
5. Verify engine oil level. Oil level should be at the FULL mark on engine
dipstick.
6. Install oil filler cap and secure.
7. Start engine and check for leaks. Run the engine for one minute. Stop the
engine and check for leaks again. Check the engine oil level at the dipstick, if
low repeat steps 1 thru 6.
Engine Oil Quick Fill (Option)
Figure 6-14
2. Locate the proper fitting on the quick-fill station for the engine oil and remove
the quick-fill cap and clean the fitting for the engine oil quick-fill (Figure 6-14).
3. Locate the proper quick-fill hose. Clean the hose fitting and connect to the
quick-fill fitting and engine oil source.
NOTE: Any contamination entering the engine during filling will seriously
risk damage to the engine. The system uses filtration only on the return
oil and therefore oil in the engine must be free of contamination.
4. Fill with new, clean engine oil. Use SAE 15W40 oil (Refer to OEM Engine
Manual). (See Section 6-3 Refill Capacities/Lubricants Specifications)
dipstick.
6. Remove the quick-fill hose. Replace the cover on the quick fill port.
Engine Fuel Filter/Water Separator
Check the fuel filter/water separator for signs of water. If water is in the fuel bowl, drain water
from the bowl. Place a suitable container under the drain, open drain and catch the water from
the bowl. After water is removed close the drain and dispose of the water properly. Refer to
the Engine Operation and Maintenance Manual for more information.
Fuel Tank
Check fuel tank for fuel level (See Section 6-3 Refill Capacities/Lubricants Specifications,
Diesel Fuel). Fill the fuel tank when the fuel gauge is reading 1/4 full or at beginning of shift.
Fuel Fill
Figure 6-15
WARNING
!
Do not smoke while refueling or in a refueling area. Diesel fuel is
flammable.
2. Open fuel cap and insert fuel nozzle (See Figure 6-15).
NOTE: Any contamination entering the engine during filling will seriously
risk damage to the engine.
3. Fill with new, clean fuel. (Refer to OEM Engine Manual). (See Section 6-3 Refill
Capacities/Lubricants Specifications)
4. Fuel level should be at the FULL mark.
5. Remove fuel nozzle and close fuel cap.
Fuel Quick Fill (Option)
Figure 6-16
WARNING
!
Do not smoke while refueling or in a refueling area. Diesel fuel is
flammable.
2. Locate the proper fitting on the quick-fill station for the fuel and remove the
quick-fill cap and clean the fitting for the fuel quick-fill (See Figure 6-16).
3. Locate the fuel quick-fill hose. Clean the hose fitting and connect to the quick-
fill fitting and fuel source.
NOTE: Any contamination entering the fuel during filling will seriously
risk damage to the engine. The fuel must be free of contamination.
4. Fill with new, clean fuel. (Refer to OEM Engine Manual). (See Section 6-3 Refill
Capacities/Lubricants Specifications)
5. Fuel level should be at the FULL mark
6. Remove the quick-fill hose. Replace the cover on the fuel quick fill port.
Cooling System (Radiator & CAC) and (HOC & COC)
Check the engine coolant fluid level on the Radiator cooler sight glass. The fluid should be at
the top of the sight glass (See Figure 6-17). If coolant level is low refer to the Engine Operation
and Maintenance Manual for the correct type coolant to use.
WARNING
!
Pressurized System: Hot coolant can cause serious burns or injury.
WARNING
!
Hot coolant or components can burn. Avoid contact with hot coolant or
components.
Figure 6-17
Check the cooling fins and fan guards on both coolers (Radiator & CAC and HOC & COC) for
dirt and debris. Remove all dirt and debris before operating the drill.
Receiver Separator Tank
Water condenses and must be drained daily from the bottom of the separator tank (See Figure
6-18). If water is allowed to condense into the compressor oil, the bearing life will be
considerably reduced.
Drain Water from Receiver Tank
WARNING
!
pressure before removing filler plug, drain valve, fittings or receiver
cover.
Figure 6-18
1. Locate and open the drain valve (See Figure 6-18). Allow any of the
accumulated water to drain into a container.
2. When oil starts to flow, close drain valve.
3. Dispose of all accumulation in accordance with local regulations.
Compressor Oil Level
Figure 6-19
WARNING
!
Do not attempt to open the filler plug, any drain plugs or the drain valve
before making sure all air pressure has been relieved from the system.
High Pressure can cause severe injury or death
Periodically check the compressor oil level in the receiver tank. A loss of compressor oil could
be an indication of excess oil carry over with the compressed air and would require a separator
element change.
Check the receiver separator oil level at the sight glass oil level gauge on the receiver tank.
The procedure to check the fluid level is as follows: (See Figure 6-19)
1. The engine must not be running.
2. The fluid must be in the center of the oil level sight glass.
3. If necessary, add fresh, clean synthetic oil (filtered through a 10 micron filter)
through the manual fill cap area to bring level to middle of the sight glass.
Note:
Low Pressure compressors (110 psi) use LP-150 oil.
High Pressure compressors (350 psi) use HP-350 oil.
For details on compressor oil, refer to 6.3-Refill Capacities/Lubricants
Specifications.
Receiver Tank Oil Quick Fill (Option)
Figure 6-20
WARNING
!
Do not attempt to open the filler plug, any drain plugs or the drain valve
before making sure all air pressure has been relieved from the system.
High Pressure can cause severe injury or death
2. Locate the proper fitting on the quick-fill station for the receiver tank oil and
remove the quick-fill cap and clean the fitting for the receiver tank oil quick-fill
(Figure 6-20).
3. Locate the receiver tank oil quick-fill hose. Clean the hose fitting and connect
to the quick-fill fitting and receiver tank oil source.
NOTE: Any contamination entering the receiver tank during filling will
seriously risk damage to the compressor. The receiver oil must be free of
contamination.
4. Fill with new, clean synthetic oil. (See Section 6-3 Refill Capacities/Lubricants
Specifications).
Note:
5. The fluid must be in the center of the oil level sight glass (See Figure 6-19).
6. Remove the quick-fill hose. Replace the cover on the receiver tank quick fill
port.
Hydraulic Reservoir
The hydraulic reservoir oil level must be checked daily as part of the 8-10 hour routine
maintenance procedure.
NOTICE
system to ensure its complete cleanliness. When operating, the oil level
must be between the maximum and minimum levels.
CAUTION
!
Excessive hydraulic oil can rupture hydraulic tank and cause injury or
property damage. Do not fill hydraulic tank with cylinders extended.
Retract all cylinders and fill tank to indicated level.
WARNING
!
Liquid explosion can cause severe injury. Disconnect hydraulic tank high
voltage heater before draining or filling system.
Checking Hydraulic Oil Level
The following procedure is for checking the hydraulic oil level in the reservoir.
1. The drill must be level.
2. The tower must be horizontal, the power head at the top of the tower, and all
the leveling jacks fully retracted.
3. Check the reservoir oil level by viewing the sight gauge. Verify that fluid level is
to the Full mark on the sight glass (See Figure 6-21). If hydraulic oil is required
refer to Section 3 Refill Capacities/lubricants Specifications.
Figure 6-21
Drain Water from Hydraulic Tank
1. Drain the water from the hydraulic tank at the beginning of the shift when the
hydraulic oil is cooled, setting over night.
2. Place container with a capacity of at least 1.0 gallons (4.0 liter) under the
hydraulic tank drain point (See Figure 6-22).
3. Clean the area around the drain plug.
4. Drain the water from the hydraulic tank into the container. Do not allow the used
oil and water to drain into the ground. Dispose of properly.
5. Clean the port drain plug threads and then install it.
NOTICE
Care must be taken to ensure oils are contained during any inspection or
work is performed on this component. Handle and dispose of oils
according to local regulations and mandates.
Figure 6-22
Check Hydraulic Filters
Check the filter indicators on the Main Return filter and Case Drain filter for restriction in the
hydraulic system (See Figure 6-23). Any restriction to the filter refer to the 250 hour
maintenance section on changing hydraulic oil filters.
Figure 6-23
Hydraulic Tank Filling Procedures
There are only three (3) different ways to add hydraulic oil to the hydraulic tank reservoir.
CAUTION
!
Adding hydraulic oil to the hydraulic tank reservoir by any other way than
the three (3) procedures described could damage the equipment and/or
contaminate the hydraulic oil system causing poor performance or early
equipment failure.
1. Standard Fill (Location is side of hydraulic tank reservoir, cab side of drill).
2. Hand Pump Fill (location is next to non-cab side jack, on the deck).
3. Quick Fill (location is cab side, under decking, near non-drill end).
Standard Fill Procedure:
Figure 6-24
2. The tower must be horizontal with the rotary head at the top of the tower and
all leveling jacks fully retracted.
4. Ensure the breathers on top of the tank is clean and will allow the tank to
breathe.
5. Add or fill with new and clean oil. See Section 6.3 Approximate Fill Quantities
for further information about required hydraulic oil standards and fill quantities.
6. Clean the Standard fill port and service hose connection end of dirt and debris
to eliminate contamination.
7. Connect service hose to the hydraulic oil Standard fill port (See Figure 6-24).
NOTICE
8. Fill hydraulic tank reservoir to the Full mark on the sight glass tube (See
Figure 6-21).
9. Remove service hose, cap both the service hose and Standard fill port from dirt.
Hand Pump Fill Procedure:
Figure 6-24
breathe.
6. Clean the Hand Pump quick connection fill port and service hose connection
end of dirt and debris to eliminate contamination.
7. Connect service hose to the Hand Pump quick connection fill port (See Figure
6-25).
NOTICE
Figure 6-21).
9. Remove service hose, cap both the service hose and Hand Pump quick
connection fill port from dirt.
Quick Fill Procedure:
Figure 6-26
breathe.
6. Clean the Quick connection fill port and service hose connection end of dirt and
debris to eliminate contamination.
7. Connect service hose to the hydraulic oil Quick fill port (See Figure 6-26).
NOTICE
Figure 6-21).
9. Remove service hose, cap both the service hose and Quick fill port from dirt.
NOTICE
Do not use the quick-fill system to drain or remove fluid.
Rotary Head
WARNING
!
Riding the rotary head can cause severe injury or death. Do not ride
rotary head.
WARNING
!
Climbing raised tower can cause severe injury or death. Do not climb
raised tower.
WARNING
!
Falling tower can cause severe injury or death. Ensure all locking pins are
in locked position.
WARNING
!
Rotating shafts or drill string can cause severe injury or death. Do not
service the rotary head with drill string in motion.
Rotary Head Oil Level
Check the rotary head oil level daily. Perform this maintenance with the tower up and the
rotary head at the bottom of the tower.
1. Level the drill.
2. With the tower vertical, bring the rotary head to bottom of the tower.
3. Inspect the rotary head case for leaks.
4. Inspect fluid level sight glass for damage.
5. Check the rotary head oil level. Oil must be showing to the middle of the sight
glass. (See Figure 6-27)
Figure 6-27
If the fluid level is low, add fluid using the following procedure.
1. The drill must be level. The tower must be raised and the rotary head must be
at the bottom of the tower.
2. Clean area around fill plug.
3. Remove the fill plug.
4. Add SAE 90W Gear Oil through the fill port until the oil level is visible at the
middle of the sight glass.
5. Clean and replace the fill plug.
Rotary Head Upper Bearing
Figure 6-28
There is a grease point on the top of the rotary head. Grease the rotary head upper bearing
daily at the grease point on the top of the rotary head (See Figure 6-28).
Make sure the grease at the relief is free to move and the port is not plugged. Remove the
relief fitting to perform this task. Then, add grease slowly until it is coming out the open port.
Make sure the relief fitting is operational. Replace the relief fitting and continue to add grease
until the relief indicator pops out. In a short period of time, if the relief has not popped out, stop
and determine where the grease is going. Use Extra Heavy Duty Moly 2 multi-purpose grease.
Clean the Drill
The complete drill must be given a weekly cleaning. Daily cleaning will be required if material
is adhering to the tower or truck working parts.
1. Make sure the inside of the operators cab is clean. Make sure the operators
areas, steps and grab rails are clean. Oil, grease, snow, ice or mud in these
areas can cause you to slip and fall. Clean your boots of excess mud before
getting in the cab or on the drill.
2. Check the tracks. Make sure that no material is jammed between the track
sprockets and the track tensioners.
3. Check the tower feed installation for debris buildup around the sheaves.
4. Thoroughly wash all the fittings, caps, plugs, etc. with a nonflammable,
nontoxic cleaning solution before servicing to prevent dirt from entering while
performing the service.
Note:
Protect all electric components and control panels against entry of water or steam
when using high pressure cleaning methods. Cover the fuel and the hydraulic
fill cap breathers located on each tank.
5. After cleaning, check for defects in the air cleaner ducts.
a. Check intake for accumulation of debris that could restrict air flow.
b. Check air cleaner mounting hardware for security.
c. Check all hoses for cracks, chafing or deterioration and replace them at the
first sign of probable failure.
Dust Collector
In order to insure that the dust collector system is operating to its design specifications, the
following visual inspections should be performed on a periodic basis.
Dropout Hose
Verify that the dropout hose located at the bottom of the dust collector is securely fastened to
the dropout cone(s). This hose should be free of any holes and should form a tight seal during
the period when the collector is pulling a vacuum. The hose will open momentarily during each
back-pulse of compressed air when the filter elements are being cleaned.
Suction Hose
The suction hose leading from the dust hood outlet to the dust collector inlet should be clear
of obstructions such as a build-up of dirt or mud. There should be no kinks or extremely sharp
bends in the suction hose.
Figure 6-29
Figure 6-29 illustrates the 7SB dust collector.
Figure 6-30
Figure 6-30 illustrates the 3600 and 4500 dust collector.
Blower Assembly
Observe the discharge of the blower assembly. There should be no visible dust emerging from
the outlet of the blower housing. If there is, the filter elements and/or filter gaskets should be
replaced immediately to avoid damage to the blower wheel.
Filter Elements
Listen to the back-pulsing of the filter elements. There should be a sharp pulse of air every 2-
3 seconds. If a pressure gauge is installed in the air supply line to the dust collector, verify that
the air is pulsed at a peak pressure of approximately 40 psi. The filters should be cleaned
whenever possible by pulsing the elements with the blower system turned off. This can be
done at the end of any drilling cycle, while changing drill rod and possibly between each hole.
Remove the dropout cone and inspect the filters. Replace them if they are worn, torn or
shredded. Remove the wing nut and the filter should drop out.
Figure 6-31
Figure 6-31 shows filters for a 7SB dust collector.
Figure 6-32
Figure 6-32 shows filters for a 3600 and 4500 dust collector.
Rod Seal
Inspect the integrity of the rod seal attached to the bottom of the tower. Also give attention to
the dust curtains surrounding the hole.
Manual Lubrication Points
Tower Central Bank
Shut down the engine and apply 5 shots of grease ( MPG - EP-O) to each grease fitting. If
grease will not go into the fitting, remove and replace the grease fitting. Wipe away excessive
grease after greasing all fittings and dispose of grease properly.
Figure 6-33
Tower Central Bank (See Figure 6-33) fittings from top to bottom:
1. Timing Shaft (Optional)
2. Timing Shaft (Optional)
3. Sprocket Pin Top
4. Winch
5. Sprocket Pin Top
6. Pivot Block Top - Carousel
7. Indexer Bush. Top - Carousel
8. Tower Raising Cylinder
9. Tower Raising Cylinder
10. Swing Cylinder Top
11. Sheave J ib Hoist
12. Support Center Rod Changer
13. (SPARE)
14. (SPARE)
15. (SPARE)
16. Support Lower Rod Changer
17. Swing Cylinder Bottom
18. Arm Lower
19. Pivot Block Bottom Carousel
20. Sheave Pin Bottom
21. Sheave Pin Bottom
Frame Central Bank
Shut down the engine and apply 5 shots of grease ( MPG - EP-O) to each grease fitting. If
grease will not go into the fitting, remove and replace the grease fitting. Wipe away excessive
grease after greasing all fittings and dispose of grease properly.
Figure 6-34
Frame Central Bank (See Figure 6-34) fittings from top to bottom:
1. Front J ack - Cab Side
2. Front J ack - Cab Side
3. Front J ack - D.C. Side
4. Front J ack - D.C. Side
5. Tower Raising Cylinder - Cab Side
6. Tower Raising Cylinder - D.C. Side
7. Main Shaft - Cab Side
8. Main Shaft - D.C. Side
9. Osculation Yoke - Cab Side
10. Osculation Yoke - D.C. Side
11. Yoke Pivot
12. Rear J ack - Cab Side
13. Rear J ack - D.C. Side
14. Tower Support - Cab Side
15. Tower Support - D.C. Side
Sheaves and Sprockets
Apply 5 shots of grease ( MPG - EP-O) to each grease fitting. If grease will not go into the
fitting, remove and replace the grease fitting. Wipe away excessive grease after greasing all
fittings and dispose of grease properly.
Figure 6-35
Shut down the engine and apply grease applications to both sprockets and sheaves (See
Figure 6-35) in the tower.
Carousel and Cups
Apply 5 shots of grease ( MPG - EP-O) to each grease fitting. If grease will not go into the
fitting, remove and replace the grease fitting. Wipe away excessive grease after greasing all
fittings and dispose of grease properly.
Figure 6-36
Shut down the engine, clean all grease fittings and grease all cups (See Figure 6-36).
Gearbox Driveshaft
Before greasing the gearbox driveshaft make sure the engine is STOPPED.
Open the gearbox driveshaft cover doors to grease the fittings. Apply 5 shots of grease ( MPG
- EP-O) to each grease fitting. If grease will not go into the fitting, remove and replace the
grease fitting. Wipe away excessive grease after greasing all fittings and dispose of grease
properly. (See Figure 6-37 for grease point locations)
Figure 6-37
John Bean Water Injection Pump
Check the water injection pump (See Figure 6-38) for leaks, general condition and pump oil
level. Use SAE 30 non-detergent oil if needed. See Section 6.3 Approximate Fill Quantities
for further information.
Figure 6-38
6.6 - Maintenance (50 Hours or Weekly)
General Information
WARNING
!
drill.
Always wear correct safety gear while working on or around the drill. This includes an
approved hard hat, safety glasses, steel toe shoes/boots, gloves, respirator and ear
protection. Do not wear loose fitting clothing that can become caught on rotating components.
overturning.
crushing risk.
Batteries
The following battery maintenance must be carried out as part of the 50 hour routine
maintenance schedule. Batteries are located at non-cab side of drill.
WARNING
!
Batteries contain an acid and can cause injury. Battery fumes can ignite
and explode. Skin and eye contact with battery fluid can cause injury. Do
not smoke when observing battery fluid level. Avoid skin and eye contact
with battery fluid. If contact occurs, flush area immediately with water.
Electrolyte Level
1. Check the electrolyte level and keep the electrolyte level above the plates.
2. Refill with distilled water to the FULL mark on the battery. If distilled water is
not available use clean water that is low in minerals. Do not use artificially
softened water.
CAUTION
!
Over filling can cause poor performance or early failure.
Figure 6-39
Battery Terminals
Keep the battery terminals clean and the connections tight.
Clean the battery case with one of the following cleaning solutions:
A mixture of 0.1 kg (0.2 lb.) of baking soda and 1 L ( 1 qt.) of clean water.
A mixture of 0.1 L (0.11 qt.) of ammonia and 1 L (1 qt.) of clean water.
Thoroughly rinse the battery case with clean water.
Coat the clamps and terminals with 5N-5561 silicone lubricant, petroleum jelly or MPGM.
Hoist (Winch)
WARNING
!
Do not climb a raised tower. Climbing a raised tower can cause severe
injury or death. Lower the tower to the horizontal position to service the
winch.
Never lift or transport personnel with the winch. Do not use the winch in
any manner of operation which may endanger any individual.
CAUTION
!
Stay at least 10 feet (304.80 cm) away from cable while it is under tension.
Cable should be inspected whenever unwound and replaced when
broken strands are noted or damage to the cable assembly.
Periodic Inspection
The following Hoist (Winch) maintenance must be carried out as part of the 50 hour routine
maintenance schedule.
WARNING
!
Cable clamps are not designed to hold rated winch load. At least 5 wraps
of cable must remain on the drum at all times.
Figure 6-40
1. Inspect wire rope, winch, jib arm, ball and hook assembly and hydraulic hoses
at the 50 hour routine maintenance schedule. Any defects should be corrected
immediately. (See Figure 6-40)
2. Be certain that at least 5 full wraps of cable remain on the drum at all times;
otherwise, the cable clamps may not hold the load.
3. Replace cable that has kinked or broken strands because it may fail without
warning at low loads.
4. Inspect drive lugs on motor and drum for rounding or cracking.
Refer to Feed Cable & Wire Rope information in 6.4 Maintenance As Required for additional
information on wire rope and wire rope clamps.
Hoist (Winch) Wire Rope
Wire ropes, including their anchorage and other load carrying components of the traveling
block and winch system, e.g. sheave bearings, rope sheaves and drill hooks shall be checked
at least once a week.
Wire rope used in drilling operations becomes unusable because of wear and wire breakage
and should be discarded in accordance with 3.5 of ISO 4309:1990. In table 3.5 of ISO 4309:
1990, classification groups M1 and M2 shall be used. On drills with normal hook load of more
than 1000KN, the winch rope shall be regularly paid out and shortened according to a plan laid
down by the manufacturer on the basis of experience.
1. Replace when four (4) randomly distributed broken wires are found in one lay.
2. Replace when the wire rope shows wear of one third (1/3) the original diameter
of the outside wire.
3. Replace when evidence of any heat damage from any cause is found.
4. Replace when any kinking or cracking occurs.
Refer to Feed Cable & Wire Rope information in 6.4 Maintenance As Required for additional
information on wire rope and wire rope clamps.
Pump Drive Gearbox
Oil Leaks
Inspect the hydraulic pump drive gearbox for leaks as part of the 50 hour maintenance
schedule. Follow the steps shown below.
1. Look for signs of oil on the case and around the bottom of the case.
2. If there are signs of oil leakage, clean the outside of the case and around the
bottom. Verify signs of oil are from the case and not another source.
3. If a leak is verified, contact maintenance and take corrective action.
Check Oil Level
The type of service and the operating conditions will determine the maintenance interval.
However, it is recommended that the oil level be checked as part of the 50 hour routine
maintenance schedule. At the same time, check for oil leaks. Because the lubricant system is
the heart of the unit, it is especially important that the oil be kept clean.
WARNING
!
Hot oil or components can burn. Oil must be at normal operating
temperature when draining. Avoid contact with hot oil or components. Do
not allow used oil to drain into the ground. Dispose of properly.
NOTICE
The oil in the pump drive gearbox should be changed whenever the oil
shows traces of dirt or the effects of high temperature, evidenced by
discoloration or strong odor.
Figure 6-41
1. Move the drill to a level surface.
2. Stop engine before checking or adding oil.
3. Clean around the oil dipstick and fill plug before checking or adding oil.
4. Check the oil level within the gearbox. The oil should be at full mark on the
dipstick. (See Figure 6-41)
5. If necessary, add 80W90 gear oil and fill to the correct level. Always use new
oil and a clean container to dispense from. Do not overfill. This will cause
overheating. See 6.3 Lubricant Specifications for the recommended required
oil specifications.
6. Remove the breather and pull the dip stick up for the gear box to breathe will
filling. Fill the gear box thru where the breather was removed. Check oil level
on dipstick.
7. Check and clean the gearbox breather and install.
FMC John Bean (8 GPM) Water Injection Pump
Change the initial water injection pump oil after the first 50 hours of operation. Thereafter,
water injection pump oil change maintenance must be carried out as part of the 2000 hour
routine maintenance schedule and every 1500-2000 hours thereafter or every 3 months.
WARNING
!
The water injection pump oil should be at operating temperature for
draining. Be careful. Hot oil and components can burn.
Change Initial Oil
Figure 6-42
1. Position the drill on stable, level surface.
2. Place a container with a capacity of at least 2 quarts (1.89 liters) to collect the
used oil.
3. Wipe clean the breather, fill plug and drain plug area. (See Figure 6-42)
4. Remove both fill plug and magnetic drain plug. Allow oil to drain completely.
5. After oil has drained, clean magnetic plug and replace.
6. 8 gpm John Bean Water Injection Pump - Refill the oil through the fill port
(approximately 32 ounces or .95 liters) or until oil appears at bottom of fill plug.
Fill with SAE 30 non-detergent oil.
7. Clean and install fill plug .
8. Operate the drill and water injection and check for any leaks.
Table 31: Recommended Lubricant Chart
Undercarriage
Oil Leaks
Inspect the track final drives gearboxes for leaks. Look for signs of oil on the final drive gearbox
case and around the bottom of the case. If there are signs of oil leakage, clean the outside of
the gearbox case and around the bottom of the gearbox case. Verify that the signs of oil are
from the gearbox case and not another source. If a leak is verified, contact maintenance and
take corrective action.
Type of Service
Ambient
Temp.
ISO
Grade
(cSt)
AGMA Number
SAE
Weight
SSU
Viscosity
General Service 0-95F 100 3 30 550
High Ambient
Temperatures
95-120F 220 5 50 1165
Cold Ambient
Temperatures
-30-60F 68 2 20 350
Frequent Start-
Stop Cycles
0-95F 150 4 40 775
Final Drive Mounting Bolts
Figure 6-43
1. Check the torque of the final drive mounting bolts (See Figure 6-43) with a
torque wrench. The correct bolt torque is 420 50 ft/lbs (569 Nm).
NOTE:
If new wheel nuts have been recently installed, they may require frequent
checks until they seat properly.
2. Repeat same procedure for the other track drive.
Final Drive Oil Level
The following track final drive gearbox maintenance must be carried out as part of the 50 hour
routine maintenance schedule. Follow the procedure below to check the fluid level and to add
fluid if level is low.
NOTICE
Care must be taken to ensure fluids are contained during any inspection
or work performed on this component. Handle and dispose of fluids
WARNING
!
temperature when draining. Avoid contact with hot oil or components. Do
not allow used oil to drain into the ground. Dispose of properly.
1. Move the drill to a level surface and position the track final drive, with one port
at the 3:00 oclock position and 11:00 oclock position (See Figure 6-43). Shut
off the engine.
2. Be sure that the planetary housings are not too hot to touch. If they are hot, give
them time to cool down before proceeding.
3. Clean around the fill and level plug, remove both plugs.
4. The final drive lubricant should be level up to the bottom of the level plug hole
(See Figure 6-43) .
If the final drive gearboxes need oil, proceed with the following steps and
add lubricant:
WARNING
!
Do not overfill the final drive, damage may occur.
1. Add lubricant (Cat Tracks / 50WT or AC Tracks / 90WT) into the top port (11:00
oclock port) until lubricant is level up to the bottom of the level plug (3:00
oclock port).
2. Clean the ports and plugs threads, then replace the plugs.
3. After all scheduled service is complete, start the engine and move the tracks to
check for leaks. Listen for any unusual noises that might need attention.
4. Repeat this procedure for the other track drive.
Tracks
Track Tension
The following track maintenance must be carried out as part of the 50 hour routine
maintenance schedule.
One of the more critical factors in undercarriage wear is proper track adjustment.
1. Tracks that are too tight will put extra stress on both the undercarriage and the
drive train components, while wasting horsepower.
2. Tracks that are too loose create too much back bending, snaking and poor
footing which causes needless wear on the roller flanges, sprocket teeth and
track guides.
Proper track adjustment will vary with soil conditions and drill application. For example,
packing takes up slack, thus creating tight track. With excavator type chain, internal pin and
bushing wear causes track to loosen and offset the tight track caused by packing. Proper track
adjustment is important if long life and full track value are to be received.
1. The drill should be in its working environment. Propel the drill through mud and
allow dirt to pack the tracks.
2. Propel the drill in the direction of the idlers. Stop with one track pin directly over
the front carrier roller (the one closest to the idler). (See Figure 6-44)
Figure 6-44
3. Place a straight edge on top of the shoe grousers between the front carrier
roller and the idler (See Figure 6-45).
Figure 6-45
4. The correct SAG (distance from the bottom of the straight edge to top of the
track shoe) is 3-4% of the distance between the top of the idler and the carrier
roller.
5. The track requires retightening when the top of the track sag between the top
carrier rollers exceeds 1-1/2 (38 mm). (See Figure 6-45)
Track Adjustment
If the track is too loose, the track must be tightened by adding grease to the track adjuster. If
the track is too tight, grease must be removed from the track adjuster. (See Figure 6-46)
1. Clean the single grease fitting (A).
2. Inject MPG-EP2 grease, with a high pressure grease gun, until the required
track tension is obtained. See Refill Capacities/Lubricants/Specifications for
recommended grease requirements.
3. To reduce track tension, slightly unscrew the cover plug (B). The internal buffer
spring will relax and grease will be ejected. (See Figure 6-46)
Figure 6-46
4. To readjust, secure cover plug (B) and inject grease at grease point (A) until
correct track tension is effected.
5. Repeat the same procedure for the other track drive.
6.7- Maintenance (100 - 150 Hours)
General Information
WARNING
!
drill.
overturning.
crushing risk.
Hoist (Winch)
Hoist (Winch) Mounting Bolts
Figure 6-47
Tighten all winch base mounting bolts (See Figure 6-47) to recommended torque (See Section
6-14 Torque Specifications) after the first one hundred (100) hours of operation, then every
100 operating hours or three (3) months, whichever occurs first.
WARNING
!
Do not climb a raised tower. Climbing a raised tower can cause severe
injury or death. Lower the tower to the horizontal position to service the
winch.
Track Planetary Gearbox
Final Drive Mounting Bolts
The following maintenance must be carried out after 150 hours of operation:
Figure 6-48
1. Check the torque of the final drive mounting bolts with a torque wrench. The
correct bolt torque is 420 50 ft/lbs (569 Nm).
NOTE:
If new wheel nuts have been recently installed, they may require frequent checks
until they seat properly.
Change Initial Track Planetary Oil
The gear oil should be changed after the first one hundred fifty (150) hours of operation, then
at every 1500 operating hours. This maintenance is recommended as part of a lubrication
and preventive maintenance schedule in order to help provide maximum planetary gearbox
life.
off the engine.
WARNING
!
temperature when draining. Avoid contact with hot oil or components.
2. Be sure the oil is warm before draining but be sure that the planetary housings
are not too hot to touch. If they are hot, give them time to cool down before
proceeding.
3. Place container with a capacity of at least 2.1 gallons (8.0 liter) under the track
drive drain point.
4. Clean the area around the fill and level plug and drain plug.
5. Removed the fill and level plugs. Drain the oil from the final drive into the
container. Do not allow the used oil to drain into the ground. Dispose of
properly.
NOTICE
6. Clean the port drain plug threads and then install it.
7. Refill the planetary through the oil fill plug hole (11:00 oclock position) with
about 2.1 gallons (8.0 liters) per drive of oil (Cat Tracks / 50WT or AC Tracks /
90WT), until the planetary is full. Allow the surplus oil to drain out until the oil
level is up to the bottom of the level port (3:00 oclock position). Do not allow
the excess oil to drain into the ground. Dispose of properly.
10. After scheduled service is complete, check the planetary track drive for leaks
at operating temperatures. Listen for any unusual noises that might need
attention.
6.8 - Maintenance (250 Hours)
General Information
WARNING
!
drill.
overturning.
crushing risk.
Cat Engines
Engines
The following drawing shows a typical CAT C15 and CAT C18 Engine. Due to individual
applications, your engine may appear different from the drawing.
Figure 6-49
The following drawing shows a typical CAT C27 Engine. Due to individual applications, your
engine may appear different from the drawing.
Figure 6-50
Cat Engine Oil and Filters
Change the Engine Oil and Oil Filter(s) as part of the 250 Hour Routine Maintenance
Schedule or 6 months, whichever comes first.
WARNING
!
Some state and federal agencies in the United States of America have
determined that used engine oil can be carcinogenic and can cause
reproductive toxicity. Avoid inhalation of vapors, ingestion and common
prolonged contact with used engine oil. Do not allow used oil to drain into
the ground. Always use proper procedures to dispose of the oil.
oil or hot components to contact the skin. Oil must be at normal operating
temperatures when draining. Do not allow used oil to drain into the
ground. Dispose of properly.
NOTE: Refer to the Actual Manufacturers Operation and Maintenance Manual for the
Maintenance Schedules and procedures for the Engine on the drill.
NOTE: Refer to the Actual Manufacturers Service Maintenance Manual for Maintenance
Schedule and procedures for the Engine on the drill.
Drain Engine Oil
1. Position drill on stable, level surface.
2. The engine must be shut off and not running.
Figure 6-51
3. Position a container with a capacity of at least 20 gallon (76 liter) under the
engine drain plug to collect used oil (See Figure 6-51). Remove the drain plug
and open ball valve to drain engine oil. Do not allow used oil to drain into the
ground.
4. Allow the engine oil to drain into an appropriate and approved container. Follow
all local standards and regulations for disposal of oil.
NOTICE
NOTICE
*If the engine has a oil pan heater installed, the magnet drain plug will be
missing from the oil pan.
5. After the oil has completely drained, close the ball valve and clean the drain
plug and install securely.
6. Remove the magnetic drain plug on the bottom of the engine oil pan (Read
Notice before step number 5).
7. Clean magnet drain plug from bottom of oil pan and install into oil pan and
tighten.
Remove Oil Filters
WARNING
!
Avoid contact with hot oil or components. Do not allow used oil to drain
into the ground. Dispose of properly.
2. Place a container with a capacity of at least 2 quarts (2 liter) under the engine
oil filter(s).
3. Clean around the head of the filter and then remove filter with an Oil Filter Strap
Wrench Assembly. See Figure 6-49 or Figure 6-50 for filter locations.
4. Clean the sealing surface of the filter mounting base. Ensure that all of the old
oil filter gasket is all removed.
5. Apply clean engine oil to the new oil filter gasket.
6. Install the new oil filters. Tighten the oil filter until the oil filter gasket contacts
the mounting base. Tighten the oil filter by hand according to the instructions
on the oil filter. Do not overtighten the oil filter.
NOTICE
Do not fill the oil filters with oil before installing them. This oil would not
be filtered and could be contaminated. Contaminated oil can cause
accelerated wear to engine components.
2. Locate the oil filler cap on the engine (See Figure 6-49 and Figure 6-50 for
location).
CAUTION
!
dipstick.
Quick Fill Engine Crankcase
Figure 6-52
the quick-fill cap and clean the fitting for the engine oil quick-fill. (See Figure 6-
52)
CAUTION
!
dipstick.
Cat Engine Fuel and Coolant Filters
Change the Fuel and Coolant filters as part of the 250 Hour Routine Maintenance Schedule
or 6 months, whichever comes first. See Figure 6-49 and Figure 6-50 for locations.
Refer to the Actual Manufacturers Operation and Maintenance Manual for the Maintenance
Schedules and procedures for the Engine on the drill.
WARNING
!
Fuel leaked or spilled onto hot surfaces or electrical components can
cause fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements. Clean up fuel spills
immediately.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up fuel
spills immediately.
Change Cat Engine Fuel Filters and Water Separator Element:
Figure 6-53
Secondary Fuel Filter: (See Figure 6-53)
1. Engine stopped and Start switch to the OFF position.
2. Shut off fuel supply valve.
3. Clean the secondary fuel filter base mount.
4. Use a Filter Strap Wrench Assembly to remove fuel filter.
5. Check the surface of the fuel base mount for old gasket. Remove any old
gasket and wipe clean.
6. Install new secondary fuel filter. Tighten fuel filter by hand only. Do not over
tighten fuel filter.
Water Separator Element: (See Figure 6-53)
3. If the primary fuel filter is equipped with a drain valve, open the drain valve in
order to drain any fuel from the filter case. Close the drain valve.
4. Remove the fuel filter bowl and wash the fuel filter bowl with clean diesel fuel.
5. Remove the fuel filter.
6. Clean the gasket sealing surface of the fuel filter base. Ensure that all of the old
gasket is removed
7. Apply clean diesel fuel to the new fuel filter gasket.
8. Install the new fuel filter. Spin the fuel filter onto the base until the gasket
contacts the base. Use the rotation index marks on the filters as a guide for
proper tightening. Tighten the filter for an additional 3/4 turn by hand. Do not
overtighten the filter.
NOTICE
Do not fill the fuel filters with fuel before installing them. The fuel would
not be filtered and could be contaminated. Contaminated fuel will cause
accelerated wear to the fuel system parts.
9. Install the clean fuel filter bowl on the new fuel filter.
10. Open the fuel supply valve.
11. Place a container under the fuel output port, located just to the right of water
separator element (See Figure 6-53).
12. Turn Venting / Priming knob CCW to de tent stop position and hold, push up on
electrical venting / priming toggle switch and hold. Hold in these positions until
the fuel runs out of the fuel output port. Release the toggle switch (should go or
de tent to the down position). Turn the venting knob 1/4 turn CW. Fuel should
not be coming out of the fuel output port.
13. Wipe up any fuel spillage or leaks.
14. Start the engine and check for leaks. Stop the engine and check the engine and
filters for leaks.
Racor Fuel Filter (Option)
Figure 6-54
Change the Racor Fuel filters (Option) as part of the 250 Hour Routine Maintenance
Schedule or 6 months, whichever comes first. Refer to parts book manual for further
information and ordering parts.
Change Coolant Filters:
Figure 6-54
2. Turn shut off valves to the Off position on top of coolant filters (Figure 6-55).
3. Remove both coolant filters from filter base.
4. Clean the gasket sealing surface of the coolant filter base. Ensure that all of the
old gasket is removed.
5. Apply a light film of engine oil to the gasket seal before installing the new
coolant filter.
NOTE: Do not allow oil to get in the filter. It will break down the SCA
6. Install the new coolant filters to the coolant filter base. Turn the filters onto the
base until the gasket contacts the base. Tighten filters by hand only. Do not
over tighten filters.
7. Turn both shut off valves to the On position.
8. Check the coolant level sight glass, if low add as needed.
9. Start engine and check for leaks. Stop the engine and check the engine and
filters for leaks.
Engine SCA Level
Caterpillar engine cooling systems should be tested at 250 Hour intervals for the concentration
of Supplemental Coolant Additives (SCA).
NOTICE
Never use water alone without Supplemental Coolant Additives (SCA) or
without inhibited coolant. Water alone is corrosive at engine operating
temperature. Water alone does not provide adequate protection against
boiling or freezing.
NOTE: The engine is protected against corrosion of the cooling system by adding corrosion
inhibitor to the coolant. If engine radiator has been topped off using only water, the additive
content will become diluted and the risk of corrosion will increase.
Refer to engine instruction manual for further information and procedures on this important
maintenance item.
Engine Valve Lash
The initial valve lash adjustment on new engines is recommended at the first scheduled oil
change (250 Hour Routine Maintenance). The initial adjustment is necessary due to initial
wear of the valve train components and seating of the valve train components. Thereafter,
inspect and adjust engine valve lash every 3000 Service Hours (Refer to OEM Engine
Manual).
This maintenance is recommended by Caterpillar as part of a lubrication and preventive
maintenance schedule in order to help provide maximum engine life.
Ensure that the engine is stopped before measuring the valve lash. To obtain an accurate
measurement, allow the valves to cool before this measurement is performed.
Refer to the Service Manual for more information.
WARNING
!
Ensure that the engine can not be started while this maintenance is being
performed. To help prevent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring/adjusting valve lash clearance.
NOTICE
Only qualified service personnel should perform this maintenance. Refer
to the Service Manual or your Caterpillar dealer for the complete valve
lash adjustment procedure.
Operation of Caterpillar engines with improper valve adjustment can
reduce engine efficiency. This reduced efficiency could result in
excessive fuel usage and/or shortened engine component life.
Cummins Engines
Engines
The following drawing shows a typical Cummins QSx15 and Cummins QSK19 Engine. Due to
individual applications, your engine may appear different from the drawing
Figure 6-56
Cummins Engine Oil and Filters
Change the Engine Oil and Oil Filter(s) as part of the 250 Hour Routine Maintenance
Schedule or 6 months, whichever comes first.
WARNING
!
Some state and federal agencies in the United States of America have
determined that used engine oil can be carcinogenic and can cause
reproductive toxicity. Avoid inhalation of vapors, ingestion and common
prolonged contact with used engine oil. Do not allow used oil to drain into
the ground. Always use proper procedures to dispose of the oil.
oil or hot components to contact the skin. Oil must be at normal operating
temperatures when draining. Do not allow used oil to drain into the
ground. Dispose of properly.
NOTE:
NOTE:
Refer to the Actual Manufacturers Service Maintenance Manual for Maintenance Schedule
and procedures for the Engine on the drill.
Drain Engine Oil
1. Position drill on stable, level surface.
Figure 6-57
3. Position a container with a capacity of at least 20 gallon (76 liter) under the
engine drain plug to collect used oil (See Figure 6-57). Remove the drain plug
and open ball valve to drain engine oil. Do not allow used oil to drain into the
ground.
4. Allow the engine oil to drain into an appropriate and approved container. Follow
all local standards and regulations for disposal of oil.
NOTICE
NOTICE
*If the engine has a oil pan heater installed, the magnet drain plug will be
missing from the oil pan.
5. After the oil has completely drained, close the ball valve and clean the drain
plug and install securely.
6. Remove the magnetic drain plug on the bottom of the engine oil pan (Read
Notice before step number 5).
7. Clean magnet drain plug from bottom of oil pan and install into oil pan and
tighten.
Remove Oil Filters
2. Place a container with a capacity of at least 2 quarts (2 liter) under the engine
oil filter(s).
3. Clean around the head of the filter and then remove filter with an Oil Filter Strap
Wrench Assembly. (See Figure 6-56 for filter locations)
5. Apply clean engine oil to the new oil filter gasket.
6. Fill the lubricating oil filter with clean SAE 15W40 lubricating oil. (Refer to OEM
Engine Manual for Specification)
CAUTION
!
Fill the lubricating oil filter with clean lubricating oil. The lack of
lubrication during the delay until the filters are pumped full of oil is
harmful to the engine.
2. Locate the oil filler cap on the engine (See Figure 6-56 for location).
CAUTION
!
dipstick.
Quick Fill Engine Crankcase
Figure 6-58
the quick-fill cap and clean the fitting for the engine oil quick-fill. (See Figure 6-
58)
CAUTION
!
dipstick.
Cummins Engine Fuel and Coolant Filters
Change the Fuel and Coolant filters as part of the 250 Hour Routine Maintenance Schedule
or 6 months, whichever comes first.
WARNING
!
cause fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements. Clean up fuel spills
immediately.
NOTICE
Use a suitable container to catch any fuel that might spill. Clean up fuel
spills immediately.
Change Cummins Engine Fuel Filters or Water Separator Elements:
Figure 6-59
Secondary Fuel Filters: (See Figure 6-59)
3. Clean the secondary fuel filter base mount.
4. Use a fuel filter wrench to remove the secondary fuel filters.
5. Check the surface of the fuel base mount for old gasket. Remove any old
gasket and wipe clean.
6. Add clean fuel to secondary fuel filters. Be careful not to spill the fuel inside the
new filters.
7. Install new secondary fuel filters. Tighten fuel filters by hand only. Do not over
tighten fuel filters.
Water Separator Element: (See Figure 6-59)
3. Fuel must be drained from the filter head prior to removing the filter element.
4. Place a suitable container under the primary fuel filter. Open the fuel drain valve
and allow the fuel to drain below collar on filter. Close the drain valve.
5. Use a collar / vent cap wrench to loosen the collar. To loosen the collar turn
CCW.
6. After removing collar, remove clear cover, filter spring, fuel filter element and o-
ring.
7. Remove the sealing grommet from the filter spud.
8. Discard the o-ring and sealing grommet.
9. Install new sealing grommet and o-ring.
10. Install new fuel filter element. Now re-install the filter spring, clear cover and
collar.
11. Tighten collar by hand. Do not overtighten collar.
12. Fill the filter with clean diesel fuel thru the vent cap on top of clear cover.
13. Install the vent cap in the clear cover.
14. Tighten the vent cap by hand only.
15. Open the fuel supply shutoff valve. Make sure the fuel drain valve is closed.
16. Wipe all filters down and check for leaks.
engine and check for leaks again.
Racor Fuel Filter (Option)
Figure 6-60
Change the Racor Fuel filters (Option) as part of the 250 Hour Routine Maintenance
Schedule or 6 months, whichever comes first. Refer to parts book manual for further
information and ordering parts.
Change Coolant Filters:
Figure 6-61
A manual shutoff valve is provided to prevent coolant leakage while changing the coolant filter.
With the valve in the vertical position, the coolant flows to and from the coolant filter. In the
horizontal position, the coolant flow is cut off to and from the coolant filter.
2. Turn shut off valve to the Off position on top of coolant filter.
3. Remove coolant filter from filter base.
4. Clean the gasket sealing surface of the coolant filter base. Ensure that all of the
old gasket is removed.
5. Apply a light film of engine oil to the gasket seal before installing the new
coolant filter.
NOTE: Do not allow oil to get in the filter. It will break down the SCA
6. Install the new coolant filter to the coolant filter base. Turn the filter onto the
base until the gasket contacts the base. Tighten filter by hand only. Do not over
tighten filter.
7. Turn shut off valve to the On position.
8. Check the coolant level sight glass, if low add as needed.
9. Start engine and check for leaks. Stop the engine and check the engine and
filters for leaks.
Engine SCA Level
Cummins engine cooling systems should be tested at 250 Hour intervals for the concentration
of Supplemental Coolant Additives (SCA).
NOTICE
Never use water alone without Supplemental Coolant Additives (SCA) or
without inhibited coolant. Water alone is corrosive at engine operating
temperature. Water alone does not provide adequate protection against
boiling or freezing.
Refer to OEM engine instruction manual for further information and procedures on this
important maintenance item.
QSK19 (Tier 2) Fuel Filters Maintenance
Maintenance Procedures
Table 32: QSK19 (Tier 2) Fuel Filters Maintenance
Drills with QSK19 Tier 2 power pack engines use two stages of fuel filters. The first stage is a
single 7 micron filter with water separator. The second stage is a dual 3 micron filter assembly.
This addendum has been created because there is confusion in the field on how to maintain
and service these filters.
Description: Cummins QSK19 Tier 2 engine fuel filters maintenance
Model(s): All models using Cummins QSK19 Tier 2 engines
Reason for Addendum: Clarification of maintenance procedures
Service News Number: 081007-286 (Ref: CUMMINSFF.pdf)
The following information shows a step by step procedure for replacing the filters. It also
includes instructions for draining the water separator.
General Information
Water in the fuel can cause the engine to run rough. Drain the water and sediment from the
fuel/water separator daily.
Replace the fuel filters every 250 operating hours. If the fuel has been contaminated with
water, the fuel/water separator element should be changed before the regularly scheduled
interval of 250 hours.
All maintenance checks and inspections listed in previous maintenance intervals must also be
performed at this time, in addition to those listed in this addendum.
WARNING
!
Water and sediment may contain petroleum products. Please consult
with your local environmental agency for recommended disposal
guidelines.
WARNING
!
Fuel is flammable and may cause serious injury or death. Shut down
engine, extinguish all open flames and do not smoke while draining and
replacing fuel filters. Always wipe up any spilled fuel immediately.
WARNING
!
cause a fire. To help prevent possible injury, turn the start switch off
when changing fuel filters or water separator elements.
Fuel Filter (Spin-On Type)
Stage 1 filters are mounted off the engine. The fuel priming pump is mounted with the Stage
1 filter assembly. The filter consists of the following components:
1. Stage 1 filter (7 micron filtration)
2. Water-in-fuel sensor)
3. Drain valve
4. Lift Pump
The Stage 2 filter head is mounted on the engine and is vibration isolated with vibration
dampers.
Preparatory Steps
WARNING
!
Depending on the circumstances, fuel is flammable. When inspecting or
performing service or repairs on the fuel system, to reduce the possibility
of fire and resulting personal injury, death or property damage, never
smoke or allow sparks or flames (such as pilot lights, electrical switches,
or welding equipment) in the work area.
1. The Stage 1 filtration for the QSK19 Tier 2 engine consists of a single Industrial
Pro filter head. The Stage 1 filtration must be used during normal operation.
2. The Stage 2 filtration consists of an engine mounted vibration-isolated dual
filter head. Both filters must be used during normal engine operation.
3. Shut down the engine.
4. Close the fuel supply shutoff valve.
5. Drain the filter head of fuel.
Remove
CAUTION
!
Do not allow fuel to drain onto the ground. Drained fuel must be collected
and disposed of in accordance with local environmental regulations.
1. Fuel must be drained from the Stage 1 fuel filter head prior to removing the filter
element.
2. Place a suitable container under the Stage 1 fuel filter to be replaced.
3. Use the collar/vent cap wrench (Cummins Part Number 3944451S) to open the
vent cap to break the air lock in the filter.
4. Open the fuel drain valve and allow the fuel level to drain to a point below the
collar. Close the drain valve.
5. Use the collar/vent cap wrench (Cummins Part Number 3944451S) to loosen
the collar.
6. Remove the clear cover (1), filter spring (2), fuel filter element (3) and o-ring (4).
7. Remove the sealing grommet (5) from the filter spud.
8. Discard the o-ring (4) and sealing grommet (5),
9. Remove the Stage 2 fuel filters with fuel filter wrench.
Clean
Stage 2 filtration cleaning procedure is shown here.
1. Check that the thread adapter sealing ring (1) has been removed,
2. Use a clean lint-free cloth to clean the surface of the filter head gasket. Spray
the surface of the filter head gasket with cleaning solvent.
3. Allow the filter head gasket to air dry.
Install
On the Stage 1 filter, install a new o-ring (4), filter element (3) [supplied with sealing grommet
(5) inserted into the filter element], filter spring (2) and clear cover (1).
1. Stage 1 filter element replacement includes the appropriate o-ring (4) and
sealing grommet (5). Note: Verify the used o-ring has been removed and
discarded before installing the new o-ring.
2. The o-ring and grommet must be replaced with the filter element to make sure
of correct operation.
Install the vent cap and collar onto the clear cover and hand tighten only. Do not use tools to
tighten the collar.
Install the Stage 2 fuel filters on the dual filter head. Note: Do not fill the dual Stage 2 filters
with fuel. Lubricate the filter o-rings with clean engine oil.
1. Turn the filter until the gasket touches the surface of the filter head.
2. Tighten the filter an additional 1/2 to 3/4 of a turn after the gasket touches the
filter head surface.
Prime
CAUTION
!
Do not spill or drain fuel onto the ground when disconnecting or
removing fuel lines, replacing filters and priming the fuel system. Do not
drop or throw filter elements onto the ground. The fuel and fuel filters
must be disposed of in accordance with local environmental regulations.
Stage 1 and Stage 2 filters must be primed prior to starting the engine. The procedure for
priming Stage 1 and Stage 2 filtration is covered in the same steps, as follows.
1. Verify the drain valve on the Stage 1 filter is closed at the base of the filter.
2. Close the fuel supply shutoff valve.
Remove the vent cap from the top of the filter.
1. Fill the filter with clean diesel fuel.
2. Install the vent cap.
3. Tighten the vent cap by hand only.
4. Open the fuel supply shutoff valve.
The keys witch must be cycled (2) two to (3) three times to prime the fuel system.
The fuel lift pump will operate for 120 seconds when the key is switched to the ON position.
When the lift pump stops operating, turn the keys witch to the OFF position for approximately
30 seconds before repeating.
Finishing Steps
The Industrial Pro filter head must be checked for leaks. Check the plumbing to and from the
Stage 1 and Stage 2 filter heads. Operate the engine for 1 to 2 minutes and check for leaks.
Drain
CAUTION
!
Do not spill or drain fuel when disconnecting or removing fuel lines,
replacing filters and priming the fuel system.
Accumulated water must be drained daily. For fuel that has a high water content, more
frequent draining will be necessary.
1. Shut down the engine.
2. Place a suitable container under the fuel filter.
3. With the fuel supply valve closed, open vent cap to break air lock in the filter.
4. Open the drain valve. If there is accumulated water in the system, the water will
flow out first.
5. When the fuel begins to flow out of the drain, close the drain valve.
6. The drained liquids must be disposed of in accordance with local
environmental regulations.
7. Close the vent cap.
8. Start the engine and raise the rpm for one minute to purge the air from the
system. If the engine fails to start, prime the filter to remove the excess air.
Air Cleaners (Engine and Compressor)
The air cleaner is the dry type with two elements: a primary element that is replaceable and
can be cleaned, and a safety element that should only be replaced and never cleaned.
Primary and Safety Elements
The primary and safety element must be replaced as part of the 250 hour routine maintenance
schedule. The following maintenance procedure must be carried out. (See Figure 6-62)
Figure 6-62
1. Unclip the three clamps holding the dust cover.
2. Remove dust cover.
3. Remove wing nut and washer. Carefully withdraw the primary air cleaner
element.
4. To replace the safety element, remove the cotterpin and the restriction
indicator. Carefully remove the safety element. Dispose of the used element
properly.
5. Clean the inside of the cover and the housing with a clean, damp cloth.
6. Install new safety element and secure it with the restriction indicator and cotter
pin.
7. Examine the new primary element for torn or damaged pleats, bent end covers,
liners and gaskets.
8. Ensure the primary element wing nut and washer are not cracked or damaged.
Replace if necessary.
9. Carefully install the new primary element and secure it with the wing nut and
washer.
10. Install the dust cover.
11. Inspect all air intake piping and joints between the air cleaners and the
compressor air inlets to ensure that no dusty air can enter.
12. Ensure all clamps are tight.
Air Cleaner Pre-Cleaner
The Donoclone tubes in the air cleaner pre-cleaner may become lightly plugged with dust
which can be removed with a stiff fiber brush. If heavy plugging is evident, remove the lower
body section and clean with compressed air or water not to exceed 160F (71C). (See Figure
6-63)
CAUTION
!
Never clean Donoclone tubes with compressed air unless both the safety
and primary elements are installed in the air cleaner. Do not steam clean
the tubes in the pre-cleaner.
Figure 6-63
Air Cleaner Rain Guard
1. Check the bolts fastening the rain guard around the pre-cleaner body and make
sure they are secure. (See Figure 6-63)
2. If the bolts become loose, it will allow the rain guard to fall down over the
openings in the pre-cleaner and restrict the flow of air into the air cleaner.
Air Cleaner Elements
Figure 6-64
The air cleaner is the dry type with two elements: A primary element that is replaceable and
can be cleaned, and a safety element that should only be replaced and never cleaned.
When the visual restriction indicator is RED, clean and replace the air cleaner elements. The
following maintenance procedure must be followed. (See Figure 6-64)
1. Unclip the three clamps holding the dust cover.
2. Remove the dust cover.
3. Remove the wing nut and washer. Carefully withdraw the primary air cleaner
element.
4. Inspect the safety element restriction indicator. If the indicator is RED, replace
the safety element.
NOTICE
Make sure new elements arrive enclosed in plastic or in a protective
membrane. DO NOT install elements that have been sitting on the shelf
unprotected. This is a dust hazard.
NOTICE
Make sure that the safety element wing nut is tight. Never attempt to clean
a safety element. You must change the safety element after three primary
element changes or as indicated by the safety service indicator.
5. Clean the inside of the cover and the housing with a clean, damp cloth.
Figure 6-65
6. To clean the primary element, perform the following: (See Figure 6-65)
a. To dry clean the element, carefully direct compressed air (not to exceed
100 psi or 5 bar pressure) at an angle onto the inside surface from no closer
than 1 inch (25.4mm) from the filter.
b. To wet clean the element, soak for 15 minutes in lukewarm water, not
exceeding 160F (71C), mixed with a commercially available detergent.
Rinse until water runs clear (40 psi maximum).
c. After the cleaning, the element must be thoroughly dry before using. Do not
use compressed air to dry the element.
NOTICE
Replace the primary element after six cleanings or annually, whichever
comes first.
7. Examine the new or newly cleaned primary element for torn or damaged pleats,
bent end covers, liners and gaskets.
8. Ensure the primary element wing nut and washer are not cracked or damaged.
Replace if necessary.
9. The safety element should be replaced at this time if:
a. Examination of the primary element reveals a torn or perforated element.
b. Change safety element after three primary element changes or 1 year
duration.
c. Change safety element as indicated by the safety element restriction
indicator.
d. Change safety element if the air cleaner visual restriction indicator is RED
after servicing the primary element.
10. Clean the inside of the air cleaner housing before removing safety element.
11. To replace the safety element, remove the cotterpin and restriction indicator.
Carefully remove the safety element. Dispose of the used element properly.
12. Install new safety element and secure it with the restriction indicator and
cotterpin.
13. Carefully install the cleaned or new primary element and secure it with the wing
nut and washer.
14. Install the dust cover.
15. Inspect all air intake piping and joints between the air cleaner and inspect the
compressor air inlet to ensure that no dusty air can enter.
16. Ensure all clamps are tight.
After servicing the elements, reset the restriction indicator to GREEN when the element is
replaced in the air cleaner housing.
The compressor air cleaner must be checked to verify the restriction indicator is not sticking.
Check by pressing in the rubber boot. The internal green/red indicator should move freely.
NOTICE
Never leave the air cleaner open longer than necessary.
NOTICE
The two most common servicing problems are over servicing and
improper servicing.
1. Over Servicing - New filter elements increase in dust cleaning efficiency as
dust builds up on the media. It will trap smaller particles by closing the area
between particles. Remember that if the filter is working properly, it will look
dirty. Also, if a filter looks clean, it may not be serviceable. The operator display
will indicate when the filters require servicing.
2. Improper Servicing - Your compressor is very vulnerable to abrasive
contaminants during the service process. The most common cause of
compressor damage is due to careless servicing procedures. A handful of dust
introduced into the inlet of the compressor can cause a catastrophic failure of
the compressor. Be very careful when replacing elements not to introduce dirt
into the inlet tube.
Air Cleaner Service Tips
Follow these simple service tips. Youll keep your air cleaners working at their best to protect
your compressor continuously.
1. To begin with, let restriction levels be your guide. Use a restriction indicator.
2. Service elements only when the restriction reaches the service level
recommended by the compressor or equipment manufacturer. Its only above
that point that air cleaner restriction begins to reduce performance levels.
3. If the compressor performance is poor, but restriction is still within limits, do not
change that element! The air cleaner is probably not at fault.
4. To get extra service hours out of each filter element, make sure the air inlet is
away from any heavy dust clouds caused by operation. And make sure exhaust
carbon cannot enter the air cleaner.
5. Check to see that all connections are tight and leak free and that breakaway
joints, both intake and exhaust, are aligned and sealing.
6. Make sure that the vacuator valve, on air cleaners so equipped, is not plugged.
Is the cup joint sealing? This should take care of most of the air cleaner related
performance problems.
7. When restriction readings finally indicate a change, remove the primary
element very carefully. Use a damp cloth to wipe out all excess dust in the air
cleaner.
8. If you reuse the elements, clean them with care. Rapping, tapping or pounding
dust out of them is dangerous. Severe damage to the filter will result.
9. A thorough cleaning with air or water is recommended in many cases. But be
careful. Too much pressure can break the filter paper and destroy the element.
10. Carefully check new or properly cleaned elements for damage before installing.
11. Never attempt to clean a safety element. Change safety elements only after
three primary element changes or as indicated by a Safety Signal
TM
Service
indicator.
12. Make it a habit not to disturb the element until restriction again reaches the
service limit.
General Information
WARNING
!
drill.
overturning.
crushing risk.
Hydraulic Oil Analysis
Have a hydraulic oil analysis done every 500 hours routine maintenance schedule.
Hydraulic Reservoir
Hydraulic Fluid Condition Limits
The following is for mineral based and synthetic fluids, excluding automatic transmission
fluids. Sample fluid every 500 hours. Change the fluid if any of the following conditions occur:
1. Viscosity increases by 16% or decreases by 10% (compared to new fluid)*
2. Total Acid Number (TAN) increases by 2.5 or more (compared to new fluid)*
3. Water content exceeds .1% (1000 ppm)
4. The fluid becomes contaminated with any other unfiltered contaminant; glycol,
fuel, etc.
* Oxidation of the fluid is usually indicated by an increase in viscosity and an
increase in TAN. If the fluid shows a TAN increase of 2.5 or more, and
especially if it corresponds to a viscosity increase of over 16%, the fluid should
be changed.
Notes:
1. High concentrations of soluble metals as indicated by a spectro-chemical
analysis do not necessarily indicate a deterioration of the fluid.
2. A high particle count does not necessarily indicate deterioration of the fluid. A
filter bypass alarm or particle count exceeding ISO 18/15 indicates the need for
a filter change.
Change Hydraulic Oil
Change the hydraulic tank oil (and filters) after any major hydraulic system repair and if the oil
sampling results follow the hydraulic fluid condition limits shown above. Required to change
every 5000 hours of operation or sooner, determined by the hydraulic oil analysis. When
changing the fluid, follow the procedure below to do so.
WARNING
!
Oil must be at normal operating temperature when draining. Hot oil or
components can burn. Avoid contact with hot oil or components.
Liquid explosion can cause severe injury. Disconnect high voltage tank
heater before draining or filling system.
NOTICE
clean, contaminant free system is extremely important to the machines
Do not use the quick-fill system to drain or remove fluid. Use the drain
line at the bottom of the hydraulic tank.
Drain Hydraulic Reservoir
1. Park the drill on stable, level surface and shut down engine. Tower must be in
the horizontal (down) position and all jacks up (stowed position). Allow time for
the hydraulic oil to cool.
2. Place a container with a capacity of at least 100 gallon (379 liter) under the
hydraulic tank oil drain plug (See Figure 6-66). Do not allow used oil to drain
into the ground. Dispose of properly. Follow all local standards and
regulations for disposal of used oil.
Figure 6-66
3. Clean the area around the drain plug.
4. Remove drain plug at shut off valve and open ball to allow oil to drain. Allow the
hydraulic oil to drain into a suitable container.
NOTICE
or work is performed on this component. Handle and dispose of fluids
5. After the hydraulic tank has stop draining, close ball valve. Clean drain plug,
install and tighten. Fill the hydraulic tank by one of the three filling procedures.
See section 6.3 Refill Capacities/Lubricants/ Specifications for details on
hydraulic oil.
CAUTION
!
equipment failure.
Figure 6-67
breathe.
NOTICE
8. Fill hydraulic tank reservoir to the Full mark on the sight glass tube.
Figure 6-68
breathe.
6-68).
NOTICE
Figure 6-69
breathe.
NOTICE
NOTICE
Do not ever fill hydraulic tank through the breather ports or suction
manifold plug. Only fill hydraulic tank reservoir by the three (3) hydraulic
tank fill procedures.
Hydraulic Tank Breathers
The hydraulic tank breathers should be replaced as part of the 500 hour routine maintenance
procedure.
1. Thoroughly clean the area around the hydraulic tank breathers.
Figure 6-70
2. Remove the breathers. (See Figure 6-70)
3. Install the new breathers.
4. Hand tighten breathers on installation.
Pump Drive Gearbox
The type of service and the operating conditions will determine the maintenance interval.
However, it is recommended that the pump drive gearbox oil be changed after the first five
hundred (500) hours of operation, then at every 1000 operating hours. Because the
lubricant system is the heart of the unit, it is especially important that the oil be kept clean.
Note: The oil in the pump drive gearbox should be changed whenever the oil shows traces of
dirt or the effects of high temperature, evidenced by discoloration or strong odor.
WARNING
!
components. Oil must be at normal operating temperature when draining.
Do not allow used oil to drain into the ground. Dispose of properly.
Change Initial Oil
Figure 6-71
Follow the procedure below:
1. Move the drill to a stable, level surface and shut off the engine.
2. Place a container with a capacity of at least 7 quarts (6.6 liters) under the gear
box magnetic drain plug to collect used oil. Do not allow used oil to drain into
the ground.
NOTICE
Figure 6-72
3. Clean around breather areas.
4. Remove the breather.
5. Remove magnetic drain plug and drain pump drive while the oil is still warm
(See Figure 6-72). Allow the oil to drain from the drain port into a container.
6. Examine the gearbox oil for any contamination or metal particles. Metal debris
can reveal an impending pump drive gearbox failure. If debris is found, find the
reason for the debris and perform the needed repairs.
7. Clean magnetic drain plug, re-install and tighten.
8. Refill the pump drive gearbox through the breather port with 80W90 gear oil
until the oil level reaches the full mark on the gearbox dipstick. The gearbox in
position 1 requires approximately 6.0 quarts (5.68 liters) of oil. Do not overfill.
This will result in the over heating and the possible malfunction of the gearbox.
9. Clean the breather and install securely.
10. After startup, check the pump drive for any leaks at operating temperatures.
Feed Cable and Wire Rope
Cable/Rope Lubrication
Figure 6-73
Lubrication of the wire rope should be included in the maintenance schedule. Cables should
be cleaned with a wire brush and solvent and lubricated approximately every 500 hours with
one of the following or equivalent:
1. Texaco Crater A
2. Brooks Klingfast 85 (Brooks Oil Co.)
3. Gulf Seneca 39
4. Whitmores Wire Rope Lubricant (Whitmore Manufacturing Co.)
The lubricant can be applied with either a spray or a brush and is recommended for protection
against corrosion only.
Victalic Air Hose and Clamps
Air Hoses and Clamps
Victaulic Hose Couplings
Figure 6-74
1. Always inspect each joint to ensure that the hose couplings are properly
installed. Undersized or oversized fittings, shallow grooves, eccentric grooves,
bolt pad gaps, etc. are unacceptable.
2. Hose couplings must be properly assembled with the bolt pads in firm, metal
to- metal contact.
3. The housings keys must be fully engaged in both grooves.
4. The gasket must be slightly compressed, which adds to the strength of the seal.
Coupling Installation
WARNING
!
1. Read and understand all instructions before attempting to install any
Victaulic piping products.
2. Depressurize and drain the piping system before attempting to install,
remove or adjust any Victaulic piping products.
3. Wear safety glasses, an approved hard hat and foot protection.
Failure to follow these instructions could result in serious personal
injury, improper product installation and/or property damage.
Preparatory Steps for Coupling Installation
1. Check Hose/Pipe Ends: The outside surface of the pipe from the end to the
groove must be smooth and free from indentations, projections (including weld
seams) and roll marks to ensure a leak tight seal for the gasket. All oil, grease,
loose paint and dirt bust be removed.
Figure 6-75
2. Check Gasket and Lubricate: Check the gasket to make sure it is suitable for
the intended service. Apply a thin coat of silicone lubricant to the gasket lips
and exterior. (See Figure 6-75)
CAUTION
!
Always use a compatible lubricant to prevent the gasket from pinching or
tearing during installation. Failure to follow this instruction could result
in joint leakage.
3. Position Gasket: Position the gasket over the hose end. Make sure the gasket
does not overhang the hose end. (See Figure 6-76)
Figure 6-76
4. Join Hose/Pipe Ends: Align and bring the hose end and pipe end together.
Slide the gasket into position and make sure it is centered between the grooves
in each hose/pipe end. Make sure no portion of the gasket extends into the
groove in either pipe/hose end. (See Figure 6-77)
Figure 6-77
1. Assemble Housings: Insert one bolt into the housings and thread the nut
loosely onto the bolt (nut should be flush with the end of bolt) to allow for the
swing-over feature, as shown below. (See Figure 6-78)
Figure 6-78
2. Install Housings: Using the swing-over feature, install the housings over the
gasket. Make sure the housings keys engage the grooves properly on both the
hose end and the pipe end. (See Figure 6-79)
Figure 6-79
CAUTION
!
Make sure the gasket does not become rolled or pinched while installing
the housings. Failure to follow this instruction could cause damage to the
gasket, resulting in joint leakage.
3. Install Remaining Bolt/Nut: Install the remaining bolt and thread the nut
finger-tight onto the bolt. Note: Make sure the oval necks of the bolts seat
properly in the bolt holes. (See Figure 6-80)
Figure 6-80
4. Tighten Nuts: Tighten all nuts evenly by alternating sides until metal-to-metal
contact occurs at the angle bolt pads. Make sure the housings keys completely
engage the grooves. Make sure the offsets are equal at the bolt pads.This is
necessary to ensure a rigid joint (refer to the example below). Note: It is
important to tighten all nuts evenly to prevent gasket pinching (See Figure 6-
81).
WARNING
!
Victaulic rigid, angle-pad couplings must have the nuts tightened evenly
by alternating sides until metal-to-metal contact occurs at the bolt pads.
Victaulic rigid, angle-pad couplings must have equal offsets at both bolt
pads.
Failure to follow these instructions could cause joint failures resulting in
serious personal injury and/or property damage.
Figure 6-81
Impact Wrench Usage Guidelines
DO NOT use an impact wrench after the visual installation guidelines for the coupling
are achieved.
Nuts must be tightened evenly by alternating sides until metal-to-metal contact occurs
at the bolt pads. For angle-bolt-pad couplings, even offsets must be present at the bolt
pads to obtain pipe-joint rigidity.
Failure to follow these instructions could cause gasket pinching and coupling damage
resulting in joint failure, serious personal injury and property damage.
Installation Inspection
Proper Installation
Figure 6-82
Proper pipe preparation and coupling installation is essential for maximum joint performance.
The following conditions must be present to ensure proper joint assembly.
1. The pipe O.D. and groove dimensions must be within the tolerance of current
Victaulic grooving specifications.
2. Unless stated otherwise in specific product instructions, Victaulic grooved pipe
couplings must be properly assembled with the bolt pads in firm, metal-to-
metal contact.
3. The housings keys must be fully engaged in both grooves. (See Figure 6-82)
Always re-inspect joints before and after the field test to identify points of possible failure. Look
for gaps at the bolt pads and/or keys that ride up on the shoulders. If any of these conditions
exist, depressurize the system and replace any questionable joints.
Hoist (Winch) 8000#
Check Winch Oil Level
Figure 6-83
1. Oil Level
To check the oil level, remove the large plug located in the center of the drum
support. The oil should be level with the bottom of this opening (See Figure 6-
83).
2. Add Oil
Fill thru the large plug in the center of the drum support. Use 80W90 Gear Oil.
Install large plug and tighten.
Compressor
Change Compressor Oil Filters
Under normal operating conditions, the compressor oil filters must be changed every 500
hours as part of a routine maintenance program.
DANGER
!
High pressure can cause severe injury or death. Do not attempt to remove
been relieved from the system. Completely relieve pressure before
removing filler plug, drain valve, fittings or receiver cover.
WARNING
!
1. Park the drill on stable, level surface and shut down engine. Allow time for the
drill to cool.
2. Locate the compressor oil filters and clean the oil filter base assembly.
3. Place a container with a capacity of at least 2 gallon (8 liters) under the filter(s).
Do not allow used oil to drain into the ground (See Figure 6-84).
4. Remove filter with an Oil Filter Strap Wrench Assembly.
6. Apply clean compressor oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them. This oil would not
be filtered and could be contaminated. Contaminated oil can cause
accelerated wear to compressor components.
Figure 6-84
engine and check for leaks again. Check the compressor oil level, if low fill to
middle of sight glass on receiver tank.
Note: Low Pressure compressors (110 psi / 7.58 bar) use LP-150 oil.
High Pressure compressors (350 psi / 24.13 bar) use HP-350 oil.
Tower Feed Cables and Chains
Check Feed Cables and Chain Sag
Figure 6-85
With the tower horizontal, verify cable slack adjustment. It should be 1-3/4 to 1-7/8 Per
Engineering Drawing, from the center of the cable to the bottom of the main chord (5 x 3 guide
tube), at the center of the tower with the rotary head at the top stop (See Figure 6-85). Refer
to 6.4 Maintenance As Required section Feed Cable/Chain Adjustment.
General Information
WARNING
!
drill.
overturning.
crushing risk.
Compressor Oil Analysis
Have a compressor oil analysis done every 1000 hours routine maintenance schedule.
Compressor
Change Receiver Tank Oil
Under normal operating conditions, the receiver tank oil must be changed every 1000 hours
as part of a routine maintenance program.
Figure 6-86
DANGER
!
removing filler plug, drain valve, fittings or receiver cover.
WARNING
!
Drain Receiver Tank Oil
drill to cool.
2. The best time to drain the receiver separator tank oil is when the oil is warm. At
that time the sediment in the receiver separator is in suspension and will drain
with the old oil. Temperature should not exceed 140F (60C) before draining
oil.
3. Place a container with a capacity of at least 40 gallon (151 liter) under the drain
valve on the bottom of the receiver tank (See Figure 6-86).
WARNING
!
4. The engine must be stopped and all pressure relieved from the tank and hoses.
The tank pressure gauge must read zero psi. Verify no pressure is in the
system by opening the service air valve and checking the gauge (See Figure
6-87).
Figure 6-87
5. Remove drain plug and open ball valve. Allow the compressor oil to drain into
a suitable container. After draining, clean off plug and install. Do not allow used
oil to drain into the ground. Dispose of properly. Follow all local standards and
6. Standard Filling - Fill the receiver tank through the fill cap (See Figure 6-86)
on receiver tank. Fill to the middle of the receiver tank sight glass. Install fill cap
and tighten. See section 6.3 Refill Capacities/Lubricants/ Specifications for
details on compressor oil.
7. Quick Filling (Option) - Fill the receiver tank through the quick fill port (See
Figure 6-88).
Figure 6-88
8. Fill to the middle of the receiver tank sight glass. See section 6.3 Refill
Capacities/Lubricants/ Specifications for details on compressor oil.
Hydraulic Oil Filters
The hydraulic oil filters must be changed every 1000 hours as part of the routine maintenance
procedure.
NOTICE
clean contaminant free system is extremely important to the machines
There are two system return hydraulic oil filters and one case drain filter on the drill (See Figure
6-89).
The system main return filters are located on the rear face of the hydraulic tank. The main
return low to the tank passes through these filters and into the hydraulic oil tanks internal
supercharge manifold. The supercharge of 65 psi provides supply to the piston pumps and
minimizes cavitation problems.
The case drain filter is located on the drill tower support and filters case drain oil prior to return
into the hydraulic tank.
Figure 6-89
It is important to monitor the filters restriction indicator sight glass during the routine 10 hour
walk around inspection by the operator. If the indicator window shows RED, then the filter
elements require replacement. If the window shows GREEN, the filters are satisfactory.
When restriction indicates that element servicing is required, proceed in the following manner.
Under normal operating conditions, these filters are replaced at the regular 1000 Hour service
interval.
WARNING
!
Do not attempt to service the filters before making sure all the hydraulic
pressure has been relieved from the system.
WARNING
!
NOTICE
Main Return Filters
When restriction indicates that element servicing is required, or the regular 1000 Hour service
interval is reached, proceed in the following manner for these filters:
Figure 6-90
1. Wipe all external dirt and oil from filter housing and head area to minimize
contamination from entering the system.
2. Place a container with a capacity of at least 2 gallon (8 liters) under the filters.
3. Loosen the bolt at filter housing base and remove the housing, elements and
the indicator as an assembly.
4. Remove the indicator from the element by twisting slightly with a side loading
force. Do not pull the indicator straight out or pry loose. If the indicator comes
out too easily, the snap in lugs are probably worn and the indicator should be
replaced.
5. Discard the old elements in accordance with local guidelines.
6. Inspect the indicator and O-ring seal.
7. Snap indicator onto the new element, making sure the part number on the new
element is the same as that on the element removed.
8. Clean the housing center bolt and spring in an approved cleaning solvent and
allow to dry.
9. Inspect the O-ring washer on the center bolt and replace if damaged.
10. Install the center bolt through the bottom of the housing and slide the spring
(small end first) down over the center bolt.
11. Place the element and indicator assembly into the housing and bolt the
assembly, making sure the center bolt passes through the indicator centering
hole.
12. Inspect the O-ring in the filter head and replace if damaged.
CAUTION
!
Over torquing the bolt will cause damage to the housing and/or O-ring
washer seal.
13. Install the housing assembly onto the filter head making sure the indicator ears
appear in the window and tighten the center bolt to 10-20 ft/lbs (13.55-27.11
Nm) torque.
14. After tightening, start engine and check for leaks. Correct if necessary.
Case Drain Filter
When restriction indicates that element servicing is required, or the regular 1000 Hour service
interval is reached, proceed in the following manner for this filter:
Figure 6-91
WARNING
!
Do not attempt to service the filters before making sure all the hydraulic
pressure has been relieved from the system.
1. Wipe all external dirt and oil from filter housing and head area to minimize
contamination from entering the system.
2. Place a container with a capacity of at least 2 gallon (8 liters) under the filters.
3. Remove the U-Bolt holding the filter half way down the case drain filter.
4. Carefully remove the 4 bolts that secure the retaining ring to the filter head.
5. Remove element from the filter housing.
6. Save the element connectors located between the element and discard old
elements in accordance with any local guidelines.
7. Clean the filter housing and filter head with an approved cleaning solvent.
8. Place the connectors into the element and element into the housing.
9. Attach the housing to the filter head and tighten the 4 bolts evenly and in
sequence. Care must be taken not to damage the O-ring.
10. Install U-Bolt and tighten, do not over tighten.
11. Pressurize the hydraulic system and check for leaks.
Rotary Head
Change the conventional rotary head oil as part of the 1000 hour routine maintenance
schedule.
WARNING
!
Riding the rotary head can cause severe injury or death. Do not ride the
rotary head.
WARNING
!
Climbing a raised tower can cause severe injury or death. Do not climb
raised tower.
WARNING
!
A falling tower can cause severe injury or death. Ensure all locking pins
are in a locked position.
WARNING
!
Rotating shafts or a rotating drill string can cause severe injury or death.
Do not service the rotary head with the drill string in motion.
Rotary Head Oil
To change the lubricant in the rotary head, follow the procedure below.
Figure 6-92
1. Position the drill on a stable, level surface and raise the tower vertical.
2. Remove the drill rod from the rotary head and lower the rotary head to the
bottom of the tower.
3. Shut off the engine.
4. Ensure oil is warm before draining oil.
5. Place a container with a capacity of at least 8 gallon (30 liter) under the rotary
head drain point (See Figure 6-92).
6. Clean around the fill port area to prevent debris from entering during oil change.
NOTE: Take care to prevent any contamination from entering the fill
ports.
7. Remove the drain plug and install a drain hose to the drain port. (See Figure 6-
92)
NOTICE
or maintenance on this component. Handle and dispose of fluids
8. Open drain ball valve to drain rotary head oil.
9. Remove the fill plug to allow air into tank during draining. Allow the oil to drain
into a suitable container. Do not allow used oil to drain into the ground.
Dispose of properly. Follow all local standards and regulations for
disposal of used oil.
10. After the case is drained, clean the drain plug and install.
11. Refill the rotary head gearbox through the fill port with SAE 90W gear oil until
the fluid is near the top of the fluid level sight glass. The rotary head gearbox
will hold approximately 7.5 to 8 gallons (28 to 30 liter) of gear oil.
12. Clean and install the fill plug.
13. After startup, check the rotary head for any leaks while at operating
temperatures.
Hoist (Winch) 8000 #
Figure 6-93
Oil Change
1. To drain the gear oil, align the drain plug in the drum with the hole in the support
side of the base.
2. Install a short piece of 1 in. pipe into the threaded drum port to prevent oil from
draining into winch base.
3. Insert a wrench through the 1 in. pipe and remove the drain plug.
4. Install plug securely after oil has been drained.
Add Oil (Refill)
1. Remove the large plug located in the center of the drum support (See Figure 6-
93).
2. Fill thru the large plug in the center of the drum support.
3. The oil should be level with the bottom of this opening
4. Refill with 80W90 Gear Oil, approximately 4 pints (1.9 liters) capacity. Refer to
6.3 Refill Capacities and Lubricants Specifications, under Capacities for more
detailed information.
5. Install large plug and tighten.
Vent Plug
1. The vent plug is located in the drum support as shown in Figure 6-93. It is very
important to keep this vent clean and unobstructed. Whenever gear oil is
changed, remove vent plug, clean in solvent and reinstall.
Rod Changer Reducing Gear
Change the Rod Changer Reducing Gear oil as part of the 1000 hour routine maintenance
schedule.
Figure 6-94
Drain Oil
1. Place drill on stable, level surface with tower vertical and engine off.
2. Place a container with a capacity of 1 quart under the gear drain plug
3. Clean the area around the fill port and drain plug.
4. Remove drain plug (See Figure 6-94). Drain oil from gear into container. Do not
allow the used oil to drain into the ground. Dispose of properly.
5. Clean drain plug threads and install it securely.
Refill or Add Oil
1. Remove breather and 90 degree fitting from reducing gear.
2. Fill reducing gear through the fill port (See Figure 6-94) with 80W90 gear oil
(approximate oil capacity is 1 pint). Refer to 6.3 Refill Capacities and Lubricants
Specifications.
3. Oil level is at the bottom of fill port (See Figure 6-94).
4. Install breather and 90 degree fitting as shown in figure 6-94.
6.11 - Maintenance (1500-2000 Hours)
General Information
WARNING
!
drill.
Always wear the correct safety gear while working on or around the drill. This includes an
overturning.
crushing risk.
Receiver Tank
Receiver Separator Element
Maintenance on the receiver separator element is on an as required basis. A change of the
separator element is required when there is excessive oil carryover with the compressed air.
Otherwise, change the separator element as part of the 2000 hour routine maintenance
schedule.
WARNING
!
opening the drain valve or removing the filler plug, fittings or removing
the receiver cover.
WARNING
!
components.
The following maintenance procedure must be followed:
1. Park the drill on a stable, level surface and shut down the engine. Allow time
for the drill to cool.
Figure 6-95
2. Remove the receiver cover with a hoist or lifting device. Clean the sealing
surface of the receiver cover. Ensure that all of the old element gasket is all
removed.
3. Remove the separator element from the tank.
4. Discard the used element in accordance with local guidelines.
5. When installing the new element, make sure that the gasket is equipped with a
staple. Also, install the element with the two drain holes located at the bottom.
See Figure 6-96 in section titled Compressor Fire Prevention.
6. Re-attach the cover and tighten the bolts.
a. Vertical tank - torque bolts to 353-380 ft/lbs. dry (478-515 Nm). Refer to
Section 6-14 for Torque Specifications.
7. Check the compressor oil fluid level is as follows:
a. The fluid must be in the center of the oil level sight glass.
b. If necessary, add fresh, clean synthetic oil (filtered through a 10 micron
filter) through the quick fill or fill cap area to bring level to FULL.
Note:
For details on compressor oil, refer to 6.3-Refill Capacities/Lubricants
Specifications.
8. After startup, check the drill for any leaks at operating temperatures.
Compressor Fire Prevention
CAUTION
!
When replacing the separator element, be sure there is at least one staple
that shows through on both sides of the gasket and is not covered with
glue.
Figure 6-96
A fiber gasket is installed between the outside cover of the receiver tank and the metal tube
holding the separator element in place. This gasket prevents oil from leaking around the metal
tube and down the hole.
When air and oil flow through the filter media, static electric charges are created. If these
charges are allowed to build up, a spark similar to a lightning flash will occur. This will set the
oil and the media on fire. The fire will burn from the inside of the element through the standpipe
hose and will follow the air flow until it burns through the air hose, This is NOT a fire caused
by the compressor flashing.
To prevent this from happening, several metal staples have been installed THROUGH the
gasket so each side comes in contact with the metal. This bridge serves to allow the static
charge to drain off outside the receiver tank and not cause a static buildup.
Track Planetary Gearbox
Change Planetary Gearbox Oil
The gear oil should be changed every 1500 - 2000 operating hours. This maintenance is
recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in
order to help provide maximum planetary gearbox life.
Figure 6-97
WARNING
!
off the engine.
2. Be sure the oil is warm before draining but be sure that the planetary housings
are not too hot to touch. If they are hot, give them time to cool down before
proceeding.
3. Place container with a capacity of at least 2.1 gallon (8 liters) under the track
drive drain point.
4. Clean the area around the fill and level plug. Cleaning around the fill and level
plug area, is to prevent debris from entering during oil change
5. Removed plugs and drain oil from the final drive into a suitable container. Do
not allow used oil to drain into the ground. Dispose of properly. Follow all
local standards and regulations for disposal of used oil.
7. Refill the planetary through the oil fill plug hole with about 2.1 gallons (8.0 liters)
per drive of oil (Cat Tracks / 50WT or AC Tracks / 80W90 gear oil), until the
planetary is full. Allow the surplus oil to drain out until the oil level is up to the
bottom of the level port. Do not allow the excess oil to drain into the ground.
8. Clean the fill/level plug threads and then install it.
9. After scheduled service is complete, check the planetary track drive for leaks
at operating temperatures. Listen for any unusual noises that might need
attention.
Water Injection Pump
John Bean Water Injection Pump
After the initial water injection pump oil change after the first 50 hours of operation, the
following water injection pump maintenance must be carried out every 2000 hours.
WARNING
!
The water injection pump oil should be at operating temperature for
draining. Be careful Hot oil and components can burn.
Figure 6-98
1. Position the drill on stable, level surface.
2. Place a container with a capacity of at least 2 quarts (1.90 liters) under the drain
point to collect the used oil.
3. Remove both fill / level plug and magnetic drain plug. Allow oil to drain
completely. (See Figure 6-98)
4. After oil has drained, clean magnetic drain plug and replace.
5. Clean and remove the level plug.
6. 8 gpm Water Injection Pumps - Refill the oil through the fill port
(approximately 1 quarts (0.95 liters) or until oil appears at the oil fill / level plug.
Fill with clean SAE 30 non-detergent oil.
7. Clean and install fill / level plug.
8. Operate the drill and water injection and check for any leaks.
Table 33: Recommended Lubricant Chart
Air Compressor Discharge Hose
The discharge air hose between the compressor and the receiver tank should be changed
every two (2) compressor oil changes or once every 2000 hours, which ever occurs first.
Compressor Discharge Hose
The compressor discharge hose is subject to the highest temperatures in the compressor
system and is in contact with synthetic oil all the time. If the hose is not replaced periodically,
the inner linings will begin to break down. Lining material can clog the cooler and damage the
compressor lubrication pumps.
Type of Service
Ambient
Temp.
ISO
Grade
(cSt)
AGMA Number
SAE
Weight
SSU
Viscosity
General Service 0-95F 100 3 30 550
High Ambient
Temperatures
95-120F 220 5 50 1165
Cold Ambient
Temperatures
-30-60F 68 2 20 350
Frequent Start-
Stop Cycles
0-95F 150 4 40 775
6.12 - Maintenance (3000 Hours or 3 Years)
General Information
WARNING
!
drill.
overturning.
crushing risk.
Cat Engine Coolant System
Change Engine Coolant System
The engine coolant system should be changed every 3000 operating hours or 3 Years. This
maintenance is recommended by Caterpillar as part of a preventive maintenance schedule in
order to help provide maximum engine coolant life.
WARNING
!
WARNING
!
components. Coolant must be at cool temperature when draining. Do not
allow used coolant to drain into the ground. Dispose of properly.
NOTICE
NOTE:
NOTE:
Drain Coolant
coolant to cool.
radiator coolant drain ball valve (See Figure 6-99).
Figure 6-99
3. Connect drain hose to the cooler drain ball valve.
4. Slowly open the pressure cap on top of radiator in the event there is pressure
on the system. After pressure is released, remove the pressure cap.
5. Check to make sure all heater valves are open.
6. Open drain valve and allow the coolant to drain from the engine and radiator
into a suitable container. Do not allow used coolant to drain on to the
ground. Dispose of properly. Follow all local standards and regulations
for disposal of used coolant.
7. After the coolant has stopped draining close coolant drain valve.
NOTICE
This is a good time to check water pump and hoses for working
conditions. If necessary, this would be a good time to replace the water
pump and hoses for the system.
8. Proceed to flushing coolant system.
Flush Coolant System
1. Cooling system needs to be flushed out to remove any debris.
NOTICE
Fill the cooling system no faster than 5 US gallons (19 liters) per minute
to avoid air locks in the system.
2. Recommended way to flush system is fill the cooling system with a mixture of
clean water and Caterpillar Fast Acting Cooling System Cleaner. Add 1.0 pint
(0.5 liters) of cleaner per 4 US gallon (15 liters) of the cooling system capacity.
Heavy Deposits or Plugging - Add 1.0 pint (0.5 liters) of cleaner per 1 to 2 US
gallon (3.8 to 7.6 liters) of the cooling system capacity. Install the pressure cap
on the cooling system radiator.
3. Start the engine and run at idle for a minimum of 30 minutes. Heavy Deposits
or Plugging - Start the engine and run at idle for a minimum of 90 minutes.
Coolant temperature should be at least 180 F (82C).
4. Stop engine and allow the engine and cooling system to cool. After cooling of
system loosen the pressure cap slowly in order to relieve any pressure.
Remove the pressure cap.
6. Open drain valves and allow the coolant to drain from the engine and radiator
NOTICE
Improper or incomplete rinsing of the cooling system can result in
damage to copper and other metal components.
To avoid damage to the cooling system, make sure to completely flush
the cooling system with clean water. Continue to flush the system until
all signs of the cleaning agent are gone.
8. Remove the drain hose from the coolant drain ball valve. Clean the plug or cap
threads and install plug or cap securely.
9. Proceed to filling coolant system.
Filling Coolant System
There are two (2) ways to fill the coolant system;
Standard - Filling radiator through radiator cap neck (See Figure 6-100).
Quick Fill - Filling coolant system through connection point.
Figure 6-100
NOTICE
1. Fill the cooling system the Standard way (See Figure 6-100), remove the
radiator cap and fill through the radiator cap fill neck.
a. Fill the cooling system the Quick Fill way (See Figure 6-100), locate the
coolant connection, wipe connection and connection hose clean of debris
and connect fill hose.
2. Remove the radiator fill cap either way, Standard or Quick Fill method for
system to breathe.
3. Fill the cooling system with coolant/antifreeze. Refer to Cat Operation and
Maintenance Manual, Refill Capacities and Recommendations. There are two
primary coolants used in Caterpillar Engines: Do not install the cooling system
filler cap.
Preferred - Cat ELC (Extended Life Coolant) or a commercial extended life
coolant that meets the Caterpillar EC-1 specifications.
Acceptable - Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial
heavy-duty coolant/antifreeze that meets ASTM D4985 or ASTM D5345
specifications.
NOTE: Cat DEAC DOES NOT require a treatment with SCA at the initial
fill. Commercial heavy-duty coolant/antifreeze that meets ASTM D4985
or ASTM D5345 specifications MAY require a treatment with an SCA at
the initial fill. Read the label or the instructions that are provided by the
OEM of the product.
Caterpillar recommends a 1:1 mixture of water and glycol. This mixture will provide
optimum heavy-duty performance as a coolant/antifreeze.
NOTE: The Table 33 is a list of the coolants that are recommended and
the service life (calendar) of the coolants.
Table 34: Coolant Service Life
4. Check the coolant level. Fill to the top of the top radiator sight glass (See Figure
6-100).
5. Start engine and run at idle. Increase the engine to 1500 rpm. Run the engine
at high idle for one minute to purge the air from the system (engine and
radiator). Shut the engine off.
6. Re-check the coolant level. Fill to the top of the top radiator sight glass as
needed. (See Figure 6-100)
7. Clean the cooling system filler pressure cap. Inspect the pressure cap gasket,
if the gasket is damaged replace the pressure cap with a new pressure cap.
8. Install the filler neck pressure cap. Start the engine and check for leaks. Check
for proper operating temperature and operation.
9. If filling coolant system the Quick fill way, remove hose from quick fill
connection, install cap and close cover on the quick fill systems.
Coolant Service Life
Coolant Type
Service Life
(1)
Cat ELC Six Years
Cat DEAC Three Years
Commercial Heavy-Duty Coolant/
Antifreeze that meets ASTM
D5345
Two Years
Commercial Heavy-Duty Coolant/
Antifreeze that meets ASTM
D4985
One Year
Caterpillar SCA and Water Two Years
Commercial SCA and Water One Year
(1)
The service life of coolant is also limited by (service hours). Refer to
the specific engines Operation and Maintenance Manual, Maintenance
Interval Schedule (Maintenance Section).
Hydraulic Oil
The hydraulic oil must be changed every 5000 hours as part of the routine maintenance
procedure.
WARNING
!
WARNING
!
Do not attempt to service the hydraulic system before making sure all the
hydraulic pressure has been relieved from the system.
WARNING
!
Change Hydraulic Oil
Figure 6-101
1. Park the drill on stable, level surface and shut down engine. Tower must be in
the horizontal (down) position and all jacks up (stowed position). Allow time for
the hydraulic oil to cool.
hydraulic oil drain point (See Figure 6-101).
3. Connect drain hose to hydraulic drain point to drain. Open drain valve and allow
the hydraulic oil to drain into a suitable container. Do not allow used oil to
drain into the ground. Dispose of properly. Follow all local standards and
4. After the hydraulic tank has stop draining, close ball valve. Clean drain plug,
install and tighten. Fill the hydraulic tank by one of the three filling procedures.
See section 6.3 Refill Capacities/Lubricants/ Specifications for details on
hydraulic oil.
CAUTION
!
equipment failure.
Figure 6-102
breathe.
NOTICE
Figure 6-105).
Figure 6-103
breathe.
6-103).
NOTICE
Figure 6-105).
Figure 6-104
breathe.
NOTICE
Figure 6-105).
NOTICE
Do not ever fill hydraulic tank through the breather ports or suction
manifold plug. Only fill hydraulic tank reservoir by the three (3) hydraulic
tank fill procedures.
Figure 6-105
6.13 - Maintenance (6000 Hours or 2 Years)
General Information
WARNING
!
drill.
overturning.
crushing risk.
Cummins Engine Coolant System
Change Engine Coolant System
The engine coolant system should be changed every 6000 operating hours or 2 Years. This
maintenance is recommended by Cummins as part of a preventive maintenance schedule in
order to help provide maximum engine coolant life.
WARNING
!
WARNING
!
components. Coolant must be at cool temperature when draining. Do not
allow used coolant to drain into the ground. Dispose of properly.
NOTICE
NOTE:
NOTE:
Drain Coolant
coolant to cool.
radiator coolant drain ball valve (See Figure 6-106).
Figure 6-106
3. Connect drain hose to the cooler drain ball valve.
4. Slowly open the pressure cap on top of radiator in the event there is pressure
on the system. After pressure is released, remove the pressure cap.
6. Open drain valve and allow the coolant to drain from the engine and radiator
NOTICE
This is a good time to check water pump and hoses for working
conditions. If necessary, this would be a good time to replace the water
pump and hoses for the system.
8. Proceed to flushing coolant system.
Flush Coolant System
1. Cooling system needs to be flushed out to remove any debris.
NOTICE
2. Recommended way to flush system is fill the cooling system with clean water.
3. Start the engine and run at idle for a minimum of 30 minutes. Coolant
temperature should be at least 180 F (82C).
4. Stop engine and allow the engine and cooling system to cool. After cooling of
system loosen the pressure cap slowly in order to relieve any pressure.
Remove the pressure cap.
6. Open drain valves and allow the coolant to drain from the engine and radiator
NOTICE
To avoid damage to the cooling system, make sure to completely flush
the cooling system with clean water. Continue to flush the system until
fluid is clear.
7. After the coolant has stopped draining close coolant drain ball valve.
8. Remove the drain hose from the coolant drain ball valve. Clean the plug or cap
threads and install plug or cap securely.
9. Proceed to filling coolant system.
Filling Coolant System
There are two (2) ways to fill the coolant system;
Standard - Filling radiator through radiator cap neck (See Figure 6-107).
Quick Fill - Filling coolant system through connection point.
Figure 6-107
NOTICE
1. Fill the cooling system the Standard way (See Figure 6-107), remove the
radiator cap and fill through the radiator cap fill neck.
a. Fill the cooling system the Quick Fill way (See Figure 6-107), locate the
coolant connection, wipe connection and connection hose clean of debris
and connect fill hose.
2. Remove the radiator fill cap either way, Standard or Quick Fill method for
system to breathe.
3. Fill the cooling system with coolant/antifreeze. Refer to Cummins Operation
and Maintenance Manual, Refill Capacities and Recommendations. There
are two primary coolants used in Cummins Engines:
A 50/50 mixture of good-quality water and fully formulated anti-freeze.
Fully formulated coolant.
NOTE: The coolant or fully formulated anti-freeze must meet TMC RP 329
or TMC RP 330 specifications.
NOTE: Table 34 is a Water Quality Table
Table 35: Good Quality Water
NOTICE
Do not use sealing additives or soluble oils in the cooling systems.
4. Check the coolant level. Fill to the top of the top radiator sight glass (See Figure
6-107).
5. Start engine and run at idle. Increase the engine to 1500 rpm. Run the engine
at high idle for one minute to purge the air from the system (engine and
radiator). Shut the engine off.
6. Re-check the coolant level. Fill to the top of the top radiator sight glass as
needed. (See Figure 6-107)
7. Clean the cooling system filler pressure cap. Inspect the pressure cap gasket,
if the gasket is damaged replace the pressure cap with a new pressure cap.
8. Install the filler neck pressure cap. Start the engine and check for leaks. Check
for proper operating temperature and operation.
9. If filling coolant system the Quick fill way, remove hose from quick fill
connection, install cap and close cover on the quick fill systems.
Water Quality
Calcium
Magnesium
(Hardness)
Maximum 170 ppm as
(CaCO
3
+MgCO
3
)
Chloride 40 ppm as (CI)
Sulfur 100 ppm as (SO
4
)
6.14 - Torque Specifications
Standard Torque Values
General Information
CAUTION
!
Use only the proper tools (inch or metric) on hardware. Other tools may
not fit properly. They may slip and cause injury.
Head Markings
Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original grade fastener.
Figure 6-108
Do not use these values if a different torque value or tightening procedure is listed for a specific
application. Torque values listed are for general use only. All values are suggested maximum
with dry plated hardware.
Make sure fastener threads are clean and you properly start thread engagement. This will
prevent them from falling when tightening.
The following pages list the recommended tightening torques for the various size bolts used
by Drilling Solutions. Proper torque specifications should be used at all times.
The head of grade five (5) is marked with three (3) short lines. The head of a grade eight (8)
is marked with six (6) short lines. (See Figure 6-108)
In the following tables, DRY means clean dry threads and LUBE means a light film of oil.
Excess oil in a threaded dead end hole can create a hydraulic lock giving a false torque
reading.
Recommended Torques in Foot Pounds (ft/lbs.)
This page lists the recommended tightening torques, in foot pounds (ft/lbs.), for the various
size bolts and nuts that are used. Proper torque specifications should be used at all times. The
head of a grade five (5) bolt is marked with three (3) short lines. The head of a grade eight (8)
bolt is marked with six (6) short lines. Dry means clean dry threads and LUBE means a light
film of oil. Excess oil in a threaded dead end hole can create a hydraulic lock giving false
torque readings. Suggested assembly torque values are per engineering specifications.
Table 36: Recommended Torques in Ft/Lbs.
SIZE
SAE GRADE 5 TIGHTENING
TORQUE
TORQUE
DRY LUBE DRY LUBE
1/4 - 20 NC
1/4 - 28 NF
8
10
6
7
12
14
9
10
5/16 - 18 NC
5/16 - 24 NF
17
19
13
14
25
25
18
20
3/8 - 16 NC
3/8 - 24 NF
30
35
23
25
45
50
35
35
7/16 - 14 NC
7/16 - 20 NF
50
55
35
40
70
80
55
60
1/2 - 13 NC
1/2 - 20 NF
75
90
55
65
110
120
80
90
9/16 - 12 NC
9/16 - 18 NF
110
120
80
90
150
170
110
130
5/8 - 11 NC
5/8 - 18 NF
150
180
110
130
220
240
170
180
3/4 - 10 NC
3/4 - 16 NF
260
300
200
220
380
420
280
320
7/8 - 9NC
7/8 - 14 NF
430
470
320
360
600
660
460
500
1 - 8 NC
1 - 12 NF
640
710
480
530
900
1000
680
740
1-1/8 - 7 NC
1-1/8 -12 NF
800
880
600
660
1280
1440
960
1080
1-1/4 - 7 NC
1-1/4 - 12 NF
1120
1240
840
920
1820
2000
1100
1500
1-3/8 - 6 NC
1-3/8 - 12NF
1460
1680
1100
1260
2380
2720
1780
2040
Recommended Torques in Nm
This page lists the recommended tightening torques, in Newton-meters (Nm), for the various
size bolts and nuts that are used. Proper torque specifications should be used at all times. The
head of a grade five (5) bolt is marked with three (3) short lines. The head of a grade eight (8)
bolt is marked with six (6) short lines. Dry means clean dry threads and LUBE means a light
film of oil. Excess oil in a threaded dead end hole can create a hydraulic lock giving false
torque readings. Suggested assembly torque values are per engineering specifications.
Table 37: Recommended Torques in Nm
1-1/2 - 6 NC
1-1/2 - 12 NF
1940
2200
1460
1640
3160
3560
2360
2660
SIZE
TORQUE
TORQUE
DRY LUBE DRY LUBE
1/4 - 20 NC
1/4 - 28 NF
11
14
8
9
16
19
12
14
5/16 - 18 NC
5/16 - 24 NF
23
26
18
19
34
34
24
27
3/8 - 16 NC
3/8 - 24 NF
41
47
31
34
61
68
47
47
7/16 - 14 NC
7/16 - 20 NF
68
75
47
54
95
108
75
81
1/2 - 13 NC
1/2 - 20 NF
102
122
75
88
149
163
108
122
9/16 - 12 NC
9/16 - 18 NF
149
163
108
122
203
230
149
176
5/8 - 11 NC
5/8 - 18 NF
203
244
149
176
298
325
230
244
3/4 - 10 NC
3/4 - 16 NF
353
407
271
298
515
569
380
434
7/8 - 9NC
7/8 - 14 NF
583
637
434
488
813
895
624
678
SIZE
TORQUE
TORQUE
DRY LUBE DRY LUBE
Metric Torque Values
General Information
CAUTION
!
Use only the proper tools (metric) on hardware. Other tools may not fit
properly. They may slip and cause injury.
Head Marking or Class
Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners
are used, these should only be tightened to the strength of the original grade fastener
Figure 6-109
1 - 8 NC
1 - 12 NF
868
963
651
719
1220
1356
922
1003
1-1/8 - 7 NC
1-1/8 -12 NF
1085
1193
813
895
1735
1952
1302
1464
1-1/4 - 7 NC
1-1/4 - 12 NF
1519
1681
1139
1247
2468
2712
1491
2034
1-3/8 - 6 NC
1-3/8 - 12NF
1979
2278
1491
1708
3227
3688
2413
2766
1-1/2 - 6 NC
1-1/2 - 12 NF
2630
2983
1979
2224
4284
4827
3200
3606
SIZE
TORQUE
TORQUE
DRY LUBE DRY LUBE
Do not use these values if a different torque value or tightening procedure is listed for a specific
application. Torque values listed are for general use only. All values are suggested maximum
with dry plated hardware.
Make sure fastener threads are clean and you properly start thread engagement. This will
prevent them from falling when tightening.
The following pages list the recommended tightening torques for the various size bolts used
by Drilling Solutions. Proper torque specifications should be used at all times.
Metric head marking or class see Figure 6-109.
In the following tables, DRY means clean dry threads and LUBE means a light film of oil.
Excess oil in a threaded dead end hole can create a hydraulic lock giving a false torque
reading.
Recommended Torques in Foot Pounds (ft/lbs.)
This page lists the recommended tightening torques, in foot pounds (ft/lbs.), for the various
size bolts that are used. Proper torque specifications should be used at all times. Dry means
clean dry threads and LUBE means a light film of oil. Excess oil in a threaded dead end
hole can create a hydraulic lock giving false torque readings. Suggested assembly torque
values are per engineering specifications.
Table 38: Recommended Torques in Metric Bolts in ft/lbs.
SIZE
CLASS 8.8 CLASS 10.9
CLASS 12.9 (Socket
Head Cap Screw)
DRY LUBE DRY LUBE DRY LUBE
M6x1 8 6 11 8 13 9
M8x1.25 19 15 27 20 31 23
M8x1 21 16 29 22
M10x1.5 39 29 53 40 62 47
M10x1.25 41 30 56 42
M12x1.75 67 50 93 70 108 81
M12x1.25 73 55 101 76
M14x2 107 80 148 111 173 130
M14x1.5 116 87 161 121
M16x2 167 125 231 173 269 202
M16x1.5 177 133 245 184
M20x2.5 325 244 450 337 525 394
Recommended Torques in Newton-meters (Nm)
This page lists the recommended tightening torques, in Newton-meters (Nm), for the various
size bolts that are used. Proper torque specifications should be used at all times.Dry means
clean dry threads and LUBE means a light film of oil. Excess oil in a threaded dead end
hole can create a hydraulic lock giving false torque readings. Suggested assembly torque
values are per engineering specifications.
Table 39: Recommended Torques in Metric Bolts in Nm
M20x1.5 361 271 500 375
M24x3 562 422 778 583 908 681
M24x2 612 459 846 635
M30x3.5 1117 838 1545 1159 1804 1353
M30x2 1237 928 1711 1283
M36x4 1952 1464 2701 2026 3154 2366
M36x2 2187 1640 3025 2269
M42x4.5 3123 2342 4320 3240
M42x2 3513 2635 4860 3645
M48x5 4684 3513 6479 4860
M48x2 5321 3991 7361 5521
SIZE
CLASS 12.9 (Socket
Head Cap Screw)
M6x1 11 8 15 11 17 13
M8x1.25 26 20 37 27 42 32
M8x1 28 22 39 30
M10x1.5 53 39 72 54 84 64
M10x1.25 56 41 76 60
M12x1.75 91 68 126 95 146 110
SIZE
CLASS 12.9 (Socket
Head Cap Screw)
M12x1.25 99 75 137 103
M14x2 145 108 201 150 234 176
M14x1.5 157 118 218 164
M16x2 226 169 313 235 365 274
M16x1.5 240 180 332 249
M20x2.5 440 331 610 457 712 534
M20x1.5 489 267 678 508
M24x3 762 572 1055 780 1231 923
M24x2 830 622 1147 861
M30x3.5 1514 1136 2095 1571 2446 1834
M30x2 1677 1258 2320 1740
M36x4 2647 1985 3662 2747 4276 3208
M36x2 2965 2223 4101 3076
M42x4.5 4232 3175 5857 4393
M42x2 4763 3573 6589 4942
M48x5 6351 4763 8784 6889
M48x2 7214 5411 9980 7485
SIZE
CLASS 12.9 (Socket
Head Cap Screw)
Section 7 - Troubleshooting
DM45,DM50,DML Instruction Manual Section 7 - Systems/Troubleshooting
7.1 - Introduction
Safety Precautions
approved hard hat, safety glasses, steel toed shoes/boots, gloves, respirator and ear
Most accidents involving product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially dangerous situations before trouble occurs. Some of the potential problems and
ways to prevent them are shown below.
Fluid Penetration
1. Always use a wooden board or cardboard when checking for leaks.
2. Leaking fluid under pressure can cause serious injury or death.
3. If fluid is injected into the skin, see a physician immediately.
Lines, Tubes and Hoses
1. Repair any loose or damaged oil lines, tubes and hoses. Leaks can cause fires.
2. Inspect all lines, tubes and hoses carefully. Do not use your bare hands to
check for leaks.
3. Tighten all connections to the recommended torque.
4. Make sure all clamps, guards and heat shields are installed correctly to prevent
vibration, rubbing against other parts and excessive heat during operation.
5. Check for the following:
a. End fittings damaged, leaking or displaced.
b. Outer covering chafed or cut and wire reinforcing exposed.
c. Outer covering ballooning locally.
d. Evidence of kinking or crushing of the flexible part of the hose.
e. Armoring embedded in the outer cover.
Burn Prevention
1. Do not touch any part of an operating engine or its components.
2. Allow the engine to cool before any repair or maintenance is performed.
Section 7 - Systems/Troubleshooting DM45,DM50,DML Instruction Manual
3. Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings
or related items are disconnected or removed.
Coolant
1. Use caution when removing filler cap, grease fittings, pressure taps, breathers
or drain plugs.
a. At operating temperature, the engine coolant is hot and under pressure.
The radiator and all lines to heaters or the engine contain hot water. When
pressure is relieved rapidly, this hot water can turn into steam. Allow cooling
system components to cool before draining. Any contact with hot water or
steam can cause severe burns. Check the coolant level only after the
engine has been stopped and the filler cap is cool enough to remove with
your bare hand.
2. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids
under pressure.
3. Remove the cooling system filler cap slowly to relieve pressure.
4. Cooling system additive (conditioner) contains alkali. To prevent personal
injury, avoid contact with the skin and eyes and do not drink.
Oils
1. Hot oil and components can cause personal injury. Do not allow hot oil or
components to contact the skin.
2. Keep all exhaust manifold and turbocharger shields in place to protect hot
exhaust from oil spray in case of a line, tube or seal failure.
Batteries
1. Battery electrolyte contains acid and can cause injury. Avoid contact with the
skin and eyes. Wash hands after touching batteries and connectors. Use of
gloves is recommended. Batteries give off flammable fumes, which can
explode. Ensure there is proper ventilation for batteries, which are located in an
enclosure.
2. Always thaw a frozen battery before jump starting. Frozen batteries can
explode.
3. Do not smoke when observing the battery electrolyte levels.
4. Always wear protective glasses when working with batteries.
5. Never disconnect any charging unit circuit or battery circuit cable from the
battery when charging unit is operating. A spark can cause the flammable
vapor mixture of hydrogen and oxygen to explode.
Fire or Explosion Prevention
1. Fire may result from lubricating oil or fuel sprayed on hot surfaces causing
personal injury and property damage. Inspect all lines and tubes for wear or
deterioration. They must be routed correctly, supported or clamped securely.
Tighten all connections to the recommended torque. Leaks can cause fires.
2. Determine whether the engine will be operated in an environment in which
combustible gases could be drawn through the air inlet system. These gases
could cause the engine to overspeed, which in turn could seriously damage the
engine and result in bodily injury or property damage.
3. All fuels, most lubricants and some coolant mixtures are flammable.
4. Diesel fuel is flammable. Gasoline is flammable. Mixtures of diesel and
gasoline fumes are extremely explosive.
5. Do not smoke while refueling or in a refueling area. Do not smoke in areas
where batteries are charged, or where flammable materials are stored.
6. Batteries give off flammable fumes which can explode. Keep all fuels and
lubricants stored in properly marked containers and away from all unauthorized
persons. Store all oily rags or other flammable material in a protective
container, in a safe place.
7. Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean
them thoroughly with nonflammable solvent before welding or flame cutting on
them. Remove all flammable materials such as fuel, oil and other debris before
they accumulate on the drill. Do not expose the engine to flames, burning
brush, etc., if possible.
8. Shields (if equipped), which protect hot exhaust components from oil or fuel
spray in the event of a line, tube or seal failure, must be installed correctly.
9. Provide adequate and proper waste oil disposal. Oil and fuel filters must be
properly installed and housing covers tightened to proper torque when being
changed.
10. Batteries must be kept clean, covers kept on all cells, recommended cables
and connections used and battery box covers kept in place when operating.
11. When starting from an external source, always connect the positive (+) jumper
cable to the POSITIVE (+) terminal of the battery of the engine to be started.
To prevent potential sparks from igniting combustible gases produced by some
batteries, attach the negative () boost ground cable last, to the starter
NEGATIVE () terminal (if equipped) or to the engine block. See the Operation
Section of this manual for specific starting instructions.
12. Clean and tighten all electrical connections. Check regularly for loose or frayed
electrical wires. Refer to maintenance schedules for interval. Have all loose or
frayed electrical wires tightened, repaired or replaced before operating the drill.
13. All wiring must be kept in good condition, properly routed and firmly attached.
Routinely inspect wiring for wear or deterioration. Loose, unattached, extra or
unnecessary wiring must be eliminated. All wires and cables must conform to
the recommended gauge and be fused if necessary. Do not use smaller gauge
wire or bypass fuses. Tight connections, recommended wiring and cables that
are properly cared for will help to prevent arcing or sparking which could cause
a fire.
Fire Extinguisher
1. Have a fire extinguisher available and know how to use it.
2. Inspect fire extinguisher and have it serviced as recommended on its
instruction plate.
Crushing or Cutting Prevention
1. Support equipment and attachments properly when working beneath them.
2. Never attempt adjustments while the engine is running unless otherwise
specified in this manual.
3. Stay clear of all rotating and moving parts. Guards should be in place whenever
maintenance is not being performed.
4. Keep objects away from moving fan blades. They will throw or cut any object
or tool that falls or is pushed into them.
5. Wear protective glasses when striking objects to avoid injury to your eyes.
6. Chips or other debris can fly off objects when struck. Make sure no one can be
injured by flying debris before striking any object.
Mounting and Dismounting
1. Do not climb on or jump off the drill or stand on components that cannot support
your weight. Use an adequate ladder. Always use steps and hand holds when
mounting and dismounting with a three-point stance.
2. Clean steps, hand holds and areas of the drill you will be working on or around.
Before Starting Engine
1. Inspect drill for potential hazards.
2. Be sure all protective guards and covers are installed if a drill must be started
to make adjustments or checks. To help prevent an accident caused by parts
in rotation, work carefully around them.
3. Do not disable or bypass automatic shutoff circuits. They are provided to
prevent personal injury and drill damage.
4. Never start an engine with the governor linkage disconnected.
5. Make provisions for shutting off the air or fuel supply to stop the engine if there
is an overspeed condition on startup after performing repair or maintenance to
the engine.
Engine Starting
1. Do Not start the engine or move any of the controls if there is a warning tag
attached to the controls. Check with the person who attached the tag before
starting.
2. Make sure no one is working on, or close to the engine or engine driven
components before starting it. Always inspect the engine before and after
starting.
3. Start the engine only from the operators station. Never short across the starter
terminals or the batteries as this could bypass the engine neutral-start system
as well as damage the electrical system.
4. Always start the engine according to the required Engine Starting procedure
described in this manual to prevent major engine component damage and
personal injury.
6. Only use the Emergency Stop button in an emergency. Do Not start the engine
until the problem necessitating the emergency stop has been located and
corrected.
7. On initial startup or overhaul, be prepared to STOP the drill should an
8. Check the jacket water and oil temperature gauges frequently during the
operation of jacket water and/or lube oil heaters to ensure proper operation.
9. Diesel engine exhaust contains products of combustion that may be harmful to
your health. Always start and operate the engine in a well ventilated area and,
if in an enclosed area, vent the exhaust to the outside.
Starting Aids
1. Ether and other starting aids are poisonous and flammable. Do not smoke while
changing ether cylinders.
2. Use ether only in well ventilated places.
3. Keep ether cylinders out of the reach of unauthorized persons.
4. Do not store replacement ether cylinders in living areas or in the storage
compartment or the cab.
5. Do not store ether cylinders in direct sunlight or at temperatures above 39 C
(102F). Discard cylinders in a safe place. Do not puncture or burn cylinders.
Engine Stopping
2. Only use the Emergency Stop button in an emergency. Do Not start the drill
until the problem is resolved.
3. On initial startup or overhaul, be prepared to STOP the engine should an
7.2 - Hydraulic Symbols
Fluid Power Symbols
Understanding and recognizing fluid power symbols is skill used in reading schematic
drawings for trouble shooting. It will also aid in understanding the schematics used to describe
the hydraulic systems used on the DM45,50,DML drill.
Symbols on schematics are pictographs (pictures of what the object does) and are used to
represent the component. The following symbols are an international fluid power language
designed by the American National Standard Institute.
You will remember fluid power symbols more easily if you learn the significance of these three
shapes:
1. Circle =Pump, Motor or Gauge
2. Square =Valve of some sort
3. Diamond =Fluid Container
Line Symbols
Hydraulic lines, tubes and hoses that carry fluid between components are drawn as a line.
1. The Working Line is an unbroken line which connects symbols in the hydraulic
diagram together.
2. The Pilot Line denotes pilot pressure.
3. The Drain Line denotes system drainage.
Connections for lines are shown below. Pay attention to the presence of a dot at the
intersection of lines. If there is no dot and the lines cross, the lines do not connect. If the lines
intersect but one line ends, then even without a dot the lines do connect.
Crossing Line Symbols
Lets examine the crossing line symbols. These are fluid or lines that cross but do not join.
They are independent and separate of each other.
Joining Line Symbol
The symbol for joining lines is shown below. They show us that fluid paths are connected.
Pay attention to the presence of a dot at the intersection of lines. If lines intersect but one line
ends, then even without a dot the lines do connect.
Flexible Line Symbol
The symbol for a flexible line or hose is also shown above. The curve in the line illustrates the
flexible hose and the two heavy dots represent terminal points.
Arrow Symbols
The arrow symbol appears in the working line. The arrow shows the direction of flow of the
fluid.
Reservoir or Tank Symbols
Reservoirs and tanks are used to contain fluids, provide cooling, separate air and oil, and
provide pressure to the pump if the reservoir is pressurized.
The tank and reservoir symbols are shown next. They appear on hydraulic diagrams as the
vented tank or pressurized tank. It is important to note that even though these symbols may
appear in many different places on a hydraulic diagram, there is usually only one centralized
reservoir tank.
Reservoir symbols can also show the point of connection for suction and return lines as shown
above.
Fluid Container Symbols
The condition of the oil is changed from one state to another. Typical conditioners are filters,
heaters and coolers which can contain drains of various sorts. Symbols for fluid conditioners
are shown below. The symbol with a dotted line drawn from top to bottom represents an oil
filter. The same symbol with arrows at the top and bottom of it represents an oil cooler.
Accumulator Symbols
Hydraulic accumulators act as shock absorbers for the system. They are installed in parallel
with the pump and do several things. They dampen out oscillations in pressure (keep pressure
constant) and provide flow when components move and activate. The are drawn as ovals with
a line in the center which represents the diaphragm or piston that separates the oil from the
spring or gas (see below). On the left is the gas loaded type, in the center is the spring loaded
type and on the right is the weighted type.
Restrictor Symbols
Sometimes its necessary to slow down flow or to create a pressure drop at some point in the
system.
Restrictors are drawn to represent a pinch in the line, and can either be fixed or variable and
can be controlled by other systems as well, such as being temperature or pressure controlled.
Hydraulic Cylinders
Hydraulic cylinders convert fluid power to linear mechanical power. Fluid under pressure
pushes against the ends of the piston to move it in order to move some other mechanism.
Cylinders are drawn as rectangles with lines in the center to represent the piston, and lines
through the ends to represent the rod. Fluid ports are shown on the outer ends of the cylinder
barrel.
A single-acting cylinder (above) has only one port so that fluid under pressure only enters one
end and pushes only in one direction. The cylinder reverses by opening a valve to let gravity
or a spring return the piston to the other end.
A double-acting cylinder has ports at each end so pressurized fluid will enter both ends and
push against the piston in both directions.
Activating Device Symbol
There are a variety of ways to actuate control valves. These include manually by hand with a
lever, by foot with a pedal, with an electric solenoid (coil), using external pilot pressure, using
a spring, using internal pilot pressure or using any combination of the above.
There are ten basic arrangements that will appear from time to time on hydraulic diagrams.
These symbols show how a pump, motor or valve is actuated. They are shown in below.
Miscellaneous Symbols
Miscellaneous symbols are shown below.
Pump and Motor
It is important to note that the only difference in the pump and motor symbols is the direction
of the energy triangle. Remember that in the pump symbol the energy triangle is pointed
outward toward the working line. In the motor symbol the energy triangle is pointed in toward
the center of the circle, away from the working line.
Pump Symbols
Pumps are drawn as circles with triangles pointing outward from the center. The triangle
represents the direction that fluid flows out of the pump and should be viewed as an arrow. A
single arrow shows a one-direction (unidirectional) pump, while two arrows indicate a
reversible (bidirectional) pump. A diagonal arrow cutting across the pump body indicates the
pump displacement (output flow and volume) can be adjusted. A small rectangle on the side
of the pump with a small arrow inside indicates that the pump output is compensated (adjusted
or controlled) by a pressure signal from a pilot line.
Pumps are also drawn to indicate how their output can be controlled. The attachments to the
pumps look like the components they represent. The lever and pedal look like a lever and
pedal. The drive shaft is shown as a pair of lines on the side of the pump, either with or without
an arrow showing the direction of rotation. Pumps can also be drawn as stacks, which indicate
that all pumps are driven by the same driveshaft.
Hydraulic Motor Symbols
Motors are drawn as circles with triangles pointing in toward the center of the circle. Hydraulic
motors are actually hydraulic pumps that work in reverse. Except for a few differences, pumps
and motors are identical. Use the same rules to interpret motor symbols as you would for pump
symbols.
Instrument Symbols
There are three types of instrument symbols which you should know. The pressure gauge
symbol is shown on the left side below. The temperature gauge is shown in the center and the
flow meter symbol is shown at the right.
Valves
Hydraulic pressure is controlled through the use of valves that open and close at different
times to allow fluid to be bypassed from points of high pressure to points of low pressure. The
basic valve symbol is a square (box) which represents the valve body or spool. An arrow in
the center represents the path oil takes through the valve.
Pressure control valves are typically pilot operated - that is, the valve is moved automatically
by hydraulic pressure and not by a person. Pilot oil pressure is resisted by a spring, which can
often be adjusted. The higher the spring tension, the more fluid pressure required to move the
valve.
To visualize the operation of this type of valve, imagine that the entire square will move away
from the pilot line and towards the spring. If the valve is normally open, fluid flow will be cut off
by the pilot line. If the valve is normally closed, the pilot line will cause oil to start flowing.
Valves can either be ON/OFF valves with no flow in the middle, or infinitely variable, which
means flow will gradually increase or decrease as pilot pressure increases and/or decreases.
Pressure Relief Valve
A pressure relief valve (below) is a normally closed valve that senses the high pressure at its
inlet. As the pressure at the inlet increases, the pressure in the pilot line begins to push against
the valve body (spool). As the valve body moves, the ports begin to line up and fluid will begin
flowing through the relief valve. The relief valve typically dumps back into the reservoir. Most
relief valves are infinitely variable.
Sequence Valve
A sequence valve (below) is a normally closed valve that opens once the inlet pressure
reaches a pre-set point. This type of valve is designed to allow different components to act
sequentially, meaning one after the other. Once the primary actuator reaches the limit of its
travel, fluid pressure in the feed line will rise. This rising pressure opens the sequence valve
which allows fluid to flow through it to the secondary cylinder.
Pressure Reducing Valve
A pressure reducing valve (below) is a normally open valve that senses the outlet pressure
going to an actuator. As the pressure in the outlet increases, pilot pressure increases which
gradually closes the reducing valve. As the valve closes, oil from the high pressure side of the
valve is directed back to the reservoir which dumps pressure at the outlet.
Directional Control Valves
The direction that fluid flows in a line can be controlled by using valves which allow flow in only
one direction. These valves are typically referred to as check valves because they check
the flow if it tries to reverse. These valves can have simple check balls or can have machined
poppet type valves. They can also be more complex pilot operated valves that have spools.
In the case of a ball check valve, the allowed flow is opposite the arrow, or towards the ball. If
the valve has no spring, the valve offers resistance to flow only in the closed direction; in the
open direction the valve moves with any movement of fluid and does not have a pressure
setting.
If the check valve has a spring it will oppose flow in the open direction up to the point where
hydraulic pressure overcomes spring tension. Check valves can also be pilot operated.
Another method of drawing check valves (directional valves) is using composite symbols as in
the previous sequence. This method contains a blocked path and a free path. The dashed
lines represent pilot pressure lines. As pressure increases on the blocked side of the valve,
the pilot line moves the valve to reduce or cut off supply, depending upon whether the valve
is normally open or closed.
The spring keeps the valve in the normal position. If pressure builds up on the flow side of the
valve, the pilot line pressurizes and moves the valve into the open position, compressing the
spring in the process, and allowing oil to flow. If the flow attempts to reverse, the other pilot
line pressurizes and adds to spring pressure to close the valve, cutting off flow.
These valves are commonly referred to as flow dividers or flow control valves (below). This
type of valve can be a pressure relief valve or pressure reducing valve depending upon
location of pilot source and spring setting.
Two Position Flow Control Valve
Two position flow control valves (below) typically are used to make the flow reverse to an
actuator in a simple system, although other arrangements are possible. The valve spool slides
long-ways to allow one or the other valve position to direct flow. Because these valves have
no center position they must be used with a pressure relief valve that opens to dump system
pressure when the actuator bottoms out.
Note that the direction of oil flow does not change on the pump side of the valve. The direction
changes only after the valve changes the flow to redirect pressure to the retracted side of the
cylinder.
Three Position Flow Control Valves
Flow control valves are drawn as composite symbols using squares to represent the valve
spool. To visualize the operation of these valves its necessary to imagine them moving long-
ways with the spool sliding to move the different flow arrows into a position to allow oil to flow
through them.
The centers of the valves determine what type of system is in use. An open center system uses
valves that allow oil to flow through them at all times (out of the pump and back into the
reservoir) when no actuators are in use. This system does not require a pressure relief valve.
A closed center system uses valves that block flow through them when no actuators are in
use, thereby liquid locking the system. In this type of system a pressure relief valve is
mandatory to prevent the system from destroying itself when the valves are in the center.
Valve Symbols
The next area to cover is valve symbols. Begin with some of the basic symbols shown below.
Most valves are depicted by using a box as a symbol. Pressure and flow control valves usually
use one box. Directional control valves use two or more boxes. The number of boxes indicates
the number of valve positions. Notice that the box symbols shown below have lines drawn to
them. These are referred to as ports. At the left is a two port valve, commonly called a 2-way
valve. In the center is three port, or 3-way valve. On the right is a four port or 4-way valve.
Three Position 4-Way Valve
Let us examine the most common of all control valves, which is the 4-way valve shown
below.
This control valve directs fluid or oil flow to a forward position, a neutral position or a reverse
position. The picture above shows the fluid or oil flow path when the valve is in neutral position.
In neutral, oil flows from the pump into the valve and back to the reservoir.
Arrows
Arrows in the adjoining squares (below) show the fluid flow path when the valve is shifted to
the other positions.
Forward Position
With the forward position activated, the fluid or oil flows from the pump through the valve and
onto the left side of the cylinder (see below). Return oil from the cylinder is released through
the valve and back to the tank.
Neutral Position
With the valve in the neutral position, fluid or oil is allowed to flow from the pump through the
valve body and back to the tank.
Reverse Position
With the reverse position activated, fluid or oil flows from the pump through the valve and into
the right side of the cylinder. Return oil from the left side of the cylinder is released back
through the valve and returned to the tank.
Valve Centers
Lets look at valve centers now. There are four main center valve configuration symbols:
1. Closed Port - Closed Center
2. Closed Port - Opened Center
3. Open Port - Closed Center
4. Open Port - Open Center
Series Parallel Valves
Now that we have seen our directional control valves at work, lets see how we bank two or
more valves together. As shown below, one pump is supplying oil to two valves for control of
two different actuators. The valves are connected together by a parallel passage which allows
simultaneous operation of both functions.
When the bottom valve is shifted to the reverse position, oil is still available for the other spool
through the parallel passage. This is called a series parallel valve.
Pilot Operated Lock Check Valve
The pilot line symbol indicates a pilot operated lock check valve (see below). This valve will
allow reverse flow when pilot pressure is present.
Bypass Valve
The check valve symbol is also used to show a bypass valve. In this application, the ball is
held seated by spring pressure and the valve opens when pressure drop across the filter
becomes too great.
Overcenter Valve
The overcenter valve shown below throttles return oil to prevent a runaway condition on a
heavily loaded cylinder or motor. If the cylinder should try to collapse faster than the pump is
supplying oil, the pilot pressure will drop and the overcenter valve will throttle the exhaust oil
leaving the cylinder.
Review
Lets review. A typical hydraulic diagram (schematic) is shown in below. Can you name all the
components?
1.
2.
3.
4.
5.
6.
7.
8.
9.
7.3 - Hydraulic System
Hydraulic System
The DM45,50,DML is a hydraulically driven production blast hole drill. Power to drive the
hydraulic system is supplied by a diesel engine which drives a gearbox which in turn drives
three hydraulic pumps. These three pumps convert the rotary energy from the engine to
hydraulic energy which can be used by the various motors and cylinders to perform the
necessary drilling and propelling tasks. The result is a relatively simple and flexible drilling
system.
The hydraulic system consists of a 82 gallon (310 Liter) hydraulic reservoir, hydraulic pumps
mounted on a pump drive gearbox and various hydraulic motors, valves, cylinders, pipes,
hoses and filters. A hydraulic oil cooler assures cool oil temperatures to maximize system
efficiency and component life.
The three hydraulic pumps (See Figure 7-1) are mounted for convenient service access on a
single pump drive gear box driven off the diesel engine through a drive shaft and coupling
configuration.
The rotation and feed pumps supply hydraulic power to either drilling functions or tramming
(propel) functions. The triple drive pump supplies oil for the fan motor(s) circuit. The triple drive
pump supply oil for all other functions through a 6-spool, 9-spool and manifolds.
The hydraulic system is made up of a closed loop system. Each circuit includes one or more
pumps which supply pressurized streams of hydraulic fluid to hydraulic cylinders and motors.
The main hydraulic circuits on the DM45,50,DML are the Propel Circuit, the Feed and
Rotation Circuit, the Fan Cooling Circuit, Auxiliary Hydraulic Circuits and the Manifold
System.
Figure 7-1
Always reference to the DM45,50,DML (electric/hydraulic controls) hydraulic schematic
2657810442 for trouble shooting the hydraulic system or hydraulic questions.
Main Pumps
The main pumps are closed-loop hydrostatic transmission piston type package pumps. The
main pump symbol is shown in Figure 7-2. The entire pump is depicted as a package.
Figure 7-2
The main rotating group is depicted in Figure 7-2 as a large circle with two triangles pointing
towards the work port lines. It has a displacement of 7.25 cu.in./rev. when adjusted to achieve
full volume output. A long arrow through the circle means the pump displacement is variable.
The two main work ports are the A and B ports. Either port can discharge oil depending on
the position of the pump displacement controls. Which ever port is not discharging oil is
receiving oil. In other words, if oil is leaving port A, practically the same amount of oil is being
returned to port B.
Two ports that are connected to ports A and B are AG and BG respectively. These ports
provide a place to attach a pressure gauge. On the DM45/DM50 DML series, these ports are
used to interface with the hot oil shuttle (See Figure 7-10).
An auxiliary charge pump, housed within the pump package, is driven off the main pump shaft.
This is represented schematically by a circle with one triangle pointed toward the work port
(See Figure 7-2). The purpose of this small pump is to provide oil to work the pump controls
and to charge the main pump loop so that it never runs out of oil.
Oil is supplied to the charge pump through port C (See Figure 7-2). Oil leaving the charge
pump is directed to the swashplate control system. Any oil that is not used for swashplate
control passes over the servo relief into the loop replenishment circuit.
Replenishment oil can flow through the check valves that correspond to the A and B ports
or it can flow over the 200 psi charge relief valve to the pump case. As long as pressure on
either side of the loop does not exceed 200 psi, the relief valve will not open. Any excess oil
which does dump over the relief valve mixes with leakage oil already in the pump case and
leaves the package pump through port D1 or port D2 (See Figure 7-2).
Pump controls used with the main pump are proportional. Operator input is supplied
electrically to the pump through the electric stroker via a proportional electric controller. When
the operator moves the control handle, the electric input is converted to a hydraulic input (top
triangle).Here it is amplified (left triangle) and the resulting output (lower triangle) drives the
pump swashplate positioning system.
Pump controls used with this pump are the electric stroker, rotary servo control and the
pressure compensator (See Figure 7-3). The electric stroker is represented schematically by
the box with the diagonal arrow that indicates variability. The rotary servo is represented
schematically by the box containing three triangles and a circle. The pump compensator (main
relief valve) is represented schematically by the box containing an arrow (between the servo
control and the main pump symbols).
Figure 7-3
The Pressure Compensator can override the swashplate controls whenever its pressure
setting is reached. The compensator can be remotely set by regulating the pressure at port
VA or port VB (See Figure 7-2). If ports VA and VB are plugged, the compensator will
limit the pressure in either A port or B port to 4500 PSI.
If port VA is remotely relieved to a lower pressure, (i.e. torque limit control) pump port A
pressure will be limited to the remote pressure instead of the higher internal setting. The same
principal governs the operation of the VB port.
The Main Pump Compensator adjustments should not normally change. If it becomes
necessary to replace a pump, a trained factory service representative should be called.
Propel Circuit
Propel Motors
Propel motors rotate the final drive mechanism in the undercarriage system to make the tracks
move forward or backward. The more flow provided to a motor, the faster it turns.
Figure 7-4
The Propel Motors are closed loop, axial piston, fixed displacement hydrostatic transmission
motors. Oil is supplied to the basic motor through either the A port or the B port (Figure 7-
4). Supplying oil to the A port will cause the motor to rotate in one direction. After the oil is
used to rotate the motor it leaves through port B. Oil supplied to port B will cause the motor
to rotate in the opposite direction and will leave through port A.
Propel motors all have case drain lines that must be connected to prevent pressure buildup in
the motor housing.
Motor Brake
The Motor Brake (See Figure 7-5) is a spring actuated, hydraulically released multiple disc
unit. It is a unit that fits between the propel motor and the track disc drive gear box. In normal
operation, springs load the brake discs to keep the motor shaft from turning. This fail-safe
operation ensures that the brake will apply automatically if oil is not supplied to the brake oil
port.
Figure 7-5
Hydraulic oil pressure is supplied from the main pump to the diverter valves. Oil pressure from
the triple pump (P2) goes through a drill/propel valve (set at 500 psi) to the brake release valve.
When the brake release valve is energized the oil pressure is sent to the brake chamber to
release the brakes. Pressure pushes on the springs to release the load on the brake discs.
This allows the motor shaft to turn. The brake discs will remain released as long as pressure
is being supplied.
Diverter Valve
The purpose of the diverter valves is to shift the flow of a pump from one actuator to another.
For example, the propel system is not needed while in the drilling mode, so the diverter valve
shifts the flow from the propel circuit to the rotation circuit. Thus, one pump is used for two
functions.
The Diverter Valves are two-position, hydraulically shifted, three way valves. The valve is
represented schematically in Figure 7-5. The spring on the left side of the valve requires the
valve to be shifted so that P is connected to B and T is connected to A when no hydraulic
shift signal is present. The shift operators are represented by a triangle in a box on each end
of the valve.Hydraulic pressure applied to either operator will cause the valve spool to shift to
the position corresponding to the signal. In other words, pressure applied to the right end of
the spool will cause the valve to shift to the P to A, B to T position. Approximately 100
psi is needed to override the spring and shift the valve. Note that the T ports are plugged.
The main part of the valve consists of a housing with a sliding spool and spool operators. The
valve is bolted to a sub plate with six socket head cap screws. The sub plate provides threaded
ports to interface with the rest of the system. The two pilot ports are represented by X and Y.
Figure 7-6
There is a spring installed within the valve body to actuate the spool on the X end. This is to
assist in moving the diverter valve to the Drill position. In the event of a loss of hydraulic
pressure, the spring will shift the valve into the Drill mode position. This position vents
hydraulic brake pressure to tank and prevents the drill from moving. Refer to the Oil Path
Selection information shown with Figure 7-6.
The diverter valves and sub-plates are mounted directly under the hydraulic tank, facing the
drilling end of the drill (See Figure 7-6). They can be replaced by simply unbolting the valve
and installing a new one. No hoses have to be removed.
Propel/Drill Mode Selector
Figure 7-7
The mode of operation (Drill or Propel) is determined by the operator of the drill. This is done
with the use of the Mode Selector switch, commonly called the Drill/Propel switch on the
operators console (See Figure 7-7). There are two positions for proper operation, DRILL and
PROPEL. The mode selector switch is a two position electric switch. The switch is energized
whenever the ignition key switch is in the ON position. When the operator moves the mode
selector switch from one position to the other, electric power is diverted from one circuit to
another. The two circuits control the mode of operation in which the drill can be used. When
the drill mode is selected, only controllers used for drilling are energized. When propel mode
is selected, only the controllers for propel are energized.
At the same time the propel mode is selected, the drill/propel switch energizes the solenoid
operated drill/propel valve (See Figure 7-8).When this solenoid is energized, the valve is
shifted to divert pilot pressure to the Y ports of the main diverter valves (See Figure 7-7) and
at the same time to release the track brakes. The internal, normally open pilot operated check
valves are piloted closed. This effectively isolates the pump compensator, allowing it to control
the maximum system pressure. The drill/propel hydraulic valve and the schematic
representation are shown below in Figure 7-8.
Drill/Propel Control Valve
The Drill/Propel valve (Figure 7-8) is a manifold and valve assembly that contains all the
components required to: (1) control diverter valve shifting from the drill mode to propel position
and vice versa, (2) control propel brake operation, (3) limit torque of the drill rotation circuit and
(4) limit drill feed force. The valve assembly consists of a steel manifold with 4 cartridge valves
and an electrically operated two position four way valve. The drill operator selects the mode
of operation by the use of an electric mode selector switch on the operators panel (See Figure
7-7). The drill/propel valve is located on the dust collector side decking beside the tower
support (Figure 7-8).
Figure 7-8
Hydraulic pilot pressure is provided by the fan circuit to the P port of the drill / propel valve.
When propel mode is selected, the electric coil on the solenoid operated valve is energized,
the valve shifts and flow is directed from the P port of the drill/propel valve through the 4 way
valve to the Y ports. At the same time, the pilot operated two way valves are piloted to the
closed position. Oil at the manifold Y port is also available to the brake pressure reducing
cartridge. Oil crossing this cartridge is reduced to 500 psi. The check valve in parallel with the
reducing valve allows rapid return of oil at the BR port to the drill/propel control valve to allow
monitoring of function pressure as well as diagnosis of problems.
Within the CP1 and CP2 ports are normally open pilot operated check valves. These
valves allow communication between the pump compensator and the remotely operated
device for controlling pump pressure. When the operator selects propel mode, pilot pressure
closes these two pilot operated check valves, isolating the pump compensator. Therefore, in
propel mode the pump compensator determines the maximum pressure limit, not the operator.
Loop Filling/Replenishment
The oil needed to initially charge the main loop, and keep it full, is picked up by the charge
pump at port C. Port C connects to the reservoir through the suction hoses. Oil is
continuously injected into the main loop to make up for normal leakage in the pump, motor and
diverter valves, and to make up for the oil being stripped out of the loop by the hot oil shuttle
in the loop flushing circuit.
Leakage from the main pump is collected in the pump case and returned to the main hydraulic
reservoir by way of the pump D port. Leakage oil, combined with hot oil shuttle flow also
returns to the system reservoir through the case drain manifold included in another circuit.
Figure 7-9
When the pump is in neutral, the leakage flow from the pump is supplemented by charge flow
that comes from the charge relief valve in the pump.Propelmotor leakage is collected in the
motor case and it is also returned to the drain manifold.
Loop Flushing Circuit
The Loop Flushing Circuit removes a small portion of the total oil available in the transmission
loop. This oil, leaving the loop, carries with it some heat and contamination that may be
present in the system.
The valve circuit, commonly called the hot oil shuttle valve, is represented schematically by a
three position directional valve and relief valve (Figure 7-10). The three position directional
valve is normally centered by its springs. In this position, no oil flows out of either the A side
or the B side of the loop. The valve shifts whenever there is an unbalance of pressures
across the circuit. For example, if the A side of the loop is at a higher pressure than the B
side, the shuttle valve shifts to allow B side oil (low pressure oil) to leave the loop.
Figure 7-10
The relief valve guarantees that the minimum desired loop pressure will always be maintained.
In other words, the shuttle cant cause the main loop to run out of oil. A relief valve is set at
150 PSI or +/- 10 GPM to maintain a minimum of 150 PSI system pressure.
There is one loop flushing circuit for each main pump. The circuits work with their respective
pump what ever the mode of operation (drilling or propelling).
Figure 7-11
Each hot oil shuttle valve is mounted on the inside of the power pack base in front of, and
below, each main pump (Figure 7-11).
Circuit Operation
The primary oil path in the propel circuit are the closed hydrostatic loops indicated by the solid
lines connecting the main pumps to the propel motors on the schematic below ( Figure 7-12).
There is a transmission system to drive each track. The main pump swashplate controls are
moved by an electrical input via a proportional electric controller. There is a controller for each
of the two main pumps corresponding to the left and right track drive systems.
Figure 7-12
Whenever the main pump is destroked (swashplate in neutral), oil does not flow in the loop
and the propel motor does not rotate. Moving the swashplate control out of its neutral position
in one direction causes oil to flow counter clockwise in the loop. The oil flow causes the propel
motor to rotate. Moving the swashplate control out of its neutral position in the other direction
causes oil to flow clockwise in the loop. The propel motor now turns in the opposite direction.
The speed of the motor in either direction is governed by the amount of pump swashplate
control movement.
The two transmission systems (two pumps and two motors) allow each drill track to operate
independently of each other. The tracks can turn at different speeds or even in different
directions to provide maximum drive and steering flexibility.
Oil Path Selection
The only interruptions in the main loops are the four Diverter Valves. The diverter valves are
shifted to connect the main pumps to the propel motors whenever the propel circuit is
energized. These valves are shifted to connect P to A and B to T whenever the propel
circuit is energized. The propel circuit uses the P and A ports on all four valves. The valves
are all shifted by supplying oil to the X or Y ports. This is done by shifting the Drill/Propel
valve. Oil for this purpose is supplied by the auxiliary circuit manifold through the drill/propel
control valve assembly.
In the Propel Mode, the Drill/Propel Selector Valve directs oil to the Diverter valve Y ports
and drains the X ports. At the same time, oil is also directed to release both motor brakes
and to energize the propel alarm switch. A point to remember is that with the drill off, the control
system defaults to the Drill Mode. This is why the spring in the Diverter is on the X port side.
Feed & Rotation Circuit
The primary components of the Drill Feed and Rotation Circuits are the Main Pumps, Rotation
Motors, Pulldown Cylinders, Filters, Valves and Controls.
Main Pumps
The Main Pumps used for the Drill Feed and Rotation Circuits are also used for the Propel
Circuit. A description of their characteristics and schematic can be found in the Propel Circuit
Section of this manual.
Rotation Motors
Depending on the type of rotary head used, the rotation motor on the two motor head uses two
fixed displacement closed loop motors.
Figure 7-13
Closed loop, as previously mentioned, means that the reservoir is not included in the pump/
motor circuit. Hydrostatic Transmission means that the motor is designed for use in a system
in which power is transmitted by the pressure of a fluid. The schematic for the rotation motors
is shown in Figure 7-13. The main motor section is shown by the circle with two triangles
pointed inward from the two main ports. The long arrow through the circle means that the
motor displacement can be changed to give different speed and torque levels.
The motor displacement is controlled by the swashplate servo system shown on the schematic
as a box sitting on the motor. Inside the box are three triangles and a circle which represent
the servo input, summing and output functions. The servo receives oil to power its systems
from the motor H port. It also receives an input from a mechanical arrangement of springs
and pistons indicated by the hat and spring on top of the servo envelope. The displacement of
the motor can be set at its maximum level or its minimum level by energizing the X port or
the Y port, respectively, on the motor.
Rotation Motor Adjustment
The displacement of the pump can be set by turning the Motor Volume stop screws clockwise
or counter clockwise.
Turning the screw clockwise decreases the motor swashplate angle. This causes the motor to
turn faster, trying to displace the flow from the rotation pump. Turning the screw counter
clockwise increases the motor swashplate angle. This causes the motor to turn slower due to
the increase in oil volume displaced per revolution. The Main Pump must be at full volume in
order to set the motor speed correctly.
Rotation Motor Control Valve
Oil must be supplied to the motor H ports to drive the swashplate positioning servo system.
Oil for this purpose must be at a lower pressure than that normally found in the loop. A
pressure reducing valve (motor control valve) externally mounted on one motor provides this
oil (See Figure 7-13).
The motor control valve (Figure 7-14) is an assembly that bolts to the top of one of the rotation
motors. The assembly contains a shuttle valve and a pressure reducing valve. The shuttle
valve receives oil from both sides of the motor into its two ends. If the pressure available at
one end is higher than the pressure at the other end, the shuttle ball shifts toward the low
pressure and seals off that port. The higher pressure is then free to flow to the pressure
reducing valve.
Figure 7-14
The pressure reducing valve is responsible for reducing the pressure of the oil to a lower
pressure so that it can be used in the rotation motor server system (about 500 psi). The
pressure reducing valve will open, close or even take oil in reverse to keep the REG port
pressure at the value set by the spring adjustment. Any oil that the valve takes back from the
REG port flows to the valve drain port where it can be passed back to the motor case.
The motor control valve must be replaced as a complete unit. There are no adjustments
required.
Check Valves
The rotation motor allows normal leakage within the rotation motor case. Oil pressure in the
case drain must exceed 15 psi to open the check valve in the case drain line. After the valve
has opened, oil can flow back to the system reservoir. The check valve is there to prevent the
rotary head gearbox oil from draining back through the motor case when the tower is in the
horizontal position.
The main function of the check valve is to keep the motor cases full of oil in all positions of the
drill tower.On the variable displacement motor, there is a 140 psi relief valve mounted on the
side of the case to serve as a safety backup for the case drain line in the event that the line
becomes plugged or kinked. (Refer to Figure 7-13).
Diverter Valve Assembly
The diverter valve assemblies used for the drill feed and rotation circuits are also used for the
propel circuit. A description of their characteristics and schematic can be found in the propel
circuit section of this manual.
The Drill/Propel Control Valve used for the drill feed and rotation circuits is also used for the
propel circuit. A description of their characteristics and schematic can be found in the propel
section of this manual.
Feed Cylinders
The feed cylinders (also called pull down cylinders) are mounted inside the tower. The feed
cylinder and cylinder schematic symbol are shown in Figure 7-15.
Figure 7-15
The Feed Cylinders are double acting, single rod cylinders. Double Acting means that the
cylinder can be powered by the hydraulic system to extend and to retract. Single Rod means
that the cylinder only has one rod extending from one end of the cylinder tube.
Remote Compensator Control
In the drill mode, the compensator vent connections are utilized to provide interface with
remote pressure control devices.
This allows for the main pumps to be remotely controlled by the operator and gives variability
and infinite control of actuator speeds and pressures. The -4 line in Figure 7-16 shows the
connection at the pump for remote control of the compensator. The other end of this hose
connects to the drill/propel valve at the CP1 port (compensator pressure). The cab side main
pump provides flow for the feed system. A hose from the VA port connects to the CP2 port.
When in drill mode, the oil from the VA port flows through the drill/propel valve to an
electrically operated, proportional control valve called the FEMA control valve.
Figure 7-16
Increasing the electrical power to the FEMA valve coil proportionally blocks off the path from
VB to tank. The more current the higher the pressure rises. The less flow through the valve,
the higher the pump pressure potential. When the path is fully blocked, the pump can generate
full compensator pressure.
NOTE: De-energizing the coil opens the valve fully. Therefore, if the electrical circuit is open
to the FEMA valve, no feed pressure or rotation torque pressure will develop (If torque limit is
on the drill).
Over Pressure Control
The connections for the over pressure controls are part of the drill/propel valve. When in the
drill mode, the drill has the capacity to apply forty five thousand pounds of force on the bit. The
drill is designed to vent pulldown force if the ground gives way beneath the jacks or for some
other reason the drill is unsupported.
The ports labeled OP1 and OP2 are common to the feed pump VA port and are connected
by hoses to the overpressure control valves. These valves are mounted, one on each of the
front (side) drilling end leveling jacks (See Figure 7-17). If for any reason the drill is
unsupported by the leveling jack, the pipe nipple will drop to gravity and mash the button as
shown. This opens the path to tank, venting the feed pump compensator VA port.
Figure 7-17
Note: The Over Pressure control system should be tested daily to insure proper functionality.
If the system does not function properly, the drill should be shut down immediately. The drill
must remain shut down and not used until the Over Pressure control system is repaired.
THE OPERATOR IS RESPONSIBLE FOR THE SAFE OPERATION OF THE DRILL.
Over Pressure System Test
This Test Must Be Performed At The Start Of Each Shift.
1. Raise the drill on all jacks until the tracks are about one (1) inch off the ground.
2. Level the drill using bubble level gauge in the cab.
3. Raise the tower to vertical position by following instructions in Raising The
Tower Procedure.
4. Pin (lock) tower pinning by following instructions in Tower Pinning (Vertical)
Procedure.
5. Stall maximum pulldown with the power head at the bottom of the tower.
6. Lift (retract) the Cab Side J ack off the ground and verify the feed pressure
drops below 500 psi on the feed pressure gauge on the gauge panel in the cab,
if not re-extend jack and fix the problem.
7. Slowly lower (extend) the Cab Side J ack on to the ground, re-level drill and
verify the feed pressure returns to maximum pulldown pressure.
8. Lift (retract) the Non-Cab Side J ack off the ground and verify the feed pressure
drops below 500 psi on the feed pressure gauge on the gauge panel in the cab,
if not re-extend jack and fix the problem.
9. Slowly lower (extend) the Non-Cab Side J ack on to the ground, re-level drill and
verify the feed pressure returns to maximum pulldown pressure .
Regen Valve
The Regen valve in the Drill Feed loop performs three functions in the feed circuit (See Figure
7-18).
First, it acts as a regenerative valve when the load is not too great, allowing oil from the rod
end to add to the pump flow into the base end and increase the head speed downward.
Second, it prevents the head and drill pipe from coming down the tower too quickly. Third, it
allows excess oil from the base end to return to the tank when the pump is supplying oil to the
rod ends, even though it is a closed loop system.
Figure 7-18
The assembly contains an overcenter or holding circuit to hold back pressure at the CR ports,
and another overcenter circuit to control oil flow from the PB port.
The overcenter circuit that controls pressure at the CR ports is illustrated on the left half of
the schematic in Figure 7-18. When oil flows from the PR port to the CR ports, the check
valve opens and the oil goes around the overcenter valve. When oil is flowing from the CR
ports to the PR port, the overcenter valve provides a flow resistance. The overcenter valve
resistance is influenced by the spring setting, the CR pressure and the PB pressure. The
spring setting is always fixed for a particular application, but the CR and PB pressures
change due to influences outside the valve.
The overcenter circuit that controls flow from the PB port is represented on the right half of
the schematic in Figure 7-18. The overcenter valve opening is influenced by its spring setting
and by pressures at PR and PB. The valve is set so that pressure at PB alone is not
sufficient to cause valve opening. Pressure applied at the PR port will open the valve,
however, since this pressure acts on a larger area within the valve.
Feed Circuit
The drill feed circuit is shown in Figure 7-19 and continues into Figure 7-20. The feed circuit,
in conjunction with the overpressure control, contains all pumps, motors, valves, feed
cylinders and components needed to form a safe, highly efficient drilling system.
Figure 7-19
Figure 7-20
FEED
The Drill Feed circuit uses the cab side Right Pump and the Pulldown Cylinders in a closed
loop circuit. This pump is controlled by moving a proportional electric controller located on the
operators console in the operators cab. The controller operates the pump stroker to control
oil flow. When the pump is destroked (controller in center/off position), no oil flows in the
transmission loop and the feed cylinders do not move. If the pump is stroked (either forward
or reverse), the cylinder rod moves up or down correspondingly. The speed of cylinder travel
is proportional to the amount of main pump flow (amount of controller lever movement).
The main components of the feed system are the main pumps, diverter valves, feed system
control valve and feed cylinders.
MAIN PUMPS
DIVERTER VALVE ASSEMBLY
The Diverter Valves used for the Drill Feed and Rotation Circuits are also used for the Propel
DRILL / PROPEL MODE SELECTOR
The Drill/Propel Mode Selector Switch used for the Drill Feed and Rotation Circuits is also
used for the Propel Circuit. A description of its characteristics and schematic can be found in
the Propel Circuit Section of this manual.
DRILL / PROPEL CONTROL VALVE
The Drill/Propel Valve used for the Drill Feed and Rotation Circuits are also used for the Propel
Circuit. A description of its characteristics and schematic can be found in the Propel Circuit
FEED CYLINDERS
The Feed Cylinder and cylinder schematic symbol are shown in Figure 7-15.
CLOSED LOOP FEED CONTROL
The use of closed loop hydraulics, in conjunction with typical double acting cylinders, is unique
to Drilling Solution products. This is accomplished with the use of the feed system control
valve, commonly called the Regen Valve (See Figure 7-20).
Figure 7-20
High pressure drills utilize Regen Valve #57448144. Low pressure drills use #57448136. See
Feed System Control Valves, in this manual, for a technical explanation of the valves,
including their differences and functions.
When drilling with a down hole drill, commonly called Hammer Drilling, keeping the correct
weight on the bit is critical. Too much weight can cause bit or hammer damage, and poor
penetration rate. Too little weight is not good either. It is necessary for the driller to be able to
easily control the weight on the bit as the hole depth increases. This is accomplished by the
use of a Holdback system. This feed system balances the pressures within the feed cylinders
to counteract gravity, string weight and pulldown force.
The holdback system allows the driller to control the rod end oil path remotely. This is
accomplished by connecting remote controls to the R port of the regen valve. See Figure 7-
21 for R port location.
Figure 7-21
Much like the pulldown FEMA control system, the operator controls the oil from the feed
cylinder through a solenoid operated proportional control valve. As the current to the coil
increases, the path is restricted. As the valve closes off the pathway, oil is trapped within the
rod end of the feed system. Pressure in the rod end of the cylinder counter acts the string
weight. The holdback FEMA control is located on the back of the tower beside the regen valve
(HP drills only).
Note: Holdback on the drill will not lift the drill string off the bottom of the hole.
It only counteracts gravity and string weight. Adding slight pulldown will overcome the
holdback system. This is done in some cases to prevent the bit from bouncing. Do not add too
much weight. Weight/100 PSI is explained in the Feed System Control Valves Section of this
manual.
LOOP FLUSHING CIRCUIT
There is a loop flushing circuit in the Drill Feed circuit even though make up oil is allowed into
the system via the supercharge inlet on port B and excess oil is removed from the system
via the regen valve reliefs. When the cylinders are extended, extra make up oil is supplied to
the base end by the supercharge system. When the cylinders are retracted, there is less oil
required to fill the rod end than coming out of the base end, so the excess oil is diverted to the
Return by the two relief valves in the Regen Valve in Figure 7-21.
Figure 7-22
Two Relief Valves are used in the Drill Feed Circuit together with other controls (See Figure
7-19 and Figure 7-20). The Relief Valves are the Pulldown and Pullback Reliefs (High
Pressure models only). The same type valve is used on the Torque Limit Control.
They are schematically shown in Figure 7-22. Oil flows from the P port to the T port when
the valve is open. Oil cannot flow from the T port to the P port. The basic valve symbol is a
box with an arrow showing no cross connection of the P and T ports (normally closed). The
symbol arrow (representing the valve spool) is held in the closed position by an adjustable
length spring. Inlet oil pressure (dashed pilot line) will open the valve whenever oil force
exceeds the spring force.
Load Holding
Load holding is needed in this application because the system is biased by the weight of the
rotary head and drill rod. The holding circuit provides a resistance (hydraulically) to the
tendency of the rotary head to fall. Although there is only one valve in the assembly that is
called a holding valve, load holding is accomplished by both the Holding Valve and the
Sequence Valve .
Figure 7-23
Holding Valve Circuit
The Holding Valve circuit is shown in Figure 7-23. Note that there are two parts to this valve
circuit; a check valve (illustrated by the ball and seat symbol) and a counterbalance valve
(illustrated by the box and associated spring and pilot symbols).
During cylinder retract, oil is directed by the pump directly to the PR port in the feed system
control valve assembly. Oil flows through the check valve to the rod end of the hydraulic
cylinder, causing the cylinder to retract.
When the cylinder is not being directed by the pump to move, there is no oil being directed to
either side of the circuit. There is, however, a pressure at the CR port. This pressure is
generated by the tendency of the hydraulic cylinder to extend under the influence of the
external weight as mentioned above. The check valve reacts to this pressure by closing, thus
blocking the path for oil to escape in this way. The pressure also acts on the counter balance
section through the pilot line a. Note that the pressure tries to open the valve and the spring
tries to keep the valve closed. If the spring setting exceeds the pressure at a, the valve will
stay closed and the cylinder will not move.
When the cylinder is being directed by the pump to extend, the pilot section of the counter
balance valve influences the opening of the valve. Pressure to the pilot comes from the
cylinder side of the circuit through the line marked b. This pressure works with a 2:1
mechanical advantage against the valve spring. The extend pressure needed to open the
valve is:
[Spring Setting (psi) - CR pressure (psi)] / 2
So if the spring setting is 6000 psi and the CR pressure is 1250 psi, the valve will open and
the cylinder will begin to move when the extend pressure reaches 2375 psi.
[6000 - 1250] / 2 =2375
It is important to keep in mind that this is a simplified example and that actually there are
endless combinations of extend and CR pressure that will cause the valve to open. If you were
to work out all these possible combinations and plot them all on a graph of extended pressure
vs. cylinder force, the results would look like those in Figure 7-24. Note that there is no cylinder
force (no cylinder movement) until the extend pressure reaches a certain level.
Figure 7-24
Sequence Valve Circuit (LP Drills)
The sequence valve circuit for LP (low pressure) drills is shown in Figure 7-25. One of the
valve parts shown is actually called a sequence valve (the box with associated parts). A check
valve is also included in this circuit.
Figure 7-25
During cylinder retract, oil is directed by the pump to the rod end of the cylinder as explained
earlier. The oil acts on the sequence valve in 2 ways: 1) retract pressure at PR port passes
through the pilot line b to the spring chamber, and 2) retract pressure at the CR port passes
through another pilot line a and tries to open the valve. During retract, PR pressure is always
higher than CR pressure so the spring and pressure difference keeps the sequence valve
closed.
When the cylinder is not being directed to move, there is still pressure at port CR as explained
in the previous section. This pressure acts on the sequence valve (through the pilot line a)
to try to open it. In this case, there is no pressure at PR to help keep the valve closed but as
long as the CR pressure does not exceed the spring setting, the valve will stay closed anyway
and the cylinder will not move.
When the cylinder is being directed by the pump to extend, the pressure on the cylinder piston
c begins to increase. The increase in pressure on the cylinder piston causes movement and
a corresponding proportional pressure increase in the pressure at d and CR. When the
pressure at CR has been forced to increase to a level that exceeds the valve spring setting,
the valve will open and there will be controlled, continuous movement of the cylinder. The
valve will always open at the same extend pressure unless the load changes. Remember that
adding or subtracting a drill rod changes weight and therefore changes the extend pressure at
which cylinder movement begins.
Beyond the point at which the valve opens, cylinder force is proportional to extend pressure.
If this relationship is plotted like the holding valve plot, the results look like those in Figure 7-27.
Sequence Valve Circuit (HP Drills)
The sequence valve circuit for HP (high pressure) drills is shown in Figure 7-26. Removing
a configuration plug from the LP valve assembly and replacing it with a different configuration
plug makes the changes required to add remote control capability to the sequence valve. The
HP configuration plug makes the following changes to the sequence circuit:
Figure 7-26
The sequence valve circuit for HP (high pressure) drills is shown in Figure 7-26. Removing
a configuration plug from the LP valve assembly and replacing it with a different configuration
plug makes the changes required to add remote control capability to the sequence valve. The
HP configuration plug makes the following changes to the sequence circuit:
1. Disconnects the sequence valve spring chamber from the assembly PR port.
2. Connects the spring sequence spring chamber to the assembly CR port
through an orifice.
3. Provides a remote control port R.
The operator controls the holdback pressure by regulating the rotary controller mounted in the
cab. The rotary controller sends a electrical signal to the tower fema valve, which regulates
the holdback pressure thru the R port on the regen valve.
Oil at the assembly CR port is available to both ends of the sequence valve spool. The oil
provided to the spring end of the sequence valve flows through an orifice and fills the spring
chamber and the remote control line all the way to the tower fema valve. As long as the fema
valve is closed, the oil in the sequence valve spring chamber can not escape.The pressure
acting to open the sequence valve is the same as the pressure acting to close the sequence
valve (in the spring chamber) and the sequence valve spring keeps the valve closed. When
the fema valve is actuated it opens and begins to flow oil. The oil flow out of the sequence
valve spring area causes a pressure drop across the orifice. The pressure to open the
sequence valve exceeds the closing pressure and the spring force and the sequence valve
opens to allow regen flow.
Varying the holdback setting with the rotary controller causes a corresponding change in the
pressure at which the regen valve starts and therefore varies the amount of holdback.
Figure 7-27
Automatic Holding Selection
Figure 7-28 shows what happens if Figure 7-24 and Figure 7-27 are combined. The first
section a of the resulting curve belongs to the sequence valve. The extend pressure at which
cylinder movement begins is identified by the b. When movement does begin, oil is flowing
through the sequence valve, not the holding valve. If feed pressure increases to c, some of
the oil at CR begins to flow through the holding valve. Note that when the extend pressure is
less than b, there is no cylinder force and no cylinder movement.
Figure 7-28
Regeneration
Regeneration is a redirection of oil from the cylinder rod end back to the cylinder base end to
increase the cylinder extend speed. When the cylinder is in regen, the extend speed does
increase but the available cylinder force decreases. It is therefore desirable to keep the
cylinder out of regen when high forces are needed (See Figure 7-28).
Referring to Figure 7-28 (Combined Force Plot), it can be seen that there is a certain range of
feed pressures that cause oil to flow across the sequence valve. When oil is flowing through
this path, the cylinder is in regen. Rod oil is being forced back to the cylinder extend side where
it combines with pump flow and causes the cylinder speed to increase.
There is also a certain range of extend pressures that cause oil to flow across the holding
valve. Any oil that flows across the holding valve is not available for regen and therefore not
available to help the cylinder reach its maximum possible speed. In the case where all the rod
end oil is flowing across the holding valve, the cylinder is not in regen.
Automatic Regen Selection
The cylinder extend pressure automatically controls the mode of cylinder operation. If there is
not much resistance to cylinder movement (generally during rod handling), the extend
pressure is low and the cylinder is allowed to be in regen. Maximum extend speed can be
reached in this mode. On the other hand, if there is resistance to cylinder movement (as during
drilling for example), the valves direct oil out of the regen path and the cylinder speed goes
down as the force goes up.
Removing Excess Oil
The remaining section of the Feed System Control Valve is the exhaust valve which removes
oil from the cylinder extend side when the cylinder is retracting. The excess oil is present
during retract because the cylinder extend side holds more oil than the retract side. Refer to
Figure 7-29 for this circuit.
Figure 7-29
During cylinder extend, oil is directed by the pump to the extend side of the cylinder. Oil is also
available to one end of the exhaust valve through the pilot line a. Pilot line b is connected
to the opposite side of the circuit at PR. Because the cylinder is in the extend mode, there is
no pressure at PR and therefore no pressure available to b. As long as the extend pressure
at a is less than the spring setting, the valve will remain closed so that oil needed to develop
maximum extend force is not lost to tank.
During cylinder retract, oil is directed to the rod end of the cylinder and to the pilot side of the
exhaust valve through b. The pressure acting on the pilot acts with a 3:1 mechanical
advantage against the valve spring.
In addition to this opening influence, there is also an influence at a from the pressure in the
extend side of the circuit (caused by the oil surplus and the retracting cylinder). When the
combination of pressures acting to open the valve (at a and b) exceeds the spring setting,
the valve opens and allows excess oil to bypass the pump and return to the system tank.
Adjustment Procedure
1. Install a test gauge in the Cylinder Feed Pressure Test Port (Figure 7-30).
Figure 7-30
2. Low Pressure Drills
With the rotary head moving slowly down the tower, adjust the Sequence Valve
until the test gauge reads 700 psi. Lock the adjustment in place. Adjustment is
complete.
3. High Pressure Drills
For drills equipped with a remote control sequence valve (holdback control).
4. With the engine off and the rotary head at the bottom of tower, screw in the
holdback remote control (on the operators console).
5. Turn the Sequence Valve adjustment all the way out (ccw) and lock in place.
6. Turn engine on and move the rotary head to the top of the tower. Then move
the feed control lever slightly forward from neutral so the rotary head is moving
slowly (between 2 and 10 feet per minute) down the tower. Set the holdback
remote control to 700 psi feed pressure. The adjustment is complete.
Adjustment Check
Low Pressure Drills
With the rotary head moving slowly down the tower (2 to 10 feet per minute), the feed down
gauge should read about 700 psi.
High Pressure Drills
High pressure drills are provided with a remote sequence valve adjustment (holdback control)
the operator can set from the operators console. While moving the rotary head slowly down
the tower, verify that the feed down gauge reading can be influenced by screwing in and out
on the holdback control. Readings between 500 and 1800 psi are typical (depending on the
feed down pressure setting).
Conversion Procedure
Low pressure and high pressure feed control valve assemblies are a like except for the
removable conversion plug (see Figure 7-30) and the sequence cartridge. The conversion
plug for an HP assembly has an SAE port R in the hex end of the cartridge. A fitting, hose
and relief valve attached to this port will allow remote control of the adjustment of the sequence
cartridge. The conversion plug for an LP assembly does not have an external R port.
To convert an LP assembly to a HP assembly, remove the non-ported conversion plug and
replace it with a ported conversion plug. The sequence cartridge must also be changed to the
HP version which has a lower adjustment range. Install the assembly on the drill, connect the
R port and adjust the Sequence Cartridge according to the adjustment procedure in this
manual.
To convert an HP assembly to a LP assembly, remove the ported conversion plug and replace
it with a non-ported conversion plug. The sequence cartridge must also be changed to the LP
version which has a higher adjustment range. LP drills do not have the R port control piping.
Hook up the other connections and adjust the Sequence Cartridge according to the adjustment
procedure in this manual.
Service Procedure
The feed control valve assembly is designed with replaceable cartridges in a steel manifold.
The cartridges can be quickly replaced (in less than 10 minutes) using conventional tools if
failures occur. The manifold remains connected to the system so that contamination can be
minimized. Complete replacement of the feed control valve assembly is not required or
recommended. See the troubleshooting section of this manual for cartridge failure diagnosis
help.
Rotation Circuit
The primary components of the Rotation Circuit are the Main Pumps, Rotation Motors, Filters,
Valves and Controls.
Figure 7-31
Rotation
The non-cab side main pump (rotation) is controlled by moving a proportional electric
controller located on the operators console in the operators cab. The controller operates the
pump stroker to control oil flow. When the pump is destroked (controller in center/off position),
no oil flows in the transmission loop and the rotation motors do not turn. If the pump is stroked
(either forward or reverse), the rotation motors will turn in one direction or the other. Rotation
motor speed is proportional to the amount of main pump flow (amount of controller lever
movement).
Motor Displacement Control
Oil must be supplied to the H ports on the rotation motors to drive the motor swashplate
positioning servo system. Oil for this purpose must be at a lower pressure than that normally
found in the loop. The valve that supplies this pressure is the motor control valve.
Oil available at the motor control REG port is supplied to the H ports on both rotation
motors. The oil pressure moves the motor swashplates to the position called for by the
mechanical displacement adjustments on each motor. Adjusting the motors for smaller
displacements results in higher speed and lower torque.
Main Pumps
Diverter Valve Assembly
The Diverter Valves used for the Drill Feed and Rotation Circuits are also used for the Propel
Drill/Propel Mode Selector
The Drill/Propel Mode Selector Switch used for the Drill Feed and Rotation Circuits is also
used for the Propel Circuit. A description of its characteristics and schematic can be found in
the Propel Circuit Section of this manual.
Regen/Feed Valve
A description of the characteristics and schematic for the Regenerative Valve can be found
under Drill Feed System in this section of this manual.
Shifting the Drill/Propel Valve to Drill drains oil from the Propel Alarm and the Y ports of the
Diverter valves. This action also pressurizes the X ports of the Diverter valves and shifts
them into the Drill Mode.
Since both pumps will be operating at different pressures in Drill and Propel, a means of
changing the Relief settings had to be found. This was done with the Pilot to Open Check
valves. By allowing flow through the Check valve in the Drill Mode, the Compensator can be
adjusted with a remote Relief valve for both Feed and Rotation. Thus, when the Drill/Propel
valve is shifted, pilot pressure is applied to the back side of the two Check valves and they are
held open. This allows each Compensator to be regulated by the Pulldown Relief valve or the
Torque Relief valve, both on the operators panel.
Oil Path Selection
The only interruptions in the main loops are the four Diverter Valves (See Figure 7-6). The
diverter valves are shifted to connect the dust collector side (non cab side) main pump to the
rotation motors whenever Drill mode is selected. This is done by supplying oil to the X ports
and venting the Y ports on the diverter manifolds. Oil for this purpose is supplied by the fan
circuit manifold through the drill/propel control valve assembly.
In the Drill Mode, the Drill/Propel Selector Valve directs oil to the Diverter manifold X ports
and drains the Y ports. At the same time, oil is drained from the propel brakes so that they
will lock. In this mode, the Drill/Propel valve also connects the main pump compensator to the
rotation gauge and, in some applications, a pressure control valve (Torque Limit valve for High
Pressure drills only). A point to remember is that with the drill off, the control system defaults
to the Drill Mode. This is why the spring in the Diverter is on the X port side.
Loop Filling / Replenishment
The oil needed to initially charge each main loop and keep it full is picked up by the main pump
charge pump at port C. Port C connects to the drill suction manifold. The charge pump
continuously injects oil into the main loop to make up for normal leakage in the pump, motor
and valves, and to make up for the oil being stripped out of the loop by the flushing circuit in
the diverter manifold.
Leakage from the main pump is collected in the pump case and returned to the drain manifold
by way of the pump D port. When the pump is in neutral, the leakage flow from the pump is
supplemented by charge flow that comes from the charge relief valve in the pump. Rotation
motor leakage is collected in the motor case and it also returns to the drain manifold. Oil
pressure in the case must exceed 30 psi to open a check valve in the drain manifold. The
purpose of the check valve is to keep the motor cases full of oil at all times.
Torque Limit Control (optional)
To prevent the over-torque of joints and to limit rotational pressure while drilling, a Torque Limit
Control Option can be installed. This remote relief valve can limit rotational pressure from
maximum down to 100 psi. It is adjustable by the operator.
Drill Feed Pressure
A Remote Relief valve is installed down stream from the Check Valve, on the other pump, so
the operator can control the Down Feed pressure on the bit. This Relief valve is adjustable
between 100-4500 psi.
Over-Pressure Control
Allowing flow through the Check valve in the Feed Circuit also brings the Over-Pressure
Control system into play and reduces the pressure to the Feed Pump to 0 psi if the drilling
end Leveling J acks are not set properly. Either one of the Two-Way Valves can be opened and
vent all pressure from the Main Pump to 0 psi. The Leveling J acks must be set firmly on the
ground before the Main Pump comes back on line with operating pressure.
Trouble Shooting Feed System
Vent Feed Control Valve
The feed control valve assembly is able to hold back drill string and rotary head weight
because it traps pressure in the feed cylinder rod end.
Before opening any feed circuit connections, vent any trapped pressure with the
following procedure:
Rest the rotary head on the lower tower stops, or rest the drill pipe on the ground or
lay the tower down flat. Turn the engine off and vent pressure from the feed control
valve assembly G1 port. Vent by connecting port G1 to port G2 with a small
jumper hose that fits the test ports. Do not tighten the ends of the hose onto either
test fitting until both ends of the looped hose are connected. Give the oil in port G1
time to drain and then remove the jumper hose and check the pressure at port G1
with a gauge. When the pressure has drained, re-install the jumper hose. The valve
assembly can now be safely serviced.
Leak Checks
Lay the tower down and vent the feed control valve assembly. Disconnect the feed cylinder
rod end hoses at the feed control valve and cap off the open fittings on the valve. Plug one of
the cylinder hoses and leave the other one open. Slowly raise the tower and watch for feed
system drift. Does the head drift?
Down Feed Pressure
Problem: Feed Down Is Too Slow
Is cab side propel speed also too slow?
Auxiliary Functions
The Auxiliary Function Circuit performs all of the tasks associated with the actual drilling
process except Rotation and Drill Feed. Some of these tasks are Tower Raising, Leveling J ack
Operation, Water Injection, Dust Collection, Hoisting, Breakout, Oil and Air Cooling.
The triple pump supplies two valve assemblies: a six (6) spool valve and a nine (9) spool valve.
Each section of these valve assemblies control a specific auxiliary function. An explanation of
the auxiliary functions is divided into two sections, each corresponding to the valve assemblies
and each assembly divided into the valve sections (or spools) and the functions each section
of each valve assembly controls. The examination of these circuits will follow a brief discussion
of the components found in the Auxiliary Functions Circuit.
Components
The components of the auxiliary function circuit are the triple pump, motors, cylinders, valves,
coolers and filters that re required to perform the drilling functions. A review of these
components and how they are represented schematically will help to give a clear view of the
auxiliary functions.
Triple Pump
The triple pump is a three section, fixed displacement, vane type pump. The three pumping
elements inside the housing have a common inlet and two separate outlets as shown in the
schematic in Figure 7-32.
Figure 7-32
The circle contains one triangle, signifying one direction of flow. The first section (Section 1)
on each pump is designated schematically as P1, the second section (Section 2) of each
pump is designated as P2 and the third section (Section 3) of each pump is designated as
P3. Pump section 1 is capable of delivering more oil than section 2, and section 2 delivers
more oil than section 3 for a given input shaft speed. The suction for the pump is designated
as S.
Triple Pump Location
The triple pump is located in the top position of the three hole pump drive gearbox, above the
feed/rotation and propel main pumps.
P1 Pump Circuit
Oil supply for all of the hydraulic circuits comes from the Hydraulic Reservoir through a
Strainer, a Shut Off Valve and the Suction Pipe. The three sections of the triple Pump pick up
oil from a Suction Pipe. Each section of the triple pump supplies a different set of functions.
The P1 section of the Triple Pump drives the Oil Cooler Fan Motor and the Engine Radiator
Fan Motor. This section also supplies pilot oil for use in the Propel, Drill Feed and Rotation
Circuits, and the Rod Support function.
After P1 oil has been used to drive the motors, it passes through the Oil Cooler and the system
filters and is then supplied to the Supercharge Manifold for use in other circuits.
P2 Pump Circuit
The P2 section of the Triple Pump supplies the flow requirements for the rest of the drill
systems. Oil flow from the pump is fed into the Six-Spool Valve (See Schematic in Figure 7-
41 for more information).
P2 Circuit oil, when not used by the Six-Spool Valve, is supplied to the Nine--Spool Valve
through the Six-Spool Valve. (See 9-Spool Valve Schematic in Figure 7-46).
All of the oil in the P2 circuit mixes with Return Manifold oil and enters the system Main Filters,
where it is directed to the Supercharge Circuit for use in the Drill Feed, Rotation and Propel
circuits.
P3 Pump Circuit
The P3 section of the Triple Pump assists P1 section with suppling the to Oil Cooler Fan Motor
and the Engine Radiator Fan Motor.
The P3 section supplies oil to the same components as P1 section does.
Motors
Representative Motor symbols are shown in Figure 7-33. The circle may contain one triangle
pointed inward from one work port (uni-directional) or a triangle pointed inward from both ports
(bi-directional). Both motors shown are fixed displacement.
Figure 7-33
This means that speed may only be changed by changing the motor supply flow. Dotted lines
leaving the circle show that the motor case leakage is taken away from the motor externally.
Cylinders
Representative Cylinder symbols are shown in Figure 7-34. These are all double acting, single
rod cylinders. Double-Acting means that the cylinder can be powered by the hydraulic
system to extend and to retract. Single-Rod means that the cylinder only has one rod
extending out of one end of the cylinder tube.
Figure 7-34
The Cylinder symbol on the right (Figure 7-34) shows a different porting arrangement (through
the rod porting) and an integral valve arrangement. The valve section is a dual Overcenter
Valve circuit which effectively locks the cylinder. The Feed and Rotation Circuit section of this
manual for the description of the operation of an Overcenter Valve). The valves are preset at
the factory to open at 4000 psi relief pressure.
Relief Valves
Relief Valves are used in many locations in the Auxiliary function Circuit. A representative
Relief Valve symbol is shown in figure 7-35.
Figure 7-35
The basic valve envelope (box) contains an arrow in the normally closed position. The
adjustable length spring holds the valve spool in the closed position until inlet pressure
overcomes the spring force. The valve opens and closes as required to limit the maximum
pressure at its inlet.
Restrictor Valves
By-pass type Restrictor Valves allow a restricted flow to the work load and divert any excess
oil to the valve bypass port.
Figure 7-36
The Water Injection Regulator is an example of this type of valve. The Restrictor Valve symbol
is shown in Figure 7-36.
Check Valves
The Check Valve (Figure 7-37) is a one way valve of the hydraulic circuit. Flow into the spring
end of the valve forces the ball into its seat to block fluid flow (blocked flow direction). Flow into
the seat end of the valve pushes the ball out of its seat to permit fluid flow (free flow direction).
The check valve spring is typically pre-loaded at the factory to provide a preset, non adjustable
valve opening pressure in the free flow direction.
Figure 7-37
Two Way Valve
The Two Way Valve (Figure 7-38) has a closed position and an open position that can be
activated by a plunger.
Figure 7-38
In the normal position, the valve spring holds the valve closed so that oil cannot flow from the
P to the T port. When the plunger is pressed, however, the valve shifts and free flow is
allowed.
Holding Valves
Holding Valves are used throughout the auxiliary functions circuit to keep motors and cylinders
locked and to provide smooth load movement. Holding Valves are represented schematically
below in Figure 7-39.
Figure 7-39
The Holding Valve is a pressure control device that receives pilot signals from the actuation
pressure as well as the return pressure. When the influence of both signals is sufficient to
overcome the valve spring setting, the valve opens to allow controlled flow. The valve is also
capable of providing protection against accidentally dropping a load. The valve is usually set
for an opening pressure higher than that which can be generated by the load alone so that, if
actuation pressure is lost, the valve closes.
Pilot Check Valves
The Pilot Check Valve is shown schematically below in Figure 7-40.
Figure 7-40
The Pilot Check Valve is another type of holding valve used for locking hydraulic components
in place. The valve works like a check valve in one flow direction and locks in the reverse flow
direction. In the reverse flow direction, the valve can be piloted open to allow reverse flow.
Once the valve has been piloted opened, oil flows with very little restriction.
6 - Spool Valve
Figure 7-41
Figure 7-42
The 6-Spool Valve shown in Figure 7-42 is an assembly made up of six individual 4--way
valves with a common inlet and outlet. The 4-way valves are electrically operated, closed
centered, proportional valves with load sensing capabilities and pressure compensation.
Three on the sections have individual port relief valves. The inlet section for the valve
assembly contains an unloading valve, a relief valve, and a reducing valve and filter for
supplying pilot oil to the 4-way valve sections. The 6-Spool Valve assembly is shown
schematically below (Figure 7-43).
Figure 7-43
Oil enters the inlet section (shown schematically in Figure 7-44) at the P port. Oil can exit the
section through the parallel passageway at the top right corner of the section schematic or
through the unloader to the section T port. When the parallel passageway is blocked, all of
the oil flow must exit through the unloader. The total oil flow can also be proportional by the
unloader so that some flow goes in each direction.
The inlet section unloader (Figure 7-44) receives signals from the parallel passageway and
from a load sense signal from the 4-way valves. The pressure in the parallel passageway
must be 200 psi higher than the load sense pressure in order to open the unloader. With no
load sense pressure, the unloader closes and routes oil to the parallel passageway where
it can be used by the 4-way valve sections. When a load sense signal is received back from
the valve sections, the unloader will throttle the oil flow between the two exits to keep the
parallel passageway pressure 200 psi higher than the pressure being called for by the valve
sections.
Figure 7-44
The inlet relief provides a way to control the maximum allowed load sense signal and
therefore the maximum valve working pressure. When the load sense signal rises to the relief
setting, the relief opens to keep the signal from going any higher. The unloader will allow the
parallel passageway pressure to exceed this setting by 200 psi.
The pilot filter and reducing valve in the inlet section provide a reduced working pressure for
the proportional electric controls on the individual 4-way valve sections. The operating
pressure provided by the reducing valve is 200-220 psi.
The 6-Spool Valve 4-way valve sections are all similar and are represented schematically in
Figure 7-45.
The parts of the 4-way valve are the pressure compensator (represented by the box symbol
at the top left corner), the directional valve (represented as a 3-position closed center 4-way
valve), the individual port relief valves, and the load sense shuttle valve (Refer to Figure 7-
45).
The pressure compensator (Figure 7-45) is the device that determines how much oil the
directional valve will get. The compensator receives one pressure signal from the oil that it
discharges. This signal attempts to keep the compensator open so that oil can flow freely.
When the directional valve is shifted, the compensator receives a second signal from which
ever work port is receiving the flow. This signal indicates the working pressure needed to move
the working load and this pressure (and a spring) try to close the compensator. The
compensator will throttle the oil flow in response to the two pressure signals to supply precisely
the amount of oil the directional valve needs to operate. If the pressure in the parallel
passageway happens to be higher than what the load requires, the compensator will maintain
whatever pressure drop is required to keep the directional valve at the proper operating
pressure.
Figure 7-45
The directional valve (Figure 7-45) is normally held in its center (closed) position by springs. It
is shifted by applying electric current signals to proportional electro-hydraulic pressure
controls on the ends of the valve. The pressure controls receive pilot oil from the inlet section.
When the pressure control receives an electric signal, it proportions pilot pressure to a level
proportional to the electric signal. The resulting pressure pushes the valve spool against its
centering springs. The amount of movement, and therefore the amount of flow, is proportional
to the positioning pressure.
The maximum flow available from a particular directional valve section is indicated by a
number near the pressure compensator symbol (Figure 7-45). Each spool is intended for a
particular function and maximum flow needed is selected accordingly. Each spool is also
equipped with flow limiters which are used only on the dust collector section. The port relief
valves are responsible for limiting work port operating pressure at design levels. When work
port pressure reaches the valve setting, the valve opens and oil flows to the valve section
return passageway.
A load sense shuttle is in each of the valve sections (Figure 7-45). The shuttle determines
whether or not the highest pressure from down stream is higher than the pressure within its
section. It passes its selection to the next section up stream. Ultimately the highest working
pressure (the load sense pressure) reaches the 6-Spool Valve inlet where it can be used by
the inlet unloader. Oil that is returned from the individual valve sections leaves the 6-Spool
Valve through the T port and returns to the return manifold.
6-Spool Valve Sections
1. First Valve Section
The first valve section controls the Hoist Motor
2. Second Valve Section
The second valve section controls the Tower Raising Cylinders.
3. Third Valve Section
The third valve section controls the Leveling J ack on the Dust Collector Side of
the drill.
4. Fourth Valve Section
The fourth valve section controls the Rear Leveling J ack on the Non-Drilling
End of the drill.
5. Fifth Valve Section
The fifth valve section controls the Leveling J ack on the Cab Side of the drill.
6. Sixth Valve Section
The sixth valve section controls the Dust Collector Motor and the Water Injection
Motor. These circuits are plumbed differently in that the return oil from both
motors does not return to the valve T port. This allows one motor to be
controlled by feeding oil to the A port and the other motor to be controlled by
feeding oil to the B port. Return oil from both motors is routed back to the
Return Manifold.
9- Spool Valve
Figure 7-46
The 9-Spool Valve schematic is shown in Figure 7-46. The 9-Spool Valve operates like the 6-
Spool, but it does not have an inlet unloader or and inlet relief valve. The highest load sense
signal within the assembly is used by the 6-Spool Valve unloader which keeps operating
pressure within both assemblies below 3000 psi. Another difference is that the pressure
limiting components in the 9-Spool Valve sections are not port reliefs. The common pressure
limiters in some of the 9-Spool Valve sections regulate the section load sense pressure and
a single device controls both work ports within a section. Like the 6-Spool Valve, the 9-Spool
Valve inlet has a pilot filter and reducing valve to supply its electro-hydraulic controls.
Figure 7-47
P2 Pump Circuit
P2 Circuit oil, when not used by the Six-Spool Valve, is supplied to the Nine-Spool Valve
circuits.
Circuit Operation
The oil supplied to the 6-Spool and 9-Spool valves is used by the valve circuits to do cylinder
and motor operation functions.
The spool valves are pressure compensated, load-sense components. They operate
differently from conventional spool valves in that the working pressure for the pumps is not
determined by the lowest load. In a conventional system, oil flow to a highly loaded motor or
cylinder can be interrupted by operating another spool that has a lower flow resistance. The
load sense valves, on the other hand, will attempt to satisfy the requirements of both heavy
loads and light loads at the same time. It does this by restricting flow to the light load, with a
spool pressure compensator, to make up the difference in working pressures. The only time
the valve assembly fails to satisfy all loads is when the total flow being demanded by all
actuated spools exceeds the available pump flow.
Oil is used in the valves and returned to the return manifold. The individual valve spools are
actuated by proportional or on/off electric controls controlled by the operator. The proportional
controls allow precise positioning of the valve spools and they also allow the maximum flow
from the individual spools to be limited with a maximum current adjustment.
9-Spool Valve Sections
1. First Valve Section
The first valve section controls the Rod Changer Cylinders.
2. Second Valve Section
The second valve section controls the Rod Support Cylinder.
3. Third Valve Section
The Chain Wrench Cylinder is supplied by the third valve section.
4. Fourth Valve Section
The fourth valve section controls the Tower Pinning Cylinder.
5. Fifth Valve Section
The fifth valve section controls the Telescopic Dust Curtain Cylinders
6. Sixth Valve Section
The sixth valve section controls the Air Throttle Cylinder.
7. Seventh Valve Section
The seventh valve section controls the Dust Flap (Curtain) Cylinder
8. Eighth Valve Section
The eighth valve section controls the Carousel Index Motor.
9. Ninth Valve Section
The ninth valve section controls the Sliding Breakout Cylinder.
Cooling Circuit
Figure 7-48
Figure 7-49
Oil supply for all of the DM45/50 hydraulic circuits comes from the Hydraulic Reservoir through
a Strainer, a Shut-Off Valve and the Suction Pipe. The three sections of the triple Pump pick
up oil from a Suction Pipe. Each section of the triple pump supplies a different set of functions.
Triple Pump
The triple pump is a three section, fixed displacement, vane type pump. The three pumping
elements inside the housing have a common inlet and two separate outlets as shown in the
schematic in Figure 7-49.
The circle contains one triangle, signifying one direction of flow. The first section (Section 1)
on each pump is designated schematically as P1, the second section (Section 2) of each
pump is designated as P2 and the third section (Section 3) of each pump is designated as
P3. Pump section 1 is capable of delivering more oil than section 2, and section 2 delivers
more oil than section 3 for a given input shaft speed. The suction for the pump is designated
as S.
Triple Pump Location
The triple pump is located in the top position of the three hole pump drive gearbox, above the
feed/rotation and propel main pumps.
P1 Pump Circuit
Oil supply for all of the hydraulic circuits comes from the Hydraulic Reservoir through a
Strainer, a Shut Off Valve and the Suction Pipe. The three sections of the triple Pump pick up
oil from a Suction Pipe. Each section of the triple pump supplies a different set of functions.
The P1 section of the Triple Pump drives oil to a distribution manifold that supplies the oil to
the Cooler Fan Motor and the Engine Radiator Fan Motor. This section also supplies pilot oil
for use in the Propel, Drill Feed and Rotation Circuits, and the Rod Support function. The
maximum working pressure of these circuits is determined by Fan Speed . A Relief Valve
mounted on the side of the Cooler is used to regulate the Fan Speed. Oil that is by-passed by
this valve is directed through the Main Filters to the Supercharge Manifold.
After P1 oil has been used to drive the motors, it passes through the Oil Cooler and the system
filters and is then supplied to the Supercharge Manifold for use in other circuits.
P2 Pump Circuit
P2 Circuit oil, when not used by the Six-Spool Valve, is supplied to the Nine-Spool Valve
circuits.
P3 Pump Circuit
The P3 section of the Triple Pump assists P1 section through a distribution manifold with
suppling the to Oil Cooler Fan Motor and the Engine Radiator Fan Motor.
The P3 section supplies oil to the same components as P1 section does.
Fans
All new Drills have 54 inch (1372 mm) Fan Blades with the new style cooler. This allows slower
Fan Speeds with a resulting decrease in noise. New Drills have been modified to use a 65 psi
Check Valve in place of the Amot valve. Some oil can pass through the cooler at startup,
allowing a faster warm up time. The Fan Speed Relief valve has been changed to incorporate
a coast down check valve within the valve. This means the motors will not cavitate during
shutdown.
Cooling Package
Figure 7-50
The standard cooling package used on the DM45,50,DML drills is the side by side cooler
package. The cooling package is determined by the size of the engine and compressor that is
used (See Figure 7-50).
A side by side cooler package can have an engine water cooler, charge air cooler, compressor
oil cooler, hydraulic oil cooler and an air conditioner core.
The non-standard cooling package is when the air-end is one of the following;
1. High Pressure 1250 air end
2. High Pressure 1450 air end
3. Low Pressure XL-1900
With these types of air end the CAC (Charge Air Cooler) is mounted on the power pack above
the drive line cover (See figure 7-52). The cooling package will be set up like Figure 7-51, a
HOC (Hydraulic Oil Cooler), Engine Coolant, COC (Compressor Oil Cooler).
Figure 7-51
Figure 7-52
Fan Motor Relief Valve
The Fan Motor Relief Valve is adjusted to control fan speed. To adjust, measure the fan speed
with an appropriate photo or strobe tach. Screw in on the adjustment to increase speed. Screw
out on the adjustment to decrease motor speed. (Make adjustments with system oil at normal
operating temperature).
Hydraulic OIl Cooler
The Hydraulic Oil Cooler, which is part of the cooler package, can be found on the cooling
circuit schematic (See Figure 7-53). The cooler is equipped with a bypass valve to divert oil
around the core when the oil is cold. The oil pressure in this condition will be higher than
normal. As oil temperature reaches its normal operating range, the bypass valve closes and
forces oil to go through the core.
Figure 7-53
Filters
There are two system return hydraulic oil filters and one case drain filter on the drill. The
system main return filters are located on the rear face of the hydraulic tank (See Figure 7-54).
All oil from the return manifold is directed through these filters before it is returned to the
system reservoir supercharge manifold. The supercharge of 65 psi provides supply to the
piston pumps and minimizes cavitation problems.
The case drain filter is located on the drill tower support (non-cab side) and filters case drain
oil prior to return into the hydraulic tank (See Figure 7-54).
Figure 7-54
The Oil Filters clean the oil used by the Main Pumps and Motors. Each filter incorporates a By-
pass Check Valve to protect against rupturing the element or housing if the filter becomes
plugged.
The Filter is represented schematically by a square, tipped on one corner with the inlet and
outlet connected to the two opposite corners and a dashed line connecting the two remaining
corners. Oil flows into the filter through the inlet port and leaves through the outlet port.
Contamination is captured by the porous element within the housing. An additional feature is
the Visual Indicator used to signal a clogged element.
Electric Over Hydraulic System
Overview
The primary function of the Electro-Hydraulic Controls (EHCs) used on the Mid-Range Series
Drills is to provide a link between operator command and valve or pump operation. The EHCs
are like the manual controls used on other machines in that they translate commands from the
machine operator into movement of the valve spools or pump swashplates. They differ from
manual controls however, in that the link is not direct. Before the operator commands reach
the valve spool or pump servo, they have been:
a. Translated into an electrical signal
b. Transmitted through a wire
c. Translated into a hydraulic pressure
It is the hydraulic pressure acting on the valve spool or pump servo control which actually
causes the final spool or swashplate movement.
There are two basic components to each Electro-Hydraulic Control as indicated by the name.
The electric part consists of the electronic or electrical remote controller (RC) mounted in the
control console, the associated wiring parts, and in some cases, additional relays and switches
that modify the electric signal in some way. The electrical part also includes the coil at the valve
or pump that helps to convert the electric signal back to the mechanical movement required to
develop hydraulic pressure. The second basic component of the EHC is the hydraulic part.
This part is simply an arrangement of fixed or variable orifices that oil flows through. The
adjustment of the variable orifice by the electric coil determines the amount of pressure and
the corresponding amount of valve spool movement.
From the operators point of view the EHC link will not be that much different from a direct
mechanical link. Movement of the RC in the console will still result in the corresponding
movement of the appropriate drilling function. The RC will be easier to operate and will provide
no feedback (feel) through the control handle. The operator will also find that there are some
operation sequences that the control will not allow (such as powering the rotary head into the
rod support).
From a technical point of view however, the EHC link has some distinct differences from the
direct link. The most obvious of these differences is that the EHC link is more complex. The
operators command is translated twice before reaching the end of the link. The second
primary difference is that all safety interrupts are included in the link. If the operator attempts
an illegal operation in a protected link, the electrical command that actually reaches the valve
or pump will be altered and in some cases interrupted. If however, the electrical signal actually
reaches the device coil and a pressure signal is generated, the function connected to that
device will move.
All the EHC links can be further classified as either proportional or on/off. The proportional
links provide precise movement of the valve spool that corresponds directly to movement of
the RC handle. The proportional links operate with either DC output or a Pulse Width
Modulated (PWM) current output depending on the device being controlled. The signals for
pump control for example, are 150 to 350 milliamp, DC current signal. The On/Off links provide
a DC current output which causes full travel of the valve spool whenever the RC handle moves
past the threshold position.
General Concepts and Terminology
The following pages provide a discussion of the general circuit concepts, as well as a detailed
description of each type of EHC and associated parts.
Current Control
The proportional RCs used for the Mid-Range Series are current control devices. The RCs
that drive Parker/Denison 9a stroker coils supply a current signal in the range of 1500 to 350
milliamps depending on handle position. The Rotary RCs which drive the FEMA valve coils
supply a current signal from100 to 500 milliamp range proportional to the position of the
handle.
Current control devices operate differently from voltage control devices in that their output
voltage is not always useful as an indicator of valve operation or position. It is the current, not
the voltage, that is the same for a given handle or knob position. The only reliable check of the
RC output is to measure the current flowing from the device. A simple example demonstrates
this fact:
Suppose a 24 ohm coil is supplied with a 24 volt DC input. The current that will flow through
the coil is V/R =1.00 Amp. If the voltage to the coil is reduced by half, the current will be cut
by half. If the coil fails open the current will be 0. If the coil shorts, the current will most likely
be high enough to melt the insulation from the wires.
On the other hand, suppose the same coil is supplied with a regulated current signal (1 Amp).
The voltage across the coil will be 1 Amp x 24 Ohms =24 volts. If the current is cut by half, the
voltage will be cut by half. If the coil fails open when a 1/2 Amp regulated current is called for,
the voltage goes to battery voltage, 24 volts, to try to hold up the current signal. If the coil
shorts, voltage drops to zero to try to maintain the current at 1/2 Amp.
This illustrates that the voltage on a RC output can be zero if the coil is shorted. Likewise the
voltage reading can be 24 volts if the output is open regardless of the handle position. Output
voltage is not necessarily a good indicator of circuit operation unless the circuit resistance is
known.
Pulse Width Modulation
Pulse Width Modulation (PWM) is the name given to a particular kind of electrical signal used
for some hydraulic control applications. The signal results from high speed electronic switching
of supply voltage to create a string of pulses all having the same height and varying width.
The PWM frequency for a given application is constant. That means that the amount of time
that elapses between the start of a pulse and the start of the next pulse (the period P) is
always the same. In the case of the Mid-Range Drill Series PWM signals, that time is 1/33 HZ
=.03 seconds. The time during every period P of the wave form when the voltage is switched
on is the on time or pulse width. Likewise the time during every period when the voltage is
switched off is the off time. The variation of the pulse width, or on time vs. off time, is what
gives the signal proportionality.
Threshold
The threshold is the minimum output level from an RC. The current ranges for the controllers
described above start at some level other than zero. In the case of the Parker/Denison 9a
stroker RC, for example, the current output starts at 150 milliamps. By starting at this minimum
level, current values that are too low to cause any resulting movement of the pump servo can
be tuned out. As soon as the RC handle moves off center, the current level jumps up to the
minimum level required to cause something to happen.
Maximum Out
Maximum Out is the maximum current level delivered by an RC when the handle or knob is at
full stroke. For example, the normal maximum out for the Parker/Denison 9a stroker RC is 350
milliamps. The maximum out adjustment is preset but adjusting a potentiometer on the RC
circuit board can change the level.
Dual Range
A Dual Range RC has two maximum output levels; a low range level, and a high range level.
These controllers can be identified by the R terminal on the main terminal strip. When the R
terminal is supplied with a 24 VDC signal, the controller is in high range and the corresponding
current range will be from the threshold setting to the normal maximum out setting. The high
range value is set by the maximum out pot described above. When the voltage signal to the
R terminal is interrupted, the controller is in the low range. In this range, the current output
will be from threshold to the low range setting. The low range setting is adjustable with the low
range pot on the RC circuit board.
Single Coil Controllers
The Parker/Denison 9a stroker RC can be further classified as single coil controllers. In these
circuits, there is 1 coil connected between the A and B terminal on the RC terminal strip.
When the handle is moved toward the A terminal, current flows out A, through the coil
winding in the pump stroker, and back to the RC B terminal. When the handle moves toward
the B terminal, current flows out B, through the coil winding and back to the RC A terminal.
The pump stroker interprets the direction of the current as well as the magnitude of the current.
Dual Coil Controllers
The Apitech and Fema valve coils interpret only the magnitude of the current signal, not the
direction of the current flow. In the case of the Apitech valves, there is one coil that moves the
spool in one direction and another coil moves the spool in the other direction. In these dual
coil circuits, the A terminal is connected to either of two wires on a valve coil. The remaining
coil wire is connected to ground. The B terminal of the RC is connected to either of the two
wires on the second coil. The remaining coil wire is connected to ground. When the handle is
moved toward the A terminal, current flows through the first coil, and then to ground. When
the handle is moved toward the B terminal, current flows through the second coil to ground.
Parker/Denison 9A Stroker
The 900 series electro hydraulic stroker modulates the rotary servo position in proportion to
an electrical input current.
The controller consists of an electrical proportional valve, which establishes a control pressure
in proportion to the electrical input current. This control pressure is then applied to a stroking
piston and spring box, to position the rotary servo shaft. With no external input, the piston is
positioned by the spring box; at zero displacement for pump controls, or at full displacement
for motor controls.
When an external pressure is introduced into one of the control ports, a force develops,
proportional to the pressure times the piston area. When this force exceeds the spring preload,
the piston commences to move in its bore, a distance proportional to the signal pressure. A
pin engaging the piston converts the piston motion into a proportional rotation of the rotary
servo shaft.
When the control pressure is reduced or removed from the control port, the rotary servo
position reduces or returns to the initial position. Introducing signal pressure into the opposite
port results in motion in the opposite direction.
With no pressure applied to either control port, the rotary servo may be moved manually by
applying external torque capable of overcoming the spring force, typically 30 to 60 lb.-in., 3,4
to 6,8 Nm.
Adjustable displacement stops are standard. On pump controls, stops are adjustable from
maximum to zero displacement. On motor controls, internal locknuts prevent reducing
minimum displacement below 30% displacement. Minimum and maximum displacements are
fully adjustable within this range.
For cross-center operation, a proportional valve is required for each side of center. For one
side of center operation and for motor controls, a single proportional valve is sufficient.
Figure 7-55
Figure 7-55 shows the illustration of the 9a stroker pump schematic.
Adjustment Procedure for 9A Controls on a Goldcup Pump
The 9A pump control is preset so that it is spring centered and it produces full displacement
control both sides of center (+/- 19 ). Adjustments (See Figure 7-56) to the null and maximum
volumes may be easily made in the field. The Backlash adjustment is factory adjusted to give
minimum backlash and should not be reset.
Procedure: Insure that the machine is in a safe operating condition. Install Pressure gauges
on each work port (AG and BG). With the control installed and the pump running the
adjustments are as follows:
Null Adjustment: Place the pump in a deadheaded condition, with both work ports blocked,
if possible. If it is not possible to physically block the ports, then block the load so it cannot
move.
Loosen the Null Adjustment Locknut and adjust the Null Adjustment slightly so that equal
pressures (+/- 50 PSI) are attained on each of the work ports. (If unable to deadhead the
pump, adjust for no motion on the actuator). Lock the adjustment at this time. Apply 200 mA
or more to one coil and release. The pump outlet should go to compensator pressure then
return to the null setting (+/- 100 PSI). Repeat by applying current to the opposite coil.
Maximum Volume Adjustments: Place the pump into a running condition (remove port or
load blocks) and apply full current of 350 mA to one coil. The maximum volume adjustment is
on the side opposite the energized coil. Loosen the locknut and adjust this to give the desired
maximum flow or maximum actuator speed. Lock the setting with the locknut. Repeat with the
opposite coil energized.
Figure 7-56
Operational Checks: Smoothly adjust the coil current from minimum (~150 mA) to maximum
(~350 mA). Note that the pump operates smoothly and continuously and that the actuator
moves accordingly. Repeat with current to the opposite side. Removal of current must result
in the pump returning to center and the actuator stopping.
If current is not available for setting the pumps, the control may be manually operated by
removing the Manual Control Access plug and using a 3/16 Allen wrench to stroke the pump.
Centering and maximum volume adjustments may be made by manually stroking the unit as
described above, instead of electrically stroking it.
Deadband Adjustment: This adjustment is factory preset and should not be readjusted.
Valves
Apitech Pulsars
The PULSAR VS Series (See Figure 7-57) pressure control valve is a normally closed, spring
biased, solenoid actuated, high speed, digital (on/off) valve. It consists of a removable,
replaceable cartridge assembly specifically matched with a separate orifice plate and O-ring
seal. To generate a proportional control pressure, the coil is energized 33 times per second
with a pulse width modulated (PWM) electrical signal. The resulting control pressure is directly
proportional to the duty cycle or On time per cycle of this excitation. Oil exiting the cartridge
is restricted by the 0.024 fixed orifice plate; the resulting back pressure is proportional to the
operator regulated duty cycle. This pressure is then routed within the working section to the
end of the main spool to furnish the control pressure.
Figure 7-57
6-Spool Valve
The 6-Spool Valve assembly is an electrically operated, proportional, load sensing 4-way
valve stack. The individual parts and features are shown in Figure 7-58.
The inlet section of the assembly contains the pilot pressure reducing valve and filter for the 6
spools. It also contains the unloader valve for setting the maximum working pressure for all
spool valve functions on the machine. The unloader is adjusted to 3000 psi working pressure
at the factory and should not require readjustment in the field.
The inlet section, pilot pressure reducing valve and filter are serviceable items. The pilot
reducing valve can be replaced by screwing the old cartridge out of the inlet housing and
screwing in a new cartridge.
There are 4 work port relief valves in the 6-Spool Valve assembly. The first spool section has
a port relief on both C1 and C2 ports to control hoist pressures. These pressures are set for
2000 psi pressure reading at the 6-Spool Valve test port (with C1 and C2 ports blocked). The
second spool section has a port relief on the C2 port to control tower raising pressure. This
valve is set for 2750 psi pressure reading at the 6-Spool Valve test port (with the Tower Raising
Cylinders fully stroked). The sixth spool section has a port relief on the C2 port to control
maximum Water Injection Motor pressure. This valve is set for 1000 psi pressure reading at
the 6-Spool Valve test port (with C2 port blocked). All of these pressures are adjusted at the
factory. No adjustment should be required in the field unless an entire assembly is being
replaced.
Figure 7-58
Each spool section has two Pulsar coils for shifting the spool (one for each direction). The coils
and the respective ports they control are shown in Figure 7-58. The coils can be replaced by
screwing the old part out and inserting a new one in its place. When removing a coil, the o-ring
inside the coil cavity must also be replaced. Remove the o-ring with an o-ring pick. Insert the
new o-ring into the coil cavity and be sure it is fully seated before screwing in the new Pulsar.
If the o-ring has not been inserted properly, a resistance will be felt as the Pulsar is being
screwed in place and the valve will not operate properly.
9-Spool Valve
The 9-Spool Valve assembly is an electrically operated, proportional, load sensing 4-way
valve stack. The individual parts and features are shown in Figure 7-59.
The inlet section of the assembly contains the pilot pressure reducing valve and filter for the 9
spools. The inlet does not have an unloader. This stack sends a signal to the 6-Spool Valve
unloader that controls the maximum working pressure for both assemblies.
The inlet section, pilot pressure reducing valve and filter are serviceable items. The pilot
reducing valve can be replaced by screwing the old cartridge out of the inlet housing and
screwing in a new cartridge.
Figure 7-59
There are 2 common pressure limiters in the 9-Spool Valve assembly. The common pressure
limiter controls the maximum spool compensator pressure to limit working pressure at both C1
and C2 ports. The limiter in the fourth spool section has a port relief of 1200 psi on the C1 port
to control tower pinning extend, to limit pressure in the tower pinning circuit. However, C2 is
set to allow maximum (3000 psi) pressure on the tower pinning retract. The limiter in the fifth
spool section has a port relief of 1300 psi on the C1 port to control telescopic cylinder extend,
to limit pressure in the telescopic cylinder circuit. However, C2 is set to allow maximum (3000
psi) pressure on the telescopic cylinder retract. All of these pressures are adjusted at the
factory. No adjustment should be required in the field unless an entire assembly is being
replaced.
Each spool section has two Pulsar coils for shifting the spool (one for each direction). The coils
and the respective ports they control are shown in Figure 7-59. The coils can be replaced by
screwing the old part out and inserting a new one in its place. When removing a coil, the o-ring
inside the coil cavity must also be replaced. Remove the o-ring with an o-ring pick. Insert the
new o-ring into the coil cavity and be sure it is fully seated before screwing in the new Pulsar.
If the o-ring has not been inserted properly, a resistance will be felt as the Pulsar is being
screwed in place and the valve will not operate properly.
FEMA Pulldown, Torque Limit and Holdback Control Valves
On the DM45,50,DML drill series, the FEMA Pressure controller is used in the drill feed
system. On low pressure drills it is used only in the Pulldown circuit. On high pressure drills
there are three used. One is used in Pulldown circuit, one in the Holdback circuits and one for
torque limit control circuit . The FEMA Pressure controller is a proportional pressure controller
which consists of a coil, armature, poppet, nozzle, and housing. The FEMA valve is used as
part of the main pump compensator control circuit in the Drill mode of operation. It is
hydraulically isolated from the pump by a pilot operated check valve when the machine is in
the propel mode. The FEMA valves (Pulldown and Torque Limit) are located between dust
collector and the tower support on the service decking (Figure 7-60). The FEMA valve for
Holdback is located on the cross member next to the regen valve (Figure 7-61).
Figure 7-60
Figure 7-61
Controllers
Pulldown Controller
As the operator turns the Pulldown, Holdback and Torque Limit controller (See Figure 7-62) to
the right, the DC electrical current signal to the FEMA controller is increased. As current is
increased to the valve coil, the internal poppet is pushed closer to the nozzle. This poppet
movement causes a restriction to oil flow that in turn builds pressure proportionally at the
valves C port. This valve adjustment is made by the drill operator when there is a requirement
for feed pressure increase or decrease.
The Pulldown force rotary controller is energized (wire #82) when the Drill/Propel switch is in
the Drill mode. The electrical current output of the controller is a direct current proportional
signal from 0-12 VDC w/24 Ohm Coil. When the operator turns the control knob to the right,
current signal is supplied to the FEMA valve coil. The farther the knob is turned the higher the
current signal output will be.
When the Feed control lever is in the feed down position, the feed system hydraulic pressure
can be controlled remotely by turning the Pulldown force knob. The pressure is variable from
zero to maximum Pulldown pressure.
NOTE: Maximum Pulldown pressure developed while drilling is dependent on force controller
output and ground (rock) formation conditions. While drilling in soft ground formations, it may
be impossible to reach the maximum hydraulic pressure relief setting.
Figure 7-62
Water Injection Rotary Controller
The water injection remote controller provides a proportional signal that is actuated by the drill
operator through a rotary control knob. The output it provides is the same 33Hz PWM signal
as the other controllers associated with Apitech valves.
The water injection controller electrical power is provided from wire number 80 on the electrical
circuit through the three position switch, Dust Collector/OFF/Water Injection Control Switch.
The rotary controller is energized when the switch is turned to the water injection position. As
the knob is turned from its off position, it supplies a proportional current signal to the upper coil
on the sixth spool of the 6-spool valve stack. This shifts the spool to allow oil to flow out the
C2 port to the water injection motor. The oil flow, and therefore the motor speed, is
determined by the position of the rotary remote controller knob.
Water Injection controller is the same controller as shown in Figure 7-62.
Limit Switches
In some cases, an EHC (Electro-Hydraulic Control) link must receive information about the
position of drill components so that drilling operations can be sequenced or protected against
movement that would cause damage. On the DM45,50,DML Drill Series electrical circuit, limit
switches mounted at appropriate locations in the tower assembly provide this information.
The limit switches all have two sets of contacts (four terminals). One set of contacts is normally
open (NO) and the other is normally closed (NC). When the lever is in its normal (un-actuated)
position, a circuit attached to the NO contacts will be interrupted so that no current can flow. If
the switch arm is rotated either clockwise or counter-clockwise, the contacts change state. The
NO contacts will close to enable their circuit and the NC contacts will open to interrupt their
circuit.
On the DM45,50,DML Drill Series drills with standard equipment, there is a limit switch (LS5
on the electrical schematic) used for this purpose. It is located at the upper end of the feed
cylinder on the dust collector side. The limit switch is mounted along the path of the traveling
sheave cage such that the lever is actuated as the sheave cage passes (See Figure 7-63).
This switch provides information about rotary head position for feed deceleration and optional
tram interlock circuits.
Figure 7-63
On drills equipped with additional options (Rod Support LS6, No Bump Rod Changer LS4),
there will additional switches of this type in the tower.
Relays
DPDT 24 VDC Relay
There are several relays that are used on the DM45,50,DML Drill Series in various electrical
circuits. The relay illustrated in Figure 7-64 is typical of the relays used. This is a double pole,
double throw, 24 VDC relay. Each relay includes a 24 VDC coil and two sets of contacts. Each
set of contacts (A and B) has a normally open pair and a normally closed pair. When the
coil of the relay is energized, the electro-magnetic energy causes the internal contact pairs to
change state. The normally open pairs will close, and the normally closed pairs will open.
Figure 7-64
Figure 7-64 shows Relays located behind the Engine Functions Panel of the operators
console.
Typical Coil Resistance
The resistance of a coil on an Apitech valve, Fema valve or a Parker/Denison stroker can be
checked from the cab console. Use the following procedure for the coil being checked.
Parker/Denison Stroker Coil
When checking the Denison coil, it is recommended to switch the drill propel selector switch
to the propel position. Remove the wires from the A and B terminals of the propel controller.
Measure the resistance between the two open wires. The resistance should be 24 to 30 ohms.
If checked in the drill mode, the feed circuit resistance can be greater than 30 ohms (Parker/
Denison coil resistance) due to the possibility of the deceleration resistor being in the circuit.
If checked in the drill mode, with the rotary head at the top of the tower, the resistance between
the A and B wires should be about 420 ohms. The additional resistance will come from a
390 ohm resistor in the feed deceleration circuit.
Apitech Coils
There are two coils on each Apitech valve section. To check the coil attached to the controller
A terminal, remove the wire from the A terminal and read the resistance between the open
wire and ground. The resistance should be about 65 ohms. The B side coil resistance can
be checked the same way.
Fema Coils
The Pulldown FEMA coil resistance can be checked only if the carousel is in the stowed (open)
position. Remove the wires from the controller A and B terminals. Measure the resistance
between the two open wires. The resistance should be about 24 ohms.
Proportional Remote Control Output
OEM or remote controllers can be checked for proper output with a voltmeter. To check an RC
with a voltmeter follow the procedure below.
1. Check for 24 VDC input voltage. Read from terminal + to ground -.
2. Check for good ground. Power off, read resistance from terminal - to ground.
Resistance should be zero.
3. Check the coil resistance for the particular circuit as explained in the section
above.
4. With the resistance known and the A and B wires connected back up, the
voltage from A to - or from B to - can be measured. Voltage should be in
the following ranges:
a. Apitech Circuits: Variable 0 - 24 VDC w/65 Ohm coil
b. FEMA Circuit: Variable 0 - 12 VDC w/24 Ohm coil
c. Parker/Denison Circuits: Variable 0 - 10 VDC w/27 Ohm coil
Checking Relay
The easiest way to do a quick check on a relay is to listen to or feel the relay. If the relay is
being actuated by a switch signal, it will click when the connection is made. A more reliable
check requires the use of a voltmeter. Check the coil terminals. One coil terminal should be
grounded and one should receive a voltage signal when appropriate. If the relay is switching,
check the individual contact pairs next. Check the resistance across the contact pairs (both
open and closed) with the wires disconnected or the relay pulled from its socket. Open
contacts read infinite resistance. Closed contacts read zero resistance. Make sure the
contacts are not welded together by switching the relay with 24 volts and repeating the
resistance check.
Checking Limit Switch
The easiest way to check the function of a limit switch is to rotate the arm and listen for the
click of the switch. A more reliable check requires the use of a voltmeter. Open up the cover
and check the resistance across the contact pairs (open and closed) with the wires
disconnected. Also make sure the contact pairs change from open to closed or closed to open
when the arm is switched back and forth.
Checking Diode
To check a diode, remove it from the circuit. The diode is a uni-directional device (like a check
valve) so be sure to remember exactly what end was connected to what terminal so that it can
be put back in the same orientation. One end of the diode has a line printed around it. The line
is on the end that BLOCKS current flow. Set the voltmeter to read resistance (ohms). Connect
the red lead to the end with the line. Connect the black lead to the end away from the line. The
resistance indicated should be infinite (open circuit). Now switch the meter leads black on line
and red away from the line). Resistance should be zero (closed circuit). If either test fails, the
diode is no good (See Figure 7-65).
Figure 7-65
Operation
Jack Controllers
The controllers used in conjunction with the Apitech hydraulic valves are Pulse Width
Modulated (PWM) controllers. The controllers shown in Figure 7.13--1 are representations of
the typical controllers used.
The J ack Control (A) EHCs are only energized when the Drill/Propel switch is in the DRILL
mode. The EHC links that operate the 3 jack spools are pulse width modulated (PWM) links.
These links control spools number three, four and five in the six-spool valve stack. The RCs
(Remote Controllers) are set up to drive dual coils as described in Valves, Apitech Pulsars
(See Figure 7-66, A).
Figure 7-66
The J ack remote controls (RCs) have a neutral lock that must be lifted by the operator before
the lever can be taken off center. The neutral locks are intended to prevent unintentional
movement of the handle.
Whenever a RC handle is moved away from the operator, the A terminal delivers a PWM
current signal to the upper Pulsar on the appropriate valve spool. (The current level coming
from the RC is proportional to the handle position). The upper Pulsar converts the current
signal to the proportional pressure signal required to position the valve spool and oil flows out
the valve C1 port to retract the jack cylinder. When the RC handle is moved toward the
operator, the B terminal on the RC board delivers a proportional PWM current signal to the
wire connected to the lower Pulsar. The Pulsar converts the current signal to a pressure signal
that acts on the valve spool to shift in the other direction. Oil flows out port C2 to extend the
jack cylinder.
Hoist Controller
The Hoist Control RC (Figure 7-66, A) is the same type with the same PWM output as the jacks
RC. When the control handle is moved away from the operator, the A terminal and the circuit
attached to it is powered with a proportional PWM current signal. This raises the hoist cable.
When the handle is moved in the B direction, current flows through the lower valve coil on
the hoist spool (6 spool) and oil flows out the C2 valve port to lower the hoist cable.
Tower Raising Controller
The Tower Raising Control RC (Figure 7-66, A) is the same type controller as the jacks and
hoist. It is a PWM control with a neutral lock. Current from the B terminal powers the upper
Pulsar on the second spool of the six-spool valve stack. This causes oil to flow from the C2
port to extend the tower raise cylinders and raise the tower. The A terminal is connected to
the lower Pulsar that controls oil flow out the spool valves C1 port to retract the cylinders and
lower the tower.
Rod Indexer Controller
The Rod Indexer RC (Figure 7-66, A) is the same type as the tower raise, hoist and jack
controls. PWM proportional current from B causes oil to flow from port C2 to the rod
changer to index clockwise. Current from A causes the rod changer to index counter-
clockwise.
Breakout Wrench Controller
The Breakout Wrench RC (Figure 7-66, A) is the same as the tower raise, hoist, rod index and
jack controls. A proportional current signal from B powers the upper Pulsar on the fourth
section of the nine-spool valve stack. This causes oil to flow from the C1 port to retract the
breakout fork cylinders. The lower Pulsar is powered by a proportional current signal from the
A terminal on the RC when the handle is moved in that direction. This causes oil to flow out
port C2 that extends the breakout fork cylinders to engage the fork.
Carousel Swing Controller
The Carousel Swing RC (Figure 7-66, A) is the same as the controllers for the jacks, hoist,
tower raise, rod index, and the breakout fork. When the handle is moved in the direction of the
B terminal, a proportional PWM signal is available at the B terminal. Current flows from the
terminal to the lower Pulsar on the first spool in the nine spool valve bank. The Pulsar positions
the spool so that oil flows out the C1 port and causes the carousel swing cylinders to extend
and swing the carousel toward the load position.
NOTE: Drills with No Bump rod changer protection. This complete EHC link differs because it
is protected against swinging the carousel in if the rotary head is in the way. An electrical limit
switch (LS7) protects the carousel by interrupting the current to the Pulsar. The switch is
normally open, held closed by the rotary head. If the rotary head is not at the top of the tower,
current to the Pulsar is interrupted due to the open contacts in the limit switch (LS7).
There are no interrupts in the circuit for opening the carousel. When the operator moves the
RC handle away toward the A terminal, current is supplied to the upper Pulsar on the first
nine spool section. This causes the spool to shift to flow oil out of the C2 port to retract the
carousel swing cylinders and move the carousel to the open or Stowed position.
Chain Wrench Controller
The Chain Wrench RC (Figure 7-66, A) is the same as the controllers for the jacks, hoist,
breakout fork, tower raise, rod indexer. Moving the handle toward the B terminal enables a
PWM signal to flow to the Pulsar on the C2 side of the spool valve. This signal causes the
spool to shift directing oil flow from the C2 port to the base end or extend port of the chain
wrench cylinder. Moving the handle toward the A terminal causes the spool to shift the other
direction, sending oil flow from the C1 port to the retract or rod end of the chain wrench
hydraulic cylinder.
Water Injection Controller
The Water Injection RC (Figure 7-66, B) is a proportional control with a rotary knob. The output
it provides is the same 33 Hz PWM signal that the above RCs use.
The Water Injection RC power is provided from wire number eighty (80) in the electrical circuit
through a three position switch. The RC is turned on when the Water Injection/ Off /Dust
Collector switch is turned to the Water Injection position. As the RC knob is turned away from
its off position, it supplies a proportional PWM current signal to the upper coil of the six-spool
valve stack. This shifts the spool to allow oil flow out the C2 port to the water injection motor.
The oil flow and therefore the motor speed is determined by the position of the RC knob.
Dust Collector
The EHC link for the Dust Collector is significantly less complicated than those described in
the previous discussions. This link is an on/off control that powers up the lower Pulsar on the
sixth spool in the six-spool valve stack. The 24 VDC signal comes from the dust collector/water
injection selector switch when it is shifted to the Dust Collector position. The 24 VDC signal
causes the valve spool to shift all the way to its spool stop to flow oil out the C1 port to turn
the dust collector motor.
Dust Hood Controller
The Dust Hood controller is a dual axis controller (Figure 7-67). This controller is used to
control both raising and lowering of the dust hood and raising and lowering of the front and
rear dust curtains. Moving the handle left and right lowers and raises the front and rear
curtains. Moving the handle fore and aft raises and lowers the dust hood.
This controller is not a PWM controller. It is a dual axis, On/Off, spring to neutral type and
supplies 24 VDC from the micro switch to the Pulsar that corresponds to the direction of handle
movement. There are four micro switches located at the bottom of the controller that are
actuated by the handle when moved.
Figure 7-67
Tower Pinning
The Tower Pinning is controlled by a spring centered toggle switch. The switch supplies 24
VDC to the Pulsars on section four of the nine-spool valve stack. Pushing the switch up
energizes the Pulsar corresponding to the C1 port diverting oil to extend the pinning cylinder.
Pushing the switch down energizes the Pulsar corresponding to the C2 port of the valve
section. This disengages (retracts) the pinning cylinder, unpinning the tower from the pinning
clevis.
There is a RED light right of the tower pinning switch, any time the tower pinning is not fully
pinned, the light will illuminate.
NOTE: Do not operate the machine in DRILL mode with the tower unpinned. This can result
in excessive loading of the tower support pivot area and the tower raising cylinders. Improper
operation of the machine can cause severe damage or injury.
Drill Propel Valve
The Drill/Propel Mode Control Valve manages all of the mode selection, brake and pump
compensator enabling tasks for the drill. It is a ductile iron manifold into which 4 valve
cartridges are inserted (See Figure 7-68). A solenoid operated 4-way valve, bolted to one side
of the manifold, selects the drill mode or the propel mode for the drill. The solenoid is energized
when the propel mode is selected and de-energized when in the Drill mode.
Figure 7-68
The valve assembly can be completely rebuilt by replacing the 4 valve cartridges and the
solenoid operated 4-way valve bolted to the side of the manifold. The assembly should never
be serviced as a complete unit.
Drill Feed Circuit
With the Drill/Propel selector in the Drill position, electrical power transfers from wire number
80 to wire number 82 (See Figure 7-70). This supplies power to the Feed, Rotation and
Auxiliary function controllers. These controllers are used in conjunction with the Drilling
process.
To start the rotary head moving down the tower, the operator pulls the Feed lever to the down
position. This sends a proportional electrical current from the controller to the cab side main
pump stroker. The electrical signal to the stroker results in changing the main pump swash
plate angle. The farther the lever is moved, the farther the swash plate will come on stroke,
increasing the pump displacement from zero, displacement up to the full displacement setting
of the pump. Reducing the lever movement, (reducing the current output to the stroker)
reduces the swash plate angle. Therefore, rotary head speed is affected by the amount of
Feed lever movement.
The Drill/Propel control valve and the FEMA actuator also affect the movement of the rotary
head. When the Drill /Propel switch is in the DRILL mode, power is supplied to the Feed
control lever, Pulldown Force controller and to the solenoid operated four way valve portion of
the Drill/Propel control valve. Energizing the solenoid shifts the valve, enabling communication
(hydraulically) between the main pump compensator VA port and the drain manifold through
the Drill/Propel control valve and the FEMA actuator.
The FEMA actuator is a normally open electrically controlled hydraulic valve (Figure 7-69). It
receives electrical signal from the Pulldown Force rotary controller. The Pulldown force
controller sends 24 VDC electrical signal to the FEMA valve. If the FEMA valve is receiving no
current signal, it will be in the normally open condition. In the open condition, the VA line of
the main pump compensator is open or Vented to tank. Electrical signal to the FEMA coil
causes the FEMA valve to close off the communication path of the VA port to the tank.
Increasing the current signal closes off the FEMA valve, allowing a rise of the Feed circuit
hydraulic pressure. Feed pressure is proportional to the amount of Pulldown Force control
knob movement. Turning the knob to the right increases system pressure and turning to the
left lowers system pressure.
Figure 7-69
Figure 7-70 contains a simplified sketch of electrical schematic. Only the essential
components for controlling the feed on the drill are shown. The other components and circuit
interlocks have been left off to simplify the discussion of the operation of the feed circuit.
Relay R10A and R11A are optional interlocks to the propel circuit. Relay R10A allows the rig
to propel only when all of the jacks are fully retracted. Relay R11A allows the rig to propel only
when the Rotary head is fully raised in the tower.
Terminals R, D and N on the Feed Electro-Hydraulic Controller (EHC) are used for different
applications and will be discussed in further detail in other sections of this manual.
When the Propel/Drill Selector switch is in the DRILL position, Wire 82 provides electrical
power to the Pull Down (Feed) EHC, the Rotation EHC, the Rod Support Extend/Retract
switch, and the other electro-hydraulic controls (See Figure 7-70).
Note that relays R5 & R6 are DE-ENERGIZED whenever the Mode Selector switch is in the
DRILL position. This prevents the Drill from shifting into Propel mode in the event that electrical
power is lost. As a further safety measure, only those electro-hydraulic controllers (EHC)
necessary for drilling operations are energized.
Figure 7-70
Pulling the handle of the Feed EHC toward the operator will cause the rotary head to move
down the tower at speeds depending on the displacement of the handle from the neutral
position. Similarly, pushing the handle away from the operator will cause the power head to
move up the tower.
Rotation Control
When the Drill/Propel switch is in the Drill mode, the main pump controller on the Dust
Collector side is used to control the drill pipe rotation. It controls both speed and direction of
rotation. Pushing the controller away from the operator makes the drill pipe turn counter-
clockwise or reverse for breakout. This direction of rotation is used to uncouple drill pipes from
one another.
Pulling the control lever forward starts the drill pipe turning clockwise. This direction of rotation
is used for normal drilling and for connecting pipes together. The Rotation controller is shown
in Figure 7-71.
LP Drill Feed and Rotation Controller
The EHC link for Feed pump control uses a proportional, single coil RC with a neutral safety
lock and dual range control switch. The RC output is a proportional DC current signal, not a
PWM current signal (See Figure 7-71). The Mode selector switch must be set to the DRILL
MODE before the Drill Feed and Rotation controllers will function.
Figure 7-71
The Feed and Rotation controllers are identical on XL machines. The RCs each have two
terminal strips. The first strip provides access to the +, -, A, X, B, R, and N terminals
(N is spade connection on micro switch opposite side). The second strip is mounted on the
side of the RC and it provides access to terminals 7, 8, and 9. These connect to a micro switch
that is switched by a button in the end of the RC handle. Terminals 7 and 9 area (NC) normally
closed pair. Terminals 7 and 8 are a (NO) normally open contact pair.
The normal mode for the Feed and Rotation RCs is high range mode. The NC contacts 7 and
9 switch 24 VDC from the RC + terminal to the R terminal to shift the control into high range.
If the button on the end of the handle is pressed, the NC contacts 7 and 9 open and interrupt
the power to the R terminal. This shifts the control into low range mode.
The high range mode allows a proportional DC current signal from about 150 mA to 350 mA
(no pump stroke to full pump stroke). The low range allows a proportional DC current signal
from about 150 mA to 198 mA (no pump stroke to 1/16 stroke).
In the low range, full RC handle movement corresponds to a change of only 48 mA that gives
a finer control for more precise alignment of the drill steel flats with the breakout fork. The
actual maximum low range speed can be adjusted with the low range pot on the RC circuit
board.
When the RC handle (feed or rotation) is pulled toward the operator, a proportional DC current
signal is supplied from the B terminal to the corresponding main pump stroker. This causes
the pump swashplate to position to allow flow from the pump A port. If this controller is used
for control of the rotation pump, the rotation motors will turn the drill pipe clockwise. The
amount of oil the pump supplies and therefore the forward rotation speed is proportional to the
handle position.
When the RC handle is pushed away from the operator, the proportional current signal from
the RC A terminal flows through the stroker coil in the other direction. This causes the pump
swashplate to position to allow flow from the pump B port and the drill pipe turns counter-
clockwise. The reverse rotation speed is proportional to handle position.
The EHC link for the feed pump control uses the same RC as for the rotation speed control
(Low Pressure Drills machines only). The RC output is a proportional DC current signal, not a
PWM current signal. This RC uses the dual range selection circuit described in the discussion
above. (The low range mode is particularly useful for precise positioning of the drill pipe.) This
link is different, however, in that both control directions have protection circuits.
When the feed RC handle is pulled toward the operator, a proportional DC current signal is
supplied from the RC B terminal to the feed pump stroker coil. The other side of the stroker
coil is connected to the circuit components (Limit Switches) that provide feed down interrupt
control and feed up deceleration control. If the action of any of these components closes a
direct path to RC terminal A, the pump will stroke to allow oil flow from pump port A and the
rotary head will feed down. If the action of any of the components adds resistance before
closing a path to RC terminal A, the pump will stroke slightly to allow very slow feed down
speed. If the action of any of the components interrupts the path to RC A terminal, the pump
will not stroke and the rotary head will not feed down.
Feed Controller (HP)
The Feed Controller is different on High Pressure drills than from those on low pressure drills.
Like the LP controller, the HP feed controller also has two terminal strips. It is different,
however, in that it has an additional micro switch connected to the circuit board. (See Figure
7-72)
Figure 7-72
The first terminal strip provides access to the +, -, A, X, B, and R terminals. The N
and D terminals indicated on the schematic are actually micro switches located on the circuit
board side of the controller. The D micro switch makes it different from the ones in the
previous discussion. When the handle is moved toward the operator, NO contact D within
the micro switch is actuated. This energizes wire number 81. When terminal D is energized,
24 VDC current flows through wire #81 to the coil of the holdback solenoid operated control
valve. When the solenoid operated valve coil is energized, the hydraulic Holdback circuit is
functional.
The second terminal strip is mounted on the side of the RC and it provides access to terminals
7, 8, and 9. These connect to a micro switch that is switched by a button in the end of the RC
handle. Terminals 7 and 9 are a (NC) normally closed pair. Terminals 7 and 8 are a (NO)
normally open contact pair.
On high pressure drills used for DHD drilling, the feed system requirements are different than
those of an LP low pressure Rotary drill. The additional terminal and switches interact with
the Holdback control circuit. These controls will be discussed in the Holdback Control
section.
Drill Feed Force / No Bump Rod Changer (Option)
The EHC link for feed force control uses a rotary RC with a proportional DC output. The output
range is from 100 to 500 mA.
The RC receives 24 VDC from wire number 82. When the knob is turned from its off position,
a proportional current flows from terminal A to the normally open contacts of (LS6) the Rod
Support limit switch. If the Rod Support is stowed out of the way of the rotary head, the NO
switch contacts close and allow RC output to drive the FEMA valve coil. Pressures from 400
to 4500 psi can now be commanded by the RC (3500 psi maximum for 35 foot tower drills).
On DM45,50,DML Drill Series drills that are equipped with the No Bump Rod Changer option,
the NC contacts on the carousel limit switch (LS4) are connected between the NO BUMP
resistor (located in operators console) and the FEMA valve coil. The other end of the resistor
is connected to 24 VDC from wire 82. If the carousel is loading a rod, the switch is in the
normal position and current from the resistor is supplied to the FEMA coil. The resistor can
be adjusted to limit maximum feed down pressure. This prevents the rotary head from feeding
down with enough force to damage the carousel. If the carousel is out of the way of the rotary
head, the NC contacts open and the current path through the resistor is disconnected from the
FEMA coil.
Holdback Control (HP)
Figure 7-73
The EHC link for Holdback force control uses a rotary RC with a proportional DC output. The
output range is from100 to 500 mA. Also included in the Holdback circuit is a solenoid
operated, two way valve. The two way valve is energized by a limit switch (terminal D, see
electrical schematic) on the feed controller. When the feed lever is moved in the feed down
direction, the normally open limit switch immediately closes energizing wire #81. Wire 81 is
connected to the solenoid operated two-way valve. When energized, the valve opens and the
holdback function is enabled.
The Holdback rotary controller (Figure 7-73) receives 24 VDC from wire number 82. When the
knob is turned from its off position, a proportional current flows from terminal A to the FEMA
valve coil in the Holdback circuit. As long as the Feed control lever is actuated in the feed
down direction (toward the operator), the Holdback rotary controller can be used to affect the
feed system bit loading.
As weight is added to the drill string, the operator must increase the holdback pressure to take
weight off the bit.
Rotation Control
The EHC link for Rotation Pump Control uses a proportional, single coil RC with a neutral
safety lock and dual range control switch. (See Figure 7-74). The RC output is a proportional
DC current signal, not a PWM current signal. The Drill/Propel selector switch must be set to
the DRILL MODE before the rotation controller will function.
Figure 7-74
The rotation control RC has two terminal strips. The first strip provides access to the +, -,
A, X, B, R terminals. Terminal N is located on a micro switch located on the circuit
board side of the controller. It is used for neutral start protection and is a spade connection on
the circuit board.
The second strip is mounted on the side of the RC and it provides access to terminals 7, 8,
and 9. These connect to a micro switch that is switched by a button in the end of the RC
handle. Terminals 7 and 9 are a (NC) normally closed pair. Terminals 7 and 8 are a (NO)
normally open contact pair.
The normal mode for the rotation speed RC is the high range mode. The NC contacts 7 and 9
switch 24 VDC from the RC + terminal to the R terminal to shift the control into high range.
If the button on the end of the controller is pressed, the NC contacts 7 and 9 open and interrupt
power to the R terminal. This shifts the control into low range mode. The high range mode
allows a proportional DC current signal from about 150 milliamps to 350 milliamps (no pump
stroke to full pump stroke). The low range allows a proportional DC current signal from about
150 milliamps to about 198 milliamps (no pump stroke to about 1/16 pump stroke). In the low
range, full RC handle movement corresponds to a change of only 40 mA that gives a finer
control for more precise alignment of the drill steel flats with the breakout fork. The actual
maximum low range speed can be adjusted with the low range pot on the RC circuit board.
Torque Limit Control (Option)
The EHC link for Torque Limit Control (Figure 7-75) uses a rotary RC with a proportional DC
output. The output range is from 100 to 500 mA (Same part #as Pulldown and Holdback).
Figure 7-75
The RC receives 24 VDC from wire number 82. When the knob is turned from its off position,
a proportional 24 VDC signal flows from terminal A to the FEMA valve coil in the Torque
Limit circuit. As long as the Rotation lever is actuated in the forward rotation direction (toward
the operator), the torque limit rotary controller can be used to affect (raise or lower) the rotation
system torque force. Turning the knob to the right increases the torque force available in the
rotation circuit.
EHC Adjustments
Feed and Rotation Controllers
Figure 7-76
The DM45,50,DML Series drills with (low pressure) LP compressors used for rotary drilling use
the same type controller for both the Feed and Rotation functions. The feed and rotation
controllers are only energized when the machine is in the DRILL mode. The feed and rotation
controller is shown in Figure 7-76. These controllers are located on the Drill Functions Panel
of the operators console (See Section 4 Operating Controls For Panel Location) and are used
to control the main pumps during the drilling operations.
On HP (High Pressure) drills, the Feed controller has an additional micro switch for
Holdback functions, and it works in conjunction with the Holdback regulator.
These controllers are electrical devices that send an output current of 150-350 milliamps to
the main pump 9A stroker. The electrical output current is proportional to the degree of
movement of the control lever. The farther the lever is pushed in either direction, the higher
the current signal to the pump stroker. The result is a machine that operates smoothly while
providing the operator with proportional actuation of the hydraulic functions used for drilling.
On the DM45,50,DML Drill Series, two identical controllers are used for controlling the track
functions while in the tramming mode.
The instructions for adjustment of the Feed and Rotation controllers are as follows:
Note: Put the rig in the drill mode, engine off, key-switch on. If the machine is a HP machine
turn the holdback controller knob to the half way position. The rotary head should be at the
bottom in the tower.
1. Make sure the handle is in the center, off, position. Remove the B wire from the
Feed controller and measure the resistance between the open B wire and the
controller A terminal. Resistance should be 82 ohms, indicating that the
controller is attached to the pump electric stroker coil. If not, check the wiring.
2. Connect an ammeter between the controller B terminal and the open B wire
(red lead to B and black lead to the open wire).
3. Pull the Feed controller handle slightly on stroke (till the micro switches just
click). Adjust the threshold pot until the ammeter reads 150 milliamp (mA).
4. Pull the Feed controller handle fully on stroke and set the Hi Range pot to 350
mA.
5. Leave the controller handle fully stroked and hold down the button on top on
the controller. Set the Lo Range pot to 198 mA. Return handle to center. Check
current reading in the opposite direction, return handle to center when finished.
Reconnect the wire to the B terminal.
6. Repeat steps 1 through 5 for the Rotation controller.
Propel Controller Adjustment
Propel Controls (If rig includes jack-up and/or propel interlock, make sure interlocks are in their
propel position or are by-passed for the following test.)
Note: Make sure the key is in ON position, but engine is NOT running. Put the rig in propel
mode. Remove the B wire from CS (right track) propel controller and connect an ammeter, 1
amp or less scale, between the controller B terminal and the open B wire (red lead to B and
black lead to the open wire). If no current is measured, verify optional interlocks are
operational.
1. Pull the CS controller handle slightly on stroke (till the micro switches just click).
Adjust the threshold pot until the ammeter reads 150 milliamp (mA). If you do
not get a current reading, check the wiring.
2. Pull the CS controller handle fully on stroke and set the max-out pot to 350 mA.
Return handle to center, check current reading in opposite direction, return
handle to center. Then reconnect the wire to the B terminal. It should be 198
mA at full stroke on reduced speed (knob pressed).
3. Repeat steps 1 and 2 for the DCS (left track) propel controller.
Dust Collector
Dust Collector Troubleshooting
If, upon inspection of your dust control system, it is obvious that the unit is not operating
properly, the following discussion should help you to troubleshoot the problem.
Figure 7-77
All problems with the dust collector system can be isolated through the use of a water
manometer. Measurements should be made separately on the upper and lower vacuum taps
located on the dust collector housing. Depending on whether your readings are higher or lower
than the normal values, the following explanations will apply.
Figure 7-78
Upper Tap HIGH - Lower Tap LOW
This situation indicates that the blower assembly is being choked off, causing the vacuum in
the clean air section to go up. The fact that the area around the filter elements (lower tap) is
low indicates that air is not moving through the filters (i.e. plugged filter elements). The main
reason that this occurs is failure of the back pulsing system of pulsed air. Three probable
causes are:
1. The incoming air pressure is too low. This pressure should be maintained at
about 40 psi. Insert a gauge at the point where air enters the dust collector to
make your measurement.
2. The pneumatic or electric timer could be malfunctioning. Check the timer to see
that each station is being fired at a timer interval of about 2-3 seconds between
stations.
3. Impulse valves over the filter elements may themselves be faulty. If one of the
diaphragms of the impulse valves develops a hole or a rock becomes lodged
in the valve causing the diaphragm to seat improperly, the compressed air may
never be allowed to build up to the required 40 psi pressure and/or the valve
may not fire properly. Also, for electric systems, the electric-air solenoid valve
operating the impulse valve may be faulty.
Upper Tap HIGH - Lower Tap HIGH
This situation indicates that the system is being choked off prior to the filter elements. This
generally results from a plugged suction hose due to the build-up of dirt and mud or obstruction
by a foreign obstacle such as a shot-sack.
Upper Tap LOW - Lower Tap LOW
This condition points to a loss in suction capacity. The primary concern here is fan speed. The
fan may be turning below the suggested 3000 rpm because of a problem in hydraulic oil supply
(or the air supply in the case of an air motor). Another situation often occurs when the motor
is changed out or repaired. The motor may be reconnected incorrectly to cause the blower
wheel to turn in a reverse direction.When this happens, a vacuum will be produced and some
air flow will occur. The best way to verify proper rotation of the wheel is to observe it visually
upon startup or shut down. The blower wheel should turn clockwise when viewed from the top
looking down at the dust collector.
As a final comment, one should note that the dust collector fan should be run as close to 3000
rpm as possible. Although the fan can easily tolerate higher speeds and the system will indeed
pull more air at higher speeds, operating the system at such speeds can cause unnecessary
wear of filter elements, dust collector housing and suction hose.
Table 1: Dust Collector Trouble Shooting Guide
Table 2: Excess Dust
Dust Collector Trouble Shooting Guide
Manometer Reading Indication Cause Cure
Upper Lower
HIGH LOW Loss of suction.
High reading
Plugged Filter Check Pulse Air
(Faulty timer,
impulse valves or
low pressure).
HIGH HIGH Loss of suction.
Reading of zero
Plugged Filter Clear air path
LOW LOW Loss of suction Low fan speed.
Fan runs
backwards. Dump
hose missing.
Adjust hydraulic
flow. Check
hydraulic
hookups. Replace
dump hose.
HIGH HIGH Poor Filter Life Fan speed too
high.
Reduce hydraulic
flow to fan motor.
Dust Escaping Around Dust Collector
Problem Action Correction
Damaged Dust Skirt Visual Check Repair or Replace Dust
Skirt.
Rod Seal Missing or
Damaged
Visual Check Replace Rod Seal
Suction Dust from Dust
Collector
Visual Check for Dust
Buildup in Duct
Check Fan Speed. Low Air
Volume Will Not Carry
Dust. Clean Duct.
Suction Dust From Drill To
Dust Collector Leaking
Visual Check For Holes In
Duct Work Or Leaking
J oints
Repair Or Replace As
Required.
Dust Skirt Not Touching
Ground To Form Seal
Visual Check Dust Skirt Should Be
Modified To Seal On All
Sides.
Dust Discharge Box
Plugged
Remove Dust Discharge
Box
Clean Out Dust Discharge
Box.
Table 3: Fan Dust
Table 4: Pulse
Dust Discharge Flap
Damaged
Remove Dust Discharge
Box And Inspect
Repair Or Replace Dust
Discharge Box.
Dust Collector Hopper
Plugged
Open Door Clean Out
Filters Dirty Remove Filters And
Inspect For Dirt Inside Of
Cartridge
Clean With Compressed
Air Or Replace With New
Filters.
Top Of Dust Collector Full
Of Dust
Visual Check Clean Out. Check Filters
For Holes. Check To See
That Filters Are Properly
Installed And Wing Nuts
Are Tight.
Dust Discharging From Fan
Filter Leaking Remove Filter. Check For
Holes With A Light.
Replace Filters And Clean
Out Top Section.
Filter Seal Leaking Check Seal On Filter Clean Seal and Tighten
Wing Not.
Pulse Not Functioning Properly
Air Bleeding From
Solenoid
Check Solenoid Exhaust
Port.
Check That Timer Is
Sequencing Properly.
Repair If Necessary.
Replace Solenoid.
Pulse Valve Blowing
Continuously
Check Solenoid Exhaust
Port.
Same As Above.
No Pulse Check Power To Timer. Repair Power Source.
Replace Timer.
Dust Escaping Around Dust Collector
Setting the Electric Timer
Note: There are three switches on the DET-9000 that control the action of the timer. These
switches are labeled OFF TIME, FIRST OUT and LAST OUT. A flat head screw driver can
be used to set each switch to a digital value from 0 to 9 as listed below:
1. The OFF TIME switch controls the amount of time between pulses. A value of
0 represents 0.5 seconds. Each increment adds 0.5 seconds, with value 9
representing the maximum value of 5 seconds. Set the OFF TIME value at 9.
2. The FIRST OUT switch should be set to the station number of the first
solenoid valve to be activated. A value of 0 is not allowed and will cause the
yellow error lamp to blink on and off.
3. The LAST OUT switch should be set to the last station number to be
activated. For example, if there are four filter elements in the dust collector and
the first solenoid is connected to station 1, then the LAST OUT switch should
be set to 4. 0 is not a valid setting.
4. If the power is on when any adjustments to the switches are made, then the
reset button must be pushed before the adjustments take place.
Hydraulic Tank
Figure 7-79
There are two system return hydraulic oil filters on the reservoir that are rated at 5 microns.
The system main return filters are located on the rear face of the hydraulic tank. The main
return flow to the tank passes through these filters and into the hydraulic oil tanks internal
supercharge manifold. The supercharge of 65 psi provides supply to the pumps and minimizes
cavitation problems.
7.4 - Electrical System
Electrical System Information
The following information is provided to give an understanding of the electrical system and the
relation to the operators control console described in Section 4 Operating Controls.
Cat Engine Panel
Figure 7-80
Cummins Engine Panel
Figure 7-81
CAT and Cummins Engines
Drills equipped with Caterpillar and Cummins engines have an electrical system with computer
controls for all engine functions. The Engine Monitoring System will be explained to give the
operator an understanding of the system and to emphasize the need to call for specialist
assistance in the event engine system warning lights signal problems during operation.
When the engine is started, battery current is supplied to the starter motor through the starter
solenoid (S2) contacts on the starter motor. To close the contacts, the key switch must be
turned to the ON position and the starter button depressed. This activates the (S1) coil which,
in turn, closes contact (S1). Coil (S2) is then powered and, in turn, activate (S2) contact. This
is what actually makes contact with the motor starter.
Starting Engine
Before the engine can start, the emergency stop button must be pulled out or disengaged. This
allows current to flow through the emergency stop button to the fuel solenoid. This solenoid
allows the flow of fuel into the engine. If power is cut off to the fuel solenoid, engine fuel flow
will cease and the engine will stop. This is why it is called an Energize To Run system.
The starter button should be released as soon as the engine starts. With the throttle control
at low idle, the engine will continue to run at 1200 RPM.
NOTICE
Do not operate the starter motor for more than 30 seconds at a time. Let
the starter motor cool for at least 2 minutes before attempting to start
again. Overheating, caused by excessive cranking, will seriously damage
the starter motor.
Two 12 volt batteries, connected in series, provide 24 volt direct current (DC) to the system.
The batteries use a machine ground to complete the circuit. The battery and starter ground
cables are size 2/0. They are protected by two sections of fusible link. One is attached to the
starter and the other to the alternator. Number 7 wire is the hot or (+) wire for the engine ECM.
Number 2 wire is the hot or (+) wire for the drill lighting, starting system and EARS function.
Number 6 wire supplies current to the engine function panel and EARS function.
Electrical System Components
Batteries
Each starter motor uses two 8D type batteries rated at 12 volts each, connected in series, that
provide 24 volt direct current (DC) to the system (see figure 7-82). They should be checked
every 50 operating hours as part of routine maintenance. Refer to Maintenance (50 Hours or
Weekly).
Figure 7-82
Fusible Links
Fusible links are used on all Atlas Copco drills to prevent a short circuit from causing a fire or
burning someone. They are connected between the starter and the batteries and the alternator
and the batteries. They are located at the starter and the alternator to prevent any damage to
adjacent components or other circuits.
A fusible link is a lead in an electrical wiring system designed to open the circuit when
subjected to an extreme current overload. By opening the circuit in the presence of a current
overload, no damage will occur to the wiring system protected by the fusible link.
Physically, the fusible link is a tinned, stranded conductor that is 9 inches (228.6mm) long and
insulated with a thermo setting material and enclosed in a blue cover. There should be no
burning of the insulation in the first five seconds of current application and no secondary arcing
after the conductor has separated.
A four gauge size differential is maintained between the fusible link and the smallest gauge
size in the wiring it protects. A number 12 gauge wire link is used on Atlas Copco products.
Because of this differential, the resistance per unit length will be larger in the fusible link and
the heat dissipated along the link will be greater than in the other section of cable. The heat
generated starts to melt the core at a location in the link. The copper core becomes fused and
molten. Capillary action draws the copper away from the hot spot that causes the rea to neck.
This action continues until the core is completely separated.
The links should never be removed unless they have burned out doing their job. Then they
should be replaced immediately. They should not be replaced with the regular #1 or #2 wires
since there will be no protection for the electrical system.
Bulk fusible link material is listed under CPN 56987795 and the individual 9 inch length is CPN
56999360. A spare set should be attached to every drill so it is available in case of a short
circuit. If it is not replaced immediately, there is a tendency to forget it completely over a short
period of time. Every mechanic should carry several pieces with them at all times.
The fusible links used on the drill are blue and are 9 inches (23cm) long. There is a ring
connector on one end of each link. Fasten one fusible link end ring connector to the starter and
fasten the other fusible link end ring connector to the alternator. The other end of each fusible
link is connected to the main hot wire #1 by a wire nut. The main hot wire (#1) is a red, 8 gauge
wire (See Figure 7-83).
Figure 7-83
NOTICE
Fusible Links must be in place to operate the drill. If a short circuit
destroys a fusible link, it MUST be replaced before the drill goes back in
service.
Alternator
The alternator is a 24v, 100 amp model. It is used to charge the batteries and provide current
to the electrical system and the night lights.
Key Switch
The key switch controls current to all functions but the night lights. The electrical system On-
Off key switch turns on all electrical power to the engine and controls stopping and run
operations. When it is turned on it supplies power through wire number 7 to the starter button,
primer motor, tachometer and the compressor shutdown switch.
The electrical system On-Off key switch also activates the ECM (Electronic Control Module)
that controls all aspects of the engine, including most shutdown devices. Refer to the electrical
schematics for engine water temperature switch, fuel gauge and throttle switch.
Note: Always stop the engine and remove the key when leaving the drill unattended or while
performing certain maintenance procedures.
Circuit Breakers
The bank of seven (7) circuit breakers, located on the control console, protect the drills
electrical circuits. The circuit breakers are mounted between the current producer, batteries or
alternator and the devices they are protecting. In the event of an overload of a circuit, it is
necessary to press in the tripped circuit breaker. Note: If there is a recurrence, call for
service assistance to correct the cause of the overload in the circuit.
The following is the identification of the circuit breakers on the console:
1. 5 Amp ---Engine Shutdown
2. 15 Amp - Windshield Wiper System
3. 20 Amp - Power Distribution for OEM Controllers
4. 20 Amp - Heater/AC System
5. 15 Amp - Power Distribution for Engine
6. 15 Amp - Drill Working Lights
7. 20 Amp - Tram (Propel) Lights
8. 15 Amp - Water Dump (Option)
Push Buttons
The push buttons on the operators console enable the operator to:
1. Start the engine
2. Engine Fuel Primer
3. Horn (Alert)
4. Thread Greaser (Option)
5. Engine Ether Cold Start
These push buttons are spring loaded to disconnect power when they are released.
Tachometer / Magnetic Pickup
The tachometer is driven by the magnetic pickup which receives its signal from the engine
flywheel. The pickup is a solid state device that counts teeth on the flywheel and sends a signal
to the tachometer. The wires between the pickup and tachometer are specially shielded wires
to prevent interference from outside signals.
Hour meter
Shows the number of hours and partial hours, that the key switch has been in the On position.
Relays
A starter relay is connected between the starter button and the starter motor that energizes
the starter solenoid switch. The starter relay actually engages the starter motor. There are two
parts to any relay; a coil and at least one set of contacts (points). The coil physically changes
the condition of the contacts from normally open to closed or vice versa. There can be several
sets of contacts for one coil.
Relays are used in several circuits on the drills and the schematics do not always show how
they interact with each other.
A relay consists of a coil connected to one or more sets of contacts. When the coil is energized,
the solenoid pulls the other contacts downward. In some cases, this disconnects a circuit while
in others it makes a new circuit.
Diodes
Diodes are used in many areas of the electrical system. Their function is to allow current to
flow in one direction but not in the other.
One of the locations a diode is used in is the fuel relay coil circuit. When the coil is energized,
it builds up a charge internally as it operates the magnet within the coil. When the current is
removed from the coil, a residual charge is left in the coil. This must have a path to dissipate.
That path is provided by the diode. It allows current to flow through itself and discharge without
causing any damage to the rest of the circuit. It is shown in Figure 7-84.
Figure 7-84
Other areas where diodes are used are in test circuits on larger drills. They provide a means
of testing light bulbs without activating the shutdown devices. They can be recognized by the
wire at each end and a stripe around one end as shown in Figure 7-84.
Engine Shutdown Devices
The drill is equipped with several shutdown devices to prevent harm to the engine or
compressor in case of loss of fluids or other related problems. It has a compressor discharge
temperature switch, an engine coolant temperature switch and two engine oil pressure
shutdown switches.
Compressor Discharge Temperature Switch
This Murphy Switch gauge has a gauge on the operators console and a sensor located on the
compressor discharge piping of the compressor. It monitors the temperature coming out of the
compressor. When the temperature increases to 248F (120C), a contact inside the gauge
makes electrical contact and cuts the power to the engine.
Engine Water Temperature Switch
This switch gage is also mounted in the console and the coolant temperature sensor, located
at the water manifold of most engines, monitors engine coolant temperature. Activation
temperature for the high coolant temperature fault is 224F (107C).
Engine Oil Pressure Switch
This switchgage, mounted in the console, has two pressure limit switches that close when the
pressure falls below 27 psi and 10 psi. It does not have a capillary tube but uses a hose
connected to the engine to supply pressure to the switchgage. Both gauges are normally
closed and rely on engine oil pressure to open them. They both work through the engine speed
switch and close when oil pressure falls below 27 psi or 10 psi, depending on the engine
speed.
Engine Speed Switch
This device is a heavy duty speed switch set to trigger from one input signal when a pre-
determined speed is reached. The input signal supply source is a magnetic sensor that utilizes
an electro-magnetic effect to produce an output signal of electric pulses. The frequency of the
electric pulse is determined by the number of flywheel gear teeth passing in front of the sensor
in a given time. The pulse frequency is representative of engine speed and therefore is used
to cause the speed switch to change states at different speeds. The magnetic sensor is also
used to operate the engine tachometer and elapsed time meter.
Emergency Engine Shutdown
The emergency engine shut down switch has a red light that comes on when the fuel system
is energized. If the light goes out, it normally means that the engine fuel system is not
operating. Pushing the emergency engine shut down switch shuts off power to the fuel valve
which stops fuel flow and shuts the engine down. Turning the key switch does the same thing.
All engines are energized to run, which means the fuel system must be energized in order to
pump fuel.
Cat Sensors and Electrical Components
Coolant Temperature Sensor
The engine coolant temperature sensor monitors the temperature of the engine coolant. The
coolant temperature signal is sent to the Electronic Control Module (ECM) for engine
monitoring and for improved engine control. The signal is used by the ECM for all of the
following engine functions: engine timing control, engine operating mode and engine
protection.
The ECM is capable of adjusting the engine timing relative to the engine operating
temperature. The concept of dynamic timing provides the engine with the ability to control
exhaust emissions. Timing control also aids in white smoke cleanup during cold engine
operation.
The ECM also uses the signal from the engine coolant temperature sensor to determine the
mode of operation for the engine. Several aspects of engine operation are affected by the
engine operating mode: acceleration ramp rates, engine timing and fuel injector timing.
Coolant Temperature Protection
Excessive engine coolant temperature is an undesirable operating condition. Serious damage
to the engine can result if the coolant level is too low or too high and the engine is allowed to
overheat. If the engine coolant temperature increases to excessive levels, the engine
monitoring system will initiate actions that will protect the engine from damage.
Coolant Level Sensor
The coolant level sensor is an optional sensor. This sensor monitors the engine coolant in the
cooling system. The coolant level sensor signal is sent to the ECM for the purpose of engine
monitoring.
Engine Oil Pressure Sensor
The engine oil pressure sensor provides an oil pressure signal to the Electronic Control
Module (ECM) for the purpose of engine monitoring. The electronic signal is compared to an
Oil Pressure Map that is stored in ECM memory. The Oil Pressure Map is derived from a direct
relationship between engine speed and the oil pressure that is expected at that speed. The
engine monitoring system records a low engine oil pressure condition in ECM memory if the
sensor value is not within the proper range. The monitoring system then initiates protective
measures.
WARNING
!
Low engine oil pressure is an undesirable operating condition. When a
low oil pressure condition exists in the engine, there is a possibility of
damage to major engine components. Low oil pressure protection is a
safety feature that will take the necessary measures in order to initiate an
engine shutdown in the event of a low oil pressure condition.
Fuel Temperature Sensor
The fuel temperature sensor monitors the inlet fuel temperature. The Electronic Control
Module (ECM) utilizes the signal from the fuel temperature sensor to provide fuel temperature
compensation for the engine fuel control system. Fuel temperature compensation provides the
following benefits:
1. Rated engine horsepower regardless of fuel temperature.
2. Highly accurate fuel rates and fuel consumption rates.
3. Optimum fuel economy.
Changes in the temperature of the fuel affects the power output of the engine. The ECM
adjusts the engine fuel rate according to the temperature of the fuel. This feature allows full
engine power to be realized by the operator at any fuel temperature.
WARNING
!
High Fuel Temperature is an undesirable operating condition.
Fuel temperature will also affect the calculation of fuel consumption rate that is performed by
the ECM. The ECM utilizes the fuel temperature signal to provide an adjusted value for these
calculations.
Fuel Pressure Sensor
The fuel pressure sensor monitors filtered fuel pressure. Although fuel pressures that are
outside the normal operating range may adversely affect engine performance, there should
not be any noticeable reduction in the engine horsepower. Abnormal fuel pressure will not
cause an engine shutdown. A low filtered fuel pressure may indicate that the low pressure fuel
system requires maintenance.
The fuel pressure sensor measures the fuel pressure after the fuel has been filtered. The
sensor connector for the fuel pressure sending unit is located on the machine side of the
machine connector. For more information, refer to the actual manufacturer Troubleshooting
Guide for this engine.
For more information on fuel system maintenance, refer to the maintenance section in the
actual Manufacturer Operation and Maintenance Manual.
Air Inlet Temperature Sensor
WARNING
!
Excessive inlet air temperature is an undesirable operating condition.
The air inlet temperature sensor detects the temperature of the air that is passing through the
inlet manifold. A signal is sent to the Electronic Control Module (ECM) for interpretation.
The ECM uses the information from the inlet air temperature sensor in order to accurately
control the emissions levels of the engine. As the inlet air temperature changes, the fuel
injection timing is advanced. This is done in order to maintain the exhaust emission standards.
Atmospheric Pressure Sensor
The atmospheric pressure sensor measures the pressure in the crankcase. This sensor
assumes that crankcase pressure is a representation of atmospheric pressure. A signal is sent
to the Electronic Control Module (ECM).
The ECM utilizes the value that is read by the atmospheric pressure sensor for the following
functions:
1. Reference source for pressure sensor calibrations
a. Calculating the operating altitude
b. Calculating boost pressure
c. Checking for air inlet restriction
When the ECM is powered, all of the pressure sensors that are used for engine monitoring
receive an automatic calibration. The ECM uses the value that is received from the
atmospheric pressure sensor to calculate the pressure offset value.
The ECM also utilizes atmospheric pressure to determine the active engine derate during high
elevation operation. The engine monitoring system compares the current atmospheric
pressure value to the programmed derate set point. The engine is derated by limiting the fuel
delivery at a rate of approximately 3 percent for each 1000 ft. (304 m) of elevation.
Actual boost pressure is calculated by the ECM. The difference between the turbocharger
outlet pressure and the atmospheric pressure is equal to the actual boost pressure. Boost
pressure is used for calculating fuel system adjustments.
Turbocharger Outlet Pressure Sensor
The turbocharger outlet pressure sensor measures the pressure of the turbocharged after
cooled air from a port in the air inlet manifold. The sensor provides a signal to the Electronic
Control Module (ECM) that is used to calculate turbocharger boost pressure. The ECM derives
boost pressure by taking the difference between the turbocharger outlet pressure and the
atmospheric pressure.
Engine boost and actual engine speed are used by the ECM to govern the fuel air ratio control
and the fuel rack limiting functions. During a change in speed or a change in load, the ECM
adjusts the fuel injector delivery and the engine timing in order to provide maximum engine
response while minimizing the transient smoke levels.
Speed Timing Sensor
If primary speed timing sensor cannot sense engine speed, the DIAGNOSTIC lamp will
indicate a diagnostic fault code. The diagnostic fault code will be logged into the memory of
the Electronic Control Module (ECM).
If primary speed timing sensor cannot sense engine speed, the automatic default will use
secondary speed timing sensor. The secondary speed timing sensor will be used until the
primary speed timing sensor is replaced. The engine will shut down if both speed timing
sensors fail.
Failure of the Speed Timing Sensor
If any of the following conditions are present, a failure of the speed timing sensor may have
occurred:
1. The speed timing sensor output has opened.
2. The speed timing sensor is shorted to ground.
3. The speed timing sensor is shorted to supply.
4. The speed timing sensor is missing pulses.
5. The speed timing sensor has extra pulses.
Intermittent failure causes erratic engine control. The electronic control system will detect a
failure of the primary speed timing sensor. The operator will be warned through the
DIAGNOSTIC lamp.
Engine Speed Governing
The engine speed governor monitors the throttle position and actual engine speed (rpm) in
order to help control the following items: engine speed, response, torque output and smoke
limiting. The engine speed governor also helps to maintain constant engine speed.
The engine speed is controlled by the governing of the fuel injection duration of the electronic
unit injectors. Throttle input is used to calculate the desired engine speed.
Cat Engine Diagnostics
Self Diagnostics
Caterpillar Electronic Engines have the capability to perform a self diagnostic test. When the
system detects an active problem, the DIAGNOSTIC lights are activated. Diagnostic codes
will be stored in permanent memory in the Electronic Control Module (ECM). The diagnostic
codes can be retrieved by using the DIAGNOSTIC lights or Powerview (See Powerview
information in Section 7).
Refer to diagnostic code retrieval and the diagnostic code charts for more information on
retrieving engine diagnostic codes.
Active codes represent problems that currently exist. These problems should be investigated
first. If a code is active, the DIAGNOSTIC lamp will flash the flash code at five second
intervals.
Logged codes may represent intermittent problems, recorded problems or performance
history.
The problems may have been repaired since the logging of the code. These codes do not
indicate that a repair is needed. The codes are guides or signals when a situation exists.
Codes may be helpful to troubleshoot problems.
When the problems have been corrected, the corresponding logged fault codes should be
cleared.
Diagnostic Lamp
The DIAGNOSTIC lamp is used to indicate the existence of an active fault by flashing codes.
When the ignition switch is first turned on, the DIAGNOSTIC lamp will go through the
following procedure:
1. The DIAGNOSTIC lamp will come on and will remain on for five seconds. This
checks the operation of the lamp.
2. The DIAGNOSTIC lamp will turn off.
3. The DIAGNOSTIC lamp will come on again and the lamp will flash codes for
any active diagnostic codes. Not all diagnostic codes have a unique flash code.
4. The DIAGNOSTIC lamp will turn off for five seconds.
5. The DIAGNOSTIC lamp repeats all active diagnostic codes.
A fault diagnostic code will remain active until the problem is repaired. The electronic control
module will continue flashing the flash code at five second intervals until the problem is
repaired.
Diagnostic Flash Code Retrieval
NOTE: Refer to the OEM Operation and Maintenance Manual for your
specific engine and diagnostic codes.
You can use the DIAGNOSTIC lamp to determine the diagnostic flash code. Not all
diagnostic codes have a unique flash code.
Note: Flash codes should only be used to indicate the nature of a diagnostic condition. Do not
use flash codes to perform detailed troubleshooting.
Use the following procedure to retrieve the diagnostic codes with the engine DIAGNOSTIC
lamp:
1. The DIAGNOSTIC lamp will flash to indicate a two digit code. The sequence
of flashes represents the system diagnostic message. Each digit of the two digit
code is determined by counting the number of flashes. The lamp flashes at a
rate of two times per second. The lamp will pause for one second between
digits. The lamp will pause for two seconds between codes.
2. Turn the ignition key (start/run key) to the ON position. The engine does not
need to be started in order to view codes. The engine does not need to be
running while the ignition switch (start/run switch) is in the ON position. The
DIAGNOSTIC lamp blinks on and off at five second intervals.
a. When the ignition key (start/run key) is in the ON position, the lamp is
checked for proper operation. If there are any active codes, except for Code
34, the codes are displayed at this time.
Note: The DIAGNOSTIC lamp will illuminate for five seconds. The lamp will stay
on if there is an active diagnostic code.
3. Active diagnostic codes will always be flashed. There is no toggle switch that
will shut off the lamp.
(1) The engine will shut down if both speed/timing sensors are lost.
(2) Fuel injection will not occur and the engine will not start
Event Codes
The ECM can log events. Events refer to engine operating conditions such as low oil pressure
or high coolant temperature. The following table is a cross reference for event codes. Logged
events usually indicate a mechanical problem instead of an electronic system problem.
Fault Logging
The system provides the capability of Fault Logging. When the Electronic Control Module
(ECM) generates an active diagnostic code, the code will be logged in the memory of the ECM.
The codes that have been logged in the memory of the ECM can be retrieved and cleared.
The codes that have been logged in the memory of the ECM will be automatically cleared from
the memory after 100 hours. The following faults can not be cleared from the memory of the
ECM without using a factory password: overspeed, low engine oil pressure and high engine
coolant temperature.
Engine Operation with Active Diagnostic Codes
If the diagnostic lamp starts to flash codes during normal engine operation, the system has
identified a situation that is not within the specification. Check the flash code or digital display,
if equipped, to check the active diagnostic codes.
Note: If the flash code shows DERATE and if there is a low oil pressure condition, the
Electronic Control Module (ECM) will limit the engine power until the problem is corrected. If
the oil pressure is within the normal range, the engine may be operated at the rated speed and
load. However, maintenance should be performed as soon as possible.
The active diagnostic code should be investigated. The cause of the problem should be
corrected as soon as possible. If the cause of the active diagnostic code is repaired and there
is only one active diagnostic code, the diagnostic lamp will turn off.
Operation of the engine and performance of the engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates may be significantly slower. Refer to the
OEM Operation and Maintenance Manual for more information on the relationship between
these active diagnostic codes and engine performance.
Engine Operation with Intermittent Diagnostic Codes
If the diagnostic lamp starts to flash codes during normal engine operation and the diagnostic
lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be
logged into the memory of the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine because of an intermittent code. However,
the operator should retrieve the logged fault codes and the operator should reference the
appropriate information in order to identify the nature of the event. The operator should log any
observation that could have caused the lamp to light, such as: Low power, Limits of the engine
speed or Excessive smoke, etc.
This information can be useful to help troubleshoot the situation. The information can also be
used for future reference. For more information on diagnostic codes, refer to the
Troubleshooting Guide for this engine.
Cummins Engine Diagnostics
The Cummins fuel system can display and record certain detectable fault conditions. These
failures are displayed as fault codes, which make troubleshooting easier. The fault codes are
retained in the electronic control module (ECM). The diagnostic codes can be retrieved by
using the DIAGNOSTIC lights or Powerview (See Powerview information in Section 7).
There are two types of fault codes: engine electronic fuel system fault codes and engine
protection system fault codes.
All fault codes recorded will either be active (fault code is presently active on the engine) or
inactive (fault code was active at one time, but not at the moment).
Active fault codes can be read using the warning (amber) and stop lamps (red) in the cab panel
or INSITE
TM
.
Inactive fault codes can be only be viewed with INSITE
TM
.
When the keyswitch is turned on and the diagnostic switch off, the fault code lamps (red,
amber and white) will illuminate for approximately two (2) seconds, one after another, to check
their operation.
The lights will remain off until a fault code is recorded. If a stop (red) light comes on while the
engine is in operation, the fault can disable the engine. Stop the engine in a safe manner as
soon as possible.
If the warning (amber) light illuminates, the engine can still be operated, but it can lose some
system features that can sometimes result in a power loss. The failure must be repaired as
soon as possible.
The engine protection system records separate fault codes when out of range condition is
found for any of the sensors in the engine protection system.
The following are engine protection system out of range fault codes:
1. Coolant Temperature
2. Coolant Level (optional)
3. Oil Pressure
Note: Lamp colors and labels vary by Original Equipment Manufacturer (OEM).
The engine protection system will light the maintenance lamp (white) when out of range
condition occurs.
To check for active fault codes, turn the keyswitch to the Off position and move the diagnostic
switch to the On position.
Turn the keyswitch to the On position. If no active fault codes are recorded, all three lights will
come on and stay on. If active fault codes are recorded, all three lights will come on
momentarily. The amber (warning) and red (stop) lights will begin to flash the code of the
recorded fault.
The fault code will flash in the following sequence: First, the amber (warning) lamp will flash.
Then there will be a short, one-second pause when both the white and red lights are off. The
numbers of the recorded fault code will then flash red. There will be a one-second pause
between each number. When the number is done flashing an amber light will appear again.
the number will repeat in the same sequence.
The lights will continue to flash the same fault code until the system is advanced to the next
active code. To go to the second fault code, move the engine diagnostic switch to INC
(increase), and release. You can also go back to the previous fault code by moving the engine
diagnostic switch to DEC (decrease), and release. To check the third or fourth fault code,
move the engine diagnostic switch INC, then release it when all active fault codes have been
viewed. Moving the switch to INC will go back to the first fault code.
To stop the diagnostic system, move the diagnostic switch to the Off position. Turn the
keyswitch to the Off position.
Engine Protection System
Engines are equipped with an engine protection system. The system monitors critical engine
temperatures, fluid level, switch position, and pressure and will log diagnostic faults when an
over or under normal operating range occurs. If an out of range condition exists, engine derate
action can be initiated. The out of range condition continues to get worse and engine shutdown
will occur. The operator must reduce the possibility of engine damage.
Engine protection system monitors:
Coolant Temperature
Coolant Level
Intake manifold temperature
Oil Pressure
Engine protection system monitors for:
High Coolant Temperature
Low Coolant Level
High Intake Manifold Temperature
Low / Very Low Oil Pressure
Cummins QSK19 Fault Code Tables
The fault codes for the Red light, which are the most common, are shown in the Red Light
(Engine Protection)Table. With the exception of code 432, most other codes can be acted on
by the operator.
Table 5: Red Light ( Engine Protection) Fault Codes
Amber Light Fault Codes
The failures caused by amber (and red) lights indicate wiring problems or internal ECM
malfunctions that the operator cannot repair. Call your local dealer if a amber (or red) light
comes on. Examples of the fault codes are shown tabulated in tables.
Red Light Illuminates = ON
Fault Code Description of Problem
143 Oil Pressure Sensor - Data Below Normal Range
151 Engine Coolant Temperature Sensor - Data above Normal Range
155 Intake Manifold Temperature Sensor - Data Above Normal Range
219 Oil Level Low
233 Coolant Pressure Level Low
235 Engine Coolant Level - Data above Normal Range
253 Oil Level Sensor - Low Oil Level Detected
261 Fuel Temperature High
292 OEM Temperature Out of Range
296 OEM Pressure Sensor Out of Range
415 Oil Pressure Sensor - Very Low Oil Pressure
432 Throttle Position Idle Validation Switch - Switch Position and Throttle
Percent Mismatch Failure
471 Very Low Oil Level Detected
555 High Blowby Pressure Detected
649 Maintenance Monitor Interval Warning Level Has Been Reached
Table 6: Amber Light (Engine Warning) Fault Codes
Amber Light Illuminates = ON
113 Timing Actuator - Component Shorted High
114 Timing Actuator - Component Shorted Low
118 Fuel Pump Pressure Sensor - Failed High
119 Fuel Pump Pressure Sensor - Failed Low
121 Engine Speed Sensor (ESS) - One Lost Signal
122 Boost Pressure Sensor - Component Shorted High
123 Boost Pressure Sensor - Component Shorted Low
135 Oil Pressure Sensor - Component Shorted High
141 Oil Pressure Sensor - Component Shorted Low
144 Engine Coolant Temperature Sensor - Component Shorted High
145 Engine Coolant Temperature Sensor - Component Shorted Low
153 Intake Manifold Temperature Sensor - Component Shorted High
154 Intake Manifold Temperature Sensor - Component Shorted Low
221 Ambient Air Pressure Sensor - Component Shorted High
222 Ambient Air Pressure Sensor - Component Shorted Low
223 Burn Valve Solenoid - Shorted Low
225 Makeup Valve Solenoid - Shorted Low
231 Coolant Pressure Sensor - Failed High
232 Coolant Pressure Sensor - Failed Low
237 Input Throttle Signal - Data Above or Below Normal Range
252 Oil Level Sensor Error
263 Fuel Temperature Sensor - Failed High
265 Fuel Temperature Sensor - Failed Low
293 OEM Temperature Sensor - Failed High
294 OEM Temperature Sensor - Failed Low
297 OEM Pressure Sensor - Failed High
298 OEM Pressure Sensor - Failed Low
316 Fuel Pump Actuator Is Open
318 Actual and Desired Fuel Pump Pressures Are Out of Range
343 Electronic Control Module (ECM) - Internal Communication Error
346 Electronic Control Module (ECM) - Power down Error
349 Tail shaft Governor at Greater Frequency than Threshold
384 Ether Injection Solenoid - Open or Shorted
422 Engine Coolant Level Sensors Signals - Data Invalid
423 Fuel Timing Pressure Sensor - In Range Failure
426 ECM Can Not Transmit On J 1939 Datalink
427 ECM Can Not Transmit On J 1939 Datalink at Acceptable Rate
431 Throttle Position Idle Validation Switch - Invalid
441 Battery Voltage, Unswitched - Data Below Normal Engine Range
442 Battery Voltage, Unswitched - Data Above Normal Engine Range
467 Error Between Desired Timing Fueling and Commanded Timing
Fueling Exceeds Normal Limit
468 Error Between Desired Rail Fueling and Commanded Timing Fueling
Exceeds Normal Limit
473 Remote Oil Level Sensor Error
487 Ether bottle Empty
489 Auxiliary Speed Frequency - Below Threshold
497 Multiple Unit Synchronization Switch Error
524 Alternator Droop Switch Fault
527 Dual ---Output A Signal - Open or Short Circuit
529 Dual ---Output B Signal - Open or Short Circuit
554 Fuel Pressure Sensor - In Range Failure
719 Crankcase Blowby Pressure - Failed High
729 Crankcase Blowby Pressure - Failed Low
777 Calculated Turbine Inlet Temperature or Calculated Compressor
Discharge Temperature Has Exceeded Calibrated Limit
Amber Light Illuminates = ON
White Light Fault Codes
The failures caused by white (and yellow) lights indicate wiring problems or internal ECM
malfunctions that the operator cannot repair. Call your local dealer if a white (or yellow) light
comes on. Examples of the fault codes are shown tabulated in tables.
Table 7: White Light (Maintenance Indicator) Fault Codes
QSK19 and QSK15: The explanation and correction of all fault codes is in the troubleshooting
charts of the Operation and Maintenance manual, available from Cummins.
White Light Illuminates = ON
111 Electronic Control Module (ECM) - Memory Failure
112 Timing Actuator - Fueling Flow Mismatch
115 Engine Speed Sensor (ESS) - Both Signals Lost
116 Fuel Timing Pressure Sensor - Component Shorted High
117 Fuel Timing Pressure Sensor - Component Shorted Low
131 Throttle Position Sensor - Component Shorted High
132 Throttle Position Sensor - Component Shorted Low
133 Remote Throttle Position Sensor - Failed High
134 Remote Throttle Position Sensor - Failed Low
147 Frequency Throttle Signal - Less than 100 Hz
148 Frequency Throttle Signal - More than 1500 Hz
234 Engine Speed - Data Above Normal Range
254 Fuel Shutoff Valve - Component Shorted Low
259 Fuel Shutoff Valve - Component Stuck Open
451 Fuel Pressure Sensor - Component Shorted High
452 Fuel Pressure Sensor - Component Shorted Low
455 Rail Actuator - Component Shorted High or Open
511 Rail Actuator - Component Shorted Low
514 Rail Actuator - Fueling Flow Mismatch
551 No Voltage Detected on Both of the Idle Validation Off - Idle and Idle-
--Signal Pins
553 Engine Fueling Pressure Exceeded - Data Above Normal Range
7.5- Pneumatic System
Compressed Air System Overview
Because of the compressible nature of air, it has been found convenient to generate fluid air
power in advance and store it in a tank for future use. Power exists as potential energy in the
stored air because of its pressure level above atmospheric. In practice, many branch circuits
performing unrelated functions are usually connected to a common air storage tank or
receiver. In hydraulics, because of the incompressible nature of air, the more usual practice is
to generate fluid power at the same rate it is used, as it is more difficult and costly to store it
for future use, although some hydraulic systems do work this way, using gas filled
accumulators.
Pipe, hose, or tubing conduct the air power from its point of storage to its point of use. The
diameter of piping must be suitable for transmitting the horse power with negligible loss.
In using air power, its pressure level, its volume of flow, and its direction of flow must all be
under control.
Finally, the air power is converted back into useful mechanical work with a power actuator,
which can be cylinders, air motors, or rotary actuators.
However, this is a general observation as there are some high powered air systems. A 100
horsepower air compressor may operate 200 or more unrelated branch circuits of 1/2
horsepower or less.
An air system can usually be designed to be quieter than an equivalent hydraulic system. For
one thing, it is completely silent between cycles and when holding a steady force. An air
system is usually cleaner. An air leak will not cause a mess around the machine.
Compressed air is usually faster in operating lightweight mechanisms at low power. Extremely
high speed actuation is possible by making connecting lines and valves large in size and by
over sizing the bore diameter of the air cylinder in relation to the force required. Air circuitry is
simpler, as a new circuit is usually added to a power supply (air compressor).
Compressed Air System
Introduction
The DM45,50,DML utilizes an oil flooded asymmetrical rotary screw compressor available
from 900 cfm (25.5 m
3
/min.) up to 1900 cfm (53.8 m
3
/min.) at 110 psi (7.6 bar) and from 900
cfm (25.5 m
3
/min.) up to 1450 cfm (41.0 m
3
/min.) at 350 psi (24 bar) to meet situations that
depend on hole size, pipe size and drilling conditions. The compressed air is used for hole
cleaning and keeping the bearings in the roller bit cool. It is also used for auxiliary systems,
such as powering the dust collector filter cleaners (when equipped) and operating service
tools.
System Operation
Atmospheric air is drawn in through the dry type air cleaner where 99.9% of contaminants are
removed. The clean air flows through metal ducts into the intake of the compressor. Passage
into the compressor is controlled by a butterfly valve. When the valve is opened, air flows into
the rotor housing and is compressed. While the compressor is turning, oil is being pumped into
the cavity and to all the bearings. This lubricates the bearings and the rotors, plus it seals and
cools the compressor.
The compressed air and oil mixture leaves the compressor through the discharge check valve.
The air/oil mixture travels through discharge hose into the receiver/ separator tank where the
oil is separated from the air.
The receiver tank acts as a reservoir for the oil that cools and lubricates the compressor. The
separator element is a filter that is used to separate remaining particles in the oil from the air
stream.
Any oil that migrates to the inside of the element is drawn out by means of a scavenger line.
This line has an opening in the bottom of the element and is connected to the cusp area of the
compressor. The differential pressure forces any solid oil out of the element and into the
compressor. This maintains a clean, oil free, air flow into the main air stream.
The clean air exits the receiver tank through a minimum pressure valve. The purpose of the
minimum pressure valve is to maintain enough pressure in the tank, at all times, to force the
oil through the cooler and into the oil pump and the air end. Compressed air passes through
the hoses and hard piping, called the standpipe, and down the hole by way of the rotary head
and drill pipe. This is the air that keeps the cuttings away from the bit and carries them up the
hole. This air also cools the bearings on the bit.
Compressed air is produced with the compressor mounted directly to the non drilling end of
the power pack diesel engine. The compressor includes three sub systems that support its
operation and auxiliary controls. These sub systems and auxiliary controls are:
1. Compressor Lube and Cooling Oil System
2. Electronic Air Regulation System (EARS) Optional
3. Separation System
4. Auxiliary Controls System
Standard Compressor (Non-EARS) System
Operator Observed Problems
During operations, the operator may observe some problems which may be defined in the
following Operator Observed Problems Trouble Shooting Chart.
The trouble shooting chart is limited to machine control operational problems which will guide
the operator to rectify the cause of the failure. The trouble shooting chart may not cover all
possible failures.
Table 8: Problems or Failures Chart
Operator Observed Problems Trouble Shooting Chart
Problem Cause Correction
ENGINE WILL NOT START
(Starter does not rotate)
Circuit breaker 5 tripped Reset Circuit Breaker 5
Emergency Stop switch
requires resetting
Check Emergency Stop
switch and reset if required
Drill Propel Control in
Propel
Move to Drill Mode
Track controllers not in
STOP
Move to STOP position
Batteries disconnected at
Isolator Switch
Turn battery isolator switch
to ON
Batteries discharged Check batteries. Recharge
if required
Battery cable connections
loose or disconnected
Clean and tighten terminals
a). Fusible link to starter
motor fused
Call for service to correct
fault
b). Starter relay fault
c). Starter switch defective
d). Starter solenoid or
starter defective
Compressor Switch gauge
defective
Replace Switch gauge
Shutdown Relay defective Replace Relay
Empty Fuel Tank Fill Fuel tank
ENGINE WILL NOT START
(Starter does not rotate)
Fuel solenoid at fuel pump
defective
Call for service
Defective Wiring Check with test lamp
ENGINE DIFFICULT TO
START AND HAS POOR
AND IRREGULAR
PERFORMANCE
Compressor butterfly inlet
valve open while starting
Close butterfly inlet valve
when starting
Low battery power Check battery
Batteries discharged Charge batteries if
necessary
Battery cable connections
loose or corroded causing
starter to turn too slowly
Clean and tighten terminal
connections, cover
connections with acid free
grease
Using too high viscosity oils
in low ambient temperature
Use appropriate oil grade in
winter
Fuel line blockage due to
wax separation in winter
Change fuel filters, bleed
fuel system, check for fuel
leaks and loose
connections
ENGINE DIFFICULT TO
START AND HAS POOR
AND IRREGULAR
PERFORMANCE
Incorrect valve clearances Call for service to adjust
a). Defective fuel injectors Call for specialist service
b). Defective turbo charger
Blocked air cleaner element Clean or replace element
Loose or badly adjusted
engine speed control
linkage
Call for specialist service to
make adjustments
ENGINE SHUTS DOWN Engine fault Check Engine Diagnostics
ENGINE MAKING
EXCESSIVE FUMES
Engine oil level too high Drain engine oil to correct
level on the dipstick
Blocked air cleaner element Clean or replace element
Low compression due to
poor condition of valves or
incorrect valve clearances
Call for specialist service
Compressor Fire Prevention
A fiber gasket is installed between the outside cover of the receiver and the metal tube holding
the separator element in place. This gasket prevents oil from leaking around the metal tube
and down the hole.
When air and oil flow through the filter media, static electric charges are created. If these
charges are allowed to build up, a spark similar to a lightning flash will occur. This will set the
oil and the media on fire. The fire will burn from the inside of the element through the standpipe
hose and will follow the air flow until it burns through the air hose. This is NOT a fire caused
by the compressor flashing.
To prevent this from happening, several metal staples have been installed THROUGH the
gasket so each side comes in contact with the metal. This bridge serves to allow the static
charge to drain off outside the receiver tank and not cause a static buildup (See Figure 7-85).
ENGINE OVERHEATS
!!STOP ENGINE
IMMEDIATELY!!
Excessive dirt on cooling
system blocking air flow
Clean cooling fins on
radiator / oil coolers
Engine coolant loss. Low
coolant level in engine.
defects
Defective injector nozzles
Incorrect fuel pump
calibration
Cooling system fan not
rotating or rotating at
reduced rpm.
LOW ENGINE OIL
PRESSURE
Low engine oil will activate
engine diagnostic ECM
system
Refer to Engine OEM
Operation and Maintenance
Manual
AMMETER INDICATES
LOW OR NEGATIVE
VALUE
Speed of alternator too low Check drive belt tension
Not changing due to
defective alternator or
regulator
defects
GENERAL DEFECTS ON
ELECTRICAL EQUIPMENT
Circuit breaker open Reset respective circuit
breaker
Defective parts or wiring Call for service to correct
defects
CAUTION
!
When replacing separator element, be sure there is at least one staple
that shows through on both sides of the gasket and is not covered with
glue.
Figure 7-85
Pneumatic System Information
Standard equipment for the air compressor includes a separate three stage inlet air cleaner
and full instrumentation and controls. The lubrication system includes an oil cooler, bypass
valve, oil filter, oil pump, and combination receiver and oil separator tank. A safety shutdown
system is also provided for high discharge air temperature.
The oil pump allows the operator to close the intake valve when no air is required. This greatly
reduces the engine load which saves fuel and facilitates cold weather starting.
Low Pressure compressors are those with discharge pressures of 100 to 150 psi. A
compressor is considered high pressure if the discharge pressure is 250 psi or greater. All of
the High Pressure compressors have discharge pressures of 350 psi. See Low Pressure
Compressor or High Pressure Compressor sections for specific detailed information.
There are three systems on a rotary screw compressor:
1. Lubrication System
2. Separation System
3. Regulation System
Each system is critical to the operation of the air end and the systems are all interrelated.
These systems will be described further in the appropriate areas of Low Pressure Compressor
or High Pressure Compressor sections
Compressor Oil Lube System
Oil is injected into the air end under pressure. The oil serves three purposes:
1. It cools the compressor bearings and rotors.
2. It lubricates the moving parts.
3. It seals the clearances between the male and female rotors, and between the
rotors and the housings and end plates.
Refer to the schematics specific to your drill.
Low Pressure Compressor (Non-EARS)
Lubrication System
Low Pressure compressors are those with discharge pressures of 100 to 150 psi. These
compressors are of the single stage, oil flooded, asymmetrical screw design. They are listed
by the metric diameter of the rotors. The Low Pressure Drills use a 226mm air end or a 285mm
air end.
The Lubrication System consists of the receiver, an oil pump, cooler, mixing valve, filters and
a manifold. When the compressor is compressing air, a minimum pressure valve in the
discharge line holds a certain pressure in the receiver tank to assist in pushing the oil through
the system. The minimum pressure valve is set at 65 psi.
Components:
Receiver - Separator Tank
The receiver tank (Figure 7-86) contains the compressed air and the lubricating oil for the
compressor. The oil is removed from the air by centrifugal force, gravity and velocity. The
receiver tank has an oil sight glass that shows the oil level at all times. The oil level must be
visible in the sight glass whether the drill is running or shut down.
Figure 7-86
Oil Pump
The oil pump (Figure 7-87) is a gear type pump, driven from the rear of one of the compressor
rotors. It operates as long as the compressor is turning. It is speed sensitive and pumps at
rated volume when the compressor is at full RPM.
Figure 7-87
It acts as a normal pump when the oil is cold and becomes a restriction to hold back pressure
on the receiver tank when the compressor is operating at normal pressure and temperature.
This prevents all the oil from being forced out of the receiver tank at once and flooding the
compressor.
Strainer
A 40 mesh (150 micron) strainer is mounted just before the inlet to the oil pump as shown in
figure 7-87. It protects the pump and catches any foreign debris such as hose pieces and parts
of the thermostat that could damage the pump. The metal strainer should be removed, cleaned
and reinstalled every 500 hours.
Compressor Oil
The low pressure (XL Series / 100 psi) air ends require a special oil. This oil is not compatible
with certain types of O-rings. Therefore, we use Viton type O-rings in the air end fittings and
filters. The oil is also not compatible with other oils and should never be mixed with other oil.
Low pressure compressors use Atlas Copco LP-150 oil. Be sure to change the filters every
500 hours.
Mixing Valve
Figure 7-88
The Mixing Valve (Figure 7-88) contains a thermostat that stops oil flow in one direction when
it is cold and allows oil to flow from another direction when it reaches operating temperature.
When the temperature is below 140F (63C), oil flow from port B to port A, thus bypassing
the oil cooler altogether. When the temperature increases to 160F (71C), the thermostat is
completely opened and all the oil flows from port C to A and shuts off all flow to B. At
temperatures between 140F (63C) and 160F (71C), some oil flows through port B to A
and some oil flows through the cooler and from C to A. Under normal operation, some oil
is flowing through both B abd C. The normal discharge temperature of the oil leaving the
air end should be between 180F (83C) and 220F (104C).
Oil Cooler
The Compressor Oil Cooler (See Figure 7-89) Is a single pass unit. Hot oil enters from the
bottom of the cooler and cool oil exits out of the top. This prevents any air bubbles that may
have been carried along with the oil from being trapped in the top and creating a vapor barrier.
The cooler is made up of four sections. The first section cools the hydraulic oil, the second
section cools the engine coolant, the third cools charge air (engine turbo charger) and the
fourth section cools the compressor oil.
Figure 7-89
Relief Valve
A 50 psi Relief Valve (Figure 7-90) is connected between the inlet and outlet of the oil cooler.
Figure 7-90
If the cooler becomes plugged and the inlet pressure becomes 50 psi higher than the outlet
pressure, the relief valve opens and allows oil to bypass the cooler. When the differential
pressure is reduced below 50 psi, the valve will close and normal flow resumes.
Oil Filter
A 10 micron filter (Figure 7-91) is installed at the outlet of the cooler before the oil reaches the
compressor. It catches any contaminants that may have been picked up in the circuit and
prevents them from plugging the orifices at the inlets to the bearings.
Figure 7-91
Discharge Check Valve
The Discharge Check Valve serves one purpose for two mediums, air and oil. It prevents air
and oil, under pressure, from backing up into the air end. When the drill is stopped, pressure
in the compressor drops to zero. There is still pressure in the receiver tank until it completely
blows down. If the check valve was not there, air pressure would force air and oil back through
the compressor housing and out the inlet valve, thus flooding the air cleaners.
Figure 7-92
Figure 7-92 shows the valve being held open. It has a single spring. The hinge must be
mounted on top to prevent the valve from staying open when the drill is shut down. Notice the
white nylon ring that forms a tight seal to prevent back flow when the drill is stopped.
The check valve in the compressor air discharge line is installed properly with the nameplate
located at the top and arrow pointing to tank (See Figure 7-92), therefore the hinge pivots from
the top (free flow into tank).
Oil Flow
The layout for the lubrication system is shown in Figure 7-93. Oil is stored in the receiver tank.
At startup, the pump must pull the oil from the tank. When air pressure rises in the receiver, oil
is pushed by air pressure from the tank to the oil pump. The pump then moves the oil to the
mixing valve and/or the cooler. Depending on the oil temperature, it either flows through the
mixing valve, filter and into the compressor oil manifold or through the oil cooler and then the
mixing valve, filter and to the compressor oil manifold.
From the compressor manifold, oil passes into the air end. Oil is pumped to each bearing and
rotor and into the cavity of the air end to mix with the air being compressed. This controls the
temperature of the discharge air. When the air has been compressed, the oil/air mixture
passes into the receiver tank to be separated.
Figure 7-93
Separation System
Lubricating oil is forced through the air end to cool, seal and lubricate the rotors. When the oil
is pumped into the receiver separator tank, it must be separated from the air going down the
hole. This is accomplished in three steps.
1. The Air/Oil mixture enters the receiver through the inlet pipe and splashes
against the inner walls. This forces the majority of oil to fall to the bottom of the
tank and remain there.
Figure 7-94
2. When the down stream air line is opened and air flows down the hole, some of
the remaining oil is carried along with it into the filter area. A metal canister
prevents oil from flowing through the filter directly. The air/oil mixture enters the
outer edge of the element and moves towards the center. As the oil travels
through the element, it is slowed down by friction and gravity pulls it downward.
Most of the oil drops out the bottom of the element and falls into the reservoir.
Figure 7-95
3. The final step in the separation process is removing any remaining oil from the
element so it is not carried over into the down hole air stream (Figure 7-96).
When enough excess oil is carried into the center of the element, a series of
holes in the end of the filter element allows oil to fill an area between the flange
and the element. The scavenger line is connected between the flange and the
inlet of the compressor. Since there is a differential pressure between the
receiver tank and the low pressure area of the compressor, oil and air are
forced through the scavenger line into the inlet area of the air end, thus
removing the last of the oil carry over. A 0.187 orifice in the line prevents
excessive amounts of air loss.
Figure 7-96
It is important to note when changing separator elements that the element be installed
correctly. The word TOP should always be on top to insure that the drain holes are at the
bottom (See Figure 7-97). This prevents excessive buildup in the scavenger area.
Figure 7-97
Another item to watch when changing elements is to be sure that the staples in the gaskets
are left there to prevent a static electric charge from building up and causing a fire.
Regulation System
The regulation system controls the pressure and volume of the air going down the hole to the
bit. The Butterfly Valve (also called the Inlet Valve) is manually opened and closed by the
compressor control handle in the operators control console in the cab (see Figure 7-98).
Normal drilling is performed when the operator pushes the handle away from him to open the
Inlet Valve while the engine is at full RPM. This allows air into the compressor inlet and it is
compressed as it goes through the air end. The compressed air is forced into the Receiver
Tank and as long as the pressure is greater than 20 psi, air will flow to the bit through the
standpipe. A Minimum Pressure Valve is mounted between the receiver tank and the
standpipe to insure there is always 20 psi in the tank. This pressure forces oil into the Oil Pump
to insure a positive flow to the lubrication system at all times.
Figure 7-98
A Discharge Check Valve is located at the discharge of the air end to prevent any pressure
from returning to the air end when the drill is stopped. While the drill is running, there is a flow
of oil being pumped into the air end whether air is being compressed or not. This oil is forced
out of the air end into the Receiver Tank through the Check Valve.
There is a scavenger line connected from the base of the Separator Element to the inlet area
on the air end. This line removes the excess oil from the element and returns it to the air end.
Refer to the previous SEPARATION SYSTEM Section for more information.
Regulation System Components
The 226mm and 285mm air end regulation system has one manual control to open and close
the inlet valve and several other automatic devices to operate the system.
Figure 7-99
The Inlet Butterfly Valve (See Figure 7-99) is a round, wafer valve that sits on top of the
compressor. It has a shaft that is connected to the center of the valve. This is where the linkage
for the Control Cable and the Air Cylinder are attached.
Orifice in Inlet Valve
There is an orifice drilled in the Inlet Butterfly Valve (Figure 7-99) to allow outside air to enter
the compressor at all times. This opening allows enough air into the compressor to provide
pressure to the auxiliary functions such as the air pulse on the dust collector.
Figure 7-100
A Vacuum Switch (Figure 7-100) is attached to the compressor housing just under the Inlet
Butterfly Valve.
To set the adjustable vacuum switch on the compressor air inlet located just below the butterfly
valve. Screw the adjustment knob all the way in (clockwise) and then back out 4 to 5 complete
turns. This will cause the solenoid valve to open at approximately 15" Hg vacuum under the
butterfly valve and allow air into the compressor.
The engine at maximum RPM. With the butterfly valve closed (lever off), check the vacuum
under the butterfly valve. It must be less than 27" of mercury. If it is greater, adjust the stop
bolt 1/2 turn to prevent the butterfly valve from closing all the way. Repeat as needed to obtain
less than 27" of mercury.
Control Valve
Figure 7-101
The Control Valve is a two position, three way valve that connects the Blowdown Valve with
both the suction and discharge sides of the compressor. It is operated by a 24 VDC Solenoid
Switch on one end and a spring on the other. If the solenoid is not activated, the spring will
move it to the default or pressure setting. This allows pressure from the compressor to pilot
the Blowdown Valve closed.
Figure 7-102
The Discharge Check Valve is located at the outlet of the compressor and prevents any oil or
air, under pressure, from backing up into the compressor housing. While the compressor is
running, oil and air are being forced out of the compressor housing and this keeps the
Discharge Check Valve open. When the compressor is stopped nothing is coming from the
compressor side, but pressure is built up in the receiver. This would pressurize the compressor
housing if the Discharge check Valve were not there (See Figure 7-102).
Blowdown Valve
Figure 7-103
The Control Valve (See Figure 7-103) is a two position, three way valve that connects the
Blowdown Valve with both the suction and discharge sides of the compressor. It is operated
by a 24 VDC Solenoid Switch on one end and a spring on the other. If the solenoid is not
activated, the spring will move it to the default or pressure setting. This allows pressure from
the compressor to pilot the Blowdown Valve closed.
Figure 7-104
The Discharge Check Valve (See Figure 7-104) is located at the outlet of the compressor and
prevents any oil or air, under pressure, from backing up into the compressor housing. While
the compressor is running, oil and air are being forced out of the compressor housing and this
keeps the Discharge Check Valve open. When the compressor is stopped nothing is coming
from the compressor side, but pressure is built up in the receiver. This would pressurize the
compressor housing if the Discharge check Valve were not there.
Blowdown Valve
Figure 7-105
The Blowdown Valve (Figure 7-105) maintains the balance of pressure between the air
entering through the orifice and escaping through the Minimum Pressure Valve. When the Inlet
Butterfly Valve is closed, air is still being compressed and the pressure in the Receiver Tank
would build until the Safety Valve opened. Whenever the vacuum switch closes, the Control
Valve is positioned to allow pilot pressure to bleed off from the Blowdown Valve and it opens,
allowing pressure to bleed through the silencer and maintain the same pressure in the
Receiver Tank.
Receiver Tank
Figure 7-106
The Receiver Tank (See Figure 7-106) serves several purposes. It contains the lubricating oil
that is used to cool and lubricate the compressor. It serves as a reservoir for the compressed
air. Also, the Separator Element helps to separate the oil from the air.
Minimum Pressure Valve
Figure 7-107
The minimum pressure relief valve (Figure 7-107) opens when the pressure in the Receiver
Tank reaches 20 psi. It maintains a back pressure in the Receiver to force oil out of the tank
into the lubricating system. If this valve were not present, the air pressure would drop to 0 psi
and the lubricating system would not get enough oil to keep the compressor cool.
Safety Relief Valve
All drills are equipped with safety valves (Figure 7-107). The setting on these valves is 25-50
psi higher than the maximum working pressure. The only function of a safety valve is to
prevent damage to the receiver tank in case of other failures. It should never be used as a high
pressure relief valve for two reasons. One, the pressure setting is above the allowable working
pressure of the compressor. Two, the safety valve loses a small amount of spring tension
every time it is opened. Therefore, the pop off pressure will be reduced each time it is opened
and will shortly open below the normal operating pressure and will have to be replaced.
Check Valve 100 psi
Figure 7-108
A 100 psi Check Valve (Figure 7-108) is attached to the discharge area of the compressor. In
the event that the bit becomes plugged down the hole, air pressure would build up and
normally open the safety valves. An automatic shut off system using the check valve and an
air cylinder prevents this from happening.
Air Cylinder
A single acting Air Cylinder (Figure 7-108) with a spring return is attached to the Butterfly Valve
opposite the control Cable. Whenever air pressure exceeds 100 psi, the Check Valve opens
and allows excess pressure to enter the back of the cylinder. When the pressure over comes
the spring pressure (about 40 psi), the cylinder will extend and close the Butterfly Valve
regardless of the Control Cable position. This will alert the operator that there is a problem
downstream. A small (0.06) hole is drilled in the inlet fitting of the air line to relieve the
pressure in the cylinder when the check valve closes.
Operation of Low Pressure Compressor
When the drill is first started, the Control Handle (See Figure 7-109) in the operators cab is in
the OFF position. The Inlet Butterfly Valve is closed and the only air entering the compressor
is through the Orifice in the Inlet Butterfly Valve. The closed inlet causes a high vacuum under
the Inlet Butterfly Valve and almost immediately closes the Vacuum Switch. This activates the
solenoid that shifts the Control Valve.
When the Control Valve is shifted, it connects the pilot section of the Blowdown Valve to the
vacuum side of the compressor. The vacuum assists the spring on the Blowdown Valve in
shifting the Control Valve and allows some air from the Receiver Tank to discharge through
the silencer.
When the operator pushes the Control Handle forward and opens the Inlet Butterfly Valve,
vacuum is lost at the Vacuum Switch. The Control Valve changes position to allow pressure
from the compressor discharge to pilot the Blowdown Valve closed and stop all flow from the
Receiver Tank. This is the normal RUN position.
Figure 7-109
Compressor Control Lever
On Low Pressure drills, the Compressor Control Lever (figure 7-109) is used to turn on and off
the compressed air, when on to clean the cuttings out of the hole for rotary drilling.
Start Position
The Control Handle is in the OFF position. The Inlet Butterfly Valve is closed. When the
compressor starts, some air is allowed to enter through the orifice but the vacuum increases
until it activates the solenoid in the Control Valve. When the Control Valve opens, it reduces
pilot pressure to the Blowdown Valve and the spring shifts the valve to open position. Pressure
in the Receiver Tank is allowed to escape through the Blowdown Valve. Air pressure in the
Receiver Tank is maintained at a minimum until the Inlet Butterfly Valve is opened. Refer to
START OR OFF MODE Schematic Figure 7-110.
Figure 7-110
Run Position
When the operator wishes to drill, he pushes the Control Handle to the open position to open
the Inlet Butterfly Valve. This action causes the Vacuum Switch to open and the Control Valve
shifts by spring pressure to the open position. This action pilots the Blowdown Valve closed
and stops all air from escaping through the Blowdown Valve. All air pressure is then directed
down the hole through the Minimum Pressure Valve. Refer to RUN MODE Schematic Figure
7-111.
Figure 7-111
Stuck Bit Position
In the event the drill bit becomes plugged, pressure in the system would build up until it blew
the Safety Valves. To prevent this, a Check Valve and Air Cylinder are installed in the system.
When ever the receiver pressure approaches the safety setting, the Check Valve opens and
allows pressure to flow to the Air Cylinder. The Air Cylinder is directly connected to the Inlet
Butterfly Valve and closes it when air pressure overcomes the Check Valve setting and the
spring in the Air Cylinder. Refer to STUCK BIT CONDITION Schematic Figure 7-112.
Figure 7-112
Compressor Related Problems
Trouble shooting and repairs of defects in the mechanical functioning of the compressor
systems requires specialist knowledge. All compressor related problems should be referred to
your local service support for assistance and are not considered part of operator maintenance
covered in this manual. If you are unable to determine the cause of the problem, contact your
local Drilling Solutions service office.
Table 9: Compressor Related Problems
Compressor Related Problems Trouble Shooting Chart
Drill Shuts Down After A
Short Running Time
High discharge
temperature
a). Check for low oil level
b). Check for obstructions
in oil cooler
c). Check fan speed
Excessive Oil
Consumption
Oil carryover through
discharge air hose
a). Check for high oil level
in separator
b). Check for plugged
orifice in scavenger line
Compressor Makes Air But
Volume Is Low
Volume control adjusted to
lower setting
Close volume control
Butterfly valve not
completely open
Adjust UL88 and/or linkage
Clogged air inlet filter Clean or replace filter
elements
Broken butterfly valve Replace valve
High Pressure Compressor (Non-EARS)
Overview
A compressor is considered high pressure if the discharge pressure is 250 psi or greater. All
high pressure compressors have discharge pressures of 350 psi. They are designated either
HR2 or HR2.5. These models describe the rotor sizes. for example, the HR2 and HR2.5 has
two sets of rotors; a 226 mm size and a 127.5 mm size. The internal gears make the difference
between HR2 and HR2.5. The size of the rotors and their speed determine the inlet volume of
the air end. There are five sizes total used between the DM45 and DML; 900,cfm, 1040 cfm,
1070 cfm,1250 cfm and 1450 cfm. The DM45 uses 900,cfm and 1070 cfm compressors. The
DML uses 1040 cfm, 1250 cfm and 1450 cfm compressors.
There are three systems on a rotary screw compressor: the lubrication system, the separation
system and the regulation system. Each system is critical to the operation of the air end and
the systems are all interrelated.
Lubrication System
Components:
The equipment used in the lubrication section includes the Receiver Tank, Mixing Valve, Oil
Cooler, Bypass Valve, Strainer, Filters, Oil Pump, Relief Valve, Discharge Check Valve and
special oil.
Receiver - Separator Tank
The receiver tank (Figure 7-113) contains the compressed air and the lubricating oil for the
compressor. The oil is removed from the air by centrifugal force, gravity and velocity. The
receiver tank has an oil sight glass that shows the oil level at all times. The oil level must be
visible in the sight glass whether the drill is running or shut down.
Figure 7-113
Oil Pump
The oil pump (Figure 7-114) is a gear type pump, driven from the rear of one of the compressor
rotors. It operates as long as the compressor is turning. It is speed sensitive and pumps at
rated volume when the compressor is at full RPM.
Figure 7-114
It acts as a normal pump when the oil is cold and becomes a restriction to hold back pressure
on the receiver tank when the compressor is operating at normal pressure and temperature.
This prevents all the oil from being forced out of the receiver tank at once and flooding the
compressor.
Strainer
A 40 mesh (150 micron) strainer is mounted just before the inlet to the oil pump as shown in
figure 7-87. It protects the pump and catches any foreign debris such as hose pieces and parts
of the thermostat that could damage the pump. The metal strainer should be removed, cleaned
and reinstalled every 500 hours.
Compressor Oil
The very high pressure created in these air ends require a special oil. This oil is not compatible
with certain types of O-rings. Therefore, we use Viton type O-rings in the air end fittings and
filters. The oil is also not compatible with other oils and should never be mixed with other oil.
High pressure compressors use Atlas Copco HP-350 oil. Be sure to change the filters
every 500 hours.
Mixing Valve
Figure 7-115
The Mixing Valve (Figure 7-115) contains a thermostat that stops oil flow in one direction when
it is cold and allows oil to flow from another direction when it reaches operating temperature.
When the temperature is below 140F (63C), oil flow from port B to port A, thus bypassing
the oil cooler altogether. When the temperature increases to 160F (71C), the thermostat is
completely opened and all the oil flows from port C to A and shuts off all flow to B. At
temperatures between 140F (63C) and 160F (71C), some oil flows through port B to A
and some oil flows through the cooler and from C to A. Under normal operation, some oil
is flowing through both B abd C. The normal discharge temperature of the oil leaving the
air end should be between 180F (83C) and 220F (104C).
Oil Cooler
The Compressor Oil Cooler (See Figure 7-116) Is a single pass unit. Hot oil enters from the
bottom of the cooler and cool oil exits out of the top. This prevents any air bubbles that may
have been carried along with the oil from being trapped in the top and creating a vapor barrier.
The cooler is made up of four sections. The first section cools the hydraulic oil, the second
section cools the engine coolant, the third cools charge air (engine turbo charger) and the
fourth section cools the compressor oil.
Figure 7-116
On DMLs that have a HP-1250, HP-1450 and XL-1900 sized engine, the CAC (Charge Air
Cooler) will have a separate cooler from the main oil cooler located over the drive line cover
between the gear box and engine. The main oil cooler will have only three sections (See
Figure 7-117). The first section cools the hydraulic oil, the second section cools the engine
coolant and the third cools the compressor oil.
Figure 7-117
Relief Valve / Check Valve
Figure 7-118
A 75 psi relief valve (Figure 7-118), is connected between the inlet and outlet of the oil cooler.
If the cooler becomes plugged and the inlet pressure becomes 75 psi higher than the outlet
pressure, the relief valve opens and allows oil to bypass the cooler. When the differential
pressure is reduced below 75 psi, the valve will close and normal flow resumes.
Oil Filter
Figure 7-119
Two 20 micron filters are installed at the outlet of the pump before the oil reaches the
compressor bearings. It catches any contaminants that may have been picked up in the circuit
and prevents them from plugging the orifices at the inlets to the bearings.
The Discharge Check Valve is located at the outlet of the compressor and prevents any oil or
air, under pressure, from backing up into the compressor housing. While the compressor is
running, oil and air are being forced out of the compressor housing and this keeps the
Discharge Check Valve open. When the compressor is stopped nothing is coming from the
compressor side, but pressure is built up in the receiver. This would pressurize the compressor
housing if the Discharge check Valve were not there.
Figure 7-120 shows the valve being held open. It has a single spring. The hinge must be
mounted on top to prevent the valve from staying open when the drill is shut down. Notice the
white nylon ring that forms a tight seal to prevent back flow when the drill is stopped.
Figure 7-120
The check valve in the compressor air discharge line is installed properly with the nameplate
located at the top and arrow pointing to tank (See Figure 7-120), therefore the hinge pivots
from the top (free flow into tank).
Lubricating System Operation
Figure 7-121
Use Figure 7-121 High Pressure Lube System schematic to follow the oil flow in the
Lubricating and Cooling system.
Oil is injected into the air end under pressure. The oil serves three purposes:
1. It cools the air end bearings and rotors.
2. It lubricates the moving parts
3. It seals the clearances between the male and female rotors, and between the
rotors and the housings and end plates.
The discharge check valve prevents air pressure and oil from re-entering the compressor
when the drill is stopped
The receiver separator serves two purposes:
1. It stores compressed air for future use.
2. It separates the oil from the air.
Oil is forced from the receiver by air pressure flowing through the piping towards the oil cooler.
The oil has three paths it can follow at this point.
1. When the oil is cold, the mixing valve allows oil to bypass the cooler and go
directly to the oil pump (B to A).
2. As the oil warms up to 140F (63C), the thermostat in the mixing valve starts
to open and some oil flows up through the cooler. Most of the oil still flows
through the bypass (B to A and some C to A).
3. When the oil temperature reaches 160F (71C), the valve is closed completely
and all oil flows through the cooler (C to A). The valve stays partially open
during normal operation and the discharge temperature of the oil stays
between 140F (63C) and 160F (71C).
If the oil cooler becomes plugged and the differential pressure across the cooler builds up to
75 psi, the relief valve opens and allows oil to bypass the cooler. It still flows from (C to A)
in the mixing valve.
When the oil exits the mixing valve, it passes through a 40 mesh (150:) screen into the inlet
of the oil pump. When the oil is cold or the receiver is operating at low pressure, the pump
performs as a regular pump by forcing oil into the compressor. But as the temperature and
pressure increase, the pump acts to prevent excess oil from getting into the compressor and
flooding it.
Before the oil reaches the pump, it passes through a 40 mesh 150 micron strainer that keeps
larger debris from reaching the pump.
After the oil passes the pump and before it gets to the compressor bearings, it passes through
two (2) 20 micron filters and then flows through a metal manifold that sends oil to all areas
of the compressor. Each bearing has its own supply line. The balance of the oil goes into the
low pressure area of the rotors.
A 425 psi relief valve is located between the oil pump and the compressor and bearings that
prevents damage to the system in case of a high pressure surge during cold starts and/or
blockage in the bearing lines. When the temperature of the oil warms up, the relief valve will
close.
Separation System
Lubricating oil is forced through the air end to cool, seal and lubricate the rotors. When the
oil is pumped into the receiver separator tank, it must be separated from the air going down
the hole. This is accomplished in three steps.
1. The Air/Oil mixture enters the receiver through the inlet pipe and splashes
against the inner walls. This forces the majority of oil to fall to the bottom of the
tank and remain there.
Figure 7-122
2. When the down stream air line is opened and air flows down the hole, some of
the remaining oil is carried along with it into the filter area. A metal canister
prevents oil from flowing through the filter directly. The air/oil mixture enters the
outer edge of the element and moves towards the center. As the oil travels
through the element, it is slowed down by friction and gravity pulls it downward.
Most of the oil drops out the bottom of the element and falls into the reservoir.
Figure 7-123
3. The final step in the separation process is removing any remaining oil from the
element so it is not carried over into the down hole air stream. When enough
excess oil is carried into the center of the element, a series of holes in the end
of the filter element allow the oil to fill an area between the flange and the
element. The scavenger line is connected between the flange and the inlet of
the compressor. Since there is a differential pressure between the receiver tank
and the low pressure area of the compressor, oil and air are forced through the
scavenger line into the inlet area of the air end, thus removing the last of the oil
carry over. A 0.94 orifice in the line prevents excessive amounts of air loss.
Figure 7-124
The HR2/HR2.5 air ends all have an anti-rumble valve connected in parallel with the
scavenger orifice. The anti-rumble valve is a pilot operated valve that opens when the
compressor is not making air. It allows a large volume of compressed air from the receiver
back into the air end to mix with the oil already being pumped into it. The air acts as a cushion
to prevent the rumbling sound caused by oil, in a vacuum, being forced through the rotors.
When the compressor inlet is opened, the anti-rumble valve closes and the scavenger orifice
operates in the normal fashion.
Figure 7-125
It is important to note when changing separator elements that the element be installed
correctly. The word TOP should always be on top to insure that the drain holes are at the
bottom (See Figure 7-125). This prevents excessive buildup in the scavenger area.
Another item to watch when changing elements is to be sure that the staples in the gaskets
are left there to prevent a static electric charge from building up and causing a fire (See Figure
7-126).
Figure 7-126
Regulation System - High Pressure
The regulation system controls the pressure and volume of the air going down the hole to the
bit. All Atlas Copco high pressure compressors have discharge pressures of 350 psi. Atlas
Copco uses the UL88 unloader valve to control the discharge pressure and volume.
Components:
The regulation system on high pressure compressors is designed around the UL88
modulating valve and includes several other automatic devices to operate the system.
Inlet Butterfly Valve
The Inlet Butterfly Valve is a round, wafer valve that sits on top of the compressor (See Figure
7-127). It has a shaft that is connected to the center of the valve. This is where the linkage for
the UL88 Unloader Valve is attached.
Figure 7-127
UL88 Unloader Valve
The regulation system on high pressure compressors is designed around the UL88
modulating valve. It controls the pressure and volume in the receiver by opening and closing
the inlet (butterfly) valve according to the discharge pressure in the receiver.
Figure 7-128
The UL88 consists of three chambers; the Power Chamber, the Metering Chamber and the
Pressure Chamber (Figure 7-128).
There are two diaphragms in the UL88. One is the Power diaphragm and the other is the
Metering diaphragm (Figure 7-128). Air pressure works on the Metering diaphragm to open it
against spring pressure in the Pressure Chamber and allow air to flow through the metering
seat into the Power Chamber.
Figure 7-129
When the air pressure becomes high enough in the Power Chamber, the diaphragm pushes
against the control arm which is held in place by the control spring. This pulls the linkage
connected to the inlet (butterfly) valve and closes it. This cuts off intake to the compressor.
When there is no pressure in the Power Chamber, control spring force holds the inlet valve
open (See Figure 7-129). There must be air pressure in the Power Chamber to close the inlet
valve.
There are several components needed to operate this system correctly. They include an ON-
OFF switch, a linkage control arm, inlet butterfly valve, receiver tank, 100 psi check valve and
a 50 psi relief valve.
ON-OFF Switch
This switch is located in the operators console (Figure 7-130) and allows air pressure to flow
into the Power Chamber or it can stop the flow. When the ON-OFF switch is turned OFF, air
flows through it and pressurizes the Power Chamber Diaphragm. This pushes the control arm
back and closes the inlet valve. Thus when the ON-OFF switch is OFF, it is ON or actually
flowing.
Figure 7-130
Figure 7-131
When the ON-OFF switch is turned ON, air is prevented from getting into the Power
Chamber and the inlet valve stays open making air. On the drills, there is a ball type valve
without the exhaust. Air bleeds out through the orifice in the 50 psi relief valve.
50 psi Relief Valve / Orifice
Figure 7-132
A 50 psi relief valve is located in the line between the ON-OFF switch and the UL88 Power
Chamber (Figure 7-132). There is a small orifice in the valve that allows a certain amount of
air to continuously blow through it. This relieves the pressure in the Power Chamber when the
switch is turned ON and lets the Power Chamber diaphragm return to its normal position. The
relief valve works only when a high pressure surge would damage the UL88.
100 psi Check (Cigar) Valve
Figure 7-133
The UL88 and the pressure regulator were designed to operate at 250 psi maximum pressure,
so a 100 psi check (cigar) valve, shown in Figure 7-133, was installed in line from the receiver
tank to reduce the final discharge pressure from the check (cigar) valve from 350 psi to 250
psi. When a drill is first started, air pressure in the receiver tank must increase above 100 psi
before the check valve opens and allows any air to the UL88.
Volume Control Valve
Figure 7-134
There may be times when the operator wishes to use a down hole device that uses less air
volume than the compressor is rated for. To prevent the compressor from hunting (opening
and closing the inlet valve rapidly), a volume control (Figure 7-134) was added. It consists of
a needle valve that can be opened to allow a certain volume of air into the Power Chamber to
assist in modulating the UL88. It should be closed tight for full volume.
Figure 7-135
Pressure Regulator
Discharge pressure is set by the Pressure Regulator mounted on the control console (Figure
7-136). It can be increased or decreased as the situation demands. A spring inside the
pressure chamber puts a minimum amount of pressure on the metering chamber diaphragm.
The pressure regulator increases that pressure up to the maximum psi allowed by the system.
Figure 7-136
NOTE: The regulator should not be decreased while the compressor is turned ON. Turn the
compressor OFF and bleed the system down, then back the regulator off. Otherwise, the
regulator diaphragm will be destroyed by excess pressure.
Figure 7-137
Anti-Rumble Valve
When the compressor inlet is closed, no air is flowing through the rotors but the oil pump is still
pumping the same volume of oil. This causes the rotors to try to compress oil. The result is
backlash by the rotors that causes a loud rumbling sound. To prevent this from doing any
damage to the air end, an anti-rumble valve has been installed (Figure 7-138).
Figure 7-138
This valve allows a measured volume of compressed air from the receiver tank back into the
rotor housing whenever the inlet valve is closed. This air mixes with the oil and cushions the
rotors. The valve is automatically turned off when the inlet valve is opened and all of the air
goes down the hole. The scavenger line is the tube that goes from the inlet to the outlet. An
orifice is mounted in the fitting. This carries the oil/air mixture back to the air end inlet.
Figure 7-139
Blow Down Valve
Figure 7-140
Without a shut off valve, there is still pressurized air trapped in the receiver tank when the drill
is stopped. This air must be exhausted before the drill is started again. An automatic blow
down valve (Figure 7-140) is connected to the receiver tank, on the dry side of the separator
element, to relieve the pressure in the tank. A pilot line has been installed between the
discharge of the compressor and the discharge check valve. As long as the compressor is
running, pilot pressure prevents the valve from opening. When the compressor is stopped,
there is no pilot pressure available to keep the valve closed and the spring pressure opens the
valve and allows tank air pressure to escape.
On the outlet side of the valve is an orifice and a silencer. The silencer is there to muffle the
noise of the escaping air. The orifice is there to provide enough back pressure to pilot the shut
off valve or exhaust valve closed.
Shutoff Valve
When the drill is stopped, air pressure from the receiver can still flow through the lines and
pressurize the power chamber. This would close the inlet valve and trap air pressure inside
the air end, since the discharge check valve would prevent any air/oil from getting out of the
air end. This would cause a back pressure on the inlet valve and keep it closed. Oil and air
would still be entering the air end through the scavenger line and when the inlet valve finally
opens, oil under pressure will blow through the intake tubes and soak the air cleaners.
Therefore, a shut off valve (Figure 7-141) is installed in line between the ON-OFF switch and
the volume control to shut off any air pressure from reaching the power chamber. The shutoff
valve is piloted by the back pressure caused by the orifice downstream from the blow down
valve.
Figure 7-141
Quick Exhaust Valve
Some drills are equipped with a Quick Exhaust valve (Figure 7-142) instead of a Shut Off
valve. The difference is that the shut off valve stops the flow of air to the UL88 and the exhaust
valve exhausts any air in the lines leading to the UL88.
Figure 7-142
Either system will prevent air from reaching the Power Chamber. The quick exhaust valve is
piloted from the same connection on the Blowdown Valve. When it receives pilot pressure, it
opens and exhausts all the pressure in the line leading to the Power Chamber, thus preventing
the inlet valve from closing.
Figure 7-143
Minimum Pressure Valve
A minimum pressure valve (Figure 7-144) is installed between the receiver and the main air
hose which goes to the tower air hard piping. Its only purpose is to maintain a minimum amount
of pressure in the receiver tank to force the oil into the lubrication system. On most high
pressure drills, the valve is set at 120 psi (140 psi on HR2.5 compressors). This means that
the down hole pressure may be 50 psi or 350 psi but the receiver tank never sees a pressure
less than 120 (140) psi. It does not control the volume of air in CFM. It only restricts the outlet
pressure. It has nothing to do with the pressure shown on the pressure gauge at startup.
Figure 7-144
Safety Relief Valves
All drills are equipped with safety valves (Figure 7-144). The setting on these valves is 25-50
psi higher than the maximum working pressure. The only function of a safety valve is to
prevent damage to the receiver tank in case of other failures. It should never be used as a high
pressure relief valve for two reasons. One, the pressure setting is above the allowable working
pressure of the compressor. Two, the safety valve loses a small amount of spring tension
every time it is opened. Therefore, the pop off pressure will be reduced each time it is opened
and will shortly open below the normal operating pressure and will have to be replaced.
Drill Air Throttle Valve
All high pressure drills are equipped with a drill air throttle valve (Figure 7-145) to control the
air flow down the hole. These valves can be metered to prevent excess air flow from disturbing
the formation. The throttle valve is connected downstream from the minimum pressure valve.
The throttle valve should always be opened slowly to prevent premature damage to the
separator element.
Figure 7-145
The Drill Air Throttle Controller (Figure 7-145) controls the drill air throttle valve which allows
air flow to the drill string and allows air flow down the hole to operate the DHD (Down Hole
Drill) and clean the hole. It is used to turn ON/OFF the drilling air during drill rod or hammer
changes. It can be adjusted to a lower setting while collaring the hole. This is an option for high
pressure drills only.
Service Connection
Figure 7-146
A ball valve and a pressure regulator (Figure 7-146) are connected to the main discharge
piping to accommodate tools and equipment that use air power. The pressure regulator is
used to lower the high operating pressure to the tool operating pressure, usually around 100
psi. The ball valve is there to reduce the load on the regulator when it is not being used.
Note: Do not operate the service air pressure at normal discharge pressure, since most
air tools are rated for no more than 100 psi.
Pressure Gauge
A pressure gauge (Figure 7-146) is connected to the upper manifold on the receiver tank
before the minimum pressure valve. It reads tank pressure at all times. If a rotary bit or other
device is being used down hole that requires less than minimum pressure setting, the gauge
will read only minimum pressure. A second gauge must be installed in the standpipe to read
actual down hole pressure if you are operating below minimum pressure.
Regulation System Schematic
The drawing in Figure 7-147 shows the basic layout of the regulation system for high pressure
drills. Air pressure is pumped into the receiver tank from the compressor. As the pressure
reaches 100 psi, the check valve opens and allows air to flow through the metering line into
the Metering Chamber. At the same time, air flows through the ON-OFF switch into the Power
Chamber. When the pressure builds up past 100 psi enough to overcome the control spring
(45 psi), the inlet butterfly valve will close and the compressor will stop making air. This is why
the compressor inlet butterfly valve closes at 145 psi on start up.
Figure 7-147
The drawing in Figure 7-148 shows the volume control and the pressure regulator. It also
shows the scavenger line and orifice between the receiver and the compressor low pressure
area.
Figure 7-148
The shutdown system, shown in Figure 7-149, consists of a pilot operated blowdown valve and
a shut off valve or a quick exhaust valve. When the drill is stopped, pilot pressure is lost to the
blowdown valve and the spring opens the valve so the receiver tank blows down. There is an
orifice between the blowdown valve and the muffler that causes enough back pressure to
activate the pilot on the shut off or quick exhaust valve. This will either stop all flow to the
Power Chamber of the UL88 or exhaust the pressure coming to the Power Chamber, thus
preventing the inlet butterfly valve from closing. At the same time, pilot pressure to the anti-
rumble valve is lost and it closes. This allows only scavenger air to enter the compressor
cavity.
Figure 7-149
Operation
Starting
Before starting the drill, make sure the compressor ON-OFF Switch is OFF, the Drill Air
Throttle is closed and the Pressure Regulator is set properly (See Figure 7-150). Once the drill
has started and all fluids are at operating temperatures, check the discharge pressure gauge
on the operators console. It should be about 140-145 psi. Next, turn the ON-OFF Switch to
the ON position. This action cuts off the flow to the Power Chamber. Now all the pressure is
passing through the 100 psi check valve and into the Metering Chamber.
Figure 7-150
When the pressure pushing on the Metering diaphragm overcomes the spring pressure in the
Pressure Chamber, the metering pin will be pulled out of its seat and allow air pressure into
the Power Chamber. Pressure will increase in the Power Chamber until pressure against that
diaphragm overcomes the control spring and pushes the control arm back which closes the
inlet butterfly valve.
Drill pressure is adjusted by increasing or decreasing the pressure on the regulator on the
console. To increase pressure, simply turn the T handle clockwise while watching the
pressure gauge on the panel. Once it has reached the proper pressure, release the handle.
To reduce pressure on the system, simply turn the T handle counter-clockwise.
Drilling
When the operator is ready to start a DHD (Down Hole Drill), slowly open the air throttle
controller (See Figure 7-150). This will allow the pressure in the receiver tank to escape down
the hole without damaging the separator element. Sudden release of pressure will shorten the
life of the element.
When the hole is completed or the operator wants to add another drill pipe, he simply closes
the Drill Air Throttle. Pressure increases in the receiver and control lines until the inlet butterfly
valve is closed by pressure in the Power Chamber. The operator does not have to turn the ON-
OFF switch to the OFF position unless air is not going to be needed for a time. Pressure will
stay at the setting of the regulator until the Drill Air Throttle is opened again.
Shutting Down
Before stopping the engine, the operator must release high pressure air from the
receiver tank.
1. Turn the ON-OFF Switch to OFF (See Figure 7-150).
2. Open the Drill Air Throttle slowly, and allow as much pressure as possible to
escape from the receiver tank.
3. The tank pressure should read no higher than 140-150 psi.
4. When the pressure gauge shows 140-150 psi, stop the engine.
5. The automatic blowdown valve should open and exhaust all the air pressure
from the tank.
6. If the blowdown stops blowing before all the air is out of the tank, physically
check to see if the inlet butterfly valve is open. If it is not, manually open the
valve.
If the drill is shut down under high pressure, the anti-rumble valve will still be open because
there is pressure in the Power Chamber to pilot it open. The line from the UL88 inlet valve is
still seeing pressure because the 100 psi check valve is open. This pressure causes the inlet
butterfly valve to stay closed. The discharge check valve is also closed from tank pressure so
the air end becomes a pressure vessel. Now, pressure on both sides of the inlet butterfly valve
are trying to push it up evenly and it cannot open.
If the blowdown valve does not start to blow down, it will very quickly be piloted closed from
pressure in the air end. Now oil and air are being forced into the air end and will continue to
do so until tank pressure bleeds down low enough to allow the 100 psi check valve to close,
cutting off flow to the UL88.
When the inlet butterfly valve finally opens, the air and oil mixture will escape with high velocity
through the inlet and up through the inlet tubes to the air cleaners. Enough oil will be present
to saturate the primary cleaner and render it useless.
This is why the compressor should never be shut down intentionally under high pressure. If
there is a shutdown switch triggered by low oil or engine problems, there is nothing one can
do but clean up the mess and replace the air cleaner element.
Air Pressure Regulation
Theory of Operation
The Air Pressure Regulator (See Figure 7-151) used on all high pressure drills is a pressure
reducing valve that can handle inlet pressures up to 300 psi and reduce the output pressure
to a range of 10 psi to 250 psi. It will operate within a temperature range of 0F (-17.8C) to
175F (79.4C).
When the drill is first started, there is no air pressure in the regulator or the pressure chamber
of the UL88. Air pressure builds up in the metering chamber as the compressor develops air
pressure.
At the same time, pressure is allowed into the power chamber and when receiver pressure
overcomes the 100 psi check valve and the control spring on the UL88, the inlet valve closes.
This condition is static until the compressor ON-OFF switch is turned ON.
Once the compressor is loaded by turning the ON-OFF switch to ON, pressure builds in the
metering chamber until it overcomes the spring setting in the pressure chamber. Then the
metering pin pulls away from the seat and lets pressure escape into the power chamber.
Figure 7-151
Increasing Pressure
To increase the discharge pressure down the hole, the air regulator pressure must be
increased. This is done by screwing the T handle clockwise. Each full turn increases the
discharge pressure by about 60 psi. As the T handle is screwed in, the cone in the diaphragm
forces the small pin against the inlet valve assembly and opens the valve. Inlet pressure is
allowed to flow through the valve and into the pressure chamber of the UL88. At the same time,
pressure is ported to the base of the diaphragm. As air pressure in the system increases, the
force working on the area of the diaphragm increases until it overcomes the spring setting on
top of the diaphragm. This action relieves pressure on the inlet valve spring assembly and cuts
off flow to the UL88. When the correct discharge pressure is obtained, the handle is set by
tightening the lock nut on the handle.
As air pressure varies down the hole, the metering chamber pressure varies with it. When
receiver pressure builds up enough to overcome the spring and regulator pressure in the
pressure chamber, the metering pin comes off the seat and air flows into the power chamber,
closing the inlet valve.
Increasing discharge pressure causes no problem for the air pressure regulator or the UL88.
However, reducing pressure by using the improper procedure can damage both the regulator
diaphragm and the metering chamber diaphragm.
The air pressure on the downstream side of the air regulator and in the pressure chamber of
the UL88 is trapped by the pressure on the inlet side of the air regulator. If the spring pressure
on top of the diaphragm is released by unscrewing the T handle without lowering the inlet
pressure, air pressure acting on the bottom of the diaphragm will rupture it after several
improper uses.
Decreasing Pressure
The proper procedure is to turn OFF the Compressor On-Off Switch, BLOW the receiver
pressure down to minimum using the DRILL AIR VALVE and then UNSCREW the T handle
to minimum. This action relieves the high pressure on the valve assembly and lets the higher
pressure in the downstream side open the valve assembly, thus pulling the valve pin away
from the diaphragm cone. The air trapped in the diaphragm will exhaust through the center
port of the diaphragm and relieve all pressure in the UL88 and under the diaphragm. There is
a port on the side of the air regulator cap that allows air pressure out of the system.
Damage to the metering chamber diaphragm can be caused by relieving spring pressure in
the air regulator while under high pressure in the system. This will leave high pressure in the
metering chamber and no pressure in the pressure chamber. The uneven pressure will rupture
the diaphragm prematurely.
Relieving the high pressure in the system while there is still pressure in the pressure chamber
will not cause the same problem to the metering chamber diaphragm since the metering pin
prevents the diaphragm from collapsing excessively. As soon as the pressure is relieved in the
system, the T handle can be unscrewed and the pressure will relieve in the regulator system.
Compressor Related Problems
Trouble shooting and repairs of defects in the mechanical functioning of the compressor
systems requires specialist knowledge. All compressor related problems should be referred to
your local service support for assistance and are not considered part of the operator
maintenance covered in this manual. If you are unable to determine the cause of the problem,
contact your local Drilling Solutions service office.
Table 10: Compressor Related Problems
Compressor Related Problems Trouble Shooting Chart
Drill Shuts Down After A
Short Running Time
High discharge
temperature
Check for low oil level
Check for obstructions in
oil cooler
Check fan speed
Compressor Is Turned On,
But Does Not Produce
Compressed Air
Butterfly valve stuck in
closed position
Adjust linkage and/or stop
on UL88 regulator
UL88 has hole in
diaphragm
Replace diaphragm
Pressure switch adjusted
too low
Adjust pressure switch to
required pressure setting
Excessive Oil
Consumption
Oil carryover through
discharge air hose
Check for high oil level in
separator
Check for plugged orifice in
scavenger line
Compressor Makes Air But
Volume Low
Volume control adjusted to
lower setting
Close volume control
Butterfly valve not
completely open
Adjust UL88 and/or linkage
Clogged air inlet filter Clean or replace filter
elements
Broken butterfly valve Replace valve
1. Excessive foaming of
compressor fluid.
2. Excessive oil carryover
into service air.
3. Oil or foam out of the
blowdown valve during
shutdown.
Foam and air release
characteristics of oil are
insufficient to remedy the
symptoms (problem).
Products previously used
were Mobil 626 and IR
XHP505.
Atlas Copco HP-350
replaces XHP505 as the
standard factory fill for
XHP compressors above
300 psi.
Electronic Air Regulation System (EARS) Compressor System
Introduction
The following information is general for all Atlas Copco Drilling Solutions drills using Electronic
Air Regulation. Due to differences in drill models, there will be differences in electronic air
regulation components used.
This information contains instructions for several Electronic Air Regulator systems used on
Atlas Copco Drilling Solutions drills. Therefore, you must refer to the parts book specific to your
drill for parts and schematics specific to your drill.
The Electronic Air Regulation System consists of twelve general components.
Components
System Components;
1. Flow sensor On Compressor
2. Proportional Butterfly Valve and Actuator - On Compressor Inlet
3. Pressure Sensor - On Receiver Tank
4. Proportional Vent Valve and Actuator On Receiver Tank
5. Electronic MC2 Controller
6. Flow Control Knob
7. Maximum Pressure Control Knob
8. Compressor ON/OFF Switch
9. Diagnostic Light
10. Hardware Interface Board
a. Power Control Relay
b. Diagnostics Port
c. Fuse
d. Sensor Power Conditioning Circuits
e. Electrical Noise Suppression Circuits
11. Interconnect System
12. J 1939 CAN Bus
Flow sensor
The flow sensor is mounted below the butterfly valve and detects the volume of air flowing
into the compressor and sends the data to the MC2 controller.
1. This sensor is actually a vacuum sensor with a range of 0-14.7psi (0-1 bar) At
the inlet of the compressor the Flow is directly proportional to the vacuum
pressure.
2. Then the compressor is turned completely off (engine off) some pressure will
bleed back through the compressor to the vacuum sensor. This will cause the
vacuum sensor to read about 2 psi higher then atmospheric. (at 500 ft is
approximately up to 16.5psi)
3. The sensor has error detection if voltage is less then 0.5V (does not have high
voltage detection above 4.5V because of bleed back pressure when the
compressor is turned off) Will flash error code 2.
Proportional Butterfly Valve and Actuator
The Butterfly Valve and Actuator are controlled to regulate air flow into the compressor. The
indicator is horizontal when closed and vertical at full open. The butterfly valve should be
closed at start up and slightly open during minimum air.
1. The actuator should rotate through 90deg where CCW opens (vertical position)
and CW closes (horizontal position) the valve.
2. During start up the butterfly valve and actuator should be closed. During
minimum air the butterfly valve should be slightly open about 8 to 10 deg.
3. The butterfly valve actuator command is a ramping command to over come
various frictions from wear over time. This ramping command will make the
actuator appear to not move smoothly. It will move with a small bumping type
of action.
4. A bead of silicon on both sides of the gasket is suggested to help avoid water
ingress into the actuator.
Pressure Sensor
The pressure sensor is located on the receiver tank and detects the pressure in the receiver
tank and sends the data to the MC2 controller.
1. The same pressure sensor is used on High and Low pressure machines.
Ranges from 0-725psi (0-50bar)
2. Pressure sensor has error detection below .05V and above 4.5V to detect
shorts and open circuit faults. (will flash error code 3)
Vent Valve and Actuator
The vent valve and actuator are controlled to vent air to lower receiver tank pressure. The
vent valve is used during minimum air, pressure regulation, emergency venting and shutdown.
Closed during normal regulating mode.
1. The proportional vent valve and actuator are controlled by the MC2 controller.
It is used to release air from the receiver tank to lower the pressure; the air is
vented to atmosphere through an air silencer.
2. Vent valve used during minimum air, pressure regulation, emergency venting
and shutdown. It is open during startup and closed during normal regulating
mode.
3. The proportional vent valve was previously called the blowdown valve.
4. A bead of silicon on both sides of the gasket is suggested to help avoid water
ingress into the actuator.
MC2 Controller
MC2 Controller monitors the flow and pressure inputs, operator inputs and engine data. It
controls the butterfly valve and vent valve actuators to achieve the required flow and pressure.
1. It also detects several fault conditions and alerts the operator by flashing an
error code with the diagnostic light. The controller is initially powered up with
the key switch but then latches its power on so that it can perform a shutdown
sequence after the key switch is shut off.
Controls Located on Console
Flow Control Knob
The Flow Control Knob is a variable electronic input into the electronic controller. When the
compressor On/Off switch is on it adjusts the flow into the compressor between the minimum
flow (required to prevent damage to the compressor) and maximum flow (full open on the
butterfly valve).
1. The Flow control knob is a variable voltage input into the MC2 controller (.5
VDC to 4.5 VDC).
Maximum Pressure Control Knob
The Maximum Pressure Control Knob is a variable electronic input into the electronic
controller. When the compressor On/Off switch is on it adjusts the maximum pressure in the
receiver tank between the minimum holding tank pressure and the maximum working pressure
of the compressor system.
1. The Maximum Pressure control knob is a variable voltage input into the MC2
controller (.5VDC to 4.5VDC).
2. During normal drilling the Max pressure knob should be full open for quickest
response times and the bit orifice should be sized to provide the correct back
pressure for drilling.
Compressor On/Off Switch
The Compressor On/Off Switch is used to select the source of the flow and maximum pressure
commands. When the switch is On, the Flow Control Knob and Maximum Pressure Control
Knob are active and control the compressor. When the switch is Off, the Flow Control is set to
the minimum flow required to prevent damage to the compressor and the Maximum Pressure
Control pressure is set to the minimum holding tank pressure (setting the switch to Off has the
same effect as setting the flow and pressure knobs to the minimum positions).
Diagnostic Light
The Diagnostic Light (RED) is normally off but will blink out an error code if the controller
detects an error (See Error Code Indications and Priorities section). If this light is blinking, turn
off the engine
1. At start up the error light will come on for 2 seconds to tell the operator the
controller is on and programmed. If the light does not come on when power is
applied to the controller either the controller is not programmed or the light is
wired wrong or damaged.
2. If this light is blinking, turn off the engine and fix the issue.
Hardware Interface Board
The hardware interface board is a DIN rail mounted circuit board with terminal strips down
each side. It is not intended for exposure to wash down. This board contains circuits to perform
the following functions.
1. The Power Control Relay allows the electronic controller to latch on the supply
voltage to the EAR system. This allows the system to complete the receiver
tank bleed down after the key switch has been turned off.
2. The Diagnostic Port allows a lap top computer equipped with the correct
software to monitor the system via a USB port.
3. The Fuse protects the system in the event of a wiring short.
4. Sensor Power Conditioning Circuits provide correctly regulated power to the
sensors and operator inputs.
5. Electrical Noise Suppression Circuits prevent electrical noise from being
generated by the electric motors in the valve actuators.
Interconnect System
The Interconnect System includes harness split out boxes and cables sets that connect the
various components. Several variations of the Interconnect system are required to
accommodate the wide range of drills the system can be installed on.
J1939 CAN Bus
The system monitors engine speed to determine if the compressor is turning and more
importantly when it is shutting down. The engine speed, along with the key switch, and
engagement sensor, tells the system when to enter regulating mode and when to enter shut
down mode.
If J 1939 is lost the system will not enter regulating mode, instead it will enter the rumble
mode.
A 120 Ohm terminating resistor must be located at both ends of the CAN Bus to suppress
noise. Normally one is located at the engine and one at the Murphy gauge display.
Operation
Startup Operation
For startup, the controller will command the butterfly valve closed to prevent air entry into the
compressor and command the vent valve (previously called blow down valve) open to vent the
receiver to atmosphere. This allows the engine to start with the least possible load. After the
engine speed reaches the minimum RPM there is a factory set delay time to allow the engine
to stabilize after which the controller regulates the compressor.
Shut Down Operation
When the controller detects the key has turned off and the engine is stopping, it closes the
butterfly valve and bleeds down the pressure in the receiver tank through the vent valve.
Because the system is ramping down the pressure in the receiver normal system air leaks will
usually allow the pressure to drop fast enough during the early stages of the blow down without
the controller needing to open the vent valve. This results in what appears to be a delay in
venting the tank. However, the pressure is dropping at the correct rate during this time.
Flow Regulation
The controller is always regulating the flow into the compressor. If more flow is called for than
the compressor can make under the conditions, the butterfly valve is opened all the way. There
are three sources for the amount of flow that is called for:
1. The flow control knob (direct control).
2. The compressor On/Off switch (calls for minimum flow).
3. The controllers maximum pressure regulation system. When the maximum
pressure commanded by the maximum pressure knob is reached, the
controller overrides the flow knob command and reduces the commanded flow
to lower the pressure in the receiver.
Maximum Pressure Regulation
The Controller has two methods to control the maximum pressure in the receiver:
1. Override the Flow Knob and lower the commanded flow into the compressor.
2. Open the vent valve to let air out of the receiver tank.
Method 1: When the maximum pressure commanded by the maximum pressure knob is
reached, the controller enters the pressure control mode, overrides the flow knob
command and reduces the commanded flow to lower the pressure in the receiver. The
controller then regulates the flow up and down to maintain the maximum pressure but will
not command more flow than is called for by the flow control knob. If the pressure drops to
a level where the commanded flow would be more than commanded by the flow knob, the
controller exits the pressure control mode and returns control to the flow knob.
Method 2: The controller is constantly attempting to regulate the receiver tank pressure
using a command that is 20 PSI (1.38 bar) above the maximum pressure knob command.
If the pressure is below the command, the vent valve is moved in the close direction. If the
pressure is above the command, the vent valve is moved in the open (vent) direction. For
most conditions, the pressure is below the command and results in the vent being closed.
It is the vent valve regulation system that controls the pressure when the compressor On/
Off switch is in the Off position.
Emergency Venting
If the maximum system pressure is exceeded, the controller commands the butterfly valve
closed and opens the vent valve. This allows quick system reaction to over pressure spikes.
Compressor Turning
In order to control the compressor correctly, the system needs to know if the compressor is
actually turning and more importantly if it is in the process of shutting down. On directly
coupled drills, this is accomplished by monitoring the key switch and the J 1939 engine bus.
EAR-EFR Diagnostics (Flow Chart)
This quick find diagnostic procedure is primarily designed as a guide for diagnosing Electronic
system problems on a machine that was working and has failed in the field. It could lead to an
incorrect diagnosis if the machine is incorrectly wired or assembled.
The procedure is structured as a set of questions that lead the tester through a path that will
find the problem in the minimum number of steps.
The questions are designed to be answered in sequence. Skipping a question will always lead
to an incorrect diagnoses.
These questions are designed to avoid rotating the compressor and engine where possible.
Things to remember:
Having two people a tester and a helper is strongly advised.
The following test can be preformed using a volt/ohm meter on the interface board terminal
strips, and observing the system behavior.
These tests are not intended to replace additional trouble shooting measures once the
problem is narrowed to a component or simple circuit.
The corrosion resistant coating on the interface board terminal strips can become oxidized and
interfere with meter readings. Make sure to use sharp tips and apply enough pressure and or
scraping action to get a good connection.
Note 1: The diagnostic lamp blinks 1 to 7 times with a pause at the end of the blink cycle. The
number of blinks is the error code.
Note 2: The system outputs a two second blink immediately after it is powered up. This can
be checked by turning the key off for 6 seconds then back on.
Note 3: T Terminal.
3.1 Standard Test Conditions
EAR/EFR system is fully assembled with all connectors, actuators, and sensors
connected and tight. The system has a limited number of parts that can easily be
given a quick examination. This can save a lot of time.
The engine is not running
The engine ignition (Key Switch) is ON
Machines with the capability to select a drill mode should be pre-set to that mode
Receiver tank discharged
Compressor on/off switch set to off position
Flow or volume knob set to minimum (fully counter clockwise)
Maximum pressure knob set to minimum (fully counter clockwise)
The throttle valve should be open. (if equipped)
3.2 Error Code Meaning and Diagnostic Information
3.3 Blown Fuse Check List
1. Turn off the KEY input and verify the power to the controller is off.
Terminal 32 =Zero V
Terminal 78 =Ground
2. Use multi-meter to measure resistance between Terminal 32 and terminal 78
the resistance should not be less that 20 Ohms.
3. If the resistance is less than 20 ohms there is a short in the system. Check the
resistance of every terminal to ground (Terminal 78) and eliminate the short.
Terminals 8 ,17, 33, N, 38, 47, 50, 53, 58, 64, 73 & 75 Are also ground and will
always read zero ohms
3.4 Actuator Diagnostic Table
The actuator is composed of the following components
24 volt DC motor.
Integrated gear box with life time lubrication.
Two cam operated limit switches.
Thermostat and heater.
Clockwise rotation always closes the valve
Counterclockwise rotation always opens the valve.
The actuator has 6 wires.
1. Clock Wise Supply
2. Counter Clock Wise Ground
3. Clock Wise Ground
4. Counter Clock Wise Supply
5. Heater Ground
6. Heater Supply
3.5 Actuator Test Using An Actuator Test Box
CAUTION
!
When the test box is installed, the EAR system no longer has control of
the actuator.
Extreme caution should be exercised if the compressor or engine must
be run while the test box is installed.
Closing the butterfly valve while the compressor is turning can result in
compressor damage. Insure minimum pressure is maintained at all times.
Opening the receiver tank vent valve too quickly while the compressor is
making high volumes of air can result in damage to the separator
elements.
Instructions
Make sure the white line on the actuator indicator knob is lined up with the scribed
mark on the actuator. (This requires removing the indicator knob)
Install the actuator test box in series with the actuator to be tested.
Set the speed switch to fast
Use the Clock wise and counter clockwise switch to command the actuator and
observe the actuator response.
Set the speed switch to slow
Use the Clock wise and counter clockwise switch to command the actuator and
observe the actuator operation at slow speed.
Results
The Butterfly Valve should move in the direction commanded by the switch.
The actuator should have free travel from horizontal with the long edge of the
actuator to perpendicular to the same edge. (The actuator is stopped at the end of
travel by internal limit switches that can be heard as a faint click.) (The actuator
should not load up and stop)
The actuator should stop in the horizontal position after moving clockwise and in the
perpendicular position after moving counter clock wise.
The actuator should move smoothly with a steady buzzing sound. (There should not
be any spots where the actuator loads up and slows down.)
If there appears to be a problem with the actuator.
Possible causes include.
If the actuator operates backwards of the indications on the tester there are two
possible causes.
1. The heater circuit is wired backwards. (Diagnose and repair) (This problem
does not affect operation of the system, It should however be corrected.)
(Use the schematic and connector pin diagrams to diagnose and correct.)
2. The test box is wired incorrectly (Use the tester schematic and connector
pin diagrams to diagnose and correct.)
If the actuator does not travel the full operating distance there are several possible
causes.
1. The limit switch or limit switch cams have come loose (It will be necessary
to Diagnose and repair.) (Remove the cover and correct the problem.)
2. Something inside the valve is stopping the actuator. (It will be necessary to
remove the actuator from the valve to isolate this cause then diagnose and
repair the problem)
3. The actuator has broken internal gears or other mechanical problems. (It
will be necessary to remove the actuator from the valve to isolate this cause
then diagnose and repair the problem.)
If the actuator does not stop in the horizontal position after moving clockwise and in
the perpendicular position after moving counter clock wise (the internal cams will
need to be adjusted )
Within each actuator there is a thermostatically controlled heater. The heater is a resistor that
is energized when the bi-metal thermostat closes. The purpose of the heater is to dehumidify
the box and to heat the lower gearbox, in cold weather.
For operations in arctic conditions it is also recommended to cover the actuators with an
insulation blanket of some kind to assist in retaining heat.
CAUTION
!
When the resistor is energized it becomes very hot to the touch.
3.6 Potentiometer Testing Using A Multi-Meter
Instructions
Rotate the shaft to a position approximately have way between the mechanical
stops.
Measure the resistance between the three Wires/Terminals until the pair with the
greatest resistance is found.
The resistance should correspond with the resistance marked on the pot.
The resistance between either one of these wires and the third wire should be
approximately half resistance marked on the pot.
This pair of Wires/Terminals are the two ends of the resistive element.
The third Wire/Terminal is the wiper.
Rotate the shaft fully in one direction and measure the resistance as the shaft is
rotated slowly in the other direction.
The resistance should change from approximately the resistance of the pot to
near zero ohms. (Depending on the direction you rotated the action could be
reversed.)
The resistance should change smoothly with to places where the resistance
changes or appears to be unstable.
The resistance should be stable when side loading is applied to the shaft
(provided the shaft is not rotated)
3.7 Tables
3.7.1 Voltage output for Vacuum Sensor
3.7.2 Voltage output for Pressure Sensor
3.7.3 Atmospheric Pressure to expect at various elevations and the Vacuum sensor output for
that pressure.
3.8 Summed On/Off Inputs Decode Table
The interface board sums (adds together) the three on/off inputs to create a single voltage that
the controller decodes to determine the status of these three inputs:
Key switch
Compressor on/off switch
Auxiliary on/off switch
This table can be used to determine if a specific input will be decoded as ON or OFF.
4.2 Connectors Of Sensor and Actuator
4.3 Female Control Connector
7.6 - PowerView
Murphy Link PowerView
Description
The PowerView has been developed to meet the needs for instrumentation and control on
electronically controlled engines communicating using the SAE J 1939 Controller Area
Network (CAN).
The PowerView is a multifunctional tool that enables operators to view many different engine
parameters and service codes. The PowerView includes a graphical backlit LCD screen. The
display can show either a single parameter or a quadrant display showing four parameters
simultaneously. Diagnostic capabilities include fault codes with text translation for the most
common fault conditions. The PowerView has four buttons using self-calibrating charge
transfer activation technology, which eliminates the concern for push button wear and failure.
The enhanced alarm indication has ultra bright alarm and shutdown LRDs (amber & red). It
has a wide temperature range of -40F to +185F (-40C to +85C), display viewing -40F to
+167F (-40C to +75C), and increased environmental sealing to +/- 5 PSI (35kPa).
Other components in the system are microprocessor PowerView Gages for displaying critical
engine data broadcast by an electronic engine Engine Control Unit (ECU): engine RPM, oil
pressure, coolant temperature, system voltage, etc. and a combination audible alarm and
relay unit for warning and shutdown annunciation.
Faceplate Features and Keypad Functions
The keypad on the PowerView is a capacitive touch sensing system. There are no mechanical
switches to wear or stick. It operates in extreme temperatures with gloves, through ice, snow,
mud, grease, etc., and it allows complete sealing of the front of the PowerView. The key is
touched feedback is provided by the flashing screen. The keys on the keypad perform the
following:
Menu Key - The menu key is touched to either enter or exit the menu screens.
Left Arrow Key - The left arrow key is touched to scroll through the screen either moving the
parameter selection toward the left or upward.
Right Arrow Key - The right arrow key is touched to scroll through the screen either moving
the parameter selection toward the right or downward.
Enter Key - The enter key, also known as Enter Button is touched to select the parameter that
is highlighted on the screen.
Mechanical Installation
Typical Quick Connect Installation
Electrical Installation
PowerView Unit Back View
PowerView Operation
1. When power is first applied to the PowerView, the Logo is displayed.
2. The Wait to Start message will be displayed for engines with a pre-startup
sequence. Once the Wait to Start message is no longer displayed the
operator may start the engine. Note: Displays only when SAE J 1939 message
is supported by engine manufacturer.
3. Once the engine has started the single engine parameter is displayed.
Main Menu Navigation
1. Starting at the single or four engine parameter display, touch Menu.
2. The first seven items of the Main Menu will be displayed. Touching the Arrow
Buttons will scroll through the menu selection.
3. Touching the right arrow button will scroll down to reveal the last items of Main
Menu screen highlighting the next item down.
4. Use the Arrow Buttons to scroll to the desired menu item or touch Menu
Button to exit the Main menu and return to the engine parameter display.
Engine Configuration Data
1. Starting at the single or the four engine parameter display touch the Menu
button.
2. The main menu will pop up on the display. Use the Arrow Buttons to scroll
through the menu until the Engine Configuration is highlighted.
3. Once the Engine Configuration menu has been highlighted touch the Select
Button to view the engine configuration data.
4. Use the Arrow Buttons to scroll through the engine configuration data.
5. Touch the Menu Button to return to the main menu.
6. Touch the Menu Button to exit the Main menu and return to the engine
parameter display.
Stored Fault Codes
1. Starting at the single or the four engine parameter display touch the Menu
button.
through the menu until the Stored Fault Codes is highlighted.
3. Once the Stored Fault Codes menu item has been highlighted touch the
Enter Button to view the Stored Fault Codes (when applicable, consult
engine manufacturer for the SAE J 1939 supported parameters).
4. If the word MORE appears above the Arrow Buttons there are more stored
fault codes that may be viewed. Use the Arrow Buttons to scroll to the next
Stored Diagnostic Code.
5. When the arrow appears to the right of the word MORE continue to scroll to
the right to see more Stored Diagnostic Codes. If the arrow shifts to the left
side of the word MORE the end of the stored codes has been reached. Press
the left Arrow Button to review the stored codes.
7. Touch the Menu Button to exit the Main menu and return to the engine
parameter display.
Faults and Warnings
Auxiliary Gauge Fault
1. During normal operation the single or four parameter screen will be displayed.
2. The PVA Series auxiliary gauges can be attached to the PowerView. These
auxiliary gauges communicate with the Modbus master PVA Series gage via a
daisy-chained RS-485 port. If at any time during system initialization or normal
operation an auxiliary gauge should fail, the single or four parameter screen will
be replaced with the MLink Gauge Fault message. The screen title MLink
Gage Fault will flash.
3. To acknowledge and Hide the fault and return to the single or four parameter
display touch the Select Button.
4. The display will return to the single or four parameter screen.
5. Touching the Select Button will re-display the hidden fault. Touching the
Select Button once again will hide the fault and return the screen to the single
or four parameter display. Note: The fault can only be cleared by powering the
system down, removing or replacing the auxiliary gauge.
Active Fault Codes
2. When the PowerView receives a fault code from an engine control unit the
single or four parameter screen will be replaced with the Active Fault Codes
message. The screen title will flash between the two messages Active Fault
Codes and Warning.
3. If the word MORE appears above the Arrow Buttons there are more active
fault codes that may be viewed. Use the Arrow Buttons to scroll to the next
Active Fault Code.
4. When the arrow appears to the right of the word MORE, continue to scroll to
the right to see more Active Fault Codes. If the arrow shifts to the left side of
the word MORE, the end of the active codes has been reached. Touch the left
Arrow Button to review the active fault codes.
5. To acknowledge and Hide the fault and return to the single or four parameter
display touch the Select Button.
6. The display will return to the single or four parameter display, but the display
will contain the flashing Active Fault warning icon.
7. Touching the Select Button will redisplay the hidden fault.
8. Touching the Select Button once again will hide the fault and return the screen
to the single or four parameter display. Note: Ignoring active fault codes could
result in severe engine damage.
Shutdown Codes
2. When the PowerView receives a severe fault code from an engine control unit
the single or four parameter screen will be replaced with the Shutdown
message. The screen title will flash the message Shutdown!.
3. To acknowledge and Hide the fault and return to the single or the four
parameter display, touch the Select Button.
4. The display will return to the single or four parameter display, but the display
will contain the flashing Shut Down icon.
5. Touching the Select Button will redisplay the hidden fault.
6. Touching the Select Button once again will hide the fault and return the screen
to the single or four parameter display. Note: Ignoring the Shut Down message
could lead to severe engine damage.
Back Light Adjustment
1. Starting at the single or four engine parameter display touch the Menu Button.
through the menu until the Adjust Backlight is highlighted.
3. Once the Adjust Backlight menu has been highlighted, touch the Select
Button to activate the Adjust Backlight function.
4. Use the Arrow Buttons to select the desired backlight intensity.
6. Touch the Menu Button to exit the main menu and return to the engine
parameter display.
Contrast Adjustment
1. Starting at the single or four engine parameter display, touch the Menu
Button.
through the menu until Adjust Contrast is highlighted.
3. Once the Adjust Contrast menu item has been highlighted, touch the Select
Button to activate the Adjust Contrast function.
4. Use the Arrow Buttons to select the desired backlight intensity.
parameter display.
Select Units
1. Starting at the single or four engine parameter display, touch the Menu
Button.
through the menu until the Select Units is highlighted.
3. Once the Select Units menu has been highlighted, touch the Select Button
to access the Select Units function.
4. Use the arrows to highlight the desired units. English for Imperial units i.e.
PSI, F or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, C.
5. Touch the Select Button to select the desired units or CANCEL to exit.
parameter display.
Setup 1-Up Display
1. Starting at the single engine parameter display, touch the Menu Button.
through the menu until the Setup 1-Up Display is highlighted.
3. Once the Setup 1-Up Display menu item has been highlighted, touch the
Select Button to access the Setup 1-Up Display function.
4. Three options are available for modification of the 1-Up display.
a. Use Defaults - This option contains a set of engine parameters: Engine
Hours, Engine RPM, System Voltage, % Engine Load a Current RPM,
Coolant Temperature, Oil Pressure, Etc. The OEM factory default has all
available parameters available for display.
b. Custom Setup - This option contains a list of engine parameters. Engine
parameters from this list can be selected to replace any or all the default
parameters. This option can be used to limit the number of parameters
available for scrolling in the 1-Up Display.
c. Automatic Scan - Selecting the scan function will cause the 1-Up Display
to scroll through the selected set of parameters one at a time, momentarily
pausing at each.
5. Use Defaults - To select Use Defaults use the arrow buttons to scroll to and
highlight Use Defaults in the menu display.
6. Touch the Select Button to activate the Use Defaults function. This action
will reset the unit to the OEM factory default with all parameters available for
scrolling from the 1-Up Display.
7. Custom Setup - To perform a custom setup of the 1-Up Display, use the arrow
buttons to scroll to and highlight Custom Setup on the display. Two methods
may be used:
a. Build a list by individually selecting parameters.
b. Select All Parameters then de-select those parameters not desired.
8. Touching the Select Button will display a list of engine parameters.
9. Use the Arrow Buttons to scroll to and highlight the Clear All Parameters
from the menu. Note: Highlighted parameters were previously selected.
10. Press the Select Button to clear previously selected parameters.
11. Use the Arrow Buttons to scroll to and highlight the desired parameter. Press
the Select Button to select the parameter for inclusion in the 1-Up Display.
12. Continue to scroll through and select the additional parameters for the custom
1-Up Display.
13. Automatic Scan - Selecting the scan function will cause the 1-Up Display to
scroll through the selected set of parameters one at a time. Use the Arrow
Buttons to scroll to the Automatic Scan function.
14. Touching the Select Button toggles the Automatic Scan function on.
15. Touching the Select Button again toggles the Automatic Scan function off.
16. Once the Use Defaults, Custom Setup and Automatic Scan functions have
been set, touch the Menu Button to return to the main menu.
17. Touch the Menu Button to exit the main menu and return to engine parameter
display.
4-Up Display Setup
1. From the single or four engine parameter display, touch the Menu Button.
through the menu until Setup 4-Up Display is highlighted.
3. Once the Setup 4-Up Display menu item has been highlighted, touch the
Select Button to activate the Setup 4-Up Display menu.
4. Use the Arrow Buttons to select one of the four engine parameter display
locations.
5. Pressing the Select Button will bring up a list of engine parameters.
6. Use the Arrow Buttons to scroll through and highlight the desired engine
parameter.
7. Pressing the Select Button will place the selected parameter in the pre-
selected 4-Up Display Location.
8. Use the Arrow Buttons to select the next parameter display location.
9. Press the Select Button to view the engine parameter list.
10. Use the Arrow Buttons to scroll to and highlight the desired parameter.
11. Pressing the Select Button will place the selected parameter in the pre-
selected 4-Up Display Location.
12. Repeat the parameter selection process until all spaces are filled. Note: The
parameters in any of the four display locations may be edited and saved without
affecting the other display locations.
13. Press the Menu Button to return to the main menu.
14. Press the Menu Button to exit the Main menu and return to engine parameter
display.
Utilities
This section is for use with PowerView PVA Gages. The UTILITIES Section below should
be used when working with a Murphy Technical Support.
1. Starting at the single or four engine parameter display, press the Menu
Button.
2. The main menu will be displayed. Use the Arrow Buttons to scroll through the
menu until the Utilities is highlighted.
3. Once the Utilities menu item has been highlighted, touch the Select Button
to activate the Utilities functions. When Gage Data is selected the
PowerView will communicate with the analog gages at a fixed rate of 38.4 k
Baud, 8 data bits, no parity check, 2 stop bits, half duplex.
4. Press the Select button to enter the Gages Data display.
5. Use the Arrow Buttons to scroll through the items or touch Menu to return to
the main menu.
6. Press Select to return to the Utilities menu.
7. Use the Arrow buttons to scroll to Remove All Gages. Then press Select
to highlight and enter the menu.
8. After clearing all gages is done, the display automatically returns to the
Utilities menu. Scroll to Software Version and then press Select and the
software version display will flash for a few seconds showing the version used.
9. Press the Menu Button to exit the Utilities menu and return to the engine
parameter display.
Table 11: J1939 Parameters
SAE
J1939
Section
Description PGN Parameter Display Value
5.3.6 Elec Eng Cont #2 - EEC2 61443 Accelerator Pedal Position Throttle
Percent Load at Current RPM Load@RPM
5.3.7 Elec Eng Cont #1 - EEC1 61444 Actual engine % torque Eng Torque
Engine Speed Eng RPM
5.3.19 Engine hours, Revolutions 65253 Total Engine Hours Eng Hrs
5.3.23 Fuel Consumption 65257 Trip Fuel Trip Fuel
Total Fuel Used Fuel Used
5.3.28 Engine Temperature 65262 Engine Coolant Temp Cool Temp
Fuel Temperature Fuel Temp
Engine Oil Temperature Oil Temp
Engine Intercooler Temp Inte Temp
5.3.29 Engine Fluid Level/Pressure 65263 Fuel Delivery Pressure Fuel Press
Engine Oil Level Oil Lvl
Engine Oil Pressure Oil Press
Coolant Pressure Cool Press
Coolant Level Cool Lvl
5.3.32 Fuel Economy 65266 Fuel Rate Fuel Rate
Instantaneous Fuel Economy Fuel Econ
Average Fuel Economy Avg Econ
5.3.35 Ambient Conditions 65269 Barometric Pressure Baro Press
Air Inlet Temperature Air In Temp
Electrical schematic on how the powerview gauges connect.
5.3.36 Inlet/Exhaust Conditions 65270 Boost Pressure Bst Press
Intake Manifold Temp Mani Tmp
Aie Filter Differential Press. AirDifPr
Exhaust Gas Temperature Exh Temp
5.3.37 Vehicle Electrical Power 65271 Electrical Potential (Voltage) Sys Volt
Battery Pot. Voltage (Switched)
Bat Volt
5.3.46 Engine Fluid Level/Press #2 65243 Injector Metering Rail 1 Press Inj Pres1
Injector Metering Rail 2 Press Inj Pres2
5.3.58 Fan Drive 65213 Fan Spd
5.3.111 Auxiliary Temperatures 65164 Auxiliary Temperature Aux Temp
Auxiliary Pressure Aux Press
Diagnostic Messages 65226 DM1 - Active Diagnostic SrvcCode
65227 DM2-Previously Act Diag Codes StorCode
65228 DM3 - Diagnostic Clear
J 1939 N/A Machine Hours(PowerView
Calculated)
N/A Machine Hours Mach Hrs
5.3.17 Engine Conf. 65251 Engine Configuration Eng Conf
Source: SAEJ 1939-71 Surface Vehicle Recommended Practice
SAE
J1939
Section
Description PGN Parameter Display Value
Murphy interface module signal input for the J 1939 gauges.
7.7 - HNBR Hose / Victaulic Coupling Installation
The following text contains Installation Instructions for HNBR hose using 2-bolt Victaulic rigid
couplings.
WARNING
!
1. Read and understand all instructions before attempting to install any Victaulic
piping products.
2. Depressurize and drain the piping system before attempting to install, remove
or adjust any Victaulic piping products.
3. Wear safety glasses, an approved hard hat and foot protection.
Failure to follow these instructions could result in serious personal injury, improper product
installation and/or property damage.
Preparatory Steps for Coupling Installation
1. Check Hose/Pipe Ends: The outside surface of the pipe from the end to the
groove must be smooth and free from indentations, projections (including weld
seams) and roll marks to ensure a leak tight seal for the gasket. All oil, grease,
loose paint and dirt bust be removed.
2. Check Gasket and Lubricate: Check the gasket to make sure it is suitable for
the intended service. Apply a thin coat of silicone lubricant to the gasket lips
and exterior.
CAUTION
!
Always use a compatible lubricant to prevent the gasket from pinching or
tearing during installation. Failure to follow this instruction could result
in joint leakage.
3. Position Gasket: Position the gasket over the hose end. Make sure the gasket
does not overhang the hose end.
4. Join Hose/Pipe Ends: Align and bring the hose end and pipe end together.
Slide the gasket into position and make sure it is centered between the grooves
in each hose/pipe end. Make sure no portion of the gasket extends into the
groove in either pipe/hose end.
1. Assemble Housings: Insert one bolt into the housings and thread the nut
loosely onto the bolt (nut should be flush with the end of bolt) to allow for the
swing-over feature, as shown below.
2. Install Housings: Using the swing-over feature, install the housings over the
gasket. Make sure the housings keys engage the grooves properly on both the
hose end and the pipe end.
CAUTION
!
Make sure the gasket does not become rolled or pinched while installing
the housings. Failure to follow this instruction could cause damage to the
gasket, resulting in joint leakage.
3. Install Remaining Bolt/Nut: Install the remaining bolt and thread the nut
finger-tight onto the bolt. Note: Make sure the oval necks of the bolts seat
properly in the bolt holes.
4. Tighten Nuts: Tighten all nuts evenly by alternating sides until metal-to-metal
contact occurs at the angle bolt pads. Make sure the housings keys completely
engage the grooves. Make sure the offsets are equal at the bolt pads.This is
necessary to ensure a rigid joint (refer to the example below). Note: It is
important to tighten all nuts evenly to prevent gasket pinching.
WARNING
!
Victaulic rigid, angle-pad couplings must have the nuts tightened evenly
by alternating sides until metal-to-metal contact occurs at the bolt pads.
Victaulic rigid, angle-pad couplings must have equal offsets at both bolt
pads.
Failure to follow these instructions could cause joint failures resulting in
serious personal injury and/or property damage.
Impact Wrench Usage Guidelines
DO NOT use an impact wrench after the visual installation guidelines for the coupling
are achieved.
Nuts must be tightened evenly by alternating sides until metal-to-metal
contact occurs at the bolt pads. For angle-bolt-pad couplings, even
offsets must be present at the bolt pads to obtain pipe-joint rigidity.
Failure to follow these instructions could cause gasket pinching and
coupling damage resulting in joint failure, serious personal injury and
property damage.
Installation Inspection
WARNING
!
Proper Installation
Proper pipe preparation and coupling installation is essential for maximum joint performance.
The following conditions must be present to ensure proper joint assembly.
1. The pipe O.D. and groove dimensions must be within the tolerance of current
Victaulic grooving specifications.
2. Unless stated otherwise in specific product instructions, Victaulic grooved pipe
couplings must be properly assembled with the bolt pads in firm, metal-to-metal
contact.
3. The housings keys must be fully engaged in both grooves.
Always re-inspect joints before and after the field test to identify points of possible failure. Look
for gaps at the bolt pads and/or keys that ride up on the shoulders. If any of these conditions
exist, depressurize the system and replace any questionable joints.
7.8 - Dixon Boss Clamp Installation Instructions
Torque Procedure For Dixon 4 Bolt Clamp With Atlas Copco Hose
Notes:
1. Periodic bolt re-tightening is necessary due to "Cold-Flow" present in all rubber
hoses.
2. Dixon Boss clamps (including nuts and bolts) are for a single use only! Once
removed, discard. Only use nuts and bolts that come with the clamps. Do not
replace hardware.
3. DO NOT USE AN IMPACT WRENCH.
Clamp and Hose Selection:
Refer to rig BOM for correct hose and clamps to use.
Process:
1. Install whip checks on hose and hard pipe for both ends of the hose.
2. Insert hose into stem.
3. Position the clamp gripping fingers behind the stem collar. See illustration
above.
4. Tighten the bolts by hand until there is equal thread engagement. DO NOT
USE AN IMPACT WRENCH
5. Set a calibrated torque wrench to the final torque value for the clamp.
6. Using the calibrated torque wrench to tighten bolts to required torque following
the procedure below:
NOTE: Torque values are based upon " dry bolts" . Lubricant on bolts will
adversely affect clamp performance.
3" ID clamps (2657546061 and 2658006735) should be torqued to 100 ft lbs using the
procedure below: (Note: Torque value for 3" Dixon clamps (2657546061 and 2658006735) on
Atlas Copco hose is lower then normal catalog torque specs. DO NOT torque assemblies to
150 ft lbs)
2.5" and 2" ID clamps (2656918832 and 2650743731) should be torqued to 60 ft lbs using the
procedure below:
6. Bolt tightening sequence (FIGURE 1):
a. Back bolt (nut 1), 1 full turn.
b. Front bolt (nut 2), 1 full turn.
c. Snug by hand, nuts on opposite side of bolts just tightened. (nut 3 and nut 4)
d. Opposite side back bolt (nut 3), 1 full turn.
e. Opposite side front bolt (nut 4), 1 full turn.
f. Snug by hand, nuts on opposite side of bolts just tightened. (nut 1 and nut 2)
g. Repeat "a" to "f" until all bolts are tightened to specified torque. Once the torque
value is reached on a bolt move to the next step in the tightening sequence.
NOTE: It is common for one bolt to reach torque before the others.
Continue sequence until all four bolts have reached torque in sequence.
7. Inspect results using " Criteria for Sufficient Fit of a Boss Clamp" (FIGURE 2 ):
a. Sufficient fit criteria provides inspection guidelines when the clamp has been
assembled in accordance with the torque procedure and all the bolts are
tightened to the correct torque.
b. Failure to adhere to these guidelines could produce poor clamp performance.
Minimum Range:
- 1/16" clearance between clamp halves (both sides for 4 bolt clamps).
Maximum Range:
- 1/16" interlock between gripping fingers and stem collar (all gripping fingers).
- 1/16" interlock between dovetail extensions. (all gripping fingers).
Torque Procedure For Dixon 6 Bolt Clamp With Atlas Copco Hose
Notes:
1. Periodic bolt re-tightening is necessary due to "Cold-Flow" present in all rubber
hoses.
2. Dixon Boss clamps (including nuts and bolts) are for a single use only! Once
removed, discard. Only use nuts and bolts that come with the clamps. Do not
replace hardware.
3. DO NOT USE AN IMPACT WRENCH.
Clamp and Hose Selection:
Refer to rig BOM for correct hose and clamps to use.
Process:
1. Install whip checks on hose and hard pipe for both ends of the hose.
2. Insert hose into stem.
3. Position the clamp gripping fingers behind the stem collar. See illustration
above.
4. Tighten the bolts by hand until there is equal thread engagement. DO NOT
USE AN IMPACT WRENCH
5. Set a calibrated torque wrench to the final torque value for the clamp.
6. Using the calibrated torque wrench to tighten bolts to required torque following
the procedure below:
NOTE: Torque values are based upon " dry bolts" . Lubricant on bolts will
adversely affect clamp performance.
4" ID clamps (2657823932) should be torqued to 200 ft lbs using the procedure below
6. Bolt tightening sequence (FIGURE 1):
a. Bolt 1 (nut 1), 1 full turn
b. Bolt 2 (nut 2), 1 full turn
c. Bolt 3 (nut 3), 1 full turn
d. Bolt 4 (nut 4), 1 full turn
e. Bolt 5 (nut 5), 1 full turn
f. Bolt 6 (nut 6), 1 full turn
g. Repeat "a" to "f" until all bolts are tightened to specified torque. Once the torque
value is reached on a bolt move to the next step in the tightening sequence.
NOTE: It is common for one bolt to reach torque before the others.
Continue sequence until all four bolts have reached torque in sequence.
7. Inspect results using " Criteria for Sufficient Fit of a Boss Clamp" :
a. Sufficient fit criteria provides inspection guidelines when the clamp has been
assembled in accordance with the torque procedure and all the bolts are
tightened to the correct torque.
b. Failure to adhere to these guidelines could produce poor clamp performance.
Minimum Range:
- 1/16" clearance between clamp halves (both sides for 4 bolt clamps).
Maximum Range:
- 1/16" interlock between gripping fingers and stem collar (all gripping fingers).
- 1/16" interlock between dovetail extensions. (all gripping fingers).
7.9 - IC Clamp Installation and Instructions
Instructions
IC (Campbell) clamps are 360 U-Bolt interlocking clamps. These clamps will be used on low
pressure machines Only.
1. Insert fitting fully into hose.
2. Place cast part of clamp on top of hose so interlocking fingers fit into collar of
fitting.
3. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.
4. Install U-bolts around steel liner and through clamp casting.
5. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting
on both sides and interlocking fingers engage collar of fitting.
6. Clamp assembly gives 360 of clamping pressure.
7. Clamps should be checked for tightness during use and retightened when
necessary.
Table 12: Clamp Size and Torque Value
Clamp Size Nut Torque # Of U-Bolts
1/2 15 ft.lbs (20.34 N-m) 1
3/4 25 ft.lbs (33.90 N-m) 1
1 25 ft.lbs (33.90 N-m) 2
1-1/4 25 ft.lbs (33.90 N-m) 2
1-1/2 35 ft.lbs (47.45 N-m) 2
2 55 ft.lbs (74.57 N-m) 2
2-1/2 55 ft.lbs (74.57 N-m) 2
3 55 ft.lbs (74.57 N-m) 3
4 100 ft.lbs (135.58 N-m) 3
6 150 ft.lbs (203.40 N-m) 3
7-10 Engine Heater (Option)
Introduction
This section is provided to present an overview of the engine block heater system currently
used on Drilling Solutions drills.
The preheater will preheat an engine block to ensure reliable starting in cold weather. At the
same time it may be used throughout the year to reduce the wear associated with cold starts.
Technical Specifications
Do Not use Gasoline.
Table 13:
Table 14:
Dimensions
Model
Heat Rating Volts Current Fuel Rate Coolant Flow
BTU/hr. (kw)
Nominal
(range)
Amps
Gallon/hour
(L/hr)
Gallon/minute
(L/min)
x45-12 45,000 (13.0) 12 (10.0-15) 7.5 .32 (1.2) 8.0 (30)
x45-24 24 (20-30) 3.75
Ignition Type: Electric spark ignition
Fuel Types: Diesel #1, #2, Kerosine
Coolant Temperature: 150F to 185F (65C to 85C) @
heater
Enclosure Dimensions: 12.5W x 11H x 20.5L inches
(318W x 280H x 521L mm)
Weight, Heater only: 40 lbs. (18 kg)
Weight, with Enclosure: 55 lbs. (25 kg)
Operating Temperature Range: -40F to 122F (-40C to 50C)
Heat Exchanger Capacity: 1 quart U.S. (0.97 liter)
Principal of Operation
1. Fuel Pump
A gear pump driven from the same motor as the compressor pulls fuel from the tank. The fuel
is filtered at the fuel pump inlet. The gear pump will develop a maximum pressure of 10 psi
(.69 bar) on the outlet side of the pump (figure 7-10-3).
2. Fuel Regulator
Reduces fuel to atmospheric pressure. Siphoning action from the nozzle draws fuel from the
regulator. Without this siphoning there is no fuel flow.
3. Air Compressor
A diaphragm type compressor supplies air to the fuel nozzle.
4. Ignition coil
An automotive type ignition coil supplies high voltage to the ignition electrode, sparking to the
combustion tube.
5. Coolant Pump
The coolant pump circulates the engine coolant. An impeller style pump is used because of its
low current draw and free flow during engine operation. It is not self priming. The pump must
be flooded and the system must be purged of all air for it to operate (DO NOT run dry).
6. PROHEAT Control Module (PMC)
Utilizes a microprocessor to monitor conditions and controls outputs to the motors and
sensors. It has powerful diagnostics to assist in troubleshooting. One of the key features is the
diagnostic display on the front of the PMC which has LEDS to indicate function or component
problems.
Figure 7-10-4
Note: The PCM is unique in that it uses ground side switching for the blower, compressor,
coolant pump and ignition coil. The positive wire to the motors and ignition coil will show
voltage even when the heater is switched OFF.
7. Nozzle
An air/fuel aspirating type spray nozzle is located inside the housing. The compressed air
flows through the nozzle at high speed creating a venturi effect. This siphons fuel from the
regulator and combines it with the air, creating an extremely fine mist which is sprayed out of
the nozzle into the combustion chamber. The nozzle determines the air/fuel ratio.
8. Blower
The blower uses an impeller type fan to supply approximately 90% of the combustion air at
low pressure. It is also used to cool and purge the combustion chamber during the 3-minute
shutdown sequence.
9. Inspection Port
The inspection port allows for visual inspection of the combustion process and is invaluable
for reducing time spent on troubleshooting and servicing the heater.
10. Heat Exchanger
The heat exchanger is a two part cast aluminum housing. Coolant will typically rise 10F to
15F (6C to 8C) in temperature as it passes through the heat exchanger, depending on the
flow rate.
11. Ignition Electrode
The electrode is located near the nozzle just out of the air/fuel mixture path. During the ignition
sequence the spark jumps the gap between the electrode and the combustion tube, igniting
the air/fuel mixture. Spark duration is 60 seconds.
12. Coolant Temperature Sensor
The coolant temperature sensor measures coolant temperature at the outlet port of the heat
exchanger.
13. Overheat Breaker Sensor
The overheat breaker sensor protects the heater from damage should it be operated without
coolant. The overheat breaker monitors the surface temperature of the heat exchanger
casting. When the temperature reaches 286F (141C) the breaker trips out. This shuts off
the power to the air compressor, extinguishing the flame. The breaker can be reset by pushing
down on the red button located under the rubber cap.
14. Flame Sensor
The flame sensor photo-electronically measures the intensity of the flame. It is the flame
sensor that signals to the PCM that the air/fuel mixture is burning properly.
15. On/Off Switch
The On/Off switch is used to switch the heater on and off . It has an indicator lamp that
displays a red light when switched on . A flashing red light indicates a heater diagnostic code
and one of the LEDs on the PCM diagnostic display will be lit. The on/off switch is not
used on DM45,50,DML drills. A timer is used on DM45,50,DML drills.
16. Seven (7) Day Timer
The 7-day timer is used to switch the heater on and off. This can be done manually or by a
preset time and day. It has an indicator lamp that displays a red light when switched or timed
on. A flashing red light indicates a heater diagnostic code and one of the LEDs on the PCM
diagnostic display will be lit (see Normal Operating Sequence for details).
Normal Operating Sequence
1. Switch ON - The timer lamp (or the on/off switch if used) and the PCM ON
LED will light. The heater goes to pre-check.
2. Pre-Check - The PCM performs a short diagnostic cycle. This takes several
seconds, checking components for proper ranges, short circuits and open
circuits. If there are no errors indicated, the heater goes to ignition.
3. Ignition - The blower starts first, followed by the coolant pump, ignition spark,
air compressor and fuel pump. The ignition electrode sparks, 60 seconds
maximum, until the flame sensor sees a flame. Once the flame sensor sees
a flame, the heater goes to full output.
4. Full Output - The heater runs at full output until the coolant temperature
reaches 185F (85C) at the heater outlet. At this time, the heater shuts the
flame off and goes to purge.
5. Purge - The air compressor and fuel pump shut off immediately. The blower
and coolant pump continue to run. After 3 minutes, the blower stops and the
heater goes to standby.
6. Standby - The coolant pump circulates the coolant through the system until the
temperature drops to 150F (65C) at the heater outlet; then it will enter
Precheck and repeat steps 2 thru 6. The heater will continue to repeat steps 2
thru 5 until it is turned OFF.
7. Switch OFF - If the heater is in Full Output, it will purge first and then shut
OFF. If the heater is in Standby, it will shut OFF immediately. Note: The
heater will purge for three reasons:
a. The coolant reaches 185F (85C).
b. There is a function or component problem (see Troubleshooting &
Repair).
c. The heater is operating at Full Output when it is shut OFF.
Function and Component Diagnostics
The microprocessor in the PCM continually monitors all the heater systems. If the internal
diagnostics discover a problem, a diagnostic code will be displayed on the PCM function
display. The timer red ON light will also flash the diagnostic code followed by a pause and
then repeated. The number of flashes correspond to the numbered diagnostic code; eg. 5
flashes indicate a VOLTAGE ERROR. See Diagnostic Code Description below for a complete
list of error flash codes. If this occurs, refer to the troubleshooting section to assist in problem
diagnosis.
Table 15: Diagnostic Codes
Code No. Description of Diagnostic Code No. of Flashes
1 Start 1
2 Flame Out 2
3 Coolant Flow 3
4 Coolant Overheat 4
5 Voltage (High/Low) 5
6 Flame Sensor 6
7 Temperature Sensor 7
* The fuel pump is a gear pump driven by the compressor motor. The fuel pump is not being
monitored electrically. Should this component diagnostic code appear, there is a fault in the
main wire harness connector or in the PCM. All mechanical problems with the fuel pump will
be indicated as either a (1) START or a (2) FLAME OUT diagnostic code.
Troubleshooting & Repair
The Troubleshooting & Repair Guide is divided into four sections:
1. Function Errors: Errors displayed on the PCM diagnostic panel will cause the
heater to shut down. These diagnostic codes are usually the result of a system
problem.
It is possible to have two or more diagnostic codes displayed at the same time.
A function diagnostic code may be displayed in conjunction with a component
diagnostic code.
2. Component Faults: This section covers the individual heater components. In
many cases there is a corresponding indicator light on the PCM function
display. The indicator light only indicates an electrical problem, not a
mechanical failure. Component problems can also cause Function diagnostic
codes.
3. Component: This section includes the electrode gap, fuse, nozzle and fuel
8 Fuel Pump* 8
9 Compressor 9
10 Ignition Coil 10
11 Coolant Pump 11
12 Blower (Combustion) 12
13 Not Used 13
Code No. Description of Diagnostic Code No. of Flashes
regulator.
4. These are problems that are not specifically described in the Functional or
Component diagnostic sections.
Note: Always let the heater run through two cycles when troubleshooting. The
heater will attempt one restart after any function or component diagnostic code.
The heater will not start if it is in a purge cycle or if the coolant temperature is
above 150F (65C).
On
A continuously flashing ON indicator indicates a problem in the PCM.
Check: Heater PCM Function
1. Turn the heater switch located on the timer to OFF. Reset the PCM by
removing the power connection for 10 seconds, then reconnecting it. If the ON
light continues to flash, replace the PCM.
Function Diagnostic
(1) Start
A START diagnostic code indicates that the flame sensor did not see a flame during the 60
second ignition period.
If the START diagnostic code is displayed, turn the heater OFF and then ON to restart.
Observe the heater operation through the inspection window.
Symptom: Flame Visible. The heater shuts down after 60 second ignition period.
1. Check: Flame Sensor
a. Inspect for open circuit in the wiring.
b. Inspect the lens for cleanliness.
2. Check: Fuel System
a. Is there restriction in the fuel system?
b. Is the nozzle plugged?
c. Is the fuel pump operating?
d. Is the pressure regulator defective?
e. Is the compressor functioning?
f. What type of fuel is being used?
Symptom: No Flame Visible. The spark continues for the 60 second ignition period. The
heater shuts down after the 60 second ignition period.
a. Is there a restriction in the fuel system?
Note: A spark should be visible across the gap between the ignition electrode
and the combustion tube.
Symptom: Heater is Backfiring. Backfiring is usually caused by a severe restriction of
combustion air or air in the fuel line.
1. Check: Inlet Air Flow
a. Is the blower error displayed?
b. Blower Operation:
(1) Is the blower turning?
(2) Is the blower turning slowly?
c. Check for restrictions at the fan inlet port and in the exhaust system.
d. Check for carbon buildup in the combustion chamber.
a. Is fuel level low?
b. Is air leaking into fuel system?
Symptom: No Flame Visible and No Spark. The heater shuts down after the 60 second
ignition period.
1. Check: Ignition System
a. Check for a poor electrical connection between the ignition coil and the high
tension lead.
b. Check for a poor electrical connection between the electrode and the high
tension lead.
c. Inspect the electrode gap. Check for carbon bridging from ignition electrode
to the combustion tube.
d. Inspect the primary electrical connections to ignition coil and coil function.
e. Is the heater chassis ground wire attached? The ground is connected to the
boss located near the fuel pump.
(2) Flame Out
A Flame Out diagnostic code occurs when the heater has started successfully but is unable to
maintain a steady flame.
If during ignition the flame sensor does not see a flame, the ignition electrode is switched on
immediately. If the flame is not reestablished within 10 seconds the heater will shut down and
the FLAME OUT diagnostic code will be displayed. The heater will go into the Purge mode
and attempt to restart in 3 minutes, depending on the coolant temperature.
If the flame fails to re-ignite on the second attempt, a START diagnostic code will be
displayed on the function control panel. If, however, the flame sensor senses enough of a
flame during Ignition, it will enter Full Output mode. During Full Output, if the flame sensor fails
to see a flame then the FLAME OUT diagnostic code will be displayed.
a. Is there restriction in the fuel system?
f. What type of fuel is being used?
(3) Coolant Flow
A COOLANT FLOW diagnostic code is displayed when the coolant temperature reaches
185F (85C) in less than one minute after ignition. This indicates that the coolant flow is
severely restricted or blocked. This feature aids in detecting coolant flow problems that can
degrade the heater performance.
An in-line flow indicator is a valuable troubleshooting tool used to check the coolant flow and
direction; check for air in the system; and check for restrictions caused by the drill systems,
ie., shuttle valves, manual valves and air operated valves.
1. Check: Coolant Flow
a. Coolant Lines: For restrictions and blockages. Are clamps tight?
b. Shutoff Valves: Ensure shutoff valves are open and functioning properly.
c. Fittings: Fittings must be at least 1/2npt or larger. Avoid using 90 fittings
where possible.
d. Coolant Flow Direction: The heater must be plumbed so the coolant
pump is pumping the coolant in the same direction as the engine coolant
pump. The heater can be used when the engine is running.
e. Coolant Pump: Does the pump function properly?
f. Coolant System Capacity: The coolant system must contain at least three
gallons (11 liters) of coolant. If system contains less the coolant may reach
185F (85C) in less than one minute causing a COOLANT FLOW
diagnostic code.
Note: If coolant system is contaminated with magnetic material, it may cause
the impeller to seize.
(4) Overheat
An OVERHEAT diagnostic code is displayed when the overheat breaker has tripped, shutting
the heater down. This occurs if the heater has been started with little or no coolant in the heat
exchanger.
1. Check: Coolant Flow
a. Is there coolant in the system?
b. Determine if there is a blockage or air in the plumbing.
The compressor motor is wired in series with the overheat breaker. The breaker
contains a normally closed thermo switch. When the thermostat reaches the
preset temperature of 286F (141C), the contacts open shutting the
compressor and fuel pump off, instantly shutting the heater down. It cannot be
restarted until the breaker is manually reset.
To reset the breaker, remove the rubber cap covering the top of the overheat
breaker and press the red reset button on top. If the breaker will not reset, allow
the heater to cool.
2. Test Procedure
Connect a multimeter (adjusted to measure resistance) to the overheat breaker
connector (figure 7-10-13). The sensor should be normally closed. If the sensor
has tripped, the circuit should be open.
Do not reset the Overheat breaker until the cause of the overheat
condition has been determined.
(5) Voltage
A VOLTAGE diagnostic code indicates that the supply voltage to the heater is out of the
normal range.
1. Voltage Ranges:
a. 12 Volt Heater - 10.0 to 15.0 Volts
b. 24 Volt Heater - 20.0 to 30.0 Volts
2. Check: Vehicle Voltage
a. The heater voltage must be within the specified range. See Heater Voltage
Measurement for procedure to measure heater voltage.
Note: Bad connections may show good voltage under no load conditions
but not under full load. With the heater OFF, measure the voltage. Then
turn the heater ON and measure again. If the voltage drop is more than
one volt, check the deck engine battery connections and the power
connection at the PCM.
b. If the measured voltage is higher than the specified range then check the
voltage regulator.
Note: If engine batteries are marginal, starting engine while the heater is
running may drop the voltage enough to cause a voltage error or cause
random component errors (brown out).
To reset the PCM, turn the heater OFF and then back ON at the timer. If the problem
continues, load test the batteries to confirm their condition. Each battery should be
independently tested.
Current: Checking current draw is done at power harness connections on the batteries.
1. Check the current draw on the red POSITIVE wire with heater not running. It
should read 80 to 100 mA.
2. Check current draw on the red POSITIVE wire with the heater running in full
output, ignition OFF. It should read 6.5 to 7.5 amps.
3. Check current draw on the black NEGATIVE wire with heater not running and
the red POSITIVE wire disconnected. It should read 0 mA. This test is to
confirm whether or not there is a power leakage from the drill through the
heater.
Heater Voltage Measurement
The positive terminal of the ignition coil is always hot relative to the heater chassis ground as
long as power is connected to the heater. This is the supply voltage to the heater.
1. Test Procedure:
a. Locate the rubber boot on end of the ignition coil and peel back to expose
the positive and negative terminals.
b. Select the DC Volts range of a multimeter and connect as shown in figure
7-10-15. The positive lead of the multimeter should be attached to positive
coil lead. The negative lead of multimeter should be attached to the heater
chassis at the heater ground boss (see figure 7-10-30).
c. Read the voltage with the heater running or trying to run.
d. Normal Voltage Ranges:
12 Volt Heater - 10.0 to 15.0 Volts
24 Volt Heater - 20.0 to 30.0 Volts
(6) Flame Sensor
A FLAME SENSOR diagnostic code indicates an electrical short circuit in the flame sensor
wiring or a flame sensor failure. It will not indicate an open circuit. The flame sensor is an
optical device which sees the flame. If the sensor lens is dirty or has an open circuit, it cannot
see the flame and results in either a START or a FLAME OUT diagnostic code to display.
1. Check: Flame Sensor
a. Inspect the flame sensor for a short circuit.
b. Inspect the flame sensor lens for cleanliness.
c. Test the flame sensor (See Flame Sensor Test Procedure).
(7) Temp Sensor
A TEMP SENSOR diagnostic code indicates a short or open circuit in the temperature sensor
wiring or the coolant temperature is out of range, below -58F (-50C) or above 266F (130C).
The resistance of the temperature sensor is proportional to temperature.
1. Check: Temperature Sensor (CODE Indicated)
a. Inspect wiring for short or open circuits.
b. Test the sensor.
2. Test Procedure
a. Connect multimeter (adjusted to measure resistance) to temperature
sensor as shown in figure 7-10-19. Polarity of sensor connections to the
multimeter is not important.
b. Measure the sensor resistance versus temperature under following
conditions:
+at room temperature
+in a freezer
+in boiling water
c. Compare the measured values against the graph in figure 7-10-20. If values
do not approximately match, then sensor is defective and must be replaced.
Coolant Temperature Sensor Graph
Table 16:
(8) Fuel Pump
Room Temperature 70F (20C) Resistance 950 ohms
Boiling Water 212F (100C) Resistance 1700 ohms
The fuel gear pump is driven by the same motor as the compressor. Therefore, there is no fuel
pump electrical diagnostic code. A FUEL PUMP diagnostic code would indicate a fault in the
PCM only.
A short or open circuit fault in the motor that drives the fuel pump will be indicated by a
COMPRESSOR diagnostic code.
A mechanical fault within the fuel pump such as stripped drive couplings, jammed gears or a
faulty pressure relief valve, would be indicated by:
1. START diagnostic code.
2. FLAME OUT diagnostic code.
3. Blown fuse in the PCM. Indicates that the pump is seized.
1. Check: Fuel Pump
a. Check fuel pump as per procedure (See Fuel System).
b. Check relief valve for contamination.
c. Check filter for contamination.
d. Check drive couplings.
(9) Compressor
A COMPRESSOR diagnostic code indicates an open circuit in the wire harness, a short in the
wire harness between the positive and negative leads or an internal short in the motor. This
component is ground side switched in the PCM.
Symptom: Air Compressor not running (code indicated).
1. Check: Air Compressor wiring & function.
a. Check that compressor is connected to harness correctly.
b. Check the connector pins for damage or corrosion.
c. Check harness for pinched or abraded wires.
d. Test compressor. If it tests OK replace PCM.
2. Test Procedure
a. Connect air compressor directly to a power source of rated voltage (12/24
Volts) and see if the motor runs. If not, replace the compressor.
b. Measure air compressor motor resistance by using a multimeter, and then
measure resistance across compressor connector pins. If resistance shows
an open or short circuit, replace the compressor assembly.
c. Measure air compressor current. Use a test lead.
Table 17:
Symptom: Air compressor running (NO CODE indicated). No or low air flow.
1. Check: Air flow using pressure gauge. Ensure gauge is accurate (0-15
psi).
2. Procedure: Install the pressure gauge as shown in figure 7-10-25. The
pressure reading for X45:6.5 psi (.45 bar) @ 12/24 Volts.
High Pressure Reading indicates:
a. Blocked nozzle. Air passage only (See Nozzle - Figure 7-10-39).
b. Compressor is out of adjustment. Re-adjust the compressor using the
adjustment screw as indicated in figure 7-10-26.
Low Pressure Reading indicates:
a. Pinched or leaking air line from the compressor outlet fitting to the fan end
inlet.
b. Plugged compressor inlet filter. Retest with the filter removed.
Normal Reading but a rich or lean flame:
a. Check for contaminated nozzle, fuel passage (See Nozzle).
b. Check the blower.
c. Check the fuel regulator.
d. Check fuel system.
MODEL CURRENT DRAW (AMPS)
X45-12 3.50 - 5.00 @ 12 VOLTS
X45-24 1.5 - 3.00 @ 24 VOLTS
3. Pressure Adjustment:
a. Locate adjusting screw on the compressor head (figure 7-10-26).
b. Adjust as necessary. Ensure that voltage is nominally 12 or 24 Volts.
Symptom: Air Compressor running (NO CODE) indicated). Fuse blown in PCM.
1. Check: Air Compressor operation.
a. Check harness for pinched or abraded wires. The positive wire must not
short to the ground.
b. Check motor for internal short.
c. Check for seized motor or fuel pump.
Disconnect the PCM electrical power prior to trying to turn the compressor counter
weight by hand.
(10) Ignition Coil
An IGNITION COIL diagnostic code indicates an open circuit in the wire harness, a short in
the wire harness between the positive and negative leads or an internal short in the coil. The
fuse will blow if there is a short to ground in the positive lead or the coil. The ignition coil is the
easiest place to measure the voltage on the heater. This component is ground side switched
in the PCM.
The heater chassis is grounded from the PCM as shown in figure 7-10-30. Ensure the
ground is securely connected. Failure to ensure a proper ground may result in electric
shock.
Symptom: No Spark at the electrode (code indicated).
1. Check: Coil Wiring
a. Inspect the wiring harness to ensure the ring terminals are secured to the
coil. Make sure the polarity is correct.
b. Inspect for broken or abraded wires in the wire harness.
c. Test coil (see figure 7-10-29).
d. if an IGNITION COIL diagnostic code occurs and no fault is found in the coil
and wiring, then the PCM must be checked.
Symptom: No Spark at the electrode (NO code indicated.)
1. Check: High tension wires and electrode.
a. Inspect the high tension lead between the coil and the electrode.
b. Inspect the ground lead between the second electrode and heater chassis.
c. Is electrode gap adjusted correctly? (See Electrode Gap figure 7-10-35).
2. Test Procedure:
a. Measure ignition coil resistance. Use a multimeter to measure resistance
across the positive and negative terminals. The resistance should be less
than 1 ohm. If the resistance is open circuit or 0 ohms (short circuit) then
replace the ignition coil.
b. Note: Remove positive and negative wires from the coil when testing.
(11) Coolant Pump
A COOLANT PUMP diagnostic code indicates an open circuit in the wire harness, a short in
the wire harness between the positive and negative leads or an internal short in the motor. This
The coolant pump is not self priming. Ensure that the coolant system has been purged of air
by running the deck engine for at least ten minutes following installation or service (Do Not run
dry).
Symptom: Coolant Pump not running (code indicated).
1. Check: Coolant Pump wiring & function.
a. Check that the coolant pump is connected to harness correctly (See the
Heater Wiring Diagram).
c. Check the harness for pinched or abraded wires.
d. Test the pump. If it tests OK replace PCM (See Test Procedure and Figure
7-10-32).
Symptom: Coolant Pump not running (no code indicated). Fuse blown in PCM.
1. Check: Coolant Pump function.
a. Coolant Pump Not Running No Code Indicated).
b. Fuse Blown In PCM
Symptom: Cooling Pump not pumping (no code indicated).
1. Check: Coolant Pump function.
a. Check to see if the impeller is turning freely. If not, replace the pump.
Symptom: Coolant Pump leaking.
1. Check: Leak location.
a. Check hose clamps. Tighten if necessary
b. Check pump housing seal. Replace pump if required.
2. Test Procedure:
a. Connect coolant pump directly to the rated voltage (12/24 Volts) and see if
it runs. If not, replace the pump.
b. Measure coolant pump motor resistance. With a multimeter, measure the
resistance across the coolant pump connector pins. If resistance shows an
open circuit or an internal short circuit, replace the coolant pump.
c. Measure coolant pump current using a test lead.
Table 18: Coolant Pump Test
Model Current Draw (Amps)
X45-12 1.5 - 4.00 @ 12 Volts
X45-24 0.75 - 2.00 @ 24 Volts
(12) Blower
A BLOWER diagnostic code indicates an open circuit in the wire harness, a short in the wire
harness between the positive and negative leads or an internal short in the motor. This
Note: An RPM check was added to the PCM. This feature measures the blower RPM and will
give an error should it fall below the necessary RPM to maintain sufficient combustion air.
When a blower fails, the combustion chamber must be checked for carbon buildup and
cleaned as necessary.
Symptom: Blower not running (code indicated).
1. Check: Blower wiring & function.
a. Check if blower is connected to harness correctly (See Wiring Diagram).
c. Check harness for pinched or abraded wires.
d. Test the blower. If the blower tests OK replace PCM (See Test Procedure
and figure 7-10-34).
Symptom: Blower not running (no code indicated). Fuse blown in PCM.
1. Check: Blower function.
a. Check harness for pinched or abraded wires. Positive lead must not short
to ground.
b. Check motor for internal short (See Test Procedure and figure 7-10-34).
Symptom: Blower turning slowly (no code indicated).
1. Check: Blower function.
a. Check for fan blade rubbing on housing.
b. Check for fan blade slipping on motor shaft.
2. Test Procedure
a. Connect the blower to a power supply of the rated voltage. Does the blower
turn? If not, replace the blower.
b. Measure blower motor resistance. Using a multimeter, measure resistance
across the blower connector pins. If resistance shows an open circuit or an
internal short circuit, replace the blower assembly.
c. Measure the blower current using a test lead.
Table 19: Blower Test
Components
The electrode gap is factory set and should not require adjustment.
Note: Ensure that the electrode is not bent during servicing. To readjust the electrode, bend it
to the correct setting.
Model Current Draw (Amps)
X45-12 .75 - 1.5 @ 12 Volts
X45-24 .5 - 1.0 @ 24 Volts
Fuse
If, when the heater is turned ON, the heater does not run and the ON light does not light,
check the fuse in the PCM. The fuse will blow if there is a short to ground in a positive lead or
internally for the following components: ON/OFF switch, air compressor, ignition coil, coolant
pump and blower. Reversing polarity at the battery will also cause the fuse to blow. This will
not harm the PCM.
Repeated replacement of the fuse or using incorrectly rated fuses without correcting
the problem can damage the PCM.
1. Check: Heater wiring
a. Check polarity of battery connections.
b. Test the internal wire harness for short circuits.
The following page describes the test procedure for a blown fuse with power connected and
the heater switched off.
Nozzle
The nozzle (and the compressor) regulate the fuel air mixture. A set orifice size allows a certain
amount of fuel and air to flow through the distributor (see figure 7-10-38). Problems in the
nozzle can cause poor burning. This will be indicated by a START or FLAME OUT diagnostic
code on the PCM function display.
1. Check: Nozzle
a. Inspect the nozzle for blockage.
b. Clean or replace nozzle as necessary.
c. Check and clean fuel passage in the fan end.
2. Nozzle Cleaning Procedure:
a. Remove nozzle from fan end.
b. Disassemble nozzle as shown in figure 7-10-38.
c. Use a cleaner/degreaser to thoroughly wash the separate parts.
d. Dislodging contaminants in distributor counterbore can be done by lightly
hand spinning a drill bit (0.060 dia.) and then washing. Do not use a tip
cleaner in the fuel orifice.
e. Reassemble nozzle and torque to 30 inch pounds (3.39 Nm).
f. Use compressed air for cleaning only in the direction indicated by the arrow
in figure 7-110-38.
g. Lubricate the o-ring with diesel fuel and reinstall nozzle in fan end.
Note: See Step 6 of Fuel System Troubleshooting to confirm that the
nozzle is functioning correctly. All of the nozzles parts are matched parts.
Do not interchange.
Fuel Regulator
The fuel regulator reduces the fuel pressure supplied by the fuel pump from 5 psi (0.34 bar)
down to atmospheric pressure. Compressed air flowing through the nozzle creates a venturi
effect which siphons fuel from the regulator. If the compressed air flow through the nozzle
stops, the regulator closes, shutting off the fuel flow.
1. Check: Fuel Regulator
a. Ensure that the vent hole in the regulator is not plugged.
b. Ensure that all fuel line connections are tight. Check the clamps.
2. Test Procedure:
a. Disconnect fuel line at the nozzle fuel inlet fitting and place it in a container.
b. Start the heater. Insert a small blunt pin in the regulator vent hole and
gently depress the diaphragm (figure 7-10-40).
c. Fuel should flow out of the fuel line. If there is no fuel flow, the regulator is
plugged.
Note: Should a fuel regulator fail, the combustion chamber must be
checked for carbon buildup and cleaned as necessary.
Fuel System
Step 1 - Is there fuel in the tank?
1. Check the fuel tank for fuel.
Step 2 - Start the heater.
1. Start the heater. The heater will try to start twice. Wait until it has gone through
two cycles (approximately 10 minutes). The heater diagnostic system will tell
you what it thinks is wrong. While it is running, observe for:
a. Is there flame? Yes, means there is ignition and fuel. Refer to Is ignition
spark turning OFF? No, go to step 3.
b. Is ignition spark turning OFF ? Yes, then the Flame Sensor sees a
flame. No, then the flame is either too weak or the Flame Sensor and/or
circuit is faulty. See Flame Sensor (figure 7-10-16).
Step 3 - Does the Fuel Pump work?
1. This component must be tested before proceeding with further troubleshooting.
a. Disconnect the fuel line at the inlet to the regulator. Start the heater. Check
fuel flow, approximately 1 pint (1/2 liter) in 60 seconds.
b. Run fuel pump by connecting remote power to compressor motor and
checking for fuel flow.
Step 4 - Does the Regulator work?
1. Disconnect the fuel line at the fuel inlet fitting. Hold the line at the same level as
the inlet. Start the heater. There should be no fuel flow. This indicates that the
regulator is holding the fuel pressure.
2. Lightly push on the regulator diaphragm (use a blunt tool). Fuel should flow
from the line (see figure 7-10-40).
3. Note: A regulator that is stuck open will produce a rich flame and blockage in
the regulator needle valve seat will produce a lean flame.
Step 5 - Does the Compressor work?
1. Check the pressure output (See figure 7-10-24 and figure 7-10-25).
Step 6 - Isolate the Nozzle and Compressor.
1. Split the fuel system by drawing fuel from a remote source. Disconnect the fuel
line at the outlet of the fuel regulator. Put this end into a small container of fuel
that is about the same level as the center of the regulator (See figure 7-10-42).
This will eliminate the fuel pump and the regulator from the system. Start the
heater. If there is still a fuel problem, it must be in the Compressor or Nozzle.
Step 7 - Is the Fuel Nozzle contaminated?
1. Clean the nozzle with a cleaner/degreaser which will wash contamination out
the back end of the nozzle.
Operational Problems
Heater Operational Problems that are not specifically described in the function or component
diagnostic section are shown below.
Smoking Exhaust and Smelly Exhaust Fumes
These symptoms are usually an indication of an extremely rich air/fuel mixture.
1. Check:
a. Is the heater connected to the correct voltage? (Refer to figure 7-10-15).
b. Is the blower functioning? Is the air inlet restricted?
c. Is the compressor functioning? (Refer to figure 7-10-24).
d. Is the exhaust restricted?
e. Is it a new heater? New heaters may smoke for 15 minutes as oil is burned
off the exhaust pipe. This is normal.
Low Heat Output
If the heater appears to be functioning properly but the driver complains of low heat, this is
often indicative of a coolant flow restriction. Refer to figure 7-10-11.
Engine Temperature Gauge Reads Low
Depending on its location, the engine temperature sensor may not be directly in the path of
coolant flow from the heater. In these cases the gauge may read significantly lower than actual
coolant temperature.
Backfiring
Backfiring occurs when there is air in the fuel supply lines.
1. Check:
a. Check fuel level in fuel tank. Is the pickup submerged?
b. Check for air leaks. Are all the fuel line clamps tight?
c. Check for severely restricted combustion air blockage at the blower inlet,
combustion chamber or in the exhaust system.
Maintenance
Weekly Maintenance
Run the heater a minimum of once a week to keep new fuel in the heaters critical components.
Annual Maintenance
Check the system annually before each heating season. There are several maintenance
procedures you can perform to keep your heater in service. Read this maintenance section
carefully. Always return to your authorized Drilling Solutions dealer or distributor for major
maintenance.
Clean Heater Enclosure
Remove the heater enclosure cover and blow out the compartment with compressed air.
Clean any accumulated debris or dust from the components. Make sure the opening around
the exhaust pipe is clear. Visually inspect all the components for wear or damage.
Heat Exchanger
To maintain optimum heat output, clean any combustion deposits that may have accumulated
on the heat exchanger fins.
1. Remove ignition lead from ignition electrode.
2. Remove blower connector.
3. Remove the three (3) bolts securing the fan end assembly.
4. Remove the fan end assembly and combustion tube to access the inside of the
heat exchanger (figure 7-10-44). Use a wire brush to loosen the deposits and
an air hose to blow them out.
Exhaust System
Check the exhaust system carefully. Make sure the exhaust pipe is vented safely away from
the vehicle cab. Check the pipe for dents, restrictions or severely corroded areas. Replace the
exhaust pipe and clamps if necessary. Ensure the exhaust pipe clamp is tight.
Electrical System
Check the internal and the external wire harnesses for damage (figure 7-10-45). Replace if
required.
Clean Air Intake
Check the combustion air inlet screen (figure 7-10-46) for restrictions. Clean as required.
Fuel System
Check the fuel system for damaged fuel lines or leakage. Make sure the clamps on the fuel
lines are secure.
Engine Batteries
Check the condition of the batteries and the power connections. The heater will not function
properly with weak batteries or corroded connections. If you are unsure of their condition, load
test each battery separately and replace as required. Clean terminals to remove all corrosion.
Operation Test
Run the system for at least 15 minutes or until the heater cycles OFF and then ON again.
Heater Wiring Diagram
The following represents the heater wiring diagram.
Heater Wiring Diagram (continued)
The following is a continuation of the heater wiring diagram.
Timer
General Description
The 7 day timer can be preset for a single start time, one day at a time or programmed start
times per day constantly activated for multiple days of the week. The clock can be preset for
12 or 24 hour time display. The heater run time duration can be preset for 1 or 3 hours. The
manual button can be used to override the program and run the heater indefinitely until it is
switched off.
Note:
1. The timer must be set for the drill system voltage.
2. If power to the timer is interrupted, the display will flash 12:00 am MON. in
12 hour format or 00:00 MON. on 24 hour format. Stored programmed times
will remain set in memory.
Heater Connection
Power to the controller must be disconnected before connecting the timer.
1. Connect the heater switch harness to the timer as follows:
a. Black to Black
b. Green to Green
c. White to White
d. Red to Red
Incorrectly wiring the timer connections may result in timer damage.
Wiring & Switch Settings
Before using timer, set the dip switch settings for your application.
Note: If the timer is connected to a heater which does not have an operational signal wire, then
the white timer wire must be jumpered to the green ON SIGNAL wire for the timers red ON
indicator to light (see figure 7-10-53).
To Set Clock (Time & Day)
1. Press and hold Clock.
2. Press Left Arrow Time Retard or Right Arrow Time Advance to set time.
3. Press Day to set day.
4. Release Clock .
Note: The 12 or 24 hour option is set using Dip Switch No. 1 on back of timer:
a. ON =12 hour mode.
b. OFF =24 hour mode.
c. (Factory preset: 12 hour mode)
To Set Single Timer Mode
1. Press and hold Timer. (Green light will go on and T1 will flash).
2. Press Left Arrow Time Retard or Right Arrow Time Advance to set ON
time.
3. Press Day to set day.
4. Release Timer . (Green light and T1 will remain lit to indicate active timer).
Timer set in the single timer mode only will allow you to set one ON time. With
the T1 time activated, the timer will go ON at the preset time and will be
deactivated at the end of its duration time. To reactivate the timer, press
Timer .
Note: When set time is reached, the heater switches on. Red and green lights
are on. The 1 or 3 hour duration option is set using Dip Switch No. 2 on back of
timer.
a. ON =3 hour duration.
b. OFF =1 hour duration.
c. (Factory preset: 3 hour duration)
To Set Dual Timer Mode
In the dual timer mode setting you can program your timer to come ON daily, Monday
through Friday, Monday through Saturday or Monday through Sunday. It also has a built in
repeat function so that you do not have to reactivate the timer after every duration time.
Note: In dual timer mode you can set T1, T2 or both T1 and T2. Timer mode option is set using
Dip Switch No. 3 on back of timer.
1. ON =single timer (T1 only).
2. OFF =dual timer (T1 and T2).
3. (Factory preset: T1 only)
1. Press and hold Timer. (Green light will go on and T1 will flash).
time.
3. Press Day to set day(s).
4. Release Timer . (Green light and T1 will remain lit to indicate active T1
program). T1 program is now activated. Follow steps 5 thru 8 for T2
program.
5. Press and hold Timer . (Green light will remain on and T2 will flash).
time
7. Press Day to set day(s).
8. Release Timer . (Green light and T2 will remain lit to indicate active T2
program).
9. Press Timer once more to activate both T1 and T2. (T1 and T2 will
remain lit to indicate active T1 and T2 program.)
Note: Timer will repeat each set day until switched off. Example: Drill timer set
T1 at 6:00 a.m. Monday thru Friday. Set T2 at 2:00 p.m. Monday thru Friday.
Timer will repeat each cycle each week until it is switched off.
Manual & Timed Heater Operation
The Manual button is used to turn the heater on and off when desired.
1. Press Manual to activate the heater. (Red light will go on and the heater will
operate indefinitely.)
2. Press Manual again to deactivate the heater. (Red light will go out and the
heater will turn off).
3. Note:
a. Manual and Timer cannot be active at the same time. If Manual is
active and Timer is pressed, the heater will turn off and the red light goes
out.
b. If Timer is active and Manual is pressed, Timer is deactivated and the
green light goes out.
c. When the heater has been turned on by the T1 Timer in a single timer
mode, the heater can be turned off by pressing either Manual or Timer.
Both red and green lights will go out.
d. If the heater has been turned on by the T1 or T2 Timer in dual mode,
pressing Manual will turn the heater off but leaves the timer(s) activated.
Pressing Timer will turn off the heater and deactivate the timer(s).
Diagnostics
When the timer is installed on a heater, the timers red Heater Activated Light will be lit
constantly while the heater is running normally. In the case of a heater error, the timers red
light will flash an error code followed by a pause.
Example: Repeatedly flashing five pulses separated by a pause indicates a heater voltage
error.
The heater error codes are as follows:
Table 20: Heater Error Codes
These errors correspond to those displayed on the Control Module diagnostic panel shown in
figure 7-10-6.
1 Flash Start Error
2 Flashes Flame Out
3 Flashes Coolant Flow
4 Flashes Overheat
5 Flashes Voltage
6 Flashes Flame Sensor
7 Flashes Temperature Sensor
8 Flashes Fuel Pump
9 Flashes Compressor
10 Flashes Ignition Coil
11 Flashes Coolant Pump
12 Flashes Blower
13 Not Used
7.11 Centro-matic Lube (Option)
Principle of Operation
The pump is operated by the time controller (see figure 7-11-1). The timer closes the electric
circuit to the solenoid air valve. The solenoid air valve opens and permits air to pass through
the air hose, operating the pump and closing the vent valve.
The pump continues to operate until the lubricant pressure in the supply lines is sufficient to
operate the injectors. After the injectors operate (discharge lubricant to bearings), the pump
continues to build up pressure in the supply lines until there is sufficient pressure to open the
pressure switch.
The opening of the pressure switch breaks the electric circuit to the solenoid air valve, which
shuts off air supply to the pump. At the same time the lubricant pressure opens the vent valve
and allows the supply line pressure to vent back into the lubricant drum. The injectors
automatically reload and the system is ready for next lubrication period.
Fill Supply Line
Refer to Figure 7.11.11 for additional information.
1. Remove pipe plugs from the injector manifold at the end of each run.
2. Set time delay relay to maximum position.
3. Place timer toggle switch in A position.
4. Close line switch to start pump.
5. Pump in operation will charge supply line with lubricant.
6. When lubricant begins to flow from the open end of injector manifold (injector
farthest from pump), open line switch to shut off pump.
7. Replace pipe plugs in all injector manifolds.
8. Re-adjust time delay relay to desired delay interval.
Prime Feed Lines
Operate the pump by rotating program disc clockwise by hand through one clip. Repeat
several times to be sure each injector is operating.
Figure 7-11-1
Operation Check
1. Open shut-off valve A which should be installed in the supply line adjacent to
the pressure gauge and pump as illustrated (See Figure 7-11-1). Allow the
pump to operate until the supply line pressure builds up to about 2500 PSIG
(for high pressure units) as indicated on the pressure gauge B or 850 PSIG
(for low pressure units).
2. Close the shut-off valve A and this will trap the lubricant pressure in the supply
line. Each individual injector can now be inspected for the correct discharge
position of the indicator stem.
Note: Pressure reading on the pressure gauge should remain constant after the shut-off valve
is closed. A pressure decline on the pressure gauge indicates a leak in the supply line.
After the system has been checked, open the shut-off valve and the system is ready for
the desired lubrication cycles.
Set timer to program the lubrication cycle frequency.
Failures without Alarm Systems
Table 21: Control Failures
Time Control Failures (for systems without an alarm system)
System Failure Symptoms Possible Cause
Pump does not start with selector switch
in position A or B.
1. Faulty Control Relay.
2. Faulty Time Delay Relay.
3. Switch Arm held down at all times
4. Faulty A-B Selector Switch.
5. Faulty Timer Switch.
6. Faulty Pressure Switch.
Pre-lube cycle normal with selector switch
in position A but no timed function
occurs with selector switch in either
position.
1. Faulty Timer Motor.
2. Switch Arm is not fully depressed.
3. Faulty Timer Switch.
4. Dial clips not positioned in inner
groove.
No operation with selector switch in
position A, normal operation with
selector switch in position B.
1. J umper wire at terminals 5 and 6
removed.
3. Faulty Selector Switch.
No operation with selector switch in
position B, normal operation with
selector switch in position A.
3. Faulty Selector Switch.
Repeat cycle with selector switch in either
position.
Table 22: System Failures
Failures with Alarm Systems
Table 23: Control Failures
Repeat cycle with selector switch in
position A only or in position B only.
System Failures (for systems without an alarm system)
Pump fails to start. 1. System pressure does not vent.
System does not reach full pressure. 1. Pressure Switch set too low.
Time Control Failures (for systems with an alarm system)
Pump fails to start. 1. Faulty Time Delay Relay.
System does not reach full pressure. 1. Faulty Time Delay Relay.
2. Time Delay Relay set too fast.
Pump fails to start. 1. Faulty Air Solenoid Valve.
2. Insufficient air pressure.
3. Faulty pump motor.
System does not reach full pressure. 1. Faulty pump.
2. Insufficient air pressure.
3. Pump has lost its prime.
4. Open Safety Unloader.
5. Broken or leaking lube supply line.
6. Pressure Switch set too high or faulty
Pressure Switch.
Time Control Failures (for systems without an alarm system)
7.12 - Bean (FMC) Water Injection Pump
Service Procedures
NOTE: FMC pumps are designed to simplify all required maintenance.
The following sections illustrate a step by step procedure for performing
most common service needs of a pump. Read and understand each
section completely before attempting to service the pump.
Replacing Piston Cup Seals
1. Remove fluid chamber from pump by removing the three cap screws holding it
to the power frame, then lift off the top of the ceramic cylinders.
2. Remove the cap screw and piston retainer from each of the two cylinders.
3. Lift the ceramic cylinder off from the top of the power frame. Friction will usually
keep the piston inside the cylinder as it is removed. Once the cylinder and
pistons are off the pump, take them to a bench and press them out from the top.
4. Inspect all o-rings, gaskets, seals, and other components for signs of damage
or wear. Any damaged components should be replaced at this time. Inspect
cylinder liners for cracks or grooves by running thumbnail around the bore of
the cylinder. Replace if grooves are detected. New cups will wear quickly if
operated in cylinders with rough or grooved bores. Note: to provide maximum
operational time between service, FMC recommends that both piston cups, not
just the one that shows signs of leakage, be replaced whenever piston service
is required.
5. Insure that the umbrella fluid shield is not damaged. A damaged umbrella could
allow fluid to contaminate the power end oil. If the umbrella requires
replacement, the best way to remove it from the pump is to cut it free with a
sharp knife.
6. Note: it is recommended that all gaskets or o-rings be replaced at each piston
cup service interval.
7. If new umbrellas are required, fold the plastic as shown and insert through the
opening and over the ends of the plunger rod. For easier installation of the
umbrella, immerse in hot water for 2-3 minutes to soften. Press tops of
umbrellas to place pilot washers over ends of plunger rods with groove in up
position.
8. Place o-rings and packing holders in position on ends of plunger rod.
9. Place ceramic cylinders and gaskets in counterbore in power frame.
10. Apply light oil or glycerin around the OD of the piston cups, then place them in
the open end of the cylinders. Use the thumb to press the cups down firmly into
the holder of each cylinder.
11. Insert the cup retainers into the cylinders with the ribbed side facing the piston
cup.
12. Secure packing assembly using cap screws. Torque as per specification n the
Fastener Torque Requirements section.
13. Insert top gasket (or o-ring and ring seal) in fluid chamber counterbore using
heavy oil or grease to hold in place.
14. Return fluid chamber to position over cylinders and insure that all seals are in
place.
15. Replace fluid end cap screws. Torque cap screws in 3 stages to values shown
in the Fastener Torque Requirements section.
Replacing Suction and Discharge Valves
1. Remove cap screw and valve cover clamp from the front of the fluid chamber.
2. Insert the end of a standard screwdriver into the valve cover groove and pry the
valve cover away from the fluid chamber.
3. Remove the discharge valve disc-spring assembly and the perforated valve
cage from each of the two-(2) pump cylinders.
4. Use a finger to reach through the opening at the center of the seat and work
the seat loose from the chamber. Note, the optional valve seat removal tool
(FMC part number 1250638) may be used to simplify this procedure.
5. Use the same procedure to remove the suction valve cage and valve seat,
which are located directly under the discharge valve seat.
6. Inspect all valve components and replace as necessary. Note that even small
damage or erosion to the sealing area of the valve or the o-ring can adversely
affect the performance of the pump.
7. With the o-ring in place on each valve seat, place a few drops of light oil around
the o-ring to aid in installation. Place each valve seat SQUARELY in the
counterbore in the bottom of the fluid chamber.
8. Place the valve cage on the valve seat and insert the disc/spring assembly
inside of the cage on the valve seat.
9. Repeat the previous two (2) steps to install the discharge valve seat and the
discharge valve cage.
10. Place the valve covers (with o-rings on BOTTOM groove) in place over the
valve assembly.
11. Replace clamp bar and cap screw and torque per specification as values
shown in the Fastener Torque Requirements section. Note: Over-tightening the
cap screw can damage the valve components.
Replacing the Power End Bearings
1. Remove bottom drain pipe plug and drain all oil from power frame.
2. Disconnect suction and discharge piping, power source, and remove pump
from mounting base.
3. Although it is not required, it is easier to remove the crankshaft if the fluid end
and pistons have been removed. To remove the fluid end, follow steps 1-3 of
the section titled Replacing Piston Cup Seals.
4. Remove the six (6) hex head cap screws, washers, and mounting base from
rear of pump. When removing the mounting base from the pump, be careful not
to damage oil seal gasket as the mounting base is broken loose.
5. Remove cap screws from the connecting rod assemblies and take out the back
half of the connecting rod shell bearing. Note the orientation of the machine
markings on the connecting rod and cap. Connecting rod halves are not
interchangeable and must be reassembled in their original positions.
6. Remove the oil slinger from the crankshaft.
7. Push the connecting rods and crosshead assemblies as far forward into the
power frame as possible to provide clearance for the crankshaft.
8. Once the crankshaft is clear of the connecting rods, remove forward half and
the split connecting rod bearing.
9. Use snap ring pliers to remove the crankshaft retainer snap ring from each side
of the pump.
10. Using a hammer and wood block or rubber mallet, drive the shaft and bearings
out either side of the power frame.
11. Remove bearings from crankshaft using a press. Be sure to provide suitable
support for the back side of the bearings during this step. Note: Never pound
directly on the bearings or they may be damaged.
12. Carefully clean and inspect all parts. Replace worn or damaged components
as necessary.
13. Install crankshaft with (new) bearings into the power frame.
14. Place the oil seals over the ends of the crankshaft with the lip of the seals facing
the inside of the power frame.
15. Seat the snap rings in the grooves in the bearing housing against the oil seals
and tap the crankshaft to allow a SLIGHT end play in the crankshaft.
16. Reassemble the connecting rods and shell bearings around the crankshaft.
The connecting rod and cap are a matched set. Be sure to properly match the
connecting rods and caps back into their original position and orientation.
Torque connecting rod bolts as shown in the Fastener Torque Requirements
section of this manual.
17. Complete the reassembly by reversing steps 1-8. Torque mounting base cap
screws as shown in the Fastener Torque Requirements section of this manual.
Be sure to replace the drain plug in the mounting base.
18. Refill the power frame with oil and turn the shaft over several revolutions by
hand. When piston cups are not installed the pump shaft should rotate freely.
Servicing the Wrist Pin Bearings
1. Remove fluid chamber, cylinders, and piston cups using steps 1-3 from the
Replacing Piston Cup Seals section, and the crankshaft as described in steps
1-10 of the section entitled Replacing the Power End Bearings.
2. Once the crankshaft has been removed the connecting rod and crosshead
assembly can be pulled from the back of the power frame opening.
3. The wrist pin is a slip fit through the connecting rod and crosshead. Check for
signs of wear on the pin and connecting rod bushing. Replace the pin if
noticeable wear is found. The complete connecting rod assembly must be
replaced if the bushing is worn, as the wrist pin bushing is not field replaceable.
4. Reverse the sequence from steps 1-3 when reassembling the crosshead rod
and cap. Insure that these parts are reassembled in their exact former
orientation and position.
Fastener Torque Requirements
NOTE: No pump service procedure is complete without insuring that the
fasteners have been properly torqued. Failure to properly tighten the
pump bolting could cause the pump to leak or even allow the bolts to fail.
Always use a calibrated torque wrench during the installation of all
critical fasteners listed below.
Trouble-Shooting Piston Pumps
NOTE: This chart is designed to aid in the solution of pump and pump
system problems. Once the problem has been identified, work through
the possible causes and solutions until the problem has been corrected.
1. No flow from pump
Tank is empty
Inlet valve is closed
Inlet strainer is clogged with debris
Crankshaft is not turning
2. Insufficient pressure from pump ONLY
Pump speed is too slow
Relief valve improperly adjusted and by-passing fluid
Oversize or worn nozzle on equipment
Worn pump valves
Excessive leakage from pump seals
3. Insufficient flow from pump ONLY
Pump speed is too slow
Relief valve improperly adjusted and by-passing fluid
Worn pump valves
Excessive leakage from pump seals
4. Insufficient flow OP pressure AND rough operation
Valve problem:
a.Pump valve stuck in open or closed position
b.Valve assembly is damaged or unseated
c.Valve seat is washed out
All pump cylinders not primed
Inlet strainer is clogged with debris
Excessive gas in liquid due to:
a. Air leaks in suction line or fittings
b. High spots in suction line that allow formation of gas pockets
c. Vortex in tank near inlet pipe opening
Pump is cavitating due to:
a. Insufficient NPSHa (tank head or charge pressure)
b. Fluid viscosity is too high
c. Inlet line is too long and/or too small diameter
5. Pump runs rough, knocks, or vibrates ONLY
Loose piston assembly
Valve assembly is damaged or has unseated
Pump is cavitating due to:
a. Insufficient NPSHa (tank head or charge pressure)
b. Fluid viscosity is too high
c. Inlet line is too long and/or too small diameter
Worn or damaged power frame components
Pump is sucking air across worn piston cups during suction stroke (usually only
observed on pumps that due not have a booster pump)
6. Suction pressure fluctuates rapidly
Pump is cavitating
7. Fluid leaking from pump
Piston cups are wearing and about to fail
Fluid cylinder bolts are not properly tightened
Fluid cylinder o-rings (or gaskets) are damaged
Piston assembly o-rings are damaged
8. Short piston seal life
High abrasive particle content in fluid
Wrong style or type of piston for service
Piston liner is damaged
Pump is cavitating (cylinders may run hot)
Piston assembly o-ring is damaged
Poor quality water used (sources like lakes, streams, or fire hydrant that has not
been purged)
Pump is allowed to run dry for extended periods of time
Liner wash system not properly maintained (if equipped)
9. Short valve life
High abrasive particle content in fluid
Valve assemblies only partially rebuilt during previous service
Valve assemblies damaged do to improper installation techniques
Poor quality water used (sources like lakes, streams, or fire hydrant that has not
been purged)
Pump is cavitating
10. Cracked fluid cylinder
Discharge pressure too high
Pump exposed to freezing conditions without properly draining
Hydraulic shock resulting from cavitation or entrained air
Discharge valve is stuck shut
Material or manufacturing defect
11. Crankshaft jerks or starts and stops rotation
V-belts are loose and slipping (if equipped)
Hydraulic system relief valve is chattering (if equipped):
a. Attempting to operate pump at excessively high discharge pressure
Discharge line is blocked or partially obstructed
12. Power end overheats (in excess of 180 F)
Low oil level
Improper oil viscosity
Contaminated power end oil
Pump speed is too fast
Pump is running backwards
Couplings are misaligned
V-belt drive tension is too tight
Pump located too close to heat source
Worn or damaged power frame bearings
13. Broken crankshaft or connecting rod
Pump exposed to freezing conditions without proper draining
Suction pressure too high
Hydraulic shock due to cavitation
Material or manufacturing defect
14. Broken Fluid End Bolts
Bolt or nut properly torqued
Excessive piping loads on fluid end
15. Power end oil is contaminated
Pump has been operated with failed piston cup for extended periods of time
Use of high-pressure wash wand to clean near breather or oil seal areas
Deflector shields are missing or damaged
Crosshead extension oil seals are damaged or improperly installed
Excessive capacity in liner wash system
Improperly adjusted liner wash nozzle
SECTION 8 - GLOSSARY
DM45,DM50,DML Instruction Manual Section 8 - GLOSSARY
8.1 - Glossary Of Terms
~A~
Actuator
A motor or cylinder that is being put into motion by the flow of a hydraulic pump.
Adapter-Adaptor (both spellings are accepted)
A device used to connect two different sizes or types of threads. It is used to connect
rotary head spindles to drill pipe, drill pipe to stabilizers and stabilizers to drill bits.
ANFO
Ammonium Nitrate Fuel Oil mixture: explosive most commonly used in blastholes.
Annulus
The space between the drill pipe and the outer diameter of the hole made by the bit.
Annunciator
An electrical signaling device on a switchboard.
API
American Petroleum Institute.
ASME
American Society of Mechanical Engineers.
ASTM
American Society of Testing Materials.
Auto Lube System
A pump that provides grease to various components of the drill through hoses. It can
be manual or computer controlled.
Axle (Main Shaft)
The tube connecting the tracks of a Blasthole drill to the main frame.
~B~
Bank
Vertical surface of an elevation; also called face.
Beco Thread
A coarse type of thread used on drill pipe for blastholes.
Bench
Work area on top edge of an elevation. The work area for blasthole drills.
Section 8 - GLOSSARY DM45,DM50,DML Instruction Manual
Bit, Auger
A type of bit used to drill soft formations. It usually has a series of flutes on the outside.
Bit, Claw
A wing-type bit that has multiple flukes. Sometimes called a Drag Bit.
Bit Breaker
A device installed in the centralizer table to hold a bit stationary while the drill pipe is
being removed from the bit by reversing the rotation. Also called Bit Basket.
Bit, DHD
A solid, one piece bit, with shaped tungsten carbide inserts in the face. Used in
percussion drilling.
Bit, Roller
Also called a Tricone bit. It usually has three conical rollers fitted with steel or tungsten
carbide teeth that rip the rock loose using down pressure.
Bits
Tools that pulverize formations so that material can be removed from the hole.
Generally 3-blade, 3-cone or percussion.
Blasthole
A drilled hole used for purposes of excavation rather than exploration, geological
information or water wells. Usually limited to 200 feet.
Blasting
The act of igniting explosives in a borehole to produce broken rock.
Blowdown
Term used when releasing compressed air from the receiver tank on a compressor
when the drill is stopped.
Blowdown Valve
The valve that opens when the drill is stopped and releases all the air pressure in the
receiver tank.
Bore
To make a hole in the ground with a drill.
Borehole
The hole made by a bit.
Box End
Fitting on the female end of a drill pipe. See Pin End.
Breakout
Refers to the act of loosening threaded pipe joints; and of unscrewing one section of
pipe from another, while coming out of the hole.
Breakout Wrench
A wrench, connected to a hydraulic cylinder, used to turn the upper piece of pipe while
the lower pipe is being held by the Fork Chuck or Sliding Wrench.
Bridge
An obstruction in the hole. Usually caused by a caving formation or something falling
in the hole.
Burden
Distance from the blasthole to the nearest face. Distance measured from face to a row
of holes.
Buttons
Short, rounded teeth of sintered tungsten carbide inserts which serve as teeth in drill
bits used for drilling very hard rock.
Butterfly Valve
The inlet valve of the air compressor.
Burden
Distance between a blasthole and the nearest free or open face; the material to be
displaced.
~C~
Cable
A strong, heavy steel, wire rope. Also known asWire Rope. Used for pulldown and
pullback in the derrick. Also used in hoisting. May be rotating or rotation resistant.
Cable Reel
A device that holds the electrical power cable on electric driven blasthole drills.
Carousel
A rotating device that holds extra drill pipe. It can be moved under the rotary head to
add and remove drill pipe from the string, or the rotary head moves over it.
Carbide, Tungsten
W
2
C. A very hard compound used in inserts in rock bits. It has a very high melting
point. It is very strong in one direction but very brittle in another.
Casing
Special pipe used to hold the overburden back in water wells. May be steel or plastic.
Casing, Drive Shoe
Coupling of forged steel to protect lower end of casing in overburden.
Cathead
Rotating drum used to spool hemp rope to pick up tools manually.
Catwalks
Walkways around a working area of a drill.
Cavitation
The pitting of a solid surface by the formation of low pressure bubbles formed in the
fluid. Air being allowed into the inlet of pumps.
Centralizer Bushing
A circular ring installed around the drill pipe in the drill table to keep the pipe aligned
properly with the rotary head. It usually has a replaceable insert in the center.
Chain Wrench
A special wrench, consisting of a chain section and a metal vee section, with jaws, that
grips the drill pipe and/or the DHD to tighten or loosen the connections.
Clinometer
A device for measuring the angle of the drill pipe with the ground. Also referred to as
an Inclinometer.
Collar the Hole
Opening at the top of the blasthole; the mouth where rock has been broken by blasting.
Usually the first few feet of the blasthole that are cracked and broken.
Compressor
An asymmetrical rotary screw driven device for compressing air. May be single or two
stages, depending on the discharge pressure.
Console
The panel that contains most of the drills controls. Also called the Operators Panel.
Conventional Mud
A drilling fluid containing essentially bentonite clay and water.
Conveyor
Equipment used to carry material to crushers and screens for reduction and
separation.
Cooler (HOC, COC)
Most drills have two coolers; one for the hydraulic fluid and the other for the
compressor oil. The engine radiator is sometimes referred to as an engine cooler.
Coring
The act of procuring a sample of the formation being drilled for geological information
purposes.
Coupling
A connector for drill rods, pipe or casing with identical threads, male or female, at each
end.
Cribbing
A set of wooden ties or metal plates used to add surface area to the jack pads to
prevent the pad from sinking into the ground. Also called blocking.
Crown Sheaves
The upper sheaves in a derrick that supports the cable that connects to the rotary
head.
Crosshead
The outer metal can surrounding the leveling jack cylinders. The crosshead slide is
the lower portion that connects to the bottom of the cylinders and the crosshead cap
is the flanged piece on top of the crosshead.
Crusher
Device used to reduce broken rock to a smaller fragment size.
Cut (verb)
Process of excavating material to lower the level of part of an elevation.
Cut (noun)
Part of an excavation of a specified depth an width.
Cuttings
Particles of formation obtained from the hole during drilling operations.
~D~
Decking
Process of alternating explosives with inert material in a blasthole to properly distribute
explosives or reduce vibrations. Also refers to the metal catwalks around the outside
of the drill.
Deephole
Rotary drills used to drill water wells, exploration holes and monitoring holes.
Delay Interval
Elapsed time between detonation of individual blastholes in a multiple hole blast.
Derrick
A tall framework over a drilled hole used to support drilling equipment. The part of the
drill that contains the feed system and the rotary head. See Tower and Mast.
DHD
Down Hole Drill. An air driven, piston powered device for drilling hard rock. It is also
called a Hammer (also called DTH).
DHD Bushings
The split bushings used to maintain alignment of the DHD while passing through the
drill table. See Split Bushings.
Differential Pressure
The difference in pressure between the inlet and outlet of a component, i.e., a cooler.
Dip
The angle between a horizontal plane and the plane of the ore vein, measured at right
angles to the Strike.
Diverter Valve
A two position, three way, valve that allows one hydraulic pump to perform two
separate functions.
Dressing a Bit
Sharpening DHD drill bits with a grinder to shape the carbides.
Drifter
An out-of-the-hole drill that rotates the drill rod and provides a percussive force, by
means of a striking bar, through the rod to the bit.
Drill
A machine for drilling rock, or unconsolidated formations. Also called a Rotary Drill.
The act of boring a hole in the ground.
Drill Collar
A heavy, thick-walled section of pipe used to add drilling weight to the bit and stabilize
the drill string.
Drill Rod
See Drill Pipe. Hollow, flush-jointed, coupled rods used on small percussion type rock
drills. Used with drifters mostly
Drill Pipe
Hollow tubing, specially welded to tool joints, used in drilling larger holes than drill rods.
Drill/Propel Valve
A switch that shifts the diverter valves to allow pump flow to go from drill functions to
propel motors.
Drill String
The string of pipe, including subs, stabilizers, collars and bit, extending from the bit to
the rotary head, that carries the air or mud down to the bit and provides rotation to the
bit.
Driller (Operator)
The employee directly in charge of a drill. Operation of the drill is their main duty.
Drill Table
The area at the bottom of the derrick that contains the centralizer bushing or master
bushing that the drill pipe travels through.
DTH
Down The Hole. Process of drilling with a pneumatic hammer at the bit end of the drill
string. Also called hammer drilling, percussion drilling, and down hole drill.
Dust Collector
A vacuum device with a hose attached to the dust hood that pulls cuttings away from
the hole and deposits them to the side of the drill.
~F~
Face
Vertical surface on an elevation. Also called bank.
Feed Cable
Cables, anchored on the top and the bottom of the derrick, that pass through the
traveling sheave block and connect to the top and bottom of the rotary head. They are
adjusted by tightening the threaded rods on each end.
Feed Chain
Heavy duty chain links connected to the rotary head through upper and lower
sprockets and the traveling sheave block. They are adjusted similar to cable.
Fill
Process of moving material into a depression to raise its level; often follows the cut
process.
Fish
An object accidentally lost in the hole.
Fishing
Operations on the drill for the purpose of retrieving the fish from the hole.
Fishing Magnet
Run in the hole on non-metallic line, to pick up any small pieces of metal.
Fishing Tools
Tools of various kinds run in the hole to assist in retrieving a fish from the hole.
Overshots fit over the pipe while Taps fit inside the pipe.
Flats
Machined areas on the side of drill pipe or other components where wrenches can be
installed to hold or break the joints. Some pipe has two flats, others have four flats.
Floor
Level area at the base of a bank or face.
Fork Chuck
The hand held or flop-down wrench used to hold the top of the pipe in the Drill Table
while adding or removing other pipe.
~G~
Grouting
To fill the hole or annulus with grout, i.e., cement and water.
~H~
Hammer
A different name for a Down Hole Drill (also called DTH drill).
Hammer Bushing
Split bushings installed in the drill table to allow the DHD to start the hole in a straight
line. It is removed once the DHD is below the table. Also called DHD Bushings.
Haul Distance
Distance material has to be moved, such as from a cut to a fill.
Hauling Equipment
Trucks and other conveyances for moving material. Also called Haul Trucks.
Hazard
Any condition of the drilling equipment or the environment that might tend to cause
accidents or fire.
Hoist
Windlass used to pick up drill pipe and other heavy objects. See Winch.
Hoist Plug
A lifting device installed in the box end of a tool. Opposite of Lifting Bail.
Hole
A bore made by rotating a bit into the ground.
Hole Openers
Large bit with pilot used to increase the diameter of a hole.
Hose, Drilling
Connects rotary head to top of hard piping to allow movement of rotary head. Also
called Standpipe Hose.
Hose, Suction
Attaches to mud pump inlet with other end submerged in mud pit.
Hydraulic Cylinders
Double acting cylinders that are extended and retracted to perform various functions
on a drill. They are powered by hydraulic fluid from a pump.
Hydraulic Motors
Piston or vane type motors, driven by hydraulic pumps, that rotate various devices on
a drill.
Hydraulic Pumps
Piston, vane and gear type hydraulic pumps that provide flow for the various actuators
on the drill.
Hydrostatic Head
The pressure exerted by a column of fluid, usually expressed in pounds per square
inch.
~I~
Inclinometer
An instrument for measuring the angle to the horizontal or vertical of a drill hole or vein.
I.W.R.C.
Abbreviation for Independent Wire Rope Center. This refers to type of construction of
wire rope. This wire rope center is in effect a separate wire rope in itself that provides
a core for the line and prevents it from crushing.
Interstage Pressure
The air pressure present between stages of a two-stage compressor while the
compressor is making air.
~J~
J Wrench
Specially shaped wrench to fit the backhead of a DHD. Used to hold DHD in the table
or to remove the backhead from the wear sleeve.
~K~
Kelly Bar
A fluted or square drill pipe that is turned by a rotary table using a set of pins.
~L~
Leveling Jacks
Hydraulic cylinders mounted in a crosshead that raise and lower the drill.
Also referred to as Outriggers or Stabilizers.
Lifting Bail
A threaded cap for picking up pipe, bits, DHDs and stabilizers. It screws on the pin end.
Some bails have a swivel hook while others have solid tops. See Hoist Plug.
Loaders
Large, front end bucket equipment used to pick up material for loading in various types
of hauling equipment.
~M~
Main Frame
The welded component of a track mounted drill. The truck frame on a wheeled drill.
Makeup
The act of tightening threaded joints. Making a connection.
Making Hole
The act of drilling.
Making Up a Joint
The act of screwing a joint of pipe into another joint or section of pipe.
Manifold
A pipe or chamber that has several openings for hose connections.
Mast
A vertical pole. See Derrick.
Micron -:- Mu
A unit of length equal to one millionth part of a meter, or one thousandth part of a
millimeter. About 4/100,000th inch.
Mid-Inlet Swivel
Device for removing cuttings from the hole while drilling with Reverse Circulation
Equipment.
Mine Plan
Plan for making cuts and creating elevations, benches for efficient removal of material.
The mine plan considers a variety of factors, including: the type and location of
material, the size and number of shovels, loaders, and hauling equipment, haul
distances, blasthole patterns, etc.
Mist Drilling
A method of rotary drilling where water is dispersed in the air as the drilling fluid.
Module
Component of the RCS control system that either reads electrical signals from senors
and or sends commands to actuators. Also called I/O module.
Mud
A water or oil -base drilling fluid whose properties have been altered by solids. Mud is
a term commonly given to drilling fluids. It is used in place of air when drilling
unconsolidated formations.
Mud Drilling
Using a bentonite clay and water as the drilling fluid.
Mud Pit
A hole dug in the ground or a steel pit to hold the drilling mud as it is being circulated
in the hole.
Mud Pump
Pumps that are used to circulate the drilling mud.
~O~
Oscillation Yoke
The beam connecting each track of a blasthole track drill with the main frame that
allows the tracks to move independently up and down.
Open Hole
Any uncased portion of a hole.
Operator
The person who performs the drilling operation with the drill. See Driller.
Overburden
Any unconsolidated material lying on top of the bedrock or the coal seam.
~P~
Parasitic Load
The load imposed on the engine by the direct connection of the compressor and main
pump drive during starting.
Pattern
Layout and distances between blastholes, specifically including burden and spacing.
Penetration Rate
Speed at which a bit advances while drilling, measured in feet per hour.
Percussion Drill
Drill that chips and penetrates rock with repeated blows.
Pin End
Fitting on male end of drill pipe. See Box End.
Pioneer Work
Drilling in rough, broken or inclined areas. Removing the original layers of dirt and
rock.
Pipe Dope
Special lubricant used to protect the threads on pipe joints. See Thread Lube.
Pipe Support
A device that holds the lower section of pipe in place while connecting to the next joint
with the rotary head when angle drilling. Also called Rod Support.
Pit
An excavation in the ground for the removal of mineral deposits.
PLC
Programmable Logic Controller. A device that monitors many aspects of a drills
operation.
Potable Water
Water that is safe to drink.
Powder Factor/Specific Charge
Relationship between the weight of explosives in a blasthole and the volume of
materials to be displaced. It is measured in pounds per cubic yard or kilograms per
cubic meter.
Power Pack Base
The welded channel frame that contains the prime mover, the compressor and the
hydraulic pumps and gearbox.
Power Pack
he complete sub-assembly of base, engine, compressor, and hydraulic drive.
Presplitting
Process of drilling a line of small diameter holes spaced relatively close together,
generally before drilling a production blast and loaded with light explosive charges to
create a clean, unbroken rock face.
Production Rate
Penetration during a given reporting period. This rate includes all lost time, including
maintenance, breakdowns, long moves, inclement weather, etc.
Propel
To cause to move forward or onward. To drive or tram.
Protectors, Thread
Steel or plastic covers to cover the box and pin ends of drill pipe when they are not
being used.
Pump, Water Injection
Pump used to pump water into the drill air stream to keep the dust settled and to assist
in flushing the hole.
Pullback
The force available to remove the drill string from the hole.
Pulldown
Force exerted on the drill bit by the thrust of the drill rig and from the weight of the drill
string.
~Q~
Quick Fill
This is a central location where fluids can be filled on a drilling rig. Fluids can be both
drained and filled while the machine is running. Also called Fast service, Wiggins
Quick Fill.
~R~
Raise
A mine opening, like a shaft, driven upward from the back of a level to a level above,
or to the surface.
Rate Of Penetration
The rate in which the drill proceeds in the deepening of the hole. It is usually expressed
in feet per hour.
RCS
Rig Control System. This is an advanced operating system for drilling rigs. It utilizes
computer control, levels of automation, production reporting, and can network.
Reamer
Bit-like tool, generally run directly above the bit to enlarge and maintain a straight hole.
Reservoir
The tank used for storing the hydraulic oil used in the hydraulic system.
Reverse Circulation Drilling
Using a double wall pipe to force air/water down the hole and removing the cuttings
between the two pipes. See Mid-Inlet Swivel.
Rod Changer
See Carousel. A device that holds extra drill rod (pipe).
Rotary Drilling
The method of drilling that depends on the rotation of a column of pipe to the bottom
of which is attached a bit. Air or fluid is circulated to remove the cuttings.
Rotary Head
A movable gearbox used to provide rotation to the drill string. It is connected to the
feed chains or cables on each end and to the drill string through the spindle.
~S~
Safety Hook
Attached to end of hoist line to secure hoist plug or lifting bail. Has a safety latch to
prevent load from slipping off hook.
Scales
Equipment used to determine the weight and value of material being transported from
a quarry.
Screens
Devices used to separate broken material into groups of similar size.
SEOH
Standard Electric Over Hydraulic. This is a operation system for blast hole drill.
Shock Sub
A device used to isolate the shock of drilling from the rotary head. It is made of hard
rubber layers mounted inside of steel outer rings.
Shooting
Exploding high explosives in a hole to shatter the rock. See Blasting.
Single Pass Drill
Drill rig with a long tower that permits drilling a blasthole without stopping to add drill
pipe (rod). Uses a Kelly in place of regular pipe. Uses a rotary table to turn the Kelly
instead of a rotary head.
Stemming
Material of a specified depth added on top of a powder column to confine the blasthole
and make the explosion more efficient.
Strip Mine
A large section of land used to remove coal deposits.
Shot
A charge of high explosives deposited in a series of holes to shatter the rock.
Shutdown
A term that can mean the end of the shift or workday or an unplanned stopping of the
drill due to a system failure.
Sliding Fork
A wrench that slides around the flats of the drill pipe to hold lower section. Controlled
by hydraulic cylinder(s). Used in place of Fork Chuck.
Slips
Used in the rotary table to hold and break out drill pipe. Also used to hold casing in the
table.
Spacing
Distance between blastholes measured parallel with the face.
Spear
Tools of various design that are screwed or wedged inside of bits, pipe, etc., that are
lodged in the hole. See Fishing Tools.
Spindle
The short section of pipe that rotates within the rotary head and protrudes out each
end.
Speed Switch
An electronic device that changes states when the engine reaches a certain speed.
Used to control dual oil pressure switches.
Split Bushings
The removable bushings that allow the DHD or Stabilizer to pass through the drill table
while drilling a straight hole. See DHD Bushings.
Stabilizer, Drill Pipe
Heavy -walled pipe having special spiral or fluted ribs extending around the diameter,
within 1/8 to 1/4 of hole size. Most stabilizers are fitted just above the bit, while in-line
stabilizers keep the hole straight.
Standpipe
Part of the circulating system. The hard and flexible piping from the main valve to the
flexible hosing leading to the rotary head. Water injection, DHD oil and foam are
injected into this line.
Static Water Level
The distance from the top of ground down to the standing water level.
Strike
The bearing of the outcrop of an inclined bed or structure on a level surface. See Dip.
Stuck In The Hole
Refers to drill pipe inadvertently becoming fastened in the hole.
Subdrilling
Bottom portion of a blasthole drilled below the floor level to permit upward
displacement of material and thereby prevent a toe at the bottom of a face.
Substitute (Sub)
A coupling with different type or diameter of threads at either end. The term pin
denotes a male thread, and box, a female thread. To connect two components with
different threads. See Adapter.
Supercharge Pressure
Inlet oil pressure to the main pump(s) that has been pressurized to prevent cavitation.
Swivel
A coupling on top of the rotary head to allow the spindle to rotate while the main hose
remains stationary.
~T~
Table Drive
Drill design that locates the drill pipe rotation mechanism on the drill deck in a
stationary position instead of using the rotary head.
Threaded and Coupled Casing (T&C)
Steel casing using a coupling between each section of pipe. Thread style is right hand,
fine thread.
Thread Lube
A special compound used to lubricate the threads of drill pipe. See Pipe Dope.
Tongs
A type of wrench used to make up and break out drill pipe using external forces, such
as hydraulic cylinders or cables.
Tool Joint
A drill pipe coupler consisting of a pin and box of various designs and sizes. Deephole
drills normally use API style threads, while Blasthole drills use Beco style threads.
Top Head Drill
Drill design that locates the drill pipe rotation head in the drill tower and it moves up
and down with the drill string. See Rotary Head.
Torque
A turning or twisting force. A moment caused by force acting on an arm. A one pound
force acting on a one foot arm would produce one lb-ft of torque.
Tower
A tall, slender structure used for observation, signaling or pumping. See Derrick and
Mast. Term used to indicate the derrick on a blasthole drill.
Turning To The Right
Slang term for making hole.
Tram
A cable car or a four-wheeled open box in a coal mine. See Propel.
Trammed
To move in a tram.
Tramming
Process of moving a drill with the tower up from a completed blasthole to the location
of the next. See propelling
Traveling Sheave Block
A series of sheaves, connected to the feed chains or cables, that are moved up and
down the derrick by the feed cylinders.
Twist Off
To twist a joint of pipe in two by excessive torque applied by the rotary head or rotary
table.
~U~
UL88
The unloader valve that controls pressure and volume on a high-pressure compressor
system.
Undercarriage
The means of moving a track type vehicle. It contains the track frame, rollers,
grousers, rock guards, drive sprocket, propel motors and planetary drive.
Uphole Velocity
The speed (in feet per minute) that the cuttings travel out of the hole.
This is dependent on the bit size, the compressor size and the pipe size.
~W~
Washpipe
Hard surfaced steel tubes inserted in swivels to allow rotation of drill string and prolong
life of packing. They are replaceable in most swivels.
Water Table
The underground level at which water is found. See Static Level.
Water Well
A hole drilled for the purpose of obtaining potable water.
Weight On Bit
In rotary drilling, a specified weight is required on the bit for maximum performance. A
gauge on the console is calibrated to correspond to the drill string weight.
Whipstock
A device inserted in the well used for deflecting or directional drilling.
Wiggins Quick Fill
A Centralized Service Station that connects to various systems on the drill to allow
remote filling of engine oil, compressor oil and hydraulic oil.
Winch
A stationary hoisting machine having a drum around which is wound a rope.
Wiper, Pipe
An annular rubber disk for wiping drill pipe clean of cuttings when it is being withdrawn
from the hole.
Wire Rope
Rope made of twisted strands of steel wire. Also called Cable.
8.2 - Manual Revisions
Table 1: Latest Revision DM45,50,DML Manual
REV.
NO.#
REVISED BY DATE REVISION
002 10/2005
003 J ames Oney 07/01/2010 Up-dated Complete Manual
004 J ames Oney 03/01/2011 Revised temperatures section 3 (pg.3-
4), added Item 5 section 5 (pg. 5-74),
added new Torque Specifications
section 6.14.
005 J ames Oney J uly 2011 Added Electrical Safety on Drill
Machines, Section 2.
006 J ames Oney October 2011 Added Stowing Hoist Hook and
Sliding Fork Information Section 2.
Up-dated Section 7.8 Dixon Boss
Clamp Installation Instructions and
Added Section 7.9 IC Clamp
Installation Instructions
Atlas Copco Drilling Solutions, LLC
A Company Within the Atlas Copco Group
P.O. Box 462288, 2100 North First Street
Garland, Texas 75040 USA
www.atlascopco.com/drillingsolutions
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