Cat MD6420 Rotary Blasthole Drill Service Manual - PDF DOWNLOAD by www.heydownloads.com

November 2015 EM005781-1

Service Manual MD6420 Rotary Blasthole Drill DS7 1-Up DT7 1-Up DT9 1-Up DN9 1-Up DR4 1-Up

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Introduction Intended Use This rotary blasthole drill and its approved attachments are specifically designed to drill blast holes for quarry, mining and construction applications. Use of this machine in any other way is prohibited and contrary to its intended use.

Important Safety Information Most accidents that involve 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 hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Before Starting Engine, Study Operator's Manual * Read and understand the warnings and cautions shown in Section 1 * Practice All Safety Precautions * Make Pre-Operations Check * Learn Controls Before Operating It is Owner/Operator's responsibility to understand and follow manufacturer's instructions on machine operation and maintenance, and to observe pertinent safety precautions, laws and regulations. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

Introduction

03/19/12 i

Introduction Important Safety Information (cont.) When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

California Proposition 65 Warnings The following warning applies to equipment supplied with lead-acid batteries: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. The following warning applies to equipment supplied with diesel powered engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Receiving and Inspection Upon receipt of the machine, Owner/Operator is required to inspect the machine and all items listed on the Warranty Registration/Delivery Service Report included with the machine, complete the report and return within 15 days of the In Service date.

Rotary Blasthole Drills Overview These rotary blasthole drills offer a wide range of hole diameter capabilites and drilling depths ensuring flexibility, versatility and productivity. The rotary blasthole drill is a crawler mounted drill rig, which consist of two (2) major assemblies: 1. 2.

Rotary Drill Assembly Excavator Type Undercarriage (Crawlers)

The rotary drill assembly is made up of the engine package, compressor package, hydraulic system, rotary drive, pull-down and hoisting system and drill pipe handling mechanism. The crawlers are powered by two (2) hydrostatic motors. Each crawler has its own independent, variable and reversible speed control, and is equipped with 29.5 inch (750 mm) wide triple cleated grousers.

Introduction

Introduction Manual Contents This manual contains detailed instructions, maintenance information, and technical data which personnel will need in order to properly operate the rotary blasthole drill, and to perform the various maintenance services that are required for keeping the machine in good working condition at all times. Included herein are descriptions of safety issues, operating controls and recommended service and maintenance procedures. Each person performing service work must be satisfied that they have adequate knowledge and training to perform the required tasks. A thorough understanding of hydraulic and pneumatic systems as well as electrical and mechanical knowledge and experience is required. This manual contains repair and adjustment information for all major operating systems on the machine. In some cases such as hydraulic pumps and motors it is better to replace the unit with a new or rebuilt unit than to perform major repairs. The instructions in this manual are not intended to cover all details about this machine, nor do they intend to provide for every possible contingency that may be encountered in connection with daily operation or maintenance of this machine. THIS MANUAL IS NOT THE PARTS BOOK, and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by part numbers for THIS SPECIFIC MACHINE. Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this manual. Should further information be desired or should particular problems arise which are not covered sufficiently in this manual, the matter should be referred to your Cat dealer.

SECTION 1.................................................................................................................... SAFETY SECTION 2............................................................................OPERATOR'S CAB / CONTROLS SECTION 3 .................................................................................... MAINFRAME / CRAWLERS SECTION 4................................................................................ DRIVE TRAIN/COMPRESSOR SECTION 5....................................................................................DUST CONTROL SYSTEMS SECTION 6.................................................................... MAST / ROTARY DRIVE / PIPE RACK SECTION 7........................................................................................... HYDRAULIC SYSTEMS SECTION 8................................................................................. ELECTRICAL COMPONENTS SECTION 9...........................................LUBRICATION AND PREVENTATIVE MAINTENANCE SECTION 10........................................................................................OPTIONAL EQUIPMENT

Introduction

iii

Introduction Safety Stand Placement

MD6420

IF DURING MAINTENANCE MACHINE REQUIRES ADDITIONAL SAFETY SUPPORTS, PLACE SUPPORTS (JACK STANDS) AS CLOSE TO LEVELING JACKS AS POSSIBLE. THESE AREAS SUPPORT THE MACHINE DURING DRILLING OPERATIONS.

Introduction

Section 1

Safety Maximum Wind Speed = 75 MPH (120.8 Km/h) at which time drilling must be stopped, mast lowered and machine shutdown.

Safety

1-1

Notes

1-2

Safety

Hazard Classification The Rotary Blasthole Drill is a heavy moving machine with a mast which raises vertically for drilling. Like all moving objects and reach extending devices, there are potential hazards associated with its use. These hazards will be minimized if the machine is properly operated, inspected and maintained. Operator's must read this manual and have been trained to use the machine in an appropriate and safe manner. Non-English speaking persons must have an interpreter explain all safety and operating procedures in this manual. Should any questions arise concerning the maintenance or operation of the machine contact your Cat dealer.

Safety Alert Symbol

The safety alert symbol is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Safety Alert Symbol

Hazard Classification A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. All are used as attention-getting devices on decals and labels fixed to the machine to assist in potential hazard recognition and prevention.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Red Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Orange Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Yellow Indicates a potentially hazardous situation which, if not avoided, may result in property or equipment damage.

Blue Safety

1-3

Overview of Potential Hazards Potential Hazard

1-4

Prevention

Crush Hazard. Falling objects can cause severe injury or death.

Do not exceed hoist capacity & stay away from lifted loads. (3500 lbs./1587 kg.) Do not use damaged cable.

Crush Hazard. Falling pipe carousel can cause severe injury or death.

Place carousel against lower stops before servicing hydraulic circuit. Purge air from circuit after servicing carousel circuit.

Entanglement Hazard. Death or serious injury can result from contact with rotating drivelines.

Keep clear of rotating drivelines. Switch off engine before performing service. Do not operate with guard removed.

Entanglement Hazard. Rotating parts can cause personal injury.

Keep away from fan and belt when engine is running. Stop engine before servicing.

Crush Hazard. Falling mast can cause severe injury or death.

Purge air from circuit after servicing mast raising cylinder(s).

Burn Hazard. Hot pressurized fluid can cause severe burns.

Allow to cool before opening.

Safety

Overview of Potential Hazards Potential Hazard

Prevention

Fall Hazard. Death or serious injury may result from climbing raised mast.

Do not climb raised mast. Lower mast completely to service.

Improper operation or maintenance can result in serious injury or death.

Read and understand operator's manual and all safety signs before using or maintaining machine. If you do not understand the information in the manuals, consult your supervisor, the owner or the manufacturer.

Safety

Electrocution Hazard. Death or serious injury can result from contacting electric power lines.

Maintain required clearance.

Crush / Fall Hazard. Riding rotary head can cause severe injury or death.

Do not ride rotary head. Lower mast completely to service.

Flying Object & Spray Hazard. Death or serious injury can result from release of pressurized liquids.

Shut off live air at source, and relieve all pressure before removing filler plug.

Entanglement Hazard. Rotating parts can cause severe injury.

Do not operate with guard removed. Keep all guards in place.

Crush Hazard. Falling rotary head can cause severe injury or death.

Purge air from circuit after servicing feed cylinder(s).

Always contact the electric power line owner. The electric power shall be disconnected or the power lines moved or insulated before machine operations begin.

1-5

Overview of Potential Hazards Potential Hazard

Prevention

Explosion / Burn Hazard. Can cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.

Keep all open flames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt. READ MANUALS Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals. Consult your supervisor, the owner or the manufacturer.

Explosion Hazard. Combustible gas can cause severe injury or death.

Do not spray "High Energy" starting aid into compressor air inlet or engine grid heaters.

Fall Hazard. Death or serious injury can result from falling.

Use the access system provided when servicing the machine.

Crush Hazard. Standing on stairway when raising or lowering can cause severe injury or death.

Keep clear of moving stairway.

Explosion/Flying Object Hazard. Death or serious injury can result from release of pressurized fluid or gas.

Relieve all pressure before servicing or disassembly.

0 PSI / BAR

Electrical Shock Hazard. Can Disconnect battery prior to electrical system service cause severe injury or death. work or any welding to avoid electrical shock and machine damage. Refer to service operator manual.

1-6

Safety

Safety Guidelines Before Operation •

Do study the OMM and fully understand the controls.

•

Do be sure all safety guards are securely in place and all access doors are closed and locked.

•

Do wear safety helmet, glasses and hearing protection when operating or working on machine.

•

Do be sure all personnel are clear of the machine and work area before starting the engine or operating machine.

•

Do be sure drill area is clear of all obstructions before operating and know the size limitations of the machine.

•

Do attach safety chain when using towbar.

•

Do Not operate machine with: • A hydraulic leak • Broken or damaged electrical wiring • Damaged hydraulic hoses or fittings

Operation •

Do provide sufficient ventilation when running the engine in an enclosed area. Exhaust gasses contain carbon monoxide, a deadly poison, which is colorless and odorless.

•

Do make sure the drill pipe is secured in the loader before raising or lowering the mast, if your machine is equipped with a drill pipe loader.

•

Do make sure the mast lock pins are engaged in the mast base before starting drilling operations.

•

Do examine the surface before drilling to determine the possible presence of unfired explosives.

•

Do use PPE (personal protection equipment) appropriate for the conditions you are working in; e.g. safety helmet, safety glasses, hearing protection, gloves, respirator.

•

Do Not wear jewelry or loose fitting clothing when working on machinery. Keep clothing, hands and hair clear of moving parts.

•

Do Not drill into or near a "bootleg" hole or any hole that may contain explosives.

•

Do Not use the machine for any other purpose than what it was designed for. This machine is designed for rotary blasthole drilling operations only.

•

Do Not travel on steep inclines soft or unstable ground or close to unsupported excavations.

•

Do Not move machine if drill is in a potentially unstable position.

•

Do Not raise or lower mast or tram with any object attached to the winch hook.

After Operation Normal Shut Down 1.

Be sure machine is on solid level ground. Lower jacks, so the jack pads just touch the ground, but do not lift machine up.

Be sure all controls are in the OFF or NEUTRAL position.

Allow engine to idle for a minimum of five (5) minutes before stopping.

Turn the ignition key to OFF position.

Check machine for any unusual conditions.

Report any defects to your immediate supervisor.

Safety

1-7

Safety Guidelines Maintenance •

Do be sure two people are present when performing service work, both being fully trained on the safety issues. One person shall supervise from the operator's position and have immediate access to an emergency stop in all situations. Visual, audible or verbal communication signals must be established and understood by both persons.

•

Do be sure each person is adequately trained to perform service and maintenance procedures.

•

Do place a warning tag on starting controls to alert personnel that someone is working on the machine and disconnect battery before making repairs or adjustments to machine.

•

Do be sure you have adequate lighting when performing service work at night.

•

Do relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.

•

Do be sure machine and components are well supported before servicing or replacing parts.

•

Do maintain a metal-to-metal contact between the fill nozzle and fuel tank when filling the fuel tank. This will prevent sparks and the possibility of an explosion.

•

Do Not hammer bit or drill pipe. Use only proper tools to make repair or adjustments.

•

Do Not weld or grind near oil lines.

•

Do Not attempt to remove radiator cap when engine is hot or has overheated.

•

Do Not smoke or use an open flame near batteries, when servicing the batteries. Batteries can give off hydrogen which is a highly explosive gas.

•

Do Not leave tools or other loose objects on the mast, engine, drive mechanisms or drilling platform. They could be thrown by this equipment with a powerful force.

Equipment Transfer •

If all or part of the equipment is shipped to a new destination, always include a complete instruction manual or a copy of the following topics from the OMM: • Safety Section • Operation Instructions including: • Pre-Start Checks • Start-up • After Start Checks • Shutdown Procedure • Propelling Machine

Clearances from High Voltage Lines Line Voltage Minimum Clearance 0 to 50 kv 10 ft (3 m) 50 to 200 kv 15 ft (4.6 m) 200 to 350 kv 20 ft (6.1 m) 350 to 500 kv 25 ft (7.6 m) 500 to 750 kv 35 ft (10.7 m) 750 to 1000 kv 45 ft (13.7 m) Table 1-1

1-8

Safety

Safety Messages Safety Messages There are several specific safety messages on this machine. The location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages. Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the safety messages, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall. Replace any safety message that is damaged, or missing. If a safety message is attached to a part that is replaced, install a safety message on the replacement part. Any Cat dealer can provide new safety messages.

Safety Message List The following safety message list, location drawings and safety messages are used where English safety messages are used. The item numbers on the list correspond to the numbers on the location drawings. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description WARNING - Falling Objects (Winch) WARNING - Falling Objects (Carousel) WARNING - Rotating Shaft WARNING - Entanglement WARNING - Falling Mast WARNING - Hot Pressurized Fluid WARNING - Climbing Raised Mast WARNING - Modification or Alteration WARNING - Hazardous Voltage WARNING - Riding Rotary Head WARNING - Flying Objects & Spray WARNING - Rotating Parts WARNING - Falling Rotary Head WARNING - Combustible Gas (Batteries) WARNING - Combustible Gas (Ether) WARNING - Explosion/Flying Object

Part No. 429414 429448 429406 428893 429418 429449 429404 429445 429437 429420 429141 429431 429426 429439 429444 1711917

Qty. 1 2 2 5 2 1 2 1 1 1 1 2 2 2 1 1

(ref. 429469-01)

Safety

1-9

Safety Message Locations

1-10

Safety

Safety Message Locations

Safety

1-11

Safety Message Locations

WARNING

1-12

Safety

Safety Messages

WARNING

Entanglement Hazard Rotating parts can cause personal injury. 3500 lbs/ 1587 kg

Crush Hazard Falling objects can cause severe injury or death.

Keep away from fan and belt when engine is running. Stop engine before servicing.

Do not exceed hoist capacity & stay away from lifted loads. (3500 lbs./1587 kg.) Do not use damaged cable. 429414

428893

429414

WARNING

Crush Hazard

Crush Hazard Falling pipe carousel can cause severe injury or death.

Place carousel against lower stops before servicing hydraulic circuit. Purge air from circuit after servicing carousel circuit.

Falling mast can cause severe injury or death.

429418

429448

Death or serious injury can result from contact with rotating drivelines.

429418

WARNING

WARNING Entanglement Hazard

Keep clear of rotating drivelines. Switch off engine before performing service. Do not operate with guard removed.

Burn Hazard

429406

Purge air from circuit after servicing mast raising cylinder(s).

Hot pressurized fluid can cause severe burns.

Allow to cool before opening. 429449

429449 Safety

1-13

Safety Messages DANGER

WARNING

Maintain required clearance. Electrocution Hazard Death or serious injury can result from contacting electric power lines. Always contact the electric power line owner. The electric power shall be disconnected or the power lines moved or insulated before machine operations begin.

Fall Hazard Death or serious injury may result from climbing raised mast.

429437

Line voltage

Required clearance

0 to 50 kv

10 ft (3 m)

50 to 200 kv

15 ft (4.6 m)

200 to 350 kv

20 ft (6.1 m)

350 to 500 kv

25 ft (7.6 m)

500 to 750 kv

35 ft (10.7 m)

750 to 1000 kv 45 ft (13.7 m)

429437

WARNING Do not climb raised mast. Lower mast completely to service.

429404

Crush / Fall Hazard Riding rotary head can cause severe injury or death.

Do not ride rotary head. Lower mast completely to service. 429420

429420

WARNING

WARNING Flying Object & Spray Hazard

Improper operation or maintenance can result in serious injury or death.

Read and understand operator's manual and all safety signs before using or maintaining machine.

Death or serious injury can result from release of pressurized liquids.

If you do not understand the information in the manuals, consult your supervisor, the owner or the manufacturer.

Shut off live air at source, and relieve all pressure before removing filler plug.

429445

429141

429445 429141

1-14

Safety

Safety Messages

WARNING

Entanglement Hazard

Explosion / Burn Hazard Can cause death, burns or blindness due to ignition of explosive gases or contact with corrosive acid.

Rotating parts can cause severe injury.

Keep all open flames and sparks away. Wear personal protective equipment, including face shield, gloves and long sleeve shirt.

Do not operate with guard removed. Keep all guards in place.

READ MANUALS Read all manuals prior to operation. DO NOT OPERATE equipment if you do not understand the information in the manuals.

429431

Consult your supervisor, the owner or the manufacturer.

429431

429439

WARNING

429439

WARNING Crush Hazard Falling rotary head can cause severe injury or death.

Purge air from circuit after servicing feed cylinder(s). Explosion Hazard 429426

429426

WARNING

Combustible gas can cause severe injury or death.

Do not spray "High Energy" starting aid into compressor air inlet or engine grid heaters. 429444

429444

Explosion/Flying Object Hazard Death or serious injury can result from release of pressurized fluid or gas. Relieve all pressure before servicing or disassembly.

xxxxxxx

1711917 Safety

1-15

Safety Messages (ISO) Safety Message List–ISO The following safety message list, location drawings and safety messages are used where International Standards Organization (ISO) safety messages are required. The item numbers on the list correspond to the numbers on the location drawings. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description WARNING - Falling Objects (Winch) WARNING - Falling Objects (Carousel) WARNING - Rotating Shaft WARNING - Rotating Fan Blade WARNING - Falling Mast WARNING - Hot Pressurized Fluid WARNING - Climbing Raised Mast WARNING - Modification or Alteration WARNING - Hazardous Voltage WARNING - Riding Rotary Head WARNING - Burst Hazard WARNING - Rotating Parts WARNING - Falling Rotary Head WARNING - Combustible Gas WARNING - Combustible Gas (Ether) WARNING - Explosion Hazard

Part No. 429721 429718 429705 429738 429715 429717 429712 429722 429709 429714 429740 429710 429719 429720 429713 1711918

Qty. 1 2 2 5 2 1 2 1 1 1 1 2 2 2 1 1

(ref. 429758-02)

1-16

Safety

Safety Message Locations (ISO)

Safety

1-17

Safety Message Locations (ISO)

1-18

Safety

Safety Message Locations (ISO)

Safety

1-19

Safety Messages (ISO)

429740

Burst Hazard (429740)

4 29712 429720

Fall Hazard–Mast (429712)

Explosion/Burn Hazard (429720)

Explosion Hazard (1711918)

429713

Explosion Hazard–Ether (429713) 429705

Entanglement Hazard (429705) 1-20

Safety

Safety Messages (ISO)

XXXX lbs/ XXXX kg 429718

Crush Hazard–Carousel (429718) Crush Hazard–Winch (429721)

429715

Crush Hazard–Mast (429715)

Safety

429719

Crush Hazard–Rotary Head (429719)

1-21

Safety Messages (ISO)

429709

Electrocution Hazard (429709)

429722

Modification or Alter Hazard (429722) 429717

Burn Hazard–Pressurized Fluids (429717)

429714

Crush/Fall Hazard–Rotary Head (429714)

429710

Entanglement Hazard (429710) 429738

Entanglement Hazard (429738) 1-22

Safety

Section 2

Operator Controls

2-1

Graphic Symbol Legend The following is a listing of the graphic symbols found on the cab control consoles and their basic description. The control functions are described in detail following the symbol descriptions.

Drill Functions

HOBO Swing

HOBO Lock

Deck Wrench

Auto Pulldown

Holdback

Hoist Pulldown

Winch

Drill Pipe Support

Oil Injection

Pipe Rack Swing

Pipe Rack Rotate

Pipe Rack Lock

Thread Lube

Mast Lock

Dust Curtain/Blower

Main Air

Drill/Propel

Dust/Water

Mast Lower/Raise

Front Jack–UP/DOWN

Left Rear/Right Rear Jack–Up/Down

OFF

2-2

Operator Controls

Graphic Symbol Legend Drill Functions

Rotation/Left Track Pressure

Pulldown Pressure

Drilling Air Pressure

Hydraulic System Pressure

Rotation–Forward/Reverse

Pulldown Pressure–Increase/Decrease

Compressor Discharge Temperature

Engine Coolant Temperature

Engine Oil Pressure

Fuel Level

Battery Charge

Engine Hourmeter

Engine Tachometer

Engine Start

Drill Hourmeter

Ether Injection

Engine Stop

Ignition–On/Off

Water Injection–Increase/Decrease

Operator Controls and Indicators

Throttle–Fast/Slow Operator Controls

2-3

Control Console

Fig. 2-1 Operator Control Panel

NOTE

"PUSH" LEVER–Move lever AWAY FROM OPERATOR "PULL" LEVER–Move lever TOWARDS OPERATOR Options are used along with or in place of standard equipment on some machines. Although every effort has been made to be as complete and thorough as possible in the following pages, not every photo and item described herein may be used on your machine and your machine may have different controls than those shown. Consult with manufacturer if you are unsure about any function or control prior to use.

Level Indicator Indicates when the machine is level.

Throttle Used to control the engine speed (Cat engines).

Engine Diagnostic Lamp Light flashes to indicate engine fault. Refer to engine manual for fault codes and remedy.

2-4

Operator Controls

Control Console 4.

Jack Levers Used for lowering and raising the jacks to level the machine. Pull the levers to lower the jacks. Push the levers to raise the jacks. Machines equipped with "tram interlock" option have an indicator light under the jack levers. When jacks are fully retracted, the green light comes on. If light is not on, jacks are not fully retracted, and machine will not tram until jacks are fully retracted.

4a.

Right Rear Jack

4b.

Front Jacks

4c.

Left Rear Jack

Mast Lever Controls the lowering and raising of the mast. • Pull lever to raise mast. • Push lever to lower mast.

Propel Levers Controls the speed and the direction of the tracks. • Push levers to propel forward (radiator end). • Pull levers to propel in reverse (cab end).

6a.

Right Track Lever

6b.

Left Track Lever

Rotation Lever Controls rotary head speed and direction. • Push lever for forward rotation. • Pull lever for reverse rotation.

Hoist/Pulldown System Lever Controls the raising and lowering of the rotary head. • Push lever to raise the rotary head. • Pull lever to lower the rotary head.

Operator Controls

2-5

Control Console

Fig. 2-2 Instrument Panel

Compressor Air Filter Indicator Shows RED when filter element needs to be changed. Indicates differential pressure across filter element.

10.

Engine Air Filter Indicator Shows RED when filter element needs to be changed. Indicates differential pressure across filter element.

11.

Rotation/Left Track Pressure Gauge indicates hydraulic pressure required to rotate the drill string and when in propel mode, indicates pressure to left track motor. Maximum pressure 5000 PSI (344.7 bar). Avoid stalling the rotary head for extended periods.

12.

Rotary Head Tachometer (Optional) Gives digital reading of rotary drive RPM.

13.

Pulldown Pressure Gauge indicates hydraulic pressure at feed cylinder. Maximum pressure 5000 PSI (345 bar). Higher pressures may cause the machine to tip.

2-6

Operator Controls

Control Console 14.

Drilling Air Pressure Gauge indicates the air pressure in the drilling air line and receiver tank.

15.

Hydraulic System Pressure Indicates auxiliary pump pressure.

16.

Compressor Discharge Temperature Gauge indicates the temperature of the compressor discharge air.

17.

Engine Coolant Temperature Gauge indicates the temperature of the engine coolant.

18.

Engine Tachometer Gauge indicates engine revolutions per minute.

19.

Engine Oil Pressure Gauge indicates engine oil pressure.

20.

Engine Hourmeter Meter records total engine hours.

21.

Drill Hourmeter Meter records actual drilling hours.

22.

Engine Stop (optional)

23.

Ether Injection (optional) Aids in starting cold engine. (a) Press for 3 seconds. (b) Release to discharge. (c) Wait 3 seconds to start engine.

24.

Starter The Start button is used to start the engine. (a) Press Start button to start the engine. (b) Release button once engine is running.

25.

Voltage Gauge indicates voltage output of the electrical charging system.

26.

Fuel Level Gauge indicates fuel level in tank.

Operator Controls

2-7

Control Console

Fig. 2-3 Instrument/Control Panel

27.

Compressor Start-Run Valve, Low Pressure Machines (optional) When starting machine, valve should be in the "Start" position and selector #28 in low position (if used) so compressor is unloaded or in low pressure mode. When machine is warmed up, turn valve to "Run" position.

28.

Compressor Start-Run Valve, High Pressure Machines (350/500 PSI) (optional) When starting machine, valve should be in the "Low" position. When machine is warmed up, turn valve to "Med" or "High" position as required.

29.

Compressor Low Oil Pressure Light used on High Pressure Machines Light ON indicates low oil pressure at compressor bearings.

30.

Rotary Torque Control used on Low Pressure Machines or Holdback Control on High Pressure Machines Turn knob clockwise to increase rotary torque.

2-8

Operator Controls

Control Console 31.

Test Switch (optional) Turn switch ON to check filter indicator lights.

32.

Loop Filter Indicator Lights (4) (optional) Light ON, indicates filter needs to be changed.

33.

Charge Filter Indicator Lights (2) (optional) Light ON, indicates filter needs to be changed.

34.

Main Hydraulic Return Filter Indicator Light (optional) Light ON, indicates filter needs to be changed.

35.

Case Drain Filter Indicator Light (optional) Light ON, indicates filter needs to be changed.

36.

Compressor Oil Filter Indicator Light (optional) Light ON, indicates filter needs to be changed.

37.

10 AMP Circuit Breaker–Air Conditioner

38.

15 AMP Circuit Breaker–Heater

Operator Controls

2-9

Control Console

Fig. 2-4 Operator Control Panel

NOTE

39.

Some machines have options for which additional switches are required to operate. Generally, these functions are self-explanatory. In some cases switch functions may not be in the location shown in fig. 2-4. Just be sure of the label or graphic symbol associated with the switch.

Remote Pulldown Relief Controls the pressure to the feed system to increase or decrease the weight on bit. • Turn control clockwise to increase pressure. • Turn counterclockwise to decrease pressure.

40.

Oil Injection Light (optional) Light comes on when oil injection pump for down-the-hole hammer is running.

2-10

Operator Controls

Control Console 41.

Not Used

42.

Drill Pipe Loader–Swing This switch is used to swing the drill pipe loader out from and into the center of the mast when adding and retracting drill pipe and for storing the drill pipe loader when propelling or lowering the mast.

43.

Water Injection/Dust Collector This switch is used to engage the water injection or dust collector systems to control drilling dust. • Push switch up to engage water injection system. • Push switch down to engage dust collector system.

44.

Hydraulically Operated Break-Out Wrench (HOBO)–Swing The break-out wrench is used to undo tight thread connections. This switch is used to swing the break-out wrench into or away from the drill pipe. • Push and hold switch up to swing break-out wrench out. • Push and hold switch down to swing break-out wrench in.

45.

Drill Pipe Support The drill pipe support is used to support the drill pipe in the center of the mast when using the drill pipe loader for multiple pass drilling. • Push and hold switch up to engage drill pipe support. Red light will come on. • Push and hold switch down to disengage drill pipe support. Red light will go out.

46.

Hydraulically Operated Break-Out Wrench (HOBO)–Clamp The break-out wrench is used to undo tight thread connections. This switch is used to clamp and unclamp the break-out wrench and to turn the wrench. • Push and hold switch right to disengage (open) break-out and unclamp wrench. • Push and hold switch left to clamp wrench and engage (close) break-out.

47.

Remote Tram (optional) When switch is toward pendant symbol, machine can be trammed using remote pendant control.

48.

Viewing Hatch Push switch DOWN to open viewing hatch. Push switch UP to close viewing hatch.

49.

Drill Stem Thread Lube (optional) Push and hold switch down to activate grease pump to lubricate drill pipe threads.

50.

Dust Curtain Switch is used to raise or lower the dust curtain at the rear of the machine. • Push and hold switch up to lift dust curtain. • Push and hold switch down to lower dust curtain.

51.

Air Line Lubricator (high pressure machines) Push switch down to activate lubricator pump to provide lubrication for "In The Hole Hammers".

Operator Controls

2-11

Control Console Continued from previous page

Fig. 2-4 Operator Control Panel

52.

Mast Lock Switch UNLOCKS or LOCKS mast in the vertical or angle drilling positions. • Push and hold switch left to unlock (retract) mast pins. Green light will come on. • Push and hold switch right to lock (engage) mast pins into mast. Red light will come on. BE SURE to visually check to see that the mast lock pins are fully engaged in the holes in the mast before drilling. Also be sure pins are fully retracted from holes before lowering mast.

53.

Drill Pipe Loader–Lock This switch is used to lock or unlock the drill pipe loader so the loader can be indexed left or right to the next position. • Push and hold switch down to lock pin IN. • Push and hold switch up to move pin OUT.

2-12

Operator Controls

Control Console 54.

Drilling Air Turns the air ON/OFF for drilling procedures. • Push switch up to turn drilling air ON. • Push switch down to turn drilling air OFF

55.

Drill/Propel Switch Engages the drill controls or propel system. • Push switch up to engage the propel system. • Push switch down to engage the drilling controls. Drill mode must be selected if not propelling the machine or when the machine is unattended. Drill mode engages the propel brakes.

56.

Tool (Deck) Wrench Switch retracts or extends the deck wrench to hold the drill pipe when breaking thread joints or when multiple pass drilling is required. • Push and hold switch up to retract tool wrench. • Push and hold switch down to engage tool wrench.

57.

Drill Pipe Loader–Rotate This switch is used to rotate the drill pipe loader left or right to the next position. • Push and hold switch left to rotate drill pipe loader left. • Push and hold switch right to rotate drill pipe loader right..

58.

Winch • Push and hold switch up to raise winch hook. • Push and hold switch down to lower winch hook.

59.

Drill Pipe Loader–Interlock This switch is connected to a proximity switch in the mast. If the pipe rack moves off it's stop inside the mast the proximity switch will activate and stop the pulldown, rotation, and auto feed. This is to prevent the rotary head from hitting the pipe rack. When this happens, use the pipe loader swing switch (40) to swing pipe rack back against stop, then drilling can resume. When adding drill pipe however, you need to use pulldown and rotation with the pipe loader out. To do this, place the switch in the OVERRIDE position (towards the UNLOCK symbol). This will allow the rotation and pulldown functions to work when the pipe loader is out.

60.

Pulldown System (Auto Feed) The pulldown system switch engages and disengages the pulldown for drilling operations. • Push switch up to disengage pulldown. • Push switch down to engage pulldown. DO NOT engage this switch on unless you are actually drilling. Once drilling is finished, this switch must be disengaged.

Operator Controls

2-13

Control Console

Fig. 2-5 Instrument Panel–Light Switches and Circuit Breakers

61.

Light Switches Turns drilling lights, cab lights and other additional lights on and off.

62.

15 AMP Circuit Breaker–Cab Lights

63.

15 AMP Circuit Breaker–Ignition 24V

64.

10 AMP Circuit Breaker–Wipers

65.

50 AMP Circuit Breaker–Main Power

66.

15 AMP Circuit Breaker–Control Panel

67.

5 AMP Circuit Breaker–Heater & Drill Lights

68.

15 AMP Circuit Breaker–Starter

69.

5 AMP Circuit Breaker–12 Volt Circuit

70.

50 AMP Circuit Breaker–Drill Lights

71.

15 AMP Circuit Breaker–Additional Lights

72.

15 AMP Circuit Breaker–ECM

73.

10 AMP Circuit Breaker–Front Lights

2-14

Operator Controls

Control Console

Fig. 2-6 Instrument Panel with optional Murphy Power View display.

74.

Fig. 2-7 Cummins Engine Panel

Murphy Power View (optional) The "power view" system is an option in place of the engine hourmeter. It monitors several engine functions, including: RPM, Engine Hours, Coolant Temperature, Oil Pressure, Fuel Consumption, Throttle Position, and Engine Service Codes.

75.

Ether Injection (optional) Aids in starting cold engine.

76.

Engine Pre-Lube Switch Prior to starting engine, place switch in the START position (toward operator). With ignition switch ON, push Engine Start Button, this activates the engine pre-lube system. You will hear the pre-lube pump running, when it stops, the engine starter will activate. After engine starts, flip switch to RUN position (ISC).

77.

Engine Fault Code Switch Turn switch ON (towards operator) to activate fault code signals from amber light (80).

78.

Engine Throttle Switch This is a 3-position switch. Position switch all the way DOWN (toward operator) for LOW IDLE, MIDDLE position for MEDIUM IDLE, UP for HIGH IDLE.

79.

Engine Protection Light (Green) Light comes on at start-up to indicated engine systems are normal.

80.

Engine Fault Code Light (Amber) When light is on, it indicates there is a fault in the engine system.

81.

Engine Stop Light (Red) Flashes in a sequence to indicate fault codes. The engine fault codes are listed in the engine operator/maintenance manual. The fault codes can also be accessed using the Power View (74) display.

Operator Controls

2-15

Cab Controls

Fig. 2-8 Water Control under Control Console

82.

Fig. 2-9 Cab Heater/Air Conditioner Unit

Water Injection Pump Motor Flow Control (optional) Controls hydraulic flow to water pump motor. Turn COUNTERCLOCKWISE to INCREASE flow.

83.

Heater–A/C Temperature Control Controls temperature of A/C or heat.

84.

OFF–Heat–A/C Switch Selects OFF, HEAT, or A/C.

85.

Fan Switch (3 position) Selects fan speed, LOW–MEDIUM–HIGH.

86.

Vent Control Selects FRESH AIR or RECIRCULATION.

2-16

Operator Controls

Cat EMS Caterpillar EMS (Electronic Monitoring System) Panel

Fig. 2-10 Optional Instrument Panel with Caterpillar EMS Panel installed.

Figure 2-10 shows the optional Caterpillar EMS panel installed. This is an electronic monitoring system that displays various engine parameters. Each time the engine is started, the EMS undergoes an automatic self-test. Refer to Caterpillar instructions in the optional equipment manual for complete information. This panel replaces the engine hour meter (20), engine oil pressure gauge (19), engine tachometer (18), engine coolant temperature gauge (17), and voltage gauge (25) shown in fig. 2-2.

Operator Controls

2-17

Cab Heater Cab Heater Fault Isolation Check out the heater as follows: 1.

Check blower motor by operating console switch, checking all three positions and observing blower operation. Check for tripped circuit breaker and reset if tripped. Check for possible shorts in wiring or loose connections.

Check for heating by first allowing diesel engine to warm up thoroughly, then turning on blower and assuring that the circulated air is warm.

If heater fails to heat, check cutoff valves at plumbing connections to engine (fig. 2-11) to be sure they are turned on, then check the heater plumbing.

Fig. 2-11 Heater Connections and Cutoff Valves (Cat. C27 Engine shown) 1. Water Outlet to Heater 2. Water Inlet from Heater

2-18

Operator Controls

AC/Heater Air Conditioner/Heater Unit

FAN MOTOR GROUND (BLK) POWER IN (RED)

TO 10A BREAKER

RELAY

TO 15A BREAKER COMP. CLUTCH (GREEN) THERMOSTAT (BKW)

CONTROL PANEL

BINARY SWITCH

LOW PRESSURE PROTECTION HIGH PRESSURE PROTECTION

30-15 PSIG (FALLING PRESSURE) 270-330 PSIG (RISING PRESSURE)

40 PSIG MAXIMUM (RISING PRESSURE) 70-90 PSIG BELOW (OPENING PRESSURE)

MAIN POWER

A/C CONDENSER

FROM STARTER

IGNITION RELAY

A/C COMPRESSOR CLUTCH

FAN MOTOR

CAB WALL

RESISTOR

BLACK (GND)

LOW (YELLOW) MED (RED) HIGH (ORANGE)

PRESSURIZER

OFF

ROTARY SWITCH

BLACK (GND)

CLUTCH (YELLOW) A/C TOGGLE SWITCH

THERMOSTAT

POWER (RED) A/C HEATER UNIT

Fig. 2-12 AC/Heater/Pressurizer Installation QST30 (ref. 425135 rev. E) Operator Controls

2-19

Air Conditioner Maintenance and Servicing Schedule Although the systems are of heavy duty, industrial design, they still need maintenance and service. They will not run indefinitely and the warranty is conditional upon these services being carried out.

Daily

Weekly

Monthly

Every 3

Every 6

Yearly

Service

Months

Service

Check for Cleanliness of Condensing Coil.

Clean Condenser Fan Motor With Dry Compressed Air.

Check for Correct Setting of Thermostat.

Check Refrigeration and Water Lines for Damaged Lines

Check Condensing Coil: 1. Refrigerant connections against leakage 2. Fixing bolts and screws

Check Condenser Fan Motor 1. Seal on motor shaft 2. Fixing clamps and screws 3. Inspect motor brushes for wear 4. Electrical Connections

Check Condenser Fan 1. For damage 2. For securing screws 3. For excessive noise

Check Compressor 1. Refrigerant piping and connections 2. Electrical connections 3. Check securing screws & bolts 4. Welds on mounting bracket

Check for Cleanliness of Fresh Air and Return Air Filters. Check Compressor Clutch: 1. Fixing screws & bracket 2. Clutch electrical connections 3. Belt tension and wear

2-20

Operator Controls

Air Conditioner Maintenance and Servicing Schedule Daily Service

Every 3 Months

Every 6 Months

Yearly Service

Check Liquid Receiver/Drier 1. Refrigerant lines & connections 2. Securing bolts 3. For possible need of replacement 4. For refrigerant leakage 5. Sight glass during operation

Check High Pressure & Low Pressure Controls 1. For correct setting 2. Securing screws tightness 3. Electrical connections

Check Securing Fasteners on Fresh Air and Return Air Filters

Check Evaporator Fan Motor 1. For tightness of securing screws 2. For electrical connections

Check Evaporator Blower 1. For tightness 2. For damaged blades 3. For excessive noise during operation

Check Electrical Connections of Thermostat

Check Control Switch 1. Electrical connections 2. Operation

Check Heater Control Valve 1. For water leakage 2. Tightness of securing screws 3. Operation

Check for Damage and Cleanliness of Louvers

Check Evaporator Coil 1. For cleanliness 2. For refrigerant leakage 3. For tightness of securing screws

Check Against Refrigerant Leakage of the Thermal Expansion Valve

Operator Controls

Weekly Service

Monthly Service

2-21

Air Conditioner Maintenance and Servicing Schedule Daily Service

Weekly Service

Monthly Service

Every 3 Months

Every 6 Months

Yearly Service

Check Condensate Drip Tray 1. For cleanliness 2. For drain pipe blockage

Check Securing Screws & Bolts for Tightness on Main Frame & Panels

Check for Leakage of Refrigeration and Water Lines

Check Evaporator Pressure Regulator 1. For leakage 2. Evaporator pressure setting

Check Fresh Air Fan Motor 1. For excessive noise during operation 2. Brushes for wear 3. For electrical connections 4. For tightness of securing screws

Inspect Motor Brushes for Wear on Evaporator Fan Motor

General Service Information System should be thoroughly serviced before and after the cooling system. Breakdown maintenance is invariably more expensive, extensive and is not carried out to the same level as preventive maintenance. This can lead to more problems down the line. Compressor Oil Level It is not necessary to frequently check or change the compressor oil. However, it may be necessary to replenish or replace the compressor oil in the following cases: 1. Whenever the compressor, evaporator, condenser or receiver-drier is replaced. 2.

Whenever the refrigerant has leaked from the system.

Whenever the refrigerant is suddenly released from the cooling cycle.

Whenever any oil-related problems occur in the cooling cycle.

Follow the component manufacturer's recommended procedures for repairs or replacements to the system.

2-22

Operator Controls

Air Conditioner Troubleshooting I. System Produces No Cooling CAUSE

INDICATIONS

REMEDY

Fuse blown or circuit breaker tripped

Electrical components will not operate.

Replace fuse or reset circuit breaker.

Broken or disconnected electrical wire

Electrical components will not operate.

Check all terminals for loose connections; check wiring for hidden breaks.

Broken or disconnected ground wire

Electrical components will not operate.

Check ground wire to see if loose, broken, or disconnected.

Clutch coil burned out or disconnected

Compressor clutch inoperative.

Check current flow to clutch; replace if inoperative.

Electric switch contacts in pressure switches burned excessively, or clutch relay not working

Compressor clutch inoperative.

Replace low pressure or high pressure switches or clutch relay.

Blower motor disconnected or burned out

Blower motor inoperative.

Check current flow to blower motor; repair or replace if inoperative.

Loose or broken drive belt

Visual inspection.

Replace drive belts and/or tighten to specifications.

Compressor partially or completely frozen

Compressor pulley slips on belt or will not turn when clutch is engaged.

Remove compressor for service or replacement.

Compressor reed valves inoperative

Only slight variations of both gauge readings at any engine speed.

Service or replace compressor reed valves.

Expansion valve stuck in open position

Head pressure normal, suction pressure high evaporator flooding.

Replace expansion valve.

Broken refrigeration line

Complete loss of refrigerant.

Examine all lines for evidence of breakage by stress or rubbing wear.

Safety valve

Complete or partial refrigerant loss.

Examine valve on drier.

Leak in system

No pressure on high and low gauges (applies to any system having complete loss of refrigerant).

Evacuate system, apply static charge leak test system, & repair leak as necessary.

Compressor shaft seal leaking

Clutch and front of compressor oily; system low or out of refrigerant.

Replace compressor shaft seal.

Clogged screen or screens in receiver dehydrator or expansion valve; plugged hose or coil

High gauge normal or may read high. Low gauge usually shows vacuum or very low pressure reading. Frosting usually occurs at point of blockage.

Repair as necessary.

Mechanical:

Refrigeration:

Operator Controls

2-23

Air Conditioner Troubleshooting II. System Will Not Produce Sufficient Cooling CAUSE

INDICATIONS

REMEDY

Electrical: Blower motor sluggish in operation

Small displacement of air from discharge duct; blower motor possibly noisy.

Remove blower motor for service or replacement.

Compressor clutch slipping

Visual inspection.

Remove clutch assembly for service or replacement.

Obstructed blower discharge passage

Blower operates at high speed but air displacement very small.

Examine entire discharge passage for kinks, waddings or failure to open passage during installation. Correct as necessary.

Clogged air intake filter

Insufficient air displacement by blower.

Replace air filter screens and service, or replace if necessary.

Insufficient air circulation over condenser coils; fins clogged with dirt or bugs.

Insufficient cooling at discharge outlet; excessive high pressure gauge reading.

Clean condenser.

Evaporator clogged

Fins clogged with lint, dust, or coated with cigarette tars.

Remove cover and clean with compressed air. Use cleaning solvent to remove cigarette tars.

Evaporator pressure regulator defective or improperly adjusted

High pressure gauge readings normal; low gauge usually reads too high.

Repair or adjust as necessary.

Insufficient refrigerant in system

Bubbles in sight glass; high gauge readings excessively low.

Test for leaks. Repair as necessary. Recharge system until bubbles disappear and gauge readings stabilize to specifications.

Clogged screen in expansion valve

Gauge pressures may be normal or may Purge system, remove screen, clean show slightly increased head pressure and replace. and low suction pressure; discharge output temperature higher than specified.

Expansion valve thermal bulb has lost charge

Excessively high or low gauge readings; may cool in excess or not enough.

Clogged screen in receiver

High pressure gauge usually higher than Purge system; replace receiver. normal; receiver cold to touch and may frost.

Excessive moisture in system

Excessive high and low gauge reading. Lack of cooling.

Mechanical:

Refrigeration:

NOTE

2-24

Purge system; replace expansion valve.

Inspect system for refrigerant overcharge. Correct. If gauges still read high, inspect condenser for oil clogging.

After completing repairs above, system MUST have dehydrator replaced purged, evacuated and charged.

Operator Controls

Air Conditioner Troubleshooting II. System Will Not Produce Sufficient Cooling (cont.) CAUSE

INDICATIONS

REMEDY

Refrigeration (cont.): Air in system

Excessive high and low gauge reading. Sight glass shows bubbles or is cloudy. System contaminated.

Purge system, replace filter/drier, evacuate and charge system with new refrigerant.

Evaporator pressure control valve improperly set

High air temperature off of evaporator coil, high evaporator coil temperature.

Adjust pressure setting on valve to 28–30 psi. (1.9–2.1 bar).

NOTE

When a unit must be removed from the system for service or replacement, the system must have the dehydrator replaced also, and the system must be purged, evacuated and recharged to remove excess moisture.

III. System Cools Intermittently CAUSE

INDICATIONS

REMEDY

Electrical: Defective fuse or circuit breaker, blower switch, or blower motor

Electrical units operate intermittently.

Remove defective part for service or replacement.

Partially open, improper ground or loose connections in compressor clutch coil

Clutch disengages prematurely during operation.

Check connections or remove clutch coil for service or replacement.

Visual inspection operates until head pressure builds up (as viewed on high pressure gauge) at which time clutch begins slipping, may or may not be noisy.

Slippage over a prolonged period will require that clutch be removed for service; may require readjustment for proper spacing.

Mechanical: Compressor clutch slipping

Refrigeration: Unit icing up may be caused by excesUnit ices up intermittently. sive moisture in system, incorrect superheat adjustment in expansion valve or thermostat adjusted too low

Replace expansion valve if excess moisture present, adjust thermostat. Purge system, evacuate, recharge.

Thermostat defective

Low side pressure may be low or excessively high; adjustments will not correct.

Replace thermostat.

Stuck regulator valve

Both head and suction pressures low; moisture in system usually indicated.

Purge system and evacuate and replace dehydrator to remove moisture; if still stuck, replace regulator valve.

Operator Controls

2-25

Air Conditioner Troubleshooting IV. Excessively Noisy System CAUSE

INDICATIONS

REMEDY

Electrical: Effective winding or improper connection in compressor clutch coil

Visual inspection; clutch vibrates.

Replace or repair as necessary.

Loose or excessively worn drive belts

Belts slip and are noisy.

Tighten or replace as required.

Noisy clutch

May or may not slip; noisy when engaged

Remove clutch for service or replacement as necessary.

Compressor noisy

Loose mounting, worn part inside compressor.

Check mountings and repair; remove compressor for service or replacement.

Loose panels

Excessive rattles during operations.

Check and tighten all panels; hose hold down clamps, or rubbing or vibrations of hoses or pipes.

Compressor oil level low

Compressor noisy and lower portion hot to touch.

If oil level low, determine cause of loss. If correction made, fill with specified oil.

Blower fan noisy; excessive wear in blower motor.

Blower motor noisy.

Remove blower motor for service or replacement as necessary.

Mechanical:

Refrigeration: Excessive charge in system

Rumbling noise or vibration in high pres- Discharge excess freon until high pressure line; thumping noise in compressor; sure gauge drops within specifications. excessive head pressure and suction pressure; bubbles in sight glass.

Low charge in system

Hissing in evaporator case at expansion valve; bubbles or cloudiness in sight glass, low head pressure.

Check system leaks, charge system.

Excessive moisture in system

Expansion valve noisy; suction pressure low.

Replace dehydrator, purge system, evacuate and charge system.

High pressure service valve closed

Compressor has excessive knocking noise; high pressure gauge reads above normal.

Open valve immediately.

2-26

Operator Controls

Operator Seat

Operator Controls

2-27

Operator Seat

2-28

Operator Controls

Murphy Power View PV-02124N Revised 05/04 Section 78 00-02-0528

Installation and Operations Manual Please read the following information before installing. A visual inspection of this product for damage during shipping is recommended before mounting. It is your responsibility to have a qualified person install this unit. GENERAL INFORMATION

Display Parameters

WARNING BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT

✔ ✔ ✔ ✔

Disconnect all electrical power to the machine. Make sure the machine cannot operate during installation. Follow all safety warnings of the machine manufacturer. Read and follow all installation instructions.

Description

The PowerView is a powerful new display in a line of components manufactured by FWMurphy as part of its J1939 MurphyLink™† Family. The J1939 MurphyLink™ Family of products have been developed to meet the needs for instrumentation and control on electronically controlled engines communicating using the SAE J1939 Controller Area Network (CAN). The PowerView System is comprised of the PowerView and the Mlink™ PowerView Gages. The PowerView is a multifunction tool that enables equipment operators to view many different engine or transmission parameters and service codes. The system provides a window into modern electronic engines and transmissions. The PowerView includes a graphical backlit LCD screen. It has excellent contrast and viewing from all angles. Back lighting can be controlled via menu or external dimmer potentiometer. 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 pushbutton wear and failure. In addition, operators can navigate the display with ease. The enhanced alarm indication has ultra bright alarm and shutdown LEDs (amber & red). It has a wide operating temperature range of -40 to +85º C (-40 to185º F), display viewing -40 to +75º C (-40 to 167º F), and increased environmental sealing to +/- 5 PSI (± 34kPa). It also features Deutsch DT style connectors molded into the case and fits quickly and easily into existing 2-1/16 in. (52 mm) gage opening with little effort. Other components in the system are microprocessor-based Mlink™ PowerView Gages for displaying critical engine data broadcast by an electronic engine or transmission’s 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. Up to 32 components may be linked to the PowerView using a simple daisy chain wire connection scheme using RS485. The PowerView and all connected components can be powered by 12- or 24-volt systems.

Warranty

A limited warranty on materials and workmanship is given with this FWMurphy product. A copy of the warranty may be viewed or printed by going to www.fwmurphy.com/warranty.html † MurphyLinkTM is a registered trademark of FWMurphy. All other trademarks and service marks used in this document are the property of their respective owners.

The following are some of the engine and transmission parameters displayed by the PowerView in English or Metric units as well as in Spanish, French, or German (when applicable, consult engine or transmission manufacturer for SAE J1939 supported parameters): ❖ Engine RPM ❖ Engine Hours ❖ Machine Hours ❖ System Voltage ❖ % Engine Load at the current RPM ❖ Coolant Temperature ❖ Oil Pressure ❖ Fuel Economy ❖ Throttle Position ❖ Engine Manifold Air Temperature ❖ Current Fuel Consumption ❖ Transmission Oil Pressure ❖ Transmission Oil Temperature ❖ Transmission Gear Position ❖ Active Service Codes ❖ Stored Service Codes (when supported) ❖ Set Units for display (English or Metric) ❖ Engine Configuration Parameters

Specifications

Display: 1.3 x 2.6 in. (33 x 66 mm), 64 x 128 pixels. Operating Voltage: 8 VDC minimum to 32 VDC max. Reversed Polarity: Withstands reversed battery terminal polarity indefinitely within operating temperatures. Operating Temperature: -40 to +85ºC (-40 to185ºF). Display Viewing Temperature: -40 to +75ºC (-40 to 167ºF). Storage Temperature: -40 to +85ºC (-40 to185ºF). Environmental Sealing: IP68, +/- 5 PSI (+/- 34.4 kPa). Power Supply Operating Current: (@ 14 VDC)= 52 mA minimum; 268 mA maximum (LCD heater on). CAN BUS: SAE J1939 Compliant. Case: Polycarbonate / Polyester. Clamp: Polyester (PBT). Connectors: 6-Pin Deutsch DTO6 Series. Maximum Panel Thickness: 3/8 in. (9.6 mm). Mounting Hole: 2.062 inch (52 mm) in diameter. Auxiliary Communications: Either: Gages: One (1) RS485 port, MODBUS RTU master. MODBUS: One (1) RS485 port, MODBUS RTU slave, selectable baud rate; 9600; 19.2K; 38.4K. Potentiometer (External Dimmer)Input: 1K ohm, 1/4 W Shipping Weights (all models): 1/2 lb. (225 g.) Shipping Dimensions (all models): 6 x 6 x 6 in. (152 x 152 x 152 mm).

PV-02124N page 1 of 18

Operator Controls

2-29

Murphy Power View GENERAL INFORMATION continued

Table of Contents

Faceplate Features

General Information page # Description................................................. 1 Display Parameters.................................... 1 Specifications............................................. 1 Key Pad Functions..................................... 2 Mechanical Installation Typical Mounting Dimensions................... 2 Typical Quick-connect Diagram................ 3 Electrical Installation PIN Connectors Nomenclature.................. 3 Typical Wiring Diagrams........................... 4 Operations First Time Start Up................................... 5 Main Menu Navigation............................. 5 Selecting a Language................................. 5 Stored Fault Codes.................................... 6 Engine Configuration Data....................... 6 Faults and Warnings............................... .7 Active Fault Codes................................... 8 Shutdown Codes...................................... 8 Back Light Adjustment............................ 9 Contrast Adjustment.............................. 10 Select Units............................................... 10 Setup 1-Up Display................................... 11 Setup 4-Up Display.................................. 14 Utilities.....................................................15 MODBUS Setup....................................... 15 J1939 Parameters....................................17 Glossary...................................................18

Amber Warning LED

Red Shutdown Derate LED

Display

Bezel

Menu Key

Enter Key

Left Arrow Key (Scroll Up)

Right Arrow Key (Scroll Down)

Keypad Functions The keypad on the PowerView is a capacitive touch sensing system. There are no mechanical switches to wear or stick, and the technology has been time proven in many applications. 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 flashing the screen. The keys on the keypad perform the following functions: – Menu Key - The Menu Key is touched to either enter or exit the menu screens. – Left Arrow - The Left Arrow Key is touched to scroll through the screen either moving the parameter selection toward the left or upward. – Right Arrow - 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.

Typical Mounting Dimensions SIDE 3.489 in. (89 mm)

HOLE CUTOUT

1.94 in. (50 mm)

FRONT

2.070 in. (53 mm) 2.41 in. (61 mm) 4.25 in. (108 mm)

0.78 in. (20 mm)

2.062 in. (52 mm) diameter

0.125 in. (3 mm)

1.972 in. (50 mm) .953 in. (24 mm) R 0.063 in. (1.6 mm)

3.18 in. (81 mm) PV-02124N page 2 of 18

2-30

Operator Controls

Murphy Power View MECHANICAL INSTALLATION

Typical Quick-Connect Diagram Last PVA Gage or PVAA Audible Alarm

To Engine ECU A

To optional external device

To PVAA Audible Alarm

Terminating Resistor PVJR

To Battery Power

PVW-CH

POWERVIEW PV100

Relay N.O.

Relay N.C.

Ext. Sonalert

PVW-PH

Relay Comm.

Optional PVW-A wire harness

Customer provided wire harness or CAN extension harnesses or power extension harnesses.

(includes terminating resistor) A

PVA Gage

Next PVA Gage

Wire harness PVW-J

External Dimmer Wire 24 inch. A

External Dimmer

B+ GRND

CAN–SHLD CAN–LO CAN–HI

Wire harness PVW-P

Wire harness PVW-J

ELECTRICAL INSTALLATION

PowerView Unit Back View Deutsch DT06-6S Style Connections Plug A

Plug B

PIN 3 CAN LO –

PIN 4 CAN SHLD –

PIN 2 CAN HI –

PIN 5 Dimmer Potentiometer

PIN 1 V+

PIN 3 RS485+

PIN 4 RS485 –

PIN 6 GRND

PIN 1 V+

PIN 6 GRND

Recommended Connectors: Body: Deustch DT06-6S Wedge Lock: W6S Terminals: 0462-201-16141 Sealing Plug: 114017

PV-02124N page 3 of 18

Operator Controls

2-31

Murphy Power View TYPICAL WIRING DIAGRAMS

IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist per inch minimum. CAN–L, CAN–H and CAN Shield should be approved J1939 CAN bus cable (CAN wire for example: RADOX plug and play cable, from Champlain cable). (RS485 wire for example: BELDEN 9841 or 3105A).

PowerView Deutsch DT06-6S Style Unit to PVA Gage NOTE 5

NOTE 4 RS485 (-) Data

NOTE 2

Green-CAN_L Yellow-CAN_H

120 ohms

Pin 4

See NOTE 6

Pin 3

120 Ω See Note

Pin 2

PVA Gage

NOTE 1 Red-V+

Ignition Switch

V+

Pin 1 Pin 5

Pin 1

(SAE J1939 Compliant)

Gray-CAN_SHLD

Pin 6

ENGINE CONTROL MODULE

RS485 (+) Data

Pin 3

Back View

GRND

Pin 6

Gray-Ground Blue-Back Light NOTE 7

Battery

Illumination Control*(optional) NOTE 3

Note 1: Place Resistor between CAN–H and CAN–L Line near PowerView (included in PVW-P or factory purchased panels).

Note 4: Only use 120 ohm

Note 2: Use SAE J1939 compliant

to PowerView end only.

wiring or equipment. Note 3: Electronic dimmer switch

recommended with 4A, capacity or heavy duty rheostat switch, 1000 ohm, 0.25 watt.

characteristic impedance cable, ex Belden 9841. Note 5: RS485 shield connected Note 6: Place Resistor at End of

Line on last PVA gage. (Included for factory purchased panels.) Note 7: If a backlight dimmer is not

used, connect the blue backlight wire to ground. Do not leave the blue backlight wire unconnected.

PowerView Deutsch DT06-6S Style Unit to MODBUS Output NOTE 5

RS485 (+) Data

Pin 3

NOTE 4 RS485 (-) Data

NOTE 2 Green-CAN_L Yellow-CAN_H

Pin 4

120 Ω See Note

Pin 3

Pin 2

NOTE 1

Ignition Switch

Pin 6

Red-V+

Note 4: Only use 120 ohm

characteristic impedance cable, ex Belden 9841.

Pin 5

(SAE J1939 Compliant)

Gray-CAN_SHLD

Pin 1

ENGINE CONTROL MODULE

to MODBUS Output See NOTES 6 and 8

Note 5: RS485 shield connected

Gray-Ground Blue-Back Light NOTE 7 Battery NOTE 3 Illumination Control*(optional)

Note 1: Place Resistor between

to PowerView end only.

CAN–H and CAN–L Line near PowerView (included in PVW-P or factory purchased panels).

Note 6: Place Resistor at End of Line.

Note 2: Use SAE J1939 compliant

Note 7: If a backlight dimmer is not

wiring or equipment. Note 3: Electronic dimmer switch

For a complete listing of MODBUS Registers visit our website at www.fwmurphy.com

recommended with 4A, capacity or heavy duty rheostat switch, 1000 ohm, 0.25 watt.

(Included for factory purchased panels.) used, connect the blue backlight wire to ground. Do not leave the blue backlight wire unconnected. Note 8: PVA gages cannot be used

with the MODBUS feature.

PV-02124N page 4 of 18

2-32

Operator Controls

Murphy Power View POWERVIEW OPERATION

PowerView Menus (First Time Start Up) 1. When power is first applied to the PowerView, the "Logo" is displayed.

3. Touching the right arrow button will scroll down to reveal the last items of “Main Menu” screen highlighting the next item down. ADJUST BACKLIGHT ADJUST CONTRAST UTILITIES

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 J1939 message is supported by engine manufacturer.

GO TO 1-UP DISPLAY

LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

WAIT TO START PREHEAT

3. Once the engine has started the single engine parameter is displayed. 0

4. Touch the "Arrows" to scroll to the desired menu item or touch "Menu" to exit the Main menu and return to the engine parameter display.

1500

98%

1000 RPM

LOAD@RPM

ENG RPM

57 PSI

14.2

OIL PRES

BAT VOLT

Selecting a Language 1. Starting at the main menu display use the "Arrows" to scroll to the "Language" menu and once highlighted touch the "Enter" button.

3000

1800 RPM

GO TO 1-UP DISPLAY LANGUAGES LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

ENG RPM COOL TEMP

Main Menu Navigation 1. Starting at the single or four engine parameter display, touch "Menu". 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

2. The language choices will be displayed. Use the "Arrow" buttons to scroll through the selections and touch "Enter" to make a selection. ENGLISH ESPAÑOL FRANÇAIS DEUTSCH

57 PSI OIL PRES

❋

2. The first seven items of the “Main Menu” will be displayed. Touching the "Arrow Buttons" will scroll through the menu selection. GO TO 1-UP DISPLAY LANGUAGES STORED CODES ENGINE CONF SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS

3. Now that you have selected the language, touch the "Menu" button to return to the main menu display.

PV-02124N page 5 of 18

Operator Controls

2-33

Murphy Power View POWERVIEW OPERATION continued 5. Touch the "Menu Button" to return to the main menu.

Stored Fault Codes 1. Starting at the single or the four engine parameter display touch the "Menu button". 1500

98%

3000

LOAD@RPM

ENG RPM

▼

1800 RPM ENG RPM

SPN110 FMI10 HIGH COOLANT TEMP

1000 RPM

14.2

COOL TEMP

BAT VOLT

HIDE

▼

1 of x

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the Stored Fault Codes is highlighted. GO TO 1-UP DISPLAY STORED CODES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display. GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

Engine Configuration Data 1. Starting at the single or four engine parameter display touch the "Menu Button". 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 or transmission manufacturer for SAE J1939 supported parameters). GO TO 1-UP DISPLAY STORED CODES STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

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. GO TO 1-UP DISPLAY STORED CODES ENGINE ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

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. 3. Once the "Engine Configuration" menu item has been highlighted touch the "Enter Button" to view the engine configuration data.

1 of x

GO TO 1-UP DISPLAY STORED CODES ENGINE ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

▼

SPN110 FMI10 HIGH COOLANT TEMP HIDE

PV-02124N page 6 of 18

2-34

Operator Controls

Murphy Power View POWERVIEW OPERATION continued 4. Use the "Arrow Buttons" to scroll through the engine configuration data. ENGINE SPEED PT 1

or normal operation an auxiliary gage should fail, the single or four parameter screen will be replaced with the "MLink Gage Fault" message.

1000 RPM

ENGINE OIL PRESSURE GAGE NOT RESPONDING

▼

1 of x

HIDE

5. Touch the "Menu Button" to return to the main menu. 3. To acknowledge and "Hide" the fault and return to the single or four parameter display, touch the "Enter Button".

ENGINE SPEED PT 1

1000 RPM

1 of x

ENGINE OIL PRESSURE GAGE NOT RESPONDING

▼

HIDE

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

4. The display will return to the single or four parameter screen.

57 PSI OIL PRES

! 0

1500

3000

1800 RPM ENG RPM COOL TEMP !

Faults and Warnings Auxiliary Gage Fault 1. During normal operation the single or four parameter screen will be displayed. 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

98%

1000 RPM

LOAD@RPM

ENG RPM

! 14.2

BAT VOLT

Indicates Auxiliary Gage Fault

Indicates Fault Warning

Indicates Derate or Shutdown Condition Fault

57 PSI OIL PRES

5. Touching the "Enter Button" will redisplay the hidden fault. Touching the "Enter 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 correcting the cause of the fault condition.

1000 RPM ENG RPM

57 PSI OIL PRES

1 of x

ENGINE OIL PRESSURE GAGE NOT RESPONDING HIDE

2. The PVA Series of auxiliary gages can be attached to the PowerView. These auxiliary gages communicate with the Modbus master PowerView via a daisy-chained RS-485 port. If at any time during system initialization PV-02124N page 7 of 18

Operator Controls

2-35

Murphy Power View POWERVIEW OPERATION continued

Active Fault Codes 1. During normal operation the single or four parameter screen will be displayed. 98%

1500

LOAD@RPM

3000

1800 RPM ENG RPM

14.2

COOL TEMP

BAT VOLT

1000 RPM

1500

COOL TEMP

ENG RPM

14.2

57 PSI OIL PRES

BAT VOLT

6. Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display. WARNING

1 of x

SPN110 FMI0 HIGH COOLANT TEMP

SPN110 FMI0 HIGH COOLANT TEMP ▼

▼

1000 RPM

LOAD@RPM

OIL PRES

WARNING

3000

1800 RPM ENG RPM

57 PSI

98%

! 0

ENG RPM

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. 1 of x

5. The display will return to the single or four parameter display, but the display will contain the "Active Fault"warning icon. Touching the "Enter Button" will redisplay the hidden fault.

HIDE

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" 1 of x

SPN110 FMI0

7. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage. GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM

LOAD@RPM

ENG RPM

14.2

57 PSI OIL PRES

BAT VOLT

▼

HIGH COOLANT TEMP HIDE

Shutdown Codes 1. During normal operation the single or four parameter screen will be displayed. 4. To acknowledge and "Hide" the fault and return to the single or four parameter display touch the "Enter Button".

1500

98%

3000

1800 RPM ENG RPM

1000 RPM

LOAD@RPM

ENG RPM

57 PSI

14.2

COOL TEMP

OIL PRES

BAT VOLT

1 of x

SPN110 FMI0

HIGH COOLANT TEMP ▼

HIDE

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. 1 of x

SHUTDOWN

SPN110 FMI0 HIGH COOLANT TEMP MORE

HIDE

PV-02124N page 8 of 18

2-36

Operator Controls

Murphy Power View POWERVIEW OPERATION continued 3. To acknowledge and "Hide" the fault and return to the single or four parameter display touch the "Enter Button".

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Adjust Backlight" is highlighted.

SHUTDOWN

1 of x

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST BACKLIGHT

SPN110 FM10 HIGH COOLANT TEMP MORE

HIDE

4. The display will return to the single or four parameter display, but the display will contain the "Shut Down" icon. Touching the "Enter Button" will redisplay the hidden fault. 98%

! 0

1500

3000

ENG RPM

14.2

ENG RPM COOL TEMP!

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM

LOAD & RPM

1800 RPM

3. Once the "Adjust Backlight" menu item has been highlighted touch the "Enter Button" to activate the "Adjust Backlight" function.

57 PSI OIL PRES

BAT VOLT

5. Touching the "Enter Button" once again will hide the fault and return the screen to the single or four parameter display. 1 of x

SHUTDOWN

4. Use the "Arrow Buttons" to select the desired backlight intensity.

SPN110 FM10 HIGH COOLANT TEMP MORE

ADJUST BACKLIGHT

HIDE

6. The Single or Four parameter screen will display the fault icon until the fault condition is corrected. NOTE: Ignoring active fault codes could result in severe engine damage. 98%

! 0

1500

3000

14.2

COOL TEMP !

BAT VOLT

ADJUST BACKLIGHT

1000 RPM

LOAD & RPM

1800 RPM ENG RPM

5. Touch the "Menu Button" to return to the main menu.

ENG RPM

57 PSI OIL PRES

Back Light Adjustment 1. Starting at the single or four engine parameter display touch the "Menu Button".

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display. GO TO 1-UP DISPLAY

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

PV-02124N page 9 of 18

Operator Controls

2-37

Murphy Power View POWERVIEW OPERATION continued

Contrast Adjustment 1. Starting at the single or four engine parameter display, touch the "Menu Button". 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

6. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display. GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1000 RPM ENG RPM

57 PSI

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until "Adjust Contrast" is highlighted. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

Select Units

1. Starting at the single or four engine parameter display touch the "Menu Button". 0

1500

1800 RPM ENG RPM

3. Once the "Adjust Contrast" menu item has been highlighted touch the "Enter Button" to activate the "Adjust Contrast" function.

4. Use the "Arrow Buttons" to select the desired contrast intensity.

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the arrow buttons to scroll through the menu until the "Select Units" is highlighted. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT SELECTUNITSD UNITS ADJUST BACKLIGHT

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT ADJUST CONTRAST

3. Once the "Select Units" menu item has been highlighted touch the "Enter Button" to access the "Select Units" function. GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT SELECTUNITSD UNITS ADJUST BACKLIGHT

ADJUST CONTRAST

5. Touch the "Menu Button" to return to the main menu.

3000

4. Use the arrows to highlight the desired units. "English" for Imperial units i.e. PSI, ºF or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, ºC. ENGLISH METRIC KPA METRIC BAR

ADJUST CONTRAST

PV-02124N page 10 of 18

2-38

Operator Controls

Murphy Power View POWERVIEW OPERATION continued 5. Touch the "Enter Button" to select the highlighted units.

3. Once the "Setup 1-up Display" menu item has been highlighted touch the "Enter Button" to access the "Setup 1-up Display" function.

ENGLISH METRIC KPA METRIC BAR

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP1-UP 1-UPDISPLAY DISPLAY SETUP SETUP 4-UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT

6. Touch the "Menu Button" to return to the "Main Menu". ENGLISH METRIC KPA METRIC BAR

❉

7. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display. GO TO 1-UP DISPLAY

98%

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

LOAD@RPM

14.2

BAT VOLT

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, Battery Voltage, % Engine Load at Current RPM, Coolant Temperature, Oil Pressure. b). Custom Setup – This option allows for the modification of what parameter, the number of parameters, and the order in which the parameters are being displayed. 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. USE DEFAULTS DEFAULTS USE CUSTOM SETUP AUTOMATIC SCAN OFF

1000 RPM ENG RPM

57 PSI OIL PRES

6. Touch the "Enter Button" to activate the "Use Defaults" function. USE USEDEFAULTS DEFAULTS CUSTOM SETUP AUTOMATIC SCAN OFF

Setup 1-Up Display 1. Starting at the single engine parameter display, touch the "Menu Button". 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 1-up Display" is highlighted.

7. A message indicating the “Single Engine” parameter display parameters are reset to the factory defaults will be displayed, then the display will return to the “Custom Setup” menu. RESTORED TO DEFAULTS

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP1-UP 1-UPDISPLAY DISPLAY SETUP SETUP 4-UP DISPLAY SELECT UNITSD ADJUST BACKLIGHT

PV-02124N page 11 of 18

Operator Controls

2-39

Murphy Power View POWERVIEW OPERATION continued 8. 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.

13. Touch the "Enter button" to select the highlighted parameter for inclusion in the Single Engine Parameter Display.

USE DEFAULTS CUSTOM CUSTOMSETUP SETUP AUTOMATIC SCAN OFF

ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMP 3

9. Touching the "Enter Button" will display a list of engine parameters. USE DEFAULTS CUSTOM CUSTOMSETUP SETUP AUTOMATIC SCAN OFF

14. Continue to scroll and select additional parameters for the custom 1-Up Display. Touch the "Menu button" at any time to return to the "Custom Setup" menu.

15. Automatic Scan - Selecting the scan function will cause the 1Up Display to scroll through the selected set of parameters one at a time. Use the "Arrow Buttons" to scroll to the "Automatic Scan" function. USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN OFF

10. Use the "Arrow Buttons" to scroll to and highlight a selected parameter (parameter with a # symbol to right of it). USE DEFAULTS ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE

This number indicates the order of display for the parameters and that the parameter is selected for display.

16. Touching the "Enter Button" toggles the "Automatic Scan" function on. USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN ON

11. Touch the "Enter Button" to deselect the selected parameter removing it from the list of parameters being displayed on the 1-up display. USE DEFAULTS ENGINE SPEED 1 PERCENT LOAD AT CURRENT RPM 3 ENGINE OIL PRESSURE 2 ENGINE COOLANT TEMPERATURE

17. Touching the "Enter Button" again toggles the "Automatic Scan" function off. USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN OFF

12. Use the "Arrow Buttons" to scroll and highlight the desired parameter that has not been selected for display. ENGINE SPEED PERCENT LOAD AT CURRENT RPM 2 ENGINE OIL PRESSURE 1 ENGINE COOLANT TEMP

Note that the numbers now indicate the new order of display for the parameters.

PV-02124N page 12 of 18

2-40

Operator Controls

Murphy Power View POWERVIEW OPERATION continued 18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" functions have been set touch the "Menu Button" to return to the main menu.

4. Touch the "Enter Button" to activate the "Use Defaults" function. This action will reset the unit to the factory default. USE USE DEFAULTS DEFAULTS CUSTOM SETUP

USE DEFAULTS CUSTOM SETUP AUTOMATIC OFF AUTOMATICSCAN SCAN ON

19. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

5. The "Use Defaults"screen will be displayed during the reseting period then will automatically return to the "Setup 4-Up Display" menu.

GO TO 1-UP DISPLAY

STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

1500

RESTORED TO DEFAULTS

3000

1800 RPM ENG RPM

COOL TEMP

6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.

Setup 4-Up Display

USE DEFAULTS CUSTOM CUSTOM SETUP SETUP

1. From the single or four engine parameter display touch the "Menu Button". 0

1500

3000

1800 RPM ENG RPM

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will pop up on the display. Use the "Arrow Buttons" to scroll through the menu until the "Setup 4-Up Display" is highlighted.

7. The quadrent with the backlit parameter value is the current selected parameter. Use the "Arrow Buttons" to highlight the parameter value in the quadrant you wish to place a new parameter.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT

3. Once the "Setup 4-Up Display" menu item has been highlighted touch the "Enter Button" to activate the "Setup 4-Up Display" menu.

125°F COOL TEMP

1000 RPM ENG RPM

14.2 14.2 BAT VOLT

57 PSI OIL PRESP

8. Touch the "Enter Button" and a list of parameters will appear.

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP SETUP 4-UP 4-UP DISPLAY DISPLAY SELECT UNITS ADJUST BACKLIGHT

125°F COOL TEMP

1000 RPM ENG RPM

14.2 14.2 BAT VOLT

57 PSI OIL PRESP

PV-02124N page 13 of 18

Operator Controls

2-41

Murphy Power View POWERVIEW OPERATION continued 9. The parameter that is highlighted is the selected parameter for the screen. Use the "Arrow Buttons" to highlight the new parameter to be placed in the quadrent selected in the previous screen. ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE ENGINE OIL PRESSURE

3 1 2 4

The number to the right of the parameter indicates the quadrant in which it is displayed. 1. = Upper Left Quadrent 2. = Lower Left Quadrent 3. = Upper Right Quadrent 4.= Lower Right Quadrent

10. Touch the "Enter Button" to change the selected parameter in the quadrant to the new parameter. ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE ENGINE OIL PRESSURE

143°F OIL TEMP

1500

3000

1800 RPM

ENG RPM

1000 RPM ENG RPM

57 PSI OIL PRES

COOL TEMP

125% COOL TEMP

143°F OIL TEMP

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted. STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

1 Note the number to the right of the selected parameter indicating that the parameter is now assigned to that display location.

3. Once the “Utilities” menu item has been highlighted, touch the “Enter Button” to activate the “Utilities” functions. STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

ØRPM 1000 RPM ENG RPM 57 PSI OIL PRESP

13. Repeat the parameter selection process until all spaces are filled. 14. Touch the "Menu Button" to return to the main menu. 125°F COOL TEMP

COOL TEMP

1. Starting at the single or four engine parameter display, touch the “Menu button”.

2 4

125%

Utilities (Information and troubleshooting)

1 2

12. The parameter in the selected quadrent has changed to the parameter selected in the previous screen. 125°F COOL TEMP

GO TO 1-UP DISPLAY STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY DISPLAY SELECT UNITS ADJUST BACKLIGHT

11. Use the "Menu Button" to return to the “4-UP Custom Setup” screen. ENGINE SPEED ENGINE HOURS ENGINE COOLANT TEMPERATURE BATTERY POTENTIAL ENGINE OIL TEMPERATURE TEMPERATURE 2 ENGINE OIL PRESSURE

15. Touch the "Menu Button" to exit the Main menu and return to the engine parameter display.

4. Touch "Select" to enter the “Gage Data” display. 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, 1 stop bits, half duplex. GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP FAULT CONVERSION DEMO MODE ON

ØRPM 1000 RPM ENG RPM 57 PSI OIL PRESP

PV-02124N page 14 of 18

2-42

Operator Controls

Murphy Power View POWERVIEW OPERATION continued 5. Use the “Arrow buttons” to scroll through the items or touch “Menu” to return to the “Utilities” menu. 1 of x

ENGINE OIL PRESSURE ADDRESS: 20 SOFTWARE REVISION #: ERRORS: NONE

11. Use the “Arrows” to scroll and highlight the version then touch “Select” and an asterisks appears to the right of the selection. NOTE: There are four (4) different methods for converting fault codes. The PowerView always looks for J1939 Version 4 and can be set to use one of the 3 other J1939 versions. Most engine ECU’s use Version 4, therefore in most cases adjustment of this menu option will not be required. Upon receiving an unrecognizable fault, change to a different J1939 Version. If the fault SPN does not change when the version is changed, the ECU generating the fault is using Fault Conversion method 4. If the SPN number does change but is still unrecognizable, try changing to another J1939 Version not yet used and continue to check the SPN number.

6. Touch “Menu Button” to return to the “Utilities” menu.

J1939 VERSION VERSION 11 J1939 VERSION 2 J1939 VERSION 3 J1939 VERSION 4

1 of x

ENGINE OIL PRESSURE ADDRESS: 20 SOFTWARE REVISION #: ERRORS: NONE

7. Use the “Arrows” to highlight “Remove All Gages”. Touch “Select” to clear gage data from memory. It takes a moment to clear all gages.

12. Touch the “Menu” button to return to “Utilities” menu. Touch the “Menu” button again to to return to the “Main” menu. STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

CLEARING GAGES PLEASE WAIT

8. When the gage data has cleared, the display automatically returns to the “Utilities” menu. Scroll to “Software Version”. Touch “Select” to view the software version currently in the PowerView.

SOFTWARE VERSION MURPHY: X.XX

MODBUS Setup 1. Starting at the single or four engine parameter display, touch the “Menu button”. 0

1500

3000

1800 RPM

ENG RPM

9. Touch “Menu” to return to “Utilities”. Highlight “Fault Conversion” using the “Arrows”. Touch “Select” to enter the Fault convertion menu.

COOL TEMP

98%

LOAD@RPM

14.2

BAT VOLT

1000 RPM ENG RPM

57 PSI OIL PRES

2. The main menu will be displayed. Use the “Arrow buttons” to scroll through the menu until the “Utilities” is highlighted, then touch “Enter”. STORED CODES ENGINE CONFG SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY SELECT UNITS ADJUST BACKLIGHT UTILITIES

GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION FAULT FAULTCONVERSION CONVERSION

PV-02124N page 15 of 18

Operator Controls

2-43

Murphy Power View POWERVIEW OPERATION continued 3. Once in the “Utilities” menu use the “Arrows” to scroll through the menu until the “Modbus Setup” menu is highlighted, then touch “Enter”. GAGE DATA REMOVE ALL GAGES SOFTWARE VERSION MODBUS SETUP MODBUS SETUP FAULT CONVERSION

4. Use the “Arrows” to scroll down to and highlight either the “Slave Active or Master Active” modes. Touch the “Enter” button to toggle between master and slave. USE FACTORY DEFAULT SERIAL PORT SETUP SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE MASTER ACTIVE

5. Use the “Arrows” to scroll to the “Serial Port” menu to highlight it, then touch “Enter”. USE FACTORY DEFAULT SERIAL PORT SETUP SETUP SERIAL PORT SOFTWARE VERSION SLAVE ADDRESS SETUP MASTER ACTIVE

6. Use the “Arrow” button to scroll to each selection to configure the MODBUS values for your application. BAUD RATE PARITY PARITY DATA BITS STOP BITS

7. When finished, touch “Menu” to return to the previous screen.

PV-02124N page 16 of 18

2-44

Operator Controls

Murphy Power View SAE J1939 MurphyLink System Implementation of J1939 Parameters Source: SAEJ1939-71 Surface Vehicle Recommended Practice SAE J1939 Section

Description

PGN

Parameter

Display Value

5.3.6

Elec Eng Cont #2 - EEC2

61443

Accelerator Pedal Position Percent Load at Current RPM

THROTTLE LOAD@RPM

5.3.7

Elec Eng Cont #1 - EEC1

61444

Actual engine % torque Engine Speed

ENG TORQ ENG RPM

5.3.14

Vehicle Distance

65248

Trip Distance Total Vehicle Distance

TRIP DIST VEH DIST

5.3.19

Engine hours, Revolutions

65253

Total Engine Hours

ENG HRS

5.3.23

Fuel Consumption

65257

Trip Fuel Total Fuel Used

TRIP FUEL FUEL USED

5.3.28

Engine Temperature

65262

Engine Coolant Temp Fuel Temperature Engine Oil Temperature Engine Intercooler Temperature

COOL TEMP FUEL TEMP OIL TEMP INTC TEMP

5.3.29

Engine Fluid Level/Pressure

65263

Fuel Delivery Pressure Engine Oil Level Engine Oil Pressure Coolant Pressure Coolant Level

FUEL PRES OIL LVL OIL PRES COOL PRES COOL LVL

5.3.31

Cruise Control /Vehicle Speed

65265

Wheel Based Vehicle Speed

VEH SPD

5.3.32

Fuel Economy

65266

Fuel Rate Instantaneous Fuel Economy Average Fuel Economy

FUEL RATE FUEL ECON AVG ECON

5.3.35

Ambient Conditions

65269

Barometric Pressure Air Inlet Temperature

BARO PRES AIR IN TP

5.3.36

Inlet/Exhaust Conditions

65270

Boost Pressure Intake Manifold Temp Air Filter Differential Pressure Exhaust Gas Temperature

BST PRES MANI TEMP AIR DIF PR EXH TEMP

5.3.37

Vehicle Electrical Power

65271

Alternator Voltage Electrical Potential (Voltage) Battery Pot. Voltage (Switched)

ALT VOLT SYS VOLT BAT VOLT

5.3.8

Electronic Transmission Controller #2

61445 61445

Selected Gear Current Gear

SLECT GEAR CURNT GEAR

5.3.38

Transmission Fluids

65272

Transmission Oil Pressure

TRAN PRES

5.3.46

Engine Fluid Level/Pressure #2

65243

Transmission Oil Temperature

TRAN TEMP

Injector Metering Rail 1 Pres Injector Metering Rail 2 Pres

INJ PRES1 INJ PRES2 FAN SPD

5.3.58

Fan Drive

65213

5.3.111

Auxiliary Pressures & Temperatures

65164

Auxiliary Temperature

AUX TEMP

Auxiliary Pressure

AUX PRES

Diagnostic Messages

65226 65227 65228

DM1 - Active Diagnostic DM2 - Previously Act Diag Codes DM3 - Diagnostic Clear

SRVCCODE STORCODE

J1939 N/A

Machine Hours (PowerView Calculated)

N/A

Machine Hours

MACH HRS

5.3.17

Engine Conf.

65251

Engine Configuration

ENG CONF

Electronic Transmission Controller #1

61442

Output Shaft Speed

OUT SFT SP

Electronic Transmission Controller #1

61442

Input Shaft Speed

IN SFT SPD

Electronic Transmission Controller #1

61442

Torque Converter Lockup Engaged

TORQ LOCK

5.3.5

PV-02124N page 17 of 18

Operator Controls

2-45

Murphy Power View GLOSSARY (Troubleshooting information)

CANBUS FAILURE PowerView has not received any CAN messages for at least 30 seconds. NO DATA PowerView has not received the particular message being displayed for at least 5 seconds. NOT SUPPORTED PowerView has received a message from the ECU stating the displayed message is not supperted. DATA ERROR PowerView has received an error message from the ECU for the displayed message. EMPTY No parameter selected for this 4-UP quadrant. WAIT TO START PREHEATING This is a message from the engine indicating it is in a preheating cycle. Wait until this message clears before starting the engine. TIMEOUT ECU NOT RESPONDING The ECU did not respond to the PowerView request. NO GAGE DATA The PowerView has no record of connected gages to the RS485 bus.

2-46

Operator Controls

Section 3 DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. Disconnect the connections to the Electronic Control Module (ECM) on the engine before welding.

Mainframe/Crawlers

3-1

Mainframe Description The mainframe of the machine consists of ASTM 500 grade B electric welded rectangular tubing heavily cross-braced and reinforced at high stress areas. Also part of the mainframe are the leveling jacks (4), mast raising cylinders (2), the drill table and work deck, lockable tool and battery boxes, handrails and tow hooks (2). The jacks, mast pivot and deck are integrally welded to the mainframe. The drill table and work deck consists of non-skid floor plates and a viewing hatch hydraulically operated from the cab. Dust curtains (4) at the rear of the machine encase the drilling area to keep dust and removed material contained. Optional hydraulic lifters for the front and rear dust curtains are operated from the cab to raise and lower the curtains when moving from hole to hole.

Repair In general, repair of the mainframe components entails removing the faulty component and replacing it with the correct part as designated in the parts manual.

Leveling Jacks COUNTERBALANCE VALVES (REFER TO SECTION 7 FOR ADJUSTMENT)

84 7/16 RETRACTED 60" STROKE 144 7/16 EXTENDED TORQUE TO 300 FT LBS

EXTEND

FRONT JACK ASSEMBLY 2 EACH SIDE RETRACT

EXTEND

FRONT

72 7/16 RETRACTED 48" STROKE 120 7/16 EXTENDED

EXTEND

RETRACT

TORQUE TO 300 FT LBS PLUMBING ORIENTATION EXTEND

REAR JACK ASSEMBLY 2 EACH SIDE RETRACT

JACK CONFIGURATION SHOWN IS NOT REPRESENTATIVE OF ALL MODELS. SOME MODELS USE FOUR 48" STROKE CYLINDERS.

RETRACT

EXTEND

REAR

RETRACT

EXTEND

Fig. 3-1 Leveling Jack Cylinders (ref. 439629 rev. 3) 3-2

Mainframe/Crawlers

Leveling Jacks Leveling Jack Cylinders Detecting Leveling Jack Troubles–Faulty leveling jacks may be detected through inspection, through operating difficulties encountered, or during hydraulic pressure tests outlined in Section 7.

Removal 1.

Lower jack pad to ground, but do not have weight of machine on jacks.

Shutdown machine. Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts.

Remove lower bolt that holds retainer cap/jack pad to cylinder.

With hydraulic pressure relieved, disconnect upper fittings to cylinder and clamps.

Remove cap screws and cap from top of cylinder outer casing.

Hydraulic cylinder may have a lifting eye installed or it will have tapped holes to install a lifting eye. Using a suitable crane or heavy lifting device lift cylinder out of casing.

Repair Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in Section 7 for type of cylinder on machine.

Replacement 1.

Replacement is reverse of removal procedure.

Rotate jack pad to align bolt hole with cylinder.

Cycle cylinder several times to remove trapped air before putting machine into service.

Lubricating Jack Casings If jack casings are equipped with grease fittings, grease by applying a small quantity of grease. If cylinder is not equipped with grease fittings, extend the jack fully and apply grease directly to the inner casing.

Mainframe/Crawlers

3-3

Mast Elevating Cylinders

Fig. 3-2 1. Mast Elevating Cylinders

Fig. 3-3 Upper Cylinder Pins 1. Grease Fitting 2. Cotter Keys 3. Upper Retaining Pin

Fig. 3-4 Lower Cylinder Pins 1. Lower Retaining Pin 2. Bolt (2)

NOTE

3-4

Replacement of the retaining pins is recommended whenever a mast raise/lower cylinder is removed or replaced.

Mainframe/Crawlers

Mast Elevating Cylinders Mast Elevating Cylinders Removal 1.

Removal of mast cylinders is easier with mast in up position. BE SURE mast lock pins are engaged before removing mast elevating cylinders, or mast will fall. Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts.

Be sure mast lock pins are engaged in mast and shut down machine. If machine is fitted with a central lube system, remove and cap grease lines from cylinder pins.

Support both cylinders and remove upper pins (fig. 3-3). Start machine and retract mast hoist cylinder rods all the way in. This will get all of the oil out of the cylinders, which allows you to save that much more oil and make tear down less messy. DO NOT touch mast lock switch! If mast lock pins are retracted, mast will fall! Shutdown machine and place a DO NOT START tag on the ignition switch. Disconnect battery.

Attach lifting strap to cylinder eye and support weight of cylinder while removing lower pin (fig. 3-4) and lift cylinder from machine for repair.

Repair Refer to parts manual for specific cylinder and repair parts. Refer to cylinder repair information in Section 7 for type of cylinder on machine.

Replacement 1.

With cylinder supported, install lower pivot pin and retainer bolts and grease fitting or grease line. DO NOT attach cylinders to mast yet. BE SURE to cycle cylinder at least six times up and down to remove trapped air before attaching to mast, otherwise mast may fall suddenly when lowered.

Connect hoses, start up machine and cycle cylinders at least six times up and down to remove trapped air, then slowly extend cylinder to line up rod end with clevis on mast.

Install upper pivot pin and retainer bolt. Install grease fittings or grease line.

DO NOT stand under mast while lowering. Lower mast and raise up again. Check for leaks. Grease all pivot pins.

Mainframe/Crawlers

3-5

Mast Elevating Cylinders

APPROX CYLINDER WEIGHT = 811 LBS (367.9 Kg) MAX OPERATING PRESSURE = 3,000 PSI (20.68 MPa)

(REF. 436573)

APPROX CYLINDER WEIGHT = 570 LBS (258.5 Kg) MAX OPERATING PRESSURE = 3,000 PSI (20.68 MPa)

(REF. 428257)

Fig. 3-5 Mast Elevation Cylinder Types Note: Refer to parts manual for specific cylinder 3-6

Mainframe/Crawlers

Undercarriage The crawler mounted, excavator type undercarriage is designed with three-point oscillation suspension which allows the drill to negotiate rugged, uneven terrain and continued stability while tramming between holes. The standard undercarriage supplied is the Intertractor B7. The B8 undercarriage is optional. Two independent axial piston motors, one per track, provide up to 290 hp (216 kW) each. Each track group is moving on sealed, oil flooded lower and upper rollers. The rollers are protected by full length rock guards. Refer to parts manual for the specific undercarriage on your machine.

Fig. 3-6 Crawler Assembly 2. Side Frame 3. Final Drive 4. Capscrew (32) 5. Washer (64) 6. Sprocket 7. Capscrew (32) 8. Track Roller (13) 9. Capscrew (52) 10. Washer (80) 11. Idler Unit

Mainframe/Crawlers

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Nitrogen Tensioner Hydraulic Tensioner Capscrew (4) Grease Fitting Sealing Ring (2) Cover Capscrew (2) Cover Capscrew (9) Cover

22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Capscrew (4) Washer (4) Nut (4) Grease Fitting Chain Guide Capscrew (24) Track Assembly with Shoes Spacer Tube (6) Threaded Rod (6) Nut (12)

3-7

Crawler Wear Limits How to Measure Undercarriage Wear The following information serves to establish wear measurement criteria for undercarriage components. Before measuring wear, all the parts must be properly cleaned. All measurements are in millimeters (mm).

Track Link Rail New A

10%

20%

25%

30%

40%

50%

60%

70%

75%

80%

90%

100%

125.5

124.7

123.8

123.4

122.9

121.9

120.9

119.8

118.6

118.0

117.5

116.1

114.7

138.0

137.0

135.9

135.3

134.8

133.5

132.3

130.9

129.4

128.7

127.9

126.3

124.5

10%

20%

25%

30%

40%

50%

60%

70%

75%

80%

90%

100%

Bushing New A B7

71.4

71.0

70.6

70.4

70.2

69.9

69.3

68.8

68.3

68.0

67.7

67.1

66.5

76.0

75.7

75.3

75.1

74.9

74.5

74.1

73.6

73.1

72.9

72.6

72.1

71.5

3-8

Mainframe/Crawlers

Crawler Wear Limits

Link Pitch New B

10%

20%

25%

30%

40%

50%

60%

70%

75%

80%

90%

100%

863.6

864.7

865.8

866.4

867.1

868.4

869.7

871.2

872.7

873.5

874.3

876.1

878.0

914.4

916.2

918.0

919.0

920.0

922.1

924.3

926.7

929.3

930.5

931.8

934.8

937.8

10%

20%

25%

30%

40%

50%

60%

70%

75%

80%

90%

100%

Shoe Grouser New A B7

30.5

28.5

26.5

25.5

24.5

22.5

20.5

18.4

16.4

15.3

14.3

12.1

10.0

30.0

28.0

26.1

25.1

24.1

22.2

20.2

18.2

16.2

15.2

14.2

12.1

10.0

Mainframe/Crawlers

3-9

Crawler Wear Limits

Track and Carrier Rollers Caliper Method New A

10%

20%

25%

30%

40%

50%

60%

70%

75%

80%

90%

100%

200.0

198.7

197.2

196.4

195.7

194.1

192.3

190.6

188.6

187.6

186.6

184.3

182.0

250

248.1

246.1

245.1

244.0

241.8

239.4

236.9

234.1

232.8

231.4

228.3

225.0

70%

75%

80%

90%

100%

Depth Gauge Method New B

10%

20%

25%

30%

40%

50%

60%

25.0

25.7

26.4

26.8

27.2

28.0

28.8

29.7

30.7

31.2

31.72

32.8

34.0

25.0

25.9

26.9

27.5

28.0

29.1

30.3

31.6

32.9

33.6

34.3

35.9

37.5

3-10

Mainframe/Crawlers

Crawler Wear Limits

Idler New A

10%

20%

25%

30%

40%

50%

60%

70%

75%

80%

90%

100%

24.0

24.5

25.1

25.4

25.7

26.3

27.0

27.7

28.4

28.8

29.3

30.1

31.0

30.0

30.5

30.9

31.2

31.4

32.0

32.6

33.2

33.8

34.2

34.5

35.2

36.0

Mainframe/Crawlers

3-11

Undercarriage Repair Crawler Component Repair It is recommended not to repair component parts of the crawler assembly. NEVER attempt to repair the track tensioner unit. The track tension spring is assembled in a fixture with several tons of force. For your safety and that of others DO NOT attempt to repair this unit. Replace the worn or damaged components with a new ones. Refer to the following Intertractor B7 Operating and Maintenance Instructions. When ordering parts for the crawler, give the serial number of the unit to be sure to get the correct parts. The serial number is stamped on the side frame adjacent to the final drive sprocket.

3-12

Mainframe/Crawlers

Crawler Repair Manual

Operating and Maintenance Instructions for Track Vehicles and Running Gear Components

Part #: UQ907B00N00005/6 Size: B7HD Mainframe/Crawlers

Status31.01.2011

3-13

Crawler Repair Manual

1.1 To be observed

1. Safety and danger instructions 1.1. To be observed 1.1.1 Warning signs Warning:

Safety regulations and measures that protect the drive and other persons against injury and danger to life and limb.

Caution:

Particular instructions to prevent damage to the vehicle. Failure to observe these instructions can lead to warranty becoming void.

NB:

Particular instructions for better handling during operating, control and setting procedures as well as maintenance work.

3-14

Mainframe/Crawlers

Crawler Repair Manual

1.1 To be observed

1.1.2 Foreword These operating instructions are a part of the scope of delivery. They are to be kept close at hand and are to remain with the machine if being sold again. All details, data and illustration contained in these operating instructions are subject to change as result of technical developments. All rights reserved. These operating instructions are not subject to any update service. The illustrations in this manual are only diagrammatic and may differ from the actually installed components of the respective undercarriage. In addition, it is possible that there may also be other components on the undercarriage that are not described in this manual. Conversely, there may also be components described in this manual that are missing on the undercarriage. All components and their functions are subject to technical change.

1.1.3 Warranty Applicable conditions of warranty are stipulated in the confirmation of order. Warranty rights become void in the event of • • •

Damage as a result of malfunctions caused by incorrect use or incorrect operation. Repairs or alterations carried out by persons who are neither trained nor authorized to do so. Damage being caused by accessories or spare parts being used for which no approval has been provided by Intertractor.

Mainframe/Crawlers

3-15

Crawler Repair Manual

1.2 Safety instructions

1.2. Safety instructions 1.2.1 In general

This undercarriage has been constructed to "state of the art" standards and is operationally safe. Nevertheless, machines can be the source of danger if they continue to be operated although a fault is suspected or has already occurred or it has been repaired incorrectly. Under these circumstances there is x

Danger to life and limb

Danger to the machine and other facilities and equipment etc.

The machine must be shut down immediately if a fault is suspected or has already occurred which could endanger the safety of the operator, other persons on site or surrounding facilities and equipment etc. All components have been carefully matched to each other. Fault-free operation and a long service life are only possible if original spare parts are used.

3-16

Mainframe/Crawlers

Crawler Repair Manual

1.2 Safety instructions

1.2.2 Regulations for work safety

Personnel Only properly trained and authorized personnel with appropriate specialist knowledge are to be appointed with maintenance and repair work. Appropriate measures must be taken before commencing any work on the undercarriage to ensure that the equipment cannot start up unintentionally or be started up inadvertently by others (e.g. blocks). All switching on and off procedures must be observed for this. Protective equipment and clothing is mandatory for all work. Wear protective helmets, shoes and gloves. Close fitting clothes help to avoid injuries. If assistants are required to help in carrying out work, responsibilities must be clarified beforehand so that there is no possibility of unclear competence occurring with regard to safety aspects.

Tools and equipment Tools, lifting gear, fastening devices, jacks and other working equipment must be in a safe operational and working condition. All lifting and fastening devices on the crawler undercarriage are only designed for the transportation of the undercarriage unless otherwise specified. Metal splinters may break off and cause injuries when driving equipment bolts in or out. For this reason, always wear safety goggles when driving bolts in or out. Equipment or components which are being fitted or removed or where their installation position is being changed must be secured against unintentional movement, slipping or falling over using suitable lifting gear of suspension/support devices. Systems and units (i.e. tensioning units) must be depressurized in an appropriate manner before opening. Damaged hydraulic or mechanical pre-tensioned spring elements must be exchanged as a complete unit. Further information in this respect can be found in the respective component descriptions and/or fitting and removal instructions.

Mainframe/Crawlers

3-17

Crawler Repair Manual

2.1 General Maintenance Instructions

2. Operating and Service Instructions 2.1. General Maintenance Instructions 2.1.1 Handling hydraulic substances and lubricants The relevant applicable safety regulations for the respective products must be observed when handling oil, grease or other chemical substances. Suitable safety measures must be taken to avoid scalding and burning when the machine has warmed up (i.e. at operating temperature), as operating media are then at least the same temperature. Do not smoke if handling combustible fluids. Caution with fire and naked flames. Not only fuel but also other operating media often have a low flash point and ignite easily. Lubricants that are not being reused must be disposed of in an environmentally friendly way.

2.1.2 Conversions or changes to the undercarriage Unauthorized conversions or changes are not permitted for safety reasons. The rated pressure of connected pressure relief valves and pressure tanks must not be altered.

Seals on units must not be removed.

2.1.3 Before starting up Before starting up: x Lubricate all lubrication points x Check all oil levels and adjust if necessary x Check function of all repaired components x Carry out visual inspection of all components

3-18

Mainframe/Crawlers

Crawler Repair Manual

2.1 General Maintenance Instructions

2.1.4 Wear limits of undercarriage parts Wear of the undercarriage is caused by movements, loads contact between parts of the undercarriage and abrasive action of the ground. This wear is increased by other factors including: x x x x x x

Track resting on hard uneven rock bed during operation One-sided undercarriage load during turning Driving long distances in reverse Driving over obstructions recklessly A track which is not tensioned according to operating conditions A large degree of dirt on complete undercarriage

Undercarriage components must be replaced by new parts if they are worn to 100 %. Otherwise, sudden machine failure is possible. Careful and regular measurements are necessary in order to establish the extent of wear and when replacements will be necessary. The parts involved and measuring parts must be cleaned thoroughly when carrying out measurements. If possible, carry out measurements at several points. The degree of wear is determined by the maximum value, not the average value. Wear limits are shown on the wear tables.

Mainframe/Crawlers

3-19

Crawler Repair Manual

2.2 Inspection intervals

2.2. Inspection intervals Table (OH: = Operating Hours) Component

Interval

Track undercarriage

daily

Inspection visual

monthly

visual

Drive

daily

visual check

Front idler unit

200 – 250 OH 300 – 1000 OH at longest 1 year monthly daily

Description

Extent of undercarriage dirtiness General condition of the undercarriage components Fastening elements of frame sections and undercarriage fastenings Fastening elements of frame sections and undercarriage fastenings – grouser shoe fastening (spot checks) Seal of gear-motor unit and possible hydraulic connections Gearbox oil level

Chapter: Track undercarriage

Chapter: Drive

Gearbox oil change

check visual

weekly

check Track rollers

Extent of maintenance work

daily monthly Carrier rollers and/or daily wearing rails monthly

visual check visual check

Crawler track with grouser shoes

daily

visual

monthly

check

Condition of and wear on sprocket General state of spring and tension system Seal of the front idler and the tensioning system Re-tensioning span of the track (max. possible tensioning span reached) Condition of and wear on front idler and sliding blocks Check for leakage Condition of and wear on track roller Check for leakage Condition of and wear on carrier roller Check for leakage (only on oil or grease lubricated tracks) Track pre-tensioning – track sag Condition of and wear on track link running surfaces, bushings (outer diameter), and stretching of track. Condition of and wear on the grouser shoes

Chapter: Front idler unit

Chapter: Track roller unit Chapter: Track roller unit Chapter: Crawler track with grouser shoes

Changes to intervals are possible depending on extent of use and operating conditions for the machine.

3-20

Mainframe/Crawlers

Crawler Repair Manual

2.3 Tightening torque tables

2.3. Tightening torque tables These tables do not apply for fastening the base plate to the track.

For standard bolts

For expansion bolts

Nm 6.9 M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 36

2,4 5,0 8,5 21,0 41,0 72,0 115,0 180,0 245,0 345,0 465,0 600,0 890,0 1.200,0

Nm 8.8

10.9

2,9 6,0 10,0 25,0 49,0 86,0 135,0 210,0 290,0 410,0 550,0 710,0 1.050,0 1.450,0

4,1 8,5 14,0 35,0 69,0 120,0 190,0 295,0 405,0 580,0 780,0 1.000,0 1.500,0 2.000,0 2.480,0

12.9 4,9 10,0 17,0 41,0 83,0 145,0 230,0 355,0 485,0 690,0 930,0 1.200,0 1.800,0 2.400,0

6.9 M4 M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30

For standard bolts with fine thread

M 8x1 M10x1,25 M12x1,25 M 12x1,5 M 14x1,5 M 16x1,5 M 18x1,5 M 20x1,5 M 22x1,5 M 24x2 M 27x2 M 30x2

23,0 44,0 80,0 76,0 125,0 190,0 275,0 385,0 520,0 650,0 970,0 1.350,0

10.9

27,0 52,0 95,0 90,0 150,0 225,0 325,0 460,0 610,0 780,0 1.150,0 1.600,0

38,0 73,0 135,0 125,0 210,0 315,0 460,0 640,0 860,0 1.100,0 1.600,0 2.250,0

12.9 45,0 88,0 160,0 150,0 250,0 380,0 550,0 770,0 1.050,0 1.300,0 1.950,0 2.700,0

6.9 M 8x1 M10x1,25 M12x1,25 M 12x1,5 M 14x1,5 M 16x1,5 M 18x1,5 M 20x1,5 M 22x1,5 M 24x2 M 27x2 M 30x2

Mainframe/Crawlers

10.9 2,2 4,6 8,0 20,0 41,0 74,0 120,0 190,0 255,0 375,0 520,0 650,0 990,0 1.350,0

12.9 2,7 5,5 9,5 24,0 50,0 88,0 140,0 225,0 305,0 450,0 620,0 780,0 1.200,0 1.600,0

14,0 27,0 52,0 48,0 81,0 125,0 190,0 265,0 365,0 450,0 670,0 950,0

8.8 17,0 33,0 61,0 57,0 96,0 150,0 225,0 315,0 430,0 530,0 790,0 1.150,0

10.9 23,0 46,0 86,0 80,0 135,0 210,0 315,0 445,0 610,0 750,0 1.100,0 1.600,0

12.9 28,0 55,0 105,0 96,0 160,0 255,0 380,0 530,0 730,0 900,0 1.350,0 1.900,0

For UNF bolts with fine thread

Nm 85,0 145,0 220,0 340,0 2.360,0

1,6 3,3 5,5 14,0 29,0 52,0 84,0 135,0 180,0 265,0 365,0 460,0 700,0 950,0

Nm 8.8

For standard bolts with fine thread

M10x1 M12x1 M14x1,5 M16x1,5 M30x2

8.8

For expansion bolts with fine thread

Nm 6.9

1,3 2,8 4,7 12,0 25,0 44,0 71,0 115,0 155,0 225,0 310,0 390,0 600,0 800,0

Nm -

95,0 160,0 250,0 380,0 2.400,0

9/16"-20 1/2"-20 9/16"-18 5/8"-18 3/4"-14 7/8"-14 1“-14

110,0 165,0 240,0 330,0 575,0 915,0 1385,0

120,0 185,0 270,0 370,0 650,0 1.030,0 1560,0

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Crawler Repair Manual

2.4 General instructions

2.4. General instructions 2.4.1 Serial number All undercarriages or side frames have a serial number for identification. This number looks like the following example: 12345-1 The first part is the order number of the order confirmation. The second part is the serial number for the undercarriage or side frame. The number is embossed on the cover plate of the side section of the drive. *1) This number is always required when calling with inquiries or complaints.

*1)

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Design can vary according to customer specification Mainframe/Crawlers

Crawler Repair Manual

2.4 General instructions

2.4.2 Structural design of a standard crawler undercarriage The Intertractor undercarriage is designed to meet universal demands. It consists of a central frame and two side frames for mounting additional machine or undercarriage parts. The central frame can be welded direct onto the side frames or bolted on with flange connection. A simplification of the complete design has been achieved through using assemblies and/or modules.

2.4.3 Operating temperatures Standard designs Special designs

-20°C to +40°C -40°C to +40°C

Please contact Intertractor for advice if intending to use the final drive or components in other operating conditions (temperatures).

2.4.4 Function and operation The crawler undercarriages are supplied by Intertractor without operating and drive units. The operating instructions of the suppliers and the manufacturers must be observed for these parts.

2.4.5 General assembly and disassembly instructions Assembly instructions The crawler undercarriages are supplied by Intertractor as a complete unit. All necessary assembly work on components to be exchanged is described in the respective individual chapters. Disassembly instructions Disassembling individual assemblies or components upon having reached their wear limits or in the case of any failure occurrences is described separately for each component in the individual chapters. We recommend not carrying out any repair work on the building site, but exchanging the component instead. We recommend getting in contact with the Intertractor Service Department in the event of any major damage or repeated failure of individual components.

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Crawler Repair Manual

3.1 Drive – Function and operation

3. Drive 3.1. Drive – Function and operation 3.1.1 General danger instructions Danger can occur in particular under the following circumstances: x x x

Product is handled insufficiently trained personnel Incorrect installation, operation and maintenance/repair The product is not being used for its designated purpose

Alterations to the product are not permitted unless approved beforehand. The transmission is designed exclusively for use as drive transmission for an undercarriage.

3.1.2 Instructions on transport and storage x x x x x x

3-24

Please ensure that the crane or hoisting equipment has a sufficient load capacity when lifting/transporting the transmission Only use approved transport elements Fasten the transmission carefully onto the crane hook and use suspension devices according to the size of the transmission Make sure that no parts attached to the transmission can be damaged by transport elements when lifting the transmission The transmission may only be stored in dry, heated rooms Make sure that the position of the transmission cannot change (tumble over, slip, fall etc.) at point of storage

Mainframe/Crawlers

Crawler Repair Manual

3.1 Drive – Function and operation

3.1.3 Design of the drive The design of the track undercarriage consists of a complete unit. This unit consists of a fully encapsulated, multi-stage high-performance planetary gear and the sprocket. The gear is driven direct by hydraulic or electric flange-mounted motors, The sprocket is available in standard, HD or special design with dirt pockets for packing ground conditions. Components adjoining the track are surface hardened to minimise wear. The connection to the driving wheel and transmission is established with HF bolts. The necessary torque levels for these are shown in the attached tables. The drive traction is transmitted to the track via the motor, transmission and sprocket.

1 Compact transmission 2 Sprocket 3 Diagram of a servo-hydraulic motor

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3.1 Drive – Function and operation

3.1.4 Description of the transmission The transmissions of the type series being used for the undercarriage have multi-stage planetary gear depending on design. A particular feature of the gear is its very compact and therefore space-saving design. The gear can be fitted with an integrated multi-disc brake, which acts as parking brake. This is activated by spring force and released hydraulically with pressure oil. The multi-disc brake must be released without fail before switching on the drive hydraulic.

As a special design, the transmission can be supplied with a mechanical disengaging mechanism enabling the transmission and hydraulic motor to be separated from each other, e.g. if towing the machine following failure of the machine's hydraulic system.

3.1.5 Commissioning

x x

Prevent the transmission from getting dirty Avoid pollution. Make sure not to spill any lubricant when filling

The transmission is supplied ready for installation without oil filling. Starting up or using the drive without any lubricant would lead to destruction of the transmission in next to no time. See the chapter "Filling with transmission oil" for filling, topping-up or checking oil. The transmission has been treated internally with a preservative agent that provides around 6 months protection against corrosion if stored under dry conditions. This internal preservation does not have to be removed when starting up. When fitting the hydraulic lines for parking brakes and hydraulic motor, make sure that no dirt or other foreign bodies get into the transmission or hydraulic motor.

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Crawler Repair Manual

3.1 Drive – Function and operation

3.1.6 Lubricants Normal operating conditions (+ 10° to + 30° C) We recommend only using lubricants that fulfil necessary viscosity requirements for lubricating the transmission. The viscosity rating on the rating plate on the transmission and the following requirements must be observed! Only the necessary viscosity ISO-VG 150 and ISO-VG 220 for normal operating conditions from 10° to 30° C is stated on the rating plate. Severe operating conditions (- 30° to + 50° C) Under severe operating conditions, e.g. in an ambient temperature range between - 30° and +50° C, we recommend 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, us oil with higher viscosity (SAE 85W - 140).

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Crawler Repair Manual

3.1 Drive – Function and operation

3.1.7 Compact transmission with drive motor Connecting the locating flange of the side frame as well as the sprocket is achieved using adequately dimensioned bolt connections. Transmission of torque is achieved by frictional locking. Remove the protective caps when connecting the hydraulic hoses. Attention must be paid that no dirt gets into the supply lines during the assembly process.

All prescribed parameters such as: x x x x

Hydraulic pressure limits, maximum and minimum volume flow rates, allowance for oil leakage, brake air pressure monitoring,

must be observed when using the undercarriage hydraulic system. Please contact the manufacturer where necessary for permitted values.

3.1.8 Parking brake The multi-disc brake incorporated into the transmission is a parking brake that is kept constantly closed by pressure springs. The maintenance-free brake is designed as a separate compact unit and should only be removed from the transmission and exchanged as a complete unit. This design protects all individual components such as discs, springs, sealing elements etc. against outside influences. Any repair work should only be carried out by a specialist workshop. Feeding hydraulic oil either direct or via the drive brake valve and a connecting line to the brake connection of the compact unit opens the brake.

Pressure ranges within which the brakes can be vented must be observed. Only completely vented brakes allow wear-free and fault free operation of the complete drive. Use of a separate hydraulic circuit for supplying the brakes is recommended if operating without parking brake valve.

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Crawler Repair Manual

3.1 Drive – Function and operation

3.1.9 Unlocking the parking brake 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. With this mechanism, it is possible to tow the undercarriage even with the diesel or electric motors switched off.

The unlocking device is located on the outside of the transmission and is held in its normal position by bolts (1). To unlock the parking brake, remove the bolts and screw in the claw clutch.

Attention must be paid that the unlocking device is returned to its original state when returning to normal operation.

Mainframe/Crawlers

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Crawler Repair Manual

3.2 Drive – Fitting and removal

3.2. Drive – Fitting and removal

Whenever working on the drive, always use suitable means to secure the device against starting up by itself or being started by others. An undercarriage that is not connected with the track by the sprocket is not secured against movement by the transmission brake. This means that the undercarriage must be secured separately when removing the drive.

Opening the track first is a precondition for fitting/removing the drive (see "Track" chapter).

x x

3-30

Notes on transmission oil must be observed All parts being fitted must be clean and free of grease

Mainframe/Crawlers

Crawler Repair Manual

3.2 Drive – Fitting and removal

3.2.1 Connecting frame-transmission sprocket

The transmission [1] must be inserted carefully into the side frame so that there is no damage to the flange surfaces. Check transmission seating for correct installation. Fasten the transmission in place by inserting bolts [5] and washers [6] in the frame. Screw into place by hand. Check again to ensure that transmission seating is correct. Pre-tighten all bolts by hand crosswise. See illustration below (example). Tighten to torque level crosswise again according to size of bolt (torque level table). Repeat this procedure with the sprocket [2] and corresponding fastening elements [3,4].

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Crawler Repair Manual

3.2 Drive – Fitting and removal

Further instructions: x x x x x x x x x x

Clean all locating/joining surfaces thoroughly. Lift the transmission carefully into the locating flange of the undercarriage using appropriate hoisting gear. Fasten the transmission securely onto the undercarriage frame, before removing the hoisting attachments. Make sure to avoid any axial forces when installing. Make sure to avoid any excessive force on the transmission housing. The transmission must not be tilted. Pay attention that no dirt or foreign particles get into the hydraulic system. The multi-disc parking brake is a transmission safety device. Make sure that no dirt or foreign bodies get into the brake air connection. Make sure that the brake air connection is carefully sealed There must not be any pressure build up in the brake line.

Connecting sprocket - transmission Clean all locating/joining surfaces thoroughly. Hoist the sprocket with hoisting gear onto the transmission and tighten onto the hub of the transmission without any heavy knocks. Insert the bolts and washers for fastening the sprocket into the holes and screw into the thread in the transmission by hand. Pre-tighten all bolts in the correct order and then to correct tension using a torque wrench (see torque level table).

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Crawler Repair Manual

3.2 Drive – Fitting and removal

3.2.2 Removing sprocket

Slacken off track and undo track lock (see "Track" chapter). Remove dirt from all parts and fastening elements. Use hoisting gear to secure the sprocket against falling over. Undo the bolts on the driving wheel crosswise and remove completely. Remove the driving wheel from transmission seat by tapping lightly with rubber hammer. If provided, insert pull-off bolts into provided threaded holes and tighten evenly. Push the sprocket off the transmission seat in this way and lift out using the hoisting gear.

3.2.3 Removing transmission

Remove dirt from all parts and fastening elements. Use hoisting gear to secure the transmission against falling over. Undo the bolts on the frame crosswise and remove completely. Loosen the transmission from the frame seat by tapping lightly with rubber hammer, then lift the transmission out of the frame carefully using the hoisting gear. x x

Catch any dripping/leaking oil in suitable containers Only use approved transporting elements for transportation

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Crawler Repair Manual

3.2 Drive – Fitting and removal

3.2.4 Drive – Maintenance and inspection General instructions The complete drive unit consists of the following components: x Motor x Sprocket x Transmission x Integrated brake (only on request) x Disengaging mechanism (only on request) Always replace the complete component if it fails. Only use specialist workshops for repairs.

3.2.5 Filling, topping-up and changing transmission oil

The transmission must be filled with fresh clean oil before starting up for the first time (see details of lubricants for types of oil). See the "Inspection intervals" table for intervals for oil checks or change. Drive the machine onto a horizontal surface in a position where appropriate access to the drive transmission is possible (see illustration). Filling/Topping up with transmission oil:

Position the transmission so that the oil drain plug (2) is positioned vertically at its lowest point (about 6 o'clock). The oil filler plug (1) should then be on the left or right outside of the transmission middle (about 10 or 2 o'clock). Fill up with oil until the level has reached the height of the filling hole. Insert filler plug with new washer and tighten.

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Mainframe/Crawlers

Crawler Repair Manual

3.2 Drive – Fitting and removal

Draining off transmission oil:

Danger of scalds and burns from hot transmission oil. The transmission housing may also be hot after running for longer periods. Always wear protective gloves and allow the transmission to cool down first. Collect draining oil in appropriate containers and dispose of in an environmentally safe manner. Place oil collection container underneath the transmission. Undo and remove oil filler plug (1) and oil drain plug (2). Drain oil completely. Insert drain plug with new washer and tighten.

3.2.6 Motor The motor is maintenance free and only has to be checked visually for leaks during inspection.

3.2.7 Multi-disc parking brake The multi-disc parking brake is integrated into the transmission on the motor side and is lubricated by the transmission oil. Because of this design, the brake is maintenance free and consequently only has to be checked for damage when carrying out a general overhaul of the complete transmission.

The brake circuit must be vented (bled) after working on the brake or the hydraulic connections.

3.2.8 Disengaging mechanism The disengaging clutch is located on the rotor gear side (opposite the motor) and is not subject to any special maintenance regulations. Mainframe/Crawlers

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Crawler Repair Manual

3.2 Drive – Fitting and removal

3.2.9 Transmission oil filling quantities

O & K Gruppo Carraro Benennung Description

Menge von Quantity from

in Liter [dm³] Menge bis Quantity to

F 10

2,70

3,30

F F F F F F F F F F F F

2,70 2,80 3,30 3,60 4,00 5,00 5,40 6,30 7,80 12,00 18,00 22,00

3,30 3,40 3,80 4,40 5,00 6,00 6,60 7,50 9,30 14,00 22,00 26,00

13 20 30 40 44 55 60 80 100 130 220 360

Lohmann + Stolterfoht Rexroth Bosch Group Benennung Description GFT 7 GFT 9 GFT 60 GFT 110 GFT 330

Menge von Quantity from 0,70 0,80 7,20 8,20 32,00

in Liter [dm³] Menge bis Quantity to 0,90 1,10 8,80 9,80 38,00

Trasmital Bonfiglioli Group Benennung Description

Menge von Quantity from

in Liter [dm³] Menge bis Quantity to

701 C1 705 C2 H

0,75 1,00

0,85 1,30

706 710 707 709 713

1,60 3,60 2,15 3,25 4,50

2,00 4,40 2,65 3,85 5,50

C3 C3 C3 C3 C3

H B B1 B1 B1

All figures are only guidelines (no liability assumed), the quantities can vary according depending auxiliary components.

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Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

4. Front idler unit 4.1. Front idler unit – Function and description 4.1.1 Design of front idler units Front idler units consist of the groups: x x x x

Pos.1 Front idler with sliding blocks Pos.2 Yoke Pos.3 Spring unit (pre-tensioned) Pos.4 Track tensioner

(Illustration of a standard front idler unit with spring unit and grease cylinder)

The front idler with sliding blocks (1) has a lifetime oil lubrication filling. The running surfaces have been hardened to reduce wear. The yoke (2) acts as a transmission element between the front idler and the following components. The spring unit (3) acts as protection for the complete undercarriage against overloads from outer influences (e.g. dirt) and is therefore an important component of the undercarriage.

Important! Any work whatsoever on the pre-tensioned spring unit may only be carried out by trained specialist personnel. The track tensioner (4) is used for correct setting of track tension. The grease cylinder maybe filled with/operated by grease or hydraulic oil.

Mainframe/Crawlers

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Crawler Repair Manual

4.1 Front idler unit – Function and

The following applies for all spring units: All spring units can either be bolted, inserted or fastened onto the front idler yoke. This ensures easy fitting and removal. The pre-tensioned spring in the frame is an exception. This spring is tensioned first when in the undercarriage frame and then secured with a locking system.

Dismantling the spring units may only be carried out by a specialist workshop. The following applies to all spring units: Replace the complete unit if a repair is necessary. Repairing spring units involves extensive safety measures and should only be carried out by a specialist workshop.

3-38

Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

4.1.2 Types of front idler units Type 1 Standard Pos.1 = Front idler Pos.2 = Yoke Pos.3 = Pre-tensioned spring unit Pos.4 = Track tensioner

Type 2 Nitrogen Pos.1 Front idler Pos.2 Yoke Pos.3 Nitrogen spring unit Pos.4 Track tensioner

Type 3 Elastomer Pos.1 Front idler Pos.2 Yoke Pos.3 Track tensioner Pos.4 Elastomer spring element

Mainframe/Crawlers

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Crawler Repair Manual

4.1 Front idler unit – Function and

Type 4 Integrated tensioning units Pos.1 = Front idler Pos.2 = Compact tensioning unit

Type 5 Special design Pos.1 =Front idler Pos.2 = Yoke Pos.3 = Thrust rod Pos.4 = Compact tensioning unit

3-40

Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

4.1.3 Front idler complete with sliding blocks and yoke The front idler unit fulfills the following functions: x x

Deflection with simultaneous guidance of the track. Positional adjustment via sliding blocks for setting track pre-tension and for guidance during spring actions

Pos.1 Front idler Pos.2 Sliding block Pos.3 Yoke

The front idler (1) runs in the steel mount (2) with its sliding blocks and can move in a longitudinal direction. The friction surfaces of the front idler guidance in the frame are greased to minimise wear (carried factory side during initial assembly).

Other components may be fastened on the front idler depending on the type of front idler. Mainframe/Crawlers

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Crawler Repair Manual

4.1 Front idler unit – Function and

4.1.4 Spring unit

The function of the spring is to secure the complete undercarriage against overloads. An overload can be caused by external influences (e.g. dirt accumulation) resulting in an increase in track tension. Under these circumstances, the spring element action provides relief for all components. The spring can only operate perfectly as long as there is no significant dirt accumulation on the spring.

4.1.5 Types of spring units Various types of design can be used as spring element depending on the intended application and load occurrence. In a compressed state the spring element requires an opening in its counterpart (e.g. in the cross-bar or panelling). Coil spring unit x Pre-tensioned by tension rod (fig. 1) x Integrated spring tensioning system (fig. 2) Fig. 1 Standard - Coil spring unit Pos.1 Coil spring Pos.2 Spring carrier Pos.3 Thrust plate Pos.4 Tension rod

(Not compressed)

(Compressed)

Fig. 2 Integrated – spring – Tensioning unit Pos.1 Coil spring Pos.2 Integrated grease tensioner

3-42

Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

Spring elements on a fluid basis Spring elements on a fluid basis are available in designs with and without reservoir tank. Nitrogen, elastomer and oil are used as medium. The systems that are fitted with a reservoir tank feed the medium into a reserve tank in the event of overpressure. The medium is returned back into the system when the pressure is reduced. On systems without a reservoir tank, the medium is fed away through a pressure relief valve in the event of overpressure. With these systems, it is then necessary to top up the tank again with new medium. The spring element is a complete modular unit. The pressure can be checked with a filling device and adjusted where necessary (i.e. topped up again). The spring element is pretensioned. The prescribed pressure levels must not be exceeded.

Observe the permitted pressure levels for the respective unit (filling pressure, max. pressure, operating pressure, test pressure)! Please note the details on the rating plate of the pressure tank (only provided with nitrogen as medium).

Medium is discharged in cases of overload. Loitering in the danger area is strictly forbidden. Observe pressure equipment guidelines. Heating the tank is forbidden. Danger of explosions. If the crawler track cannot hold pre-tension while driving, check the spring unit.

Mainframe/Crawlers

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Crawler Repair Manual

4.1 Front idler unit – Function and

With nitrogen as medium, standard commercial N2 in pressurised canisters is used.

The filling medium "Elastomer" has been tested in compliance with DIN 52900. It is in a fluid form and is odourless. Non-water soluble at 20 °C Elastomer medium table Thermal decomposition point Flash point Ignition temperature pH value Dangerous reactions Traffic regulations Protective measures Disposal Leakage/Spillage

Above 300°C from 300°C above 400°C neutral none none not applicable according to local official regulations Pick up with fluid-binding material, e.g. diatomite and dispose of in compliance with regulations

Extinguisher First aid

Water mist / spray jet, foam, CO2, powdertype extinguishers, sand not applicable

Manufacturer Wacker Silicone

Description AK 50

If the track vehicle is being used at temperatures of +10°C to –40 °C, the filling pressure in the spring unit will have to be checked using a pressure gauge and, if necessary, adjusted to the prescribed setting using a hand pump.

3-44

Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

Spring element on nitrogen basis

Spring element on elastomer basis

(nitrogen adjuster)

(Elastomer spring element)

Mainframe/Crawlers

3-45

Crawler Repair Manual

4.1 Front idler unit – Function and

Filling instructions for spring elements with elastomer as medium De-tension track and loosen (see Crawler Track chapter) Remove cover from appropriate side section. Fill up tank with elastomer using hand pump. Bleed hose by pumping slowly. Connect pump to adapter and pump spring unit up to prescribed filling pressure. Disconnect pump from adapter upon completion of the filling process. Important! Hand pump and special bolt are not included with delivery De-tensioning the spring element with elastomer as medium De-tension track and loosen (see Crawler Track chapter). Remove cover from appropriate side section. Using the special bolt, screw into the valve seat of the filling valve until about ¼ litres of elastomer emerge from the cross groove on the nut. The volume can be read off on the pressure gauge. Remove the special bolt slowly. The valve closes automatically.

3-46

Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

Filling instructions for spring elements with nitrogen as medium (Positions 2-8 are not included with delivery). Remove protective cap from nitrogen spring element and then screw the brass cap off the gas valve. Secure the valve against turning while doing so (hold tight with a wrench).

Check whether hand wheel on the filling valve has been turned back or closed completely. IMPORTANT! Turning direction anti-clockwise. Screw union nut (2) with filling valve (4) and extension (3) onto the gas valve.

Screw pressure gauge valve (6) onto the nitrogen-filling canister (8). Connect hose (5) between filling valve (4) and pressure gauge valve (6).

Mainframe/Crawlers

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Crawler Repair Manual

4.1 Front idler unit – Function and

Turn hand wheel on filling valve (4) to right (clockwise) so that the gas valve (1) opens. Open nitrogen filling canister (8) (Turn anti-clockwise):

Check filling pressure on the pressure gauge (6). When pressure level has been reached – settling time min. 5 minutes – close filling canister (8) again. Turn hand wheel back to left. Gas valve closes automatically.

Repeat individual work stages in reverse order and protect the gas valve with a protection cap. Replace brass cap and copper ring. IMPORTANT! Make absolutely sure that no dirt particles get into the gas valve.

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Mainframe/Crawlers

Crawler Repair Manual

4.1 Front idler unit – Function and

Pressure control for spring elements with nitrogen as medium Carry out work stages as in the previous section (Filling instructions for spring elements with nitrogen as medium).

Turn hand wheel on filling valve (4) to the right (clockwise) so that the gas valve on the spring element opens. The nitrogen canister (8) must remain closed. Read off the pressure on the pressure gauge. If checking without nitrogen canister, the filling connection on the pressure gauge must be plugged with a stopper.

Close as described in the previous section (Filling instructions for spring elements with nitrogen as medium). The pressure loss during the inspection procedure is about 5 bar.

Mainframe/Crawlers

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Crawler Repair Manual

4.1 Front idler unit – Function and

Releasing pressure on spring elements with nitrogen as medium Carry out work stages as in the previous section (Filling instructions for spring elements with nitrogen as medium). Turn hand wheel on filling valve (4) to the right (clockwise) so that the gas valve (1) on the spring element opens. The pressure valve must be connected to the filling canister or it must be plugged with a stopper. Release gas pressure by undoing the small pressure release screw (7) on the pressure gauge valve.

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Crawler Repair Manual

4.1 Front idler unit – Function and

Spring elements with oil as medium This spring element is not described in any further detail in this manual. Intertractor must be contacted before attempting to exchange or top-up this medium.

Instructions for spring elements with nitrogen as a medium x

If scrapping, the unit must be depressurised first in compliance with safety regulations

x x x x x x x x x

The following are forbidden: Undoing the screw connections Undoing the valve Using force of any form (knocking, jolting) on the unit Increasing the pressure beyond the level specified on the rating plate Carrying out repairs on pressurised parts Having repairs carried out by unauthorised persons Replacing components with non-authorised spare parts Heating or cooling the container excessively Transporting incorrectly (non-secured transportation)

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Crawler Repair Manual

4.1 Front idler unit – Function and

4.1.6 Track Tensioner The track is provided with the necessary pre-tension by the tensioning cylinder. In the event of wear occurring to the undercarriage components or if there are changes in terrain conditions, it will be necessary to adjust the tension of the track up or down (see chapter Setting Track Pre-tension, Crawler Track).

The tensioning cylinder (1) is supplied in standard design as a grease-tensioning cylinder. To tension or slacken off the track, grease is either applied through a special grease nipple (2) on the tensioning cylinder or the grease filling can be drained off by unscrewing the grease nipple halfway (illus. above). Access to the grease tensioner is through hand holes (2) that are located at the sides in the steel frame (1) (illus. below).

The hand holes may be closed by covering plates (3).

Attention must be paid to the state of wear of the track in order to avoid damage to the track tensioner. Re-tensioning is not permitted after reaching the wear limits for the track as this would cause excess strain on the undercarriage components beyond the permitted limits and there would no longer be any safety against forced breakage. 3-52

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Crawler Repair Manual

4.1 Front idler unit – Function and

4.1.7 Lubricant details for grease tensioning cylinders Substance/Preparation description Chemical characterisation Type of product

Lubricating grease Lithium grease NLGI class 2 or 3

Physical and chemical properties Physical condition at 20°C Colour Odour

pasty yellow characteristic

Change of state at 1013 hPa Melting point Flash point (ASTM D 92) Density at 20°C Behaviour in water at 20°C

>190°C >200°C 896 to 904 kg/m³ not soluble

Notes on disposal

Disposal in compliance with local official regulations. Disposal of the product must be in compliance with regulations for recycling and applicable refuse laws. This product is a water-endangering substance and must not be allowed to enter the ground, drains, and surface bodies of water or ground water.

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Crawler Repair Manual

4.2 Front idler unit – Fitting and removal

4.2. Front idler unit – Fitting and removal 4.2.1 Fitting front idler unit – in general Fitting and removing the front idler unit complete varies according to the design of the unit. The various designs are described in the following chapters.

Under all circumstances, appropriate steps must be taken whenever working on the front idler unit to ensure that the device cannot start up of its own accord or through intervention by others. An undercarriage, which is not connected with the track by the sprocket, is not prevented from moving by the gear brake. This means that the undercarriage must be secured separately. Furthermore, attention must be drawn to the dangers that can occur when working on or with spring elements. If a tension rod is damaged or broken, there is danger that a coil spring will not remain in its pre-tensioned position but will force the front idler out of the frame through sudden de-tensioning when the track is removed (see fig. 1., chap. Types of Spring Elements Æ Coil spring). This possible danger is detectable by the track remaining tensioned even after releasing the pre-tension pressure out of the grease tensioner. The spring elements that operate on a nitrogen or elastomer basis are high-pressure containers that under no circumstances should be subjected to additional stress through incorrect handling or external heat application.

If handling the track tensioners, make sure that any emerging oil or grease is collected and disposed of in an environmentally correct manner. The crawler track must be opened first before being able to fit or remove the front idler unit (see Crawler Track chapter).

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4.2 Front idler unit – Fitting and removal

4.2.2 Front idler unit – standard design This design consists of: x Front idler comp. with yoke (1+2) x Spring unit (3) o o

Screwed onto cross-bar Available in coil spring or hydraulic spring element designs

Track tensioner (4)

Push the piston of the track tensioner right in as far as it will go. Screw the washer and grease nipple into the hydraulic Tensioner and tighten.

Insert the track tensioner from below into the frame so that the grease nipple fits through the appropriate hole in the panelling. Set the tensioner in position using the fastening bolts and then tighten.

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4.2 Front idler unit – Fitting and removal

Place yoke on sliding blocks and fasten in place with bolts.

Place spring unit on the yoke and tighten in place with bolts.

Installation as described above though with a fluid spring element.

Insert the assembled front idler unit carefully into the greased guide rails of the side sections using appropriate lifting gear.

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4.2 Front idler unit – Fitting and removal

Installation as described above though with a fluid spring element.

Make sure that the front idler unit is pushed in far enough without any collision until the spring unit knocks against the piston of the track tensioner.

Shown with a fluid spring element.

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4.2 Front idler unit – Fitting and removal

4.2.3 Front idler unit plug-in unit The design consists of: x Front idler comp. with yoke (1) x Track tensioner (2) screwed onto the yoke

Spring unit (3)

If the spring has been designed as a plugin unit, lift carefully into the greased guide rails of the frame using appropriate lifting gear.

Alternative illustration of a plug-in unit as fluid spring element (e.g. nitrogen or elastomer)

Place yoke on sliding blocks and tighten with bolts.

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4.2 Front idler unit – Fitting and removal

Screw track tensioner onto the yoke. If the track tensioner has been supplied as complete unit with yoke, place complete unit on sliding blocks as described above and fasten in place using the fastening elements.

Push the piston of the track tensioner in as far as the cylinder pipe. Screw the washer and grease nipple into the track tensioner and tighten.

Insert the assembled front idler unit carefully into the greased guide rails of the side sections using appropriate lifting gear.

Make sure that the front idler unit is pushed in far enough without any collision until the spring unit knocks against the piston of the track tensioner.

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4.2 Front idler unit – Fitting and removal

4.2.4 Front idler unit compact tensioning unit This design consists of: x Front idler comp. with yoke (2) x Spring tensioning unit (3) screwed or pushed onto the yoke

Place yoke on sliding blocks and fasten in place using the fastening elements.

Screw the compact spring tensioning unit onto the yoke. If the unit is designed with an integrated yoke, place the complete unit on the sliding blocks and fasten in place using the fastening elements.

Push the piston of the tensioning element in as far as it will go. Screw high pressure lubricating nipple with washer into the track tensioner and tighten.

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4.2 Front idler unit – Fitting and removal

Insert the assembled front idler unit carefully into the greased guide rails of the side sections using appropriate lifting gear.

Make sure that the front idler unit is pushed in far enough without any collision until the spring unit knocks against the partitioning panel of the frame and remains there.

If the compact tensioning unit has been designed as a plug-in unit, lift carefully into the greased guide rails of the frame using appropriate lifting gear.

Place yoke on sliding blocks and fasten in place with bolts.

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4.2 Front idler unit – Fitting and removal

Insert the assembled front idler unit with yoke carefully into the greased guide rails of the side sections using appropriate lifting gear.

Make sure that the front idler unit is pushed in far enough without any collision until the yoke knocks against the spring unit.

4.2.5 Removal Removal is carried out analogue to the above in reverse order.

4.2.6 Exceptions In certain cases, as an exception, it is not possible to remove the front idler unit to the front. In this case, special installation and removal instructions are required.

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5.1 Carrier rollers/support rails – Function and operation

5. Carrier rollers/support rails 5.1. Carrier rollers/support rails – Function and operation 5.1.1 In general The carrier rollers/support rails are supplied as complete unit. The complete unit has to be exchanged in the event of any damage, repairs or upon reaching wear limits.

5.1.2 Types of carrier rollers Carrier rollers with one-sided bearing

Carrier rollers with two-sided bearing

Support rails are available in the designs: x Wear-resistant steel x Plastic support rails

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5.1 Carrier rollers/support rails – Function and operation

5.1.3 Function The carrier rollers fulfill the following functions: x x

Guiding the track in the upper strand Supporting the track in order to minimise track sag so as to prevent damage to neighbouring components.

The running surface of the carrier rollers/support rails has been hardened (not in the case of plastic support rails) to prevent wear. It is fitted with a "lifetime" seal (carrier rollers) in order to prevent penetration by dirt and any loss of oil. The carrier rollers are fitted as complete unit at the intended installation points above the steel bearers and are ready for immediate use.

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5.2 Carrier rollers/support rails – Fitting and removal

5.2. Carrier rollers/support rails – Fitting and removal Slacken off track and undo track fastener (see "Track" chapter).

Undo the bolts of the faulty carrier roller, remove and dispose.

Fit new roller using new bolts and re-join track again as described in the following chapter.

NB: These fitting/removal instructions also apply analogue for two-sided bearing support rollers and for the support rails The only difference to the displayed fitting/removal of one-sided bearing carrier rollers is the number and position of the bolts.

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6.1 Track rollers – Function and operation

6. Track rollers 6.1. Track rollers – Function and operation 6.1.1 In general The track roller is supplied as complete unit. The complete unit has to be exchanged in the event of any damage, repairs or upon reaching wear limits.

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6.1 Track rollers – Function and operation

6.1.2 Types of track roller Single flange track roller

Double flange track roller

6.1.3 Function The track rollers achieve the following functions: x x

Guidance of the track so that the dynamic forces of the track are transmitted to the ground Take-up loads coming from the machine

The surface of the roller has been hardened to reduce wear. It is fitted with "lifetime" seals in order to prevent penetration by dirt and any loss of oil. The track rollers are fitted as complete unit at the intended installation points under the rail (see chapter "Track rollers – Fitting and removal) and are ready for immediate use.

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6.2 Track rollers – Fitting and removal

6.2. Track rollers – Fitting and removal If necessary, slacken off track and undo track fastener (see "Track" chapter). Raise the track undercarriage using a lifting device and clean dirt off of all parts.

Undo the bolts of the faulty track roller, remove and dispose. If track guide is fitted, it will have to be removed first at the appropriate points before dismantling. Fit new roller using new bolts and fasten in place. Re-join track again as described in the following chapter.

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7.1 Crawler track and grouser shoe Function and description

7. Crawler track and grouser shoe 7.1. Crawler track and grouser shoe - Function and description 7.1.1 Design of the crawler track with grouser shoes The grouser shoes are bolted onto the crawler track and forms a complete unit in accordance with specification. 1 –Track segment 2 –Grouser shoe

(Bolzenauge = pin boss Buchsenauge = bushing bore)

7.1.2 Design of the crawler track The crawler track, carrier of the grouser shoes, consists of the segments, which are divided into left and right track links. These track links together with the corresponding bushings and bolts are pressed together and form a unit. This unit can be linked to any required length. The individual elements of the crawler track have been induction hardened making them extremely wear resistant.

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7.1 Crawler track and grouser shoe Function and description

7.1.3 Types of crawler tracks x x x x

Dry tracks Sealed tracks (dry) (* Grease lubricated tracks (** Oil lubricated tracks (**

Fitted with steel gaskets in order to prevent dirt penetration and therefore keep inner wear to a minimum. **) Fitted with seals in order to prevent dirt penetration, loss of grease or oil and therefore keep inner wear to a minimum.

Dry track x 1 – track links (right and left) x 2 - pin x 3 - bushing x 4 - spacer Sealed track (dry) x 1 - track links (right and left) x 2 - pin x 3 - bushing x 4 - spacer x 5 – seal washer Grease lubricated track x 1 – track links (right and left) x 2 - pin x 3 - bushing x 4 - spacer x 5 – Polyurethane seal Oil lubricated track x 1 – track links (right and left) x 2 - pin x 3 - bushing x 6 – split master link bushing side right and left x 7 – split master link bolt side x 4 – track seal x 5 – thrust ring x 8 - stopper

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7.1 Crawler track and grouser shoe Function and description

7.1.4 Grouser shoes – General description Grouser shoes The grouser shoes are supplied in forms and widths depending on requirements and demands.

Types of base plates x 1-tripple grouser shoe x 2-single grouser shoe x 3-double grouser shoe x 4-flat shoe x Box-type shoe (not illus.) x Rubber bonded shoe (not illus.) x Polyurethane bonded shoe (not illus.)

7.1.5 Function The following functions are fulfilled by crawler tracks with grouser shoes: x x

Taking-up loads coming from the machine Transmission of drive output into drive movement

The running surface of the crawler track has been hardened to reduce wear.

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7.2 Crawler track and grouser shoes – Fitting and removal

7.2. Crawler track and grouser shoes – Fitting and removal 7.2.1 In general

These instructions describe the correct method of fastening the shoes onto the track. Incorrect assembly is the most common cause for failure of the connection between grouser shoe and crawler track.

x x x

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Remove all forms of foreign bodies/materials from the contact surfaces of the links, which could get into the connection with the shoes and the bolts (e.g. paint, primer, rust, dirt etc.). Brushing or grinding lightly can achieve this. Clean the contact surfaces and the nut seats of the track links Coat the thread and contact surfaces underneath the bolt heads with a thin layer of oil (preferably) or grease

Driving hardened end bolts in or out by hammer involves considerable danger for personnel as a result of material shearing off. Take appropriate protective measures to prevent injuries (e.g. by wearing goggles).

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7.2 Crawler track and grouser shoes – Fitting and removal

7.2.2 Fitting grouser shoes It is often underestimated how important it is to observe the correct procedure when fitting grouser shoes. Work that is carried out incorrectly can result in the bolts being over-stretched and in the worst case even lead to damage to the track links. We urgently recommend always using NEW bolts and nuts for fitting grouser shoes. Used bolts can already be deformed and no longer guarantee optimum clamping force. Grouser shoes Remove all forms of foreign body/material from the contact surfaces of the shoes that could get into the connection with the track links and the bolts (e.g. paint, primer, rust, dirt etc.). Brushing or grinding lightly can achieve this. Also clean the contact surfaces and the nut seats of the track links. Place the grouser shoes with the front edge (A) over the bolthole of the track links. Coat the thread and contact surfaces underneath the bolt heads with a thin layer of oil (preferably) or grease.

Bolzenauge = pin boss Bodenplatte 3-Steg = triple grouser shoe Bodenplatte 1-Steg = single grouser shoe

Insert the bolts in the holes and screw into the nuts by a few turns. Make sure that the flatter side of the nuts is resting against the nut seat in the track link (the rounded side of the nut must be facing the running surface of the track link). Tighten all bolts fully without applying any particular force. Mainframe/Crawlers

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7.2 Crawler track and grouser shoes – Fitting and removal

Select a tightening procedure (see "Tightening procedures" on the following page) and establish the necessary torque according to the table at the end of these instructions. Tighten the bolts crosswise according to the selected tightening procedure as shown in the diagram. Caution! Do not over-tighten the bolts!

Torque check / Re-tightening Due to normal settling occurrences, all bolts should be re-tightened after about 50 operating hours. A torque system must be used for this without undoing the bolts beforehand.

Further checks must be made at regular intervals based on the experience of the machine owner/operator and/or the recommendation of the machine manufacturer. If the bolts can be turned on by more than 90° at required torque setting during an inspection, have the complete grouser shoe fitted again new as described above.

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7.2 Crawler track and grouser shoes – Fitting and removal

Fitting master links and master shoes The following recommendations especially for tracks with split master links must be observed in addition to the "Instructions for fitting grouser shoes". x x x x

Carefully clean the threaded holes of the master links Make sure that the bolts can be screwed in easily by hand Clean the contact surfaces of the master links Lubricate the cleaned thread and contact surface underneath the bolt heads with a thin coat of oil. Avoid using grease wherever possible or only use it very sparingly because otherwise it could settle at the base of the threaded hole and prevent the bolts from being tightened properly Close the master links and tighten the bolts as described

Please note that in some cases the bolts for the master links require special torque settings (see table "Master links" at the end of these instructions).

Depending on the design of the master links (if fitted), it is possible that there are different hole patterns in the master shoes.

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7.2 Crawler track and grouser shoes – Fitting and removal

Tightening procedure for track bolts The necessary torque for each individual bolt is intended for two different tightening procedures: the torque procedure and the turning angle method. The turning angle method is used in order to exclude the influence of the friction factor as far as possible. That is why it should be given preference over the torque procedure. The torque levels are for specified for ISO strength classes 11.9, 12.9 and special bolts 13.9. Torque procedure Tighten the bolts to the appropriate torque level in the above stated order. The torque level is to be achieved using a torque wrench whereby attention must be paid to an even turning movement. Sudden jerking movements result in torque peaks and lead to incorrect results. Stop tightening as soon as the prescribed torque level has been reached. Turning angle procedure (to be given preference under site conditions) With this process, the bolts are first tightened crosswise as described to a pre-set torque according to the table. After this, ideal pre-stressing of the bolts is achieved by subsequent turn through 120° (1/3 of a turn). A defined plastic deformation of the bolts can occur with this procedure so that maximum pre-stressing is achieved for the individual bolts.

In both cases, tightening the bolts in excess of specifications leads to stress on the bolts beyond the yield point combined with non-permitted plastic deformation and the danger of a premature failure of the bolt connection.

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7.2 Crawler track and grouser shoes – Fitting and removal

Tightening torque for track bolts [Nm] Strength class 11.9 Torque Turning procedure angle Bolt procedure M10 x 1 90 r 5 30 r 2 M12 x 1 160 r 10 50 r 3 M14 x 1.5 240 r 15 80 r 5 M16 x 1.5 370 r 20 180 r 10 M18 x 1.5 540 r 30 260 r 15 M19 x 1.5 650 r 35 320 r 15 M20 x 1.5 750 r 35 340 r 15 M22 x 1.5 1000 r 50 380 r 20 M22 x 2 M24 x 1.5 1320 r 65 440 r 20 M27 x 1.5 1920 r 95 630 r 30 M30 x 2 2580 r 130 850 r 40 M32 X 2 3100 r 150 1000 r 50 M36 X 2 4550 r 230 2270 r 110

[Nm]

Strength class 11.9 Torque Turning procedure angle Bolt procedure 7/16 – 20 UNF 115 r 5 40 r 2 ½ – 20 UNF 180 r 10 60 r 3 9/16 – 18 UNF 260 r 15 90 r 5 5/8 – 18 UNF 360 r 20 180 r 10 ¾ – 16 UNF 630 r 30 320 r 15 7/8 – 14 UNF 1010 r 50 350 r 15 1 – 14 UNS 1540 r 80 520 r 30 1 1/8 - 12 UNF 2250 r 110 760 r 40

[Nm]

Mainframe/Crawlers

Strength class 12.9 Torque Turning procedure angle procedure 100 r 5 32 r 2 170 r 10 55 r 3 260 r 15 85 r 5 390 r 20 190 r 10 570 r 30 280 r 15 690 r 35 340 r 15 800 r 40 360 r 20 1070 r 50 400 r 20 1410 r 70 2050 r 100 2760 r 140 3310 r 165 4860 r 245

Strength class 13.9 Torque Turning procedure angle procedure 105 r 5 35 r 2 180 r 10 60 r 3 270 r 15 90 r 5 410 r 20 200 r 10 600 r 30 290 r 15 720 r 35 360 r 20 830 r 40 380 r 20 1120 r 55 420 r 20 1080 r 50 470 r 20 1470 r 70 490 r 25 670 r 30 2140 r 100 700 r 35 910 r 50 2870 r 140 950 r 50 1070 r 50 3450 r 170 1110 r 55 2430 r 120 5070 r 250 2530 r 125

Strength class 12.9 Torque Turning procedure angle procedure 125 r 5 43 r 2 190 r 10 65 r 3 275 r 15 95 r 5 385 r 20 190 r 10 675 r 35 340 r 15 1080 r55 370 r 20 1650 r 80 560 r 30 2400 r 120 810 r 40

Strength class 13.9 Torque Turning procedure angle procedure 130 r 5 45 r 2 200 r 10 70 r 3 290 r 15 100 r 5 400 r 20 200 r 10 700 r 35 360 r 20 1130 r 55 390 r 20 1720 r 85 580 r 30 2500 r 125 850 r 40

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7.2 Crawler track and grouser shoes – Fitting and removal

Tightening torque for track bolts [ft lb] Strength class 11.9 Torque Turning procedure angle Bolt procedure M10 x 1 65 r 4 20 r 1 M12 x 1 120 r 7 35 r 2 M14 x 1.5 175 r 10 60 r 3 M16 x 1.5 275 r 15 130 r 5 M18 x 1.5 400 r 20 190 r 10 M19 x 1.5 480 r 25 235 r 10 M20 x 1.5 550 r 25 250 r 10 M22 x 1.5 740 r 35 280 r 15 M22 x 2 M24 x 1.5 975 r 50 320 r 15 M27 x 1.5 1420 r 70 460 r 20 M30 x 2 1900 r95 620 r 30 M32 X 2 2290 r 110 740 r 40 M36 X 2 3360 r 170 1675 r 80

1040 r 50 1510 r 75 2035 r 100 2440 r 120 3585 r 180

340 r 15 490 r 20 670 r 40 790 r 40 1790 r 90

Strength class 13.9 Torque Turning procedure angle procedure 75 r 4 25 r 1 130 r 7 45 r 2 200 r 10 65 r 3 300 r 15 145 r 5 440 r 20 210 r 10 530 r 30 265 r 15 610 r 30 280 r 15 825 r 40 310 r 15 800 r 40 1085 r 55 360 r 20 1575 r 80 520 r 25 2120 r 100 700 r 35 2550 r 125 820 r 40 3740 r 190 1870 r 90

Strength class 11.9 Torque Turning procedure angle Bolt procedure 7/16 – 20 UNF 85 r 4 30 r 2 ½ – 20 UNF 130 r 7 45 r 2 9/16 – 18 UNF 190 r 10 65 r 3 5/8 – 18 UNF 265 r 15 130 r 5 ¾ – 16 UNF 465 r 20 240 r 10 7/8 – 14 UNF 745 r 35 260 r 10 1 – 14 UNS 1140 r 60 380 r 20 1 1/8 - 12 UNF 1660 r 80 560 r 30

Strength class 12.9 Torque Turning procedure angle procedure 90 r 4 32 r 1 140 r 7 48 r 2 200 r 10 70 r 3 285 r 15 140 r 5 500 r 25 250 r 10 800 r 40 270 r 10 1220 r 60 410 r 20 1770 r 90 600 r 30

Strength class 13.9 Torque Turning procedure angle procedure 95 r 4 35 r 1 150 r 7 50 r 2 215 r 10 75 r 3 300 r 15 150 r 5 520 r 25 265 r 15 830 r 40 285 r 15 1270 r 65 430 r 20 1850 r 90 625 r 30

[ft lb]

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Strength class 12.9 Torque Turning procedure angle procedure 70 r 4 25 r 1 125 r 7 40 r 2 190 r 10 65 r 3 290 r 15 140 r 5 420 r 20 200 r 10 510 r 25 250 r 10 590 r 30 260 r 10 790 r 35 295 r 15

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Crawler Repair Manual

7.2 Crawler track and grouser shoes – Fitting and removal

Tightening torque for master track bolts [Nm] The bolts mentioned here can be used for closing various master links. The KLOC master links are an exception that can be closed with standard bolts according to specification. Although split master links initially appear the same, there are differences with regard to rigidity, expansion lengths and stress in the bolt connection. Because the turning angle method depends to a decisive amount on the above-mentioned parameters, different pre-set torque levels would have to be named for every combination of bolt and master link. For this reason, only the torque levels for the torque procedure have been specified in the table. The specification can be independent of the differing rigidity because of the strength of the bolt. Metric thread (ISO Std.) Bolt (mm) Torque procedure [Nm] Strength class Strength class 12.9 13.9 M10 x 1 83 ±5 89 ±6 M12 x 1 133 ±15 144 ±16 M14 x 1.5 196 ±20 212 ±22 M16 x 1.5 304 ±30 329 ±33 M18 x 1.5 515 ±35 557±38 M20 x 1.5 710 ±50 769 ±54 M30 x 2 1750 ±190 1895 ±205 M33 x 2 2100 ±200 2274 ±216 Bolt (inch) 7/16 – 20 UNF 1/2- 20 UNF 9/16 – 18 UNF 5/8 – 18 UNF 3/4 – 16 UNF 7/8 – 14 UNF 1 – 14 UNS 1 1/8 – 12 UNF 1 1/4 – 12 UNF 1 3/8 – 12 UNF

Mainframe/Crawlers

Torque procedure [Nm] Strength class Strength class 12.9 13.9 108 ±10 117 ±11 152 ±15 165 ±16 206 ±20 223 ±22 304 ±30 329 ±33 535 ±35 579 ±38 970 ±40 1050 ±43 1175 ±75 1272 ±81 1555 ±185 1684 ±200 1932 ±167 2094 ±181 2280 ±220 2469 ±238

Torque procedure [ft lb] Strength class Strength class 12.9 13.9 61 ±3 65 ±4 98 ±10 106 ±12 144 ±15 156 ±16 224 ±20 242 ±24 379 ±25 410 ±28 523 ±35 567 ±39 1290 ±140 1397 ±151 1548 ±147 1677 ±159 Torque procedure [ft lb] Strength class Strength class 12.9 13.9 79 ±7 86 ±8 112 ±10 121 ±11 151 ±15 164 ±16 224 ±20 242 ±24 394 ±25 427 ±28 715 ±29 774 ±31 866 ±55 938 ±59 1146 ±136 1242 ±147 1425 ±123 1544 ±133 1681 ±162 1821 ±175

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7.2 Crawler track and grouser shoes – Fitting and removal

Fitting the crawler track When laying out the track, pay attention to straightness and possibly track dimensions.

Place a wooden block under the end position of the track (front idler side, bushing side of the free track upwards).

Pay attention to the correct position and direction of the track segments and grouser shoes.

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7.2 Crawler track and grouser shoes – Fitting and removal

Place the complete pre-assembled side section on the track. Important! If running gears (left and right side) have to be positioned to each other, carry out an intermediate check and align appropriately.

If the trackside is standing correctly in line, pull the track over the drive unit in the direction of the front idler over the side section. Make sure that the bushings of the track grip into the gaps between the teeth of the sprocket.

End position of the track ends is the upper section of the front idler.

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7.2 Crawler track and grouser shoes – Fitting and removal

Design without split master links Grease two spacers and insert in the counter bores of the track links (use seal washers as well if necessary).

Align track segments to each other. Grease the tips of the master pin and insert in the hole. Drive in with a heavy hammer if using small track sizes. Observe safety instructions. Driving master pin in and out with a hammer can cause danger from material chipping off. Wear protective goggles.

If using larger tracks, drive the master pin in using a hydraulic pin-driving tool.

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7.2 Crawler track and grouser shoes – Fitting and removal

Designs with split master links Drive track until it is in the position shown. Secure lower track strand on front idler with wooden block. Make sure that the swivel angle is retained for feeding in. Before closing, clean paint and any other foreign bodies off the master link teething and oil lightly.

Angle master link pin end towards front idler centre. Feed in the master link pin end and join together until the grouser shoe resting surfaces are on a level plane. Important Take care not to damage grouser shoe resting surfaces. Only the bushing end can be fed in.

Clean thread of the master link halves. Apply bolt grease to the track bolts.

Tighten track bolts with a torque wrench (see Tightening Torque table)

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7.2 Crawler track and grouser shoes – Fitting and removal

Tightening the track (all models) Tightening the track. Attention must be paid that all components of the track are in the correct position. A grease gun is required for tightening. Push the connector on the end of the hose over the grease nipple of the greasetensioning valve. Activate the grease gun for as long as necessary until the track tension is correct (see notes on tensioning element in the Front idler unit chapter). On some designs, it may be necessary for a pressure gauge to be fitted on the grease gun.

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7.2 Crawler track and grouser shoes – Fitting and removal

Important! There must be sag of 2-3 cm over a length (L) of 1-1.5 m. This applies linear for the free length (L) smaller or greater than 11.5 m (at least 4 track elements). Measure the extent of sag using a ruler. This is achieved by measuring the distance f from the edge of the grouser shoe to the ruler (in the middle of the sag).

(Messlatte = ruler)

Remove the connector upon completion of the tensioning process. The undercarriage should now be moved back and forth by about 1 turn of the sprocket. Check position of the tracks on front idler and sprocket.

Tracks that are too loose can slip out of the flanges of the rollers, sprocket and front idler and increase wear.

Tracks that are too tight increase the wear on the front idler and drive bearings as well as the wear on track pins and bushings. It also requires greater motor output for driving and consequently a higher consumption of fuel.

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7.2 Crawler track and grouser shoes – Fitting and removal

Depending on the design, it is possible that there is no sag in the upper strand on some models. In this case, the track tension can be set by pressure measurement in the tensioning element or by lifting the undercarriage (measurement of the sag in the upper strand – the above rules for the distances L and f also apply in this case).

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7.2 Crawler track and grouser shoes – Fitting and removal

Removing the crawler track Position the undercarriage so that the master pin (pin has a hole in the facing side) is within the lower section of the front idler, approx. under 45° from the middle downwards). Important! Secure grouser shoe with wooden block against falling out after opening the track. The track must be de-tensioned first. This is achieved by unscrewing the grease nipple on the grease-tensioning valve until grease can emerge from the side hole of the nipple (see Front idler unit chapter Æ Tensioning element). Important! The grease in the tensioning element is under pressure. Undo the filling valve carefully and slowly – but not too far! The front idler turns back automatically or it will have to be turned back manually. Important! Observe the safety instructions for the spring elements in the Front idler unit chapter (the Front idler unit reset can occur as a result of design or damage to the spring unit).

Design without master links Establish where the master pins with the cylinder holes are positioned. Apply guide pipe (9). Insert drive mandrel (10) and knock out pin.

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7.2 Crawler track and grouser shoes – Fitting and removal

For larger tracks, press the master pin out using a hydraulic pin remover.

Design with master links Drive track to sprocket until the master link and sprocket centre are at the same height. Secure track against rolling off front idler. Remove shoe over master link.

Knock the pin end of the master link towards the drive middle or press the bushing end out of the pin end using a rod or crowbar until the track has been opened. Important for K-LOC designs! Only the bushing end can be opened outwards. Open out the end of the track. There are various designs of master links that are not shown here in detail.

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Crawler Repair Manual

7.2 Crawler track and grouser shoes – Fitting and removal

The following applies for all designs: Pull the track off in the drive direction using suitable lifting gear. Lay track out. Raise machine so that the track can be removed. Caution! Do not drive the undercarriage off the track after laying out. There is a danger of non-braked undercarriages rolling. Secure the undercarriage against any unintentional rolling.

People should not be standing within the danger area of the track when pulling it off because the track sets down on the ground suddenly. Fit new track as described under Fitting Crawler Track above, or replace damaged track element as described in next section.

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7.2 Crawler track and grouser shoes – Fitting and removal

7.2.3 Removal and repair (crawler track / grouser shoe) The repair segment differs from the element that is already fitted in the existing track. Repair segment

Kettenglied rechts = track link right Kettenglied links = track link left Endbuchse = master bushing Existing track

Necessary spare parts: x Repair segment as shown above x Master pins x Spacers (poss. seal washers)

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Crawler Repair Manual

7.2 Crawler track and grouser shoes – Fitting and removal

Repair / Replacement of a track segments The bolts have to be removed in order to be able to reach a damaged track link or replace a damaged grouser shoe.

Observe personal safety requirements and fire prevention regulations.

If a track link has been damaged, a repair segment can replace it. To do so, using a flame cutter cut through the damaged track links from above at point (A). The flame-cut section on side 1 drops out.

Also cut through the pins and bushings at the marked points (B) using the flame cutter. Remove cut parts.

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7.2 Crawler track and grouser shoes – Fitting and removal

Flame cut into the pins in the middle on sides 2 and 3 by about 20 – 40 mm depending on the track size.

(Bolzen einbrennen = flame cut into pins)

Knock out remaining track link with remaining bushing on side 2 inwards. Also knock out remaining pins. (herausschlagen = knock out)

Knock track link on side 3 from out to in until the bushing emerges from the track seat and the track link rotates around the hinge on side 4. Remove residual pins first if there is not enough play in the track. Then knock the track link with the residual pins on side 4 from in to out. (Schlagen = knock)

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Crawler Repair Manual

7.2 Crawler track and grouser shoes – Fitting and removal

Grind off protruding bushing ends at the sides and grind flat any damage caused by flame cutting the track link at the side. (abschleifen = grind off)

Insert spacers (poss. seal washers) and insert segments in track. Knock or press in (on larger tracks) both master pins. If knocking in, make sure to provide counter-pressure behind the track link. Grease tips of pins and insert in the holes. Drive in with heavy hammer on smaller track sizes. A pin-driving tool is necessary for larger tracks (see illus. in previous section).

Screw grouser shoe onto repair segment as described in previous section.

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Crawler Repair Manual

8.1 Track guide – Function and operation

8. Other/Special components 8.1. Track guide – Function and operation 8.1.1 In general Track guides are used wherever track sag occurs on undercarriages while travelling over obstructions. The result is that the track can run outside the flanges of the track rollers. There are various types of track guides. Differentiation is made between welded and bolted designs. There are also designs that cover the complete length of the undercarriage and others that are fitted in sections.

8.1.2 Types of track guide Track guide, welded design as segment (With this design, the undercarriage has to be raised for fitting or removal).

Track guide, bolted design as segment (With this design, the undercarriage does not have to be raised for fitting or removal).

Version without cross-link possible Æ "lightweight design“

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Crawler Repair Manual

8.2 Track guide – Fitting and removal

Track guide, bolted design over complete length of the side frame (With this design, the undercarriage does not have to be raised for fitting or removal).

8.1.3 Function Track guide acts as a "threading aid" for the track. If sagging occurs in the track, it comes away from the track rollers. As the sag recedes, the track guide ensures that the track and the track roller are properly aligned again.

8.2. Track guide – Fitting and removal 8.2.1 General description There are two fundamental designs of track guide. In the case of the welded design, the undercarriage has to be raised in order to be able to fit the track guide because there is no possibility of fitting the chain guide from the side. After raising the undercarriage, the track guide is mounted onto the undercarriage with bolts. Removal is analogue in reverse order. In the case of bolted designs, they can be fitted without raising the undercarriage because the track guide is in several parts. In this case, one side of the track guide is bolted onto the undercarriage. The cross link is then connected to the first side of the track guide. The second side of the track guide is then bolted onto the cross-link. The second side is then bolted onto the undercarriage. Removal is analogue in reverse order.

Attention must be paid that there is no contact between the track guide and the track roller body and that there is adequate play between the track guide and the track (pin boss of the track). Mainframe/Crawlers

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8.3 Covers

8.3. Covers 8.3.1 In general Covers are shown in the following illustration, they occur on all standard undercarriages (not all covers are present on all undercarriages). It is also possible that additional covers are present on the undercarriage that are not shown in the illustration. Typical covers are for the hydraulic motor or for the hand hole for access to the lubrication nipple of the tensioning element.

Take care when handling the plates as they can be very heavy depending on size and can therefore cause injuries.

8.3.2 Function Covers made of sheet metal are used on an undercarriage. They are used for: x Covering units and hydraulic lines x Protection against dirt and contamination x Protecting people against injury

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Final Drive Final Drive–General Description The final drive is a 3-stage planetary gear drive which is totally enclosed. The bearings are protected by special slide ring packings. It has an internal multi-disc brake which is spring applied and released by hydraulic pressure. The brake is therefore, maintenance free and no repair work should be done on the brake except by factory authorized specialists. The brake unit should be exchanged for a complete unit.

WARNING: HOT OIL will burn. Always wear work gloves and let final drive cool down after a long period of operation, before draining oil. Place an "Out of Service" tag on the ignition switch before doing any service or maintenance work on the machine.

CAUTION: Drain oil into an approved container and dispose of according to local environmental regulations. Operation of final drive with low or incorrect oil may cause irreparable damage to the gearbox. Follow recommended oil check and change intervals.

Oil Check/Change (See also "Recommended Service Intervals for F130 Gearbox" in this section.) 1.

Machine must be on level surface. Position final drive so drain plug is at bottom position.

Remove fill plug and check oil. Oil should be at bottom edge of fill plug hole. Check to see that sealing surface of fill plug is not damaged, and install plug. Add oil if necessary.

Initial oil change is at 50 hours of operation.

Regular oil change interval is 1000 hours of operation, or at least once a year.

Place an "Out of Service" tag on the ignition switch. Place a suitable container under the drain plug. Remove drain plug and fill plug.

Check sealing surface of drain and fill plug and replace if necessary. Install drain plug and fill with correct oil type to bottom of fill plug hole. Install fill plug. Refer to recommended oil list in Section 9.

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35 36

8 9

10 12

Final Drive

Fig. 3-7 Final Drive

Mainframe/Crawlers

Final Drive Item List 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

F130 Final Drive Assembly O-Ring Screws Hollow Wheel Planetary Gear Carrier Assembly Planetary Gears Snap Ring Washer Gear Planetary Gear Carrier Assembly Planetary Gears Snap Ring Washer Gear Shaft Side Gear Carrier Assembly Side Gears Pins Washer O-Ring Cover Screws O-Ring Flange O-Ring Disc Sealing Ring Screw Plug Screws Screws Motor Screws

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

O-Ring Valve Screw Plug Sealing Ring Beam Assembly Spacer Half Gasket Bearing Cup Outer Gasket Hub Assembly Bearing Cup Shims Ring Nut Snap Ring Disc Springs Piston Gasket Gasket Gasket Gasket Hub Disc Assembly Sintered Discs Steel Discs Shaft Assembly Internal Shim Bearing Snap Ring External Shim Spacer Snap Ring

See Parts Manual for Correct Items and Quantities

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Final Drive Disconnect

Fig. 3-8 Final Drive Disengagement Hub 24. Flange 26. Disengagement Cover

Towing Procedure–Gear Drive Disconnect 1.

Be sure machine is secured from movement before gear drive is disconnected, via tow bar attached to towing vehicle or by blocking tracks. When drive is disconnected the brakes are nonfunctional.

Remove the two M10 X 25 capscrews from disengagement cover. Install two M10 X 50 capscrews into the two threaded holes in the cover and screw in all the way. There should be a space of about 1 in. (23 - 25mm) from the outside of the cover to the flange as shown. This will disengage the internal splines of the cover from the pinion gear shaft. Repeat on other side. Machine is now ready to tow. Do not exceed normal tram speed of machine when towing.

After towing, but before disconnecting from tow vehicle, replace the disengagement cover so the pinion gear shaft is again connected to the cover.

Parking Brake–Description The multiple-disc parking brake is integrated as a complete unit into the transmission on the motor side. It must be removed and installed as a complete unit through the front cover side of the transmission. After any repair work on the brake, the brake line must be bled properly. Machine should be tested on jacks to ensure the tracks will not creep while the traction motors are under hydraulic pressure for tramming.

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Final Drive Brake DO NOT service, perform maintenance or make adjustments while machine is running. The parking brake is nonfunctional when the gear drive is disengaged for towing. BE SURE machine is on level ground and secured from movement, i.e. via tow bar to pulling vehicle prior to disengaging the gear drive and while re-engaging the gear drive.

Parking Brake–Removal & Installation Refer to fig. 3-7 1.

Be sure machine is on level ground and tracks are blocked or on jacks to prevent movement of machine.

Remove dirt from all parts and fastening elements prior to beginning and as you proceed through the removal process (as needed).

Disengage as per instruction for towing procedure.

Drain oil from final drive into a suitable container. Dispose of old oil according to local regulations.

Remove capscrews (32) and hydraulic motor (31) from final drive.

Remove capscrews (22) and cover (21).

Remove components to and including the pinion gear shaft (15).

Continue to disassemble the components of the transmission until reaching the brake pack assembly.

Remove the brake pack assembly (46-64).

10.

For complete disassembly and assembly of the transmission components including the brake pack, see Final Drive section in the F130 repair manual.

11.

Installation is basically the reverse of removal. Be sure to check condition of o-ring (20).

12.

Fill final drive with correct type of oil. See "Oil Check/Change" procedure in this section.

Tram Parking Brake Test The purpose of this procedure is to test the final drive park brake system for acceptable operation after reports of inefficient or unserviceable brake mechanical suitability. This requirement may arise as a scheduled maintenance item, or due to unserviceable brakes. NOTE

Testing should only be carried out by an experienced qualified technician and an experienced operator. Any report of inefficiency or unserviceable brakes would require the machine to be tagged Out Of Service until repaired and retested.

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Final Drive Brake Tram Parking Brake Test (cont.) Description The tram or travel drive park brake is a multi disc, oil immersed brake pack that is an integral component of the track final drive. The brake is spring applied and hydraulically released. The brake shares the same oil as the final drive reduction gear case. The brake is hydraulically released whenever the “Drill / Tram” selector is switched into “Tram” mode. The brake is applied when the “Drill” mode is selected. This is to ensure that the park brakes are applied to prevent the drill from moving.

Test Conditions Dependant upon the machine type, location and situation the brake test procedure may be performed with the machine either on the ground or jacked up. BE SURE machine is on level ground and block tracks before removing brake lines. Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts. Failure to depressurize system before proceeding could result in explosive loss of fluid, damage to equipment, or possible personal injury. Each person performing service work must be satisfied that they have adequate knowledge and training to perform the required tasks. A thorough understanding of hydraulic and pneumatic systems as well as electrical and mechanical knowledge and experience is required.

Brake Test Setup 1.

Ensure machine is at operating temperature before checking pressures.

Rotary drills without brake solenoid valve: Disconnect the tram brake release hose at the tee above the track equalizer bar, located just above axle pivot beam. This will ensure the brakes are mechanically applied and enable you to perform the brake testing without the machine moving.

Rotary drills with brake solenoid valve: Remove solenoid coil from brake solenoid valve located inside A-frame on left hand side (non-cab side.) This will ensure the brakes are mechanically applied and enable you to perform the brake testing without the machine moving.

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Final Drive Brake Tram Parking Brake Test (cont.) Brake Test Procedure 1.

Start machine and allow time to warm up.

If the machine is jacked up, the tram lockout must be overridden. Therefore the tram functions will operate enabling you to perform the brake testing.

With the drill in PROPEL MODE and track blocks removed, slowly move the right or left tram lever to full forward or reverse position, noting the pressure reading on the gauge in the operator cabin on a rotary drill.

The pressure reading should reach approximately 5000 psi (345 Bar). The travel drive must not rotate. Any movement of the track chains would signal the travel brakes are inefficient and require further inspection and possibly overhaul. If the hydraulic pressure does not reach full pressure, there may be an excess of internal leakage within the travel motor or the pump may be set incorrectly.

NOTE

The machine at this point should be tagged out of service until further testing and repairs are carried out and the machine retested.

At the completion of the testing reposition the track blocks, shut the machine down, release any stored hydraulic energy and reconnect the tram brake release hose / reconnect solenoid.

Restart machine, activate PROPEL MODE and check tram brake hose connection for any hydraulic leaks before putting machine back into service.

Bleed air from hose at the brake pack by cracking the hoses slightly, moving the tramming levers forward or reverse. Perform left and right side. Ensure tracks are lifted from the ground before moving the tramming levers

Brake Hold Test To test the holding ability of the final drive brake, do the following: 1.

With the mast in the lowered position and the Tram/Drill switch in TRAM, maneuver the drill up a 20o slope as shown.

Place the Mast/Drill switch in the DRILL position. The brakes should then be engaged.

Verify that the drill is then held in place by the brakes for a minimum of two minutes.

B& R

STOP

B& R

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Final Drive Maintenance and Repair Recommended Service Intervals for F130 Gearbox Oil Change 1.

First oil change to be performed after 50 machine hours.

Additional oil change to be performed after 1,000 machine hours or seasonally (at longest 1 year). Sooner, if determined necessary.

Oil Analysis 1.

Oil analysis should be performed on a regular basis (example: quarterly).

Particle ppm levels should be compared to "Warning Level Guidelines" and necessary actions should be taken.

Upon high Fe-Cr contamination levels, the sun gear/input shaft should be inspected for wear and replaced as necessary. If the sun gear is acceptable, further internal gearbox inspection should be performed.

Sun Gear 1.

The sun gear/input shaft should be changed out upon initial wear indication.

The sun gear/input shaft generally has the highest wear rate and needs to be replaced periodically to prevent other gearbox component failures. It is suggested that a maintenance program should consider replacing the sun gear at 6,000–8,000 machine hours.

Warning Level Guidelines for ContaminaƟon and Wear Metals in Crawler Type Final Drives Si (Silicon) Fe (Iron) Cu (Copper) Cr (Chromium) Al (Aluminum)

Normal 200 ppm 500 ppm 80 ppm 10 ppm 50 ppm

CauƟon >400 ppm >1500 ppm >160 ppm >15 ppm >100 ppm

Serious >600 ppm >3000 ppm >240 ppm >25 ppm >150 ppm

CauƟon: In this case the gearbox must be kept under control Serious: In this case the manufacturer suggests changing the oil and repeaƟng the tests aŌer a short period of work. If the values are sƟll serious, we suggest rebuilding or replacing gearbox. These values are only guidelines and they can be modiĮed due to speciĮc applicaƟons. Notes: Si-Al ContaminaƟon also from external sources Fe-Cr Wear metals by gears and bearings Cu Wear metal by brake discs

Repair For further detailed information and/or repair, refer to the following Final Drive repair manual. 3-104

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Final Drive Repair Manual

REPAIR MANUAL

FINAL DRIVE Mod. F130 855459

1st Edition date: November/’08 Revision date: 00/00

Mainframe/Crawlers

P/N: 257101

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GENERAL INFORMATION

Mainframe/Crawlers

Final Drive Repair Manual A.1 Manual use End users • • •

Installer. User. Maintenance operator.

Maintenance CONSULT THIS MANUAL THOROUGHLY, as proper functioning and good efficiency of mechanical organs depends mostly on constant and correct routine and extraordinary maintenance which could promote the integrity and duration of the final drive and avoid damages or any harm to the operator. In case of any damages or anomalies, quick intervention of specialized personnel can avoid future impairment and lengthen the working life.

Repair The disassembly/assembly procedures have been outlined for a total group overhauling. They have also been described in sequence through photographs with relevant explanation for specific interventions, thus obtaining a complete and safe guide for each and every phase of an operation. Operation description presumes that the final drive has already been removed from the vehicle. The manual supplied by the vehicle manufacturer should be consulted in case of a overhauling or maintenance intervention requiring the removal of the final drive. Moreover, the attentive group inspection leads to a correct repair work estimation that could merely require dismounting only few components, and thus operating partially on the group. Information property This manual should be considered as O&K Antriebstechnik GmbH & Co. KG confidential information. All rights reserved. No part of this manual may be reproduced, in any form or by any means, without prior written permission of O&K Antriebstechnik GmbH & Co. KG. Only the customer, whom the manual, together with the final drive, has been issued to, is allowed to use this document, and only in order to use, maintain and repair the final drive.

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Final Drive Repair Manual A.2 Übereinkommen und Bestimmungen

A.2 Agreements and definitions

Übereinkommen

Agreements

Die im Handbuch enthaltenen Abbildungen sind NICHT massstabsgerecht, das heisst es können KEINE Rückschlüsse auf die reellen Masse der Teile gezogen werden. Die Abbildungen dienen rein dazu die Arbeitsschritte an Fahrgetriebe zu veranschaulichen, das heisst dass die Abbildung nicht unbedingt der in Ihrem Handbuch beschriebenen Fahrgetriebe entsprechen muss. Es kann sich um ein ähnliches Fahrgetriebe handeln.

Illustrations like pictures, drawings and components of this manual are NOT in scale, because of limited space and editing limits, therefore they are NOT reliable to obtain values about size or weight. Illustrations are supposed to point out the various handling sequences and phases of the final drive and its components, therefore they could not display exactly the same group elements.

Bestimmungen

Definitions

Linke Se ite: entspricht der linken Seite des Fahrgetriebes in Fahrtrichtung der Maschine betrachtet. Rechte Seite: entspricht der rechten Seite des Fahrgetriebes in Fahrtrichtung der Maschine betrachtet

Left side: it is the left side of the final drive considering the in vehicle running conditions. Right side: it is the right side of the final drive considering the in vehicle running conditions.

Übereinkommen

Typographic agreements

Anmerkung: Wichtige Information, hervorgehoben in Bezug auf den vorgehenden und nachfolgenden Text, weil besonders wichtig. Warnung: Das teilweise oder komplette nicht Beachten dieser Anmerkung kann zu Schaden an der Maschine oder an Teilen derselben führen. Vorsicht: Das teilweise oder komplette nicht Beachten dieser Anmerkung kann zu Schaden oder schweren Verletzungen des Benutzers der Maschine führen.

Note: The notes, pointed out externally to the text they refer, include important information. Warning: Warning indications point out the procedures, whose partial or complete non-observance can damage the machine or the connected equipment. Danger: Danger indications point out the procedures, whose partial or complete non-observance can injury the operator.

Masseinheiten

Measurements

Im Handbuch werden die Masseinheiten des internationalen Systemes (SI) verwendet. Für die Umrechnung auf das englische System ist die folgende Tabelle zu verwenden.

This manual indicates all measurements in International System (SI). Use the following conversion table to convert Imperial Measure.

Umrechnungstabelle

Conversion table

S.I. 1 (mm) (mm) 10 25.4 (mm) 6.4516 (cm²) 1 (m²) (cm²) 16.378 0.473 (dm²) (l) 1 1 (l) (g) 1.772 (kg) 0.4536 0.00070308 (kg/mm²) 1 (bar) (kg.m) 1 1(daN)= 10 (N)= 1,02 (kg.f)

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ENGLISH AND USA SYSTEM 0.03937 (in) 0.3937 (in) 1 (in) 1 (sq. in) 1550 (sq. in) 1 (cu. in) 1 (U.S. pint) 61.02 (cu. in) 0.2642 (U.S. gal) 1 (oz) 1 (lb) 1 (lb/sq. in) 14.51 (psi) 7.246 (lb.ft) 2.24 (lb.f)

Mainframe/Crawlers

Final Drive Repair Manual A.2.1 Symbology

SYMBOLS

DESCRIPTION WARNING / DANGER

REMOVE / INSTALL seals / gaskets / filters

OIL FILLING OR OIL LEVEL OIL DRAIN

LUBRICATION / GREASING

ADJUSTMENTS / MEASUREMENTS tightening torques / preloads / backlash

SPECIAL TOOLS

SEALING / LOCKING FLUIDS APPLICATION

MARK OR INDICATE

DISASSEMBLY / ASSEMBLY OF BULKY PARTS OR SUBASSEMBLIES

WARNING: respect assembly orientation

CLEANING CAREFULLY

APPLY PRESSURIZED FLUID

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Final Drive Repair Manual A.3 General description The final drive should be checked and/or repaired only by qualified technicians, acquainted with its peculiar features and well aware of all safety instructions.

Before performing any operation it is advisable to carry out final drive cleaning accurately by removing oil/ grease encrustations and accumulation. All disassembled mechanical parts must be cleaned accurately with suitable products to avoid possible damage. Parts should be replaced if damaged, worn out, cracked, seized, etc. as they could affect proper functioning of the final drive.

Rotating parts (bearings, gears, shafts) and that of hardware/fasteners (O-Ring, oil seals) should be examined carefully, as they are subject to major stress, wearing and ageing.

Use appropriate spare parts, nuts and bolts to avoid any other problems. Moreover, use metric tools for metric nuts and bolts and Imperial tools for the others. Please read the disassembly instructions very carefully because some operations are destructive for some final drive components and in order to avoid the elements damage operate advertently.

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Final Drive Repair Manual A.4 General recommendations for disassembly and assembly operations

Sealing

Before starting any disassembly and assembly operations, read carefully the following recommendations.

Oil drain

Shafts seals

WARNING Disposal of used oil must be done according to laws

Respect the following recommendations during shaft seal assembly: • Clean shaft very carefully and ensure that the part in contact with the shaft seal is not damaged, cut or out of roundness. • Assemble the seals so that the lip is fitted towards the oil side. • Lubricate seal lips (use grease) and fill 3/4 of seal cavity with grease. • Use appropriate drivers. Do not use a hammer directly on the seals. • Do not damage the seals while assembling the shaft.

Use sealing as advised by specifications. Ensure that parts to be sealed are clean, dry and completely grease free.

Before disassembly, oil should be drained out.

Cleaning Wash all moving parts (gears, bearings, etc.) accurately with diesel fuel or kerosene. Avoid gasoline and watery alkaline solutions. Do not wash with steam or hot water, as it will be very difficult to eliminate surface humidity. Dry all parts with a rag or air jet to avoid scratching from abrasive residuals. All surfaces should be covered with lubricant so as to protect it from future oxidation. Checks

O-Rings Lubricate adequately before inserting them at the right place and avoid rolling while inserting the shaft. Adjusting shims Use appropriate adjusting shims and measure each one separately. Complete group measurement or stampings on the shims are not always reliable: check.

Examine accurately all bearings, external rings which may be still stuck in their position and pivot pins on which rolls rotate. Replace those which are worn out or damaged. Gears should not be spoiled and teething should not be excessively worn out. Teeth smoothing should not be deteriorated. Check all grooves: assure that they are not worn out or damaged. Replace spoiled parts with original spare parts. Replace seals on rotating shafts, before reassembly.

Bearings

Ends of flanges and tools

Its advisable to heat up bearings to 80°C - 90°C before assembling them onto their respective shafts or to cool them (dry ice) before inserting them into corresponding bore. Before reassembling the bearings, clean, check and lubricate them.

Be careful when hammering tool or flange ends, in order to avoid jeopardizing functionality and integrity of either the tools or the components on which you are operating.

Split pins Before assembling elastic pins, make sure that the notch is oriented towards the stressing force. Spiral elastic pins do not need orientation.

Mainframe/Crawlers

Reassembly ways In order to reassemble the group, an appropriate fixture must be used. In order to position the group, to disassemble and reassemble the ring gear and to support the gear housing, a lifting system is needed. To make disassembling and assembling operations easier, use a group assembly drawing.

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SAFETY INSTRUCTIONS

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Final Drive Repair Manual B.1 General safety recommendations

B.2 Safety symbols Recognize safety information

IMPORTANT: Before proceeding with any operations please read this chapter very carefully.

This is the safety alarm symbol; whenever you find it in the manual or see it on the machine, you are being warned about potential danger of accidents or harm to personnel. Follow the do’s and don’t’s to operate in total safety.

Understanding written warnings

DANGER

Safety precautions: Correct use and repair of the group and of its components is very important for safety and reliability. Recommendations and all described procedures given in this manual have been experimented and hence are effective operational methods. Please follow every procedure. Use the text as well as the illustrations. Certain procedures show use of special tools, designed so that the operations can be carried out in a clear and correct manner. Special tools must be used when a particular operation is being carried out. It is impossible to advice every working method or know all possible methodologies for carrying it out or to predict risky consequences of each operation. Hence, performing procedures or using instruments which have not been advised could be dangerous for the operator/ mechanic as well as the vehicle.

WARNING CAUTION Written warning (DANGER, WARNING or CAUTION) is used along with an alarm symbol. DANGER or WARNING signs are used near danger zones, while CAUTION sign indicates general precaution.

Follow safety instructions ! Read all suggestions given in this instruction manual very carefully.

Danger Safety goggles must be worn while carrying out every assembling or disassembling operations. Unauthorized changes could endanger the functioning, work safety and work span. If you do not understand this instruction manual, contact the nearest sales representative.

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Final Drive Repair Manual B.3 General precautions

Observe safety instructions, accident prevention rules and all general safety regulations in each and every step at work. Before going ahead with maintenance or repair work ensure that all the tools, the supporting bench, stands, levers, extractors and spanners are in good condition so that the work can be carried out easily. Risks to various parts and components will also be reduced in this way and working condition for the operator will also be safer. O&K Antriebstechnik GmbH & Co. KG declines any responsibility in case of an accident or damage resulting due to changes made arbitrarily on product. The product is used for any other purpose different from the one foreseen, than O&K Antriebstechnik GmbH & Co. KG declines any responsibility. In this case all consequences will be at the customer’s expense.

Safety maintenance rules 1 Operate in a clean and dry environment. 2 Do not lubricate, handle or adjust the group underway. 3 Keep off your hands, feet and clothing from moving parts. 4 Be always prepared for fires. Keep the extinguisher and the first aid kit within reach. 5 Keep the phone numbers of a doctor, of an ambulance, of a hospital and of the fire department within reach near the telephone set.

6 Wear suitable clothing and protections as overalls, safety gloves and ear safety devices. 7 Use suitable ear protections, like ear plugs, to keep out noise and prevent injury to the ears.

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A prolonged exposure to noise can damage your hearing.

8 The operator must be very careful with the equipment. Do not use headphones to listen music while you are working on the product or on the group.

Residual risk elimination •

•

Risk of squashing and shearing due to the presence of moving parts. Warning Carry out all maintenance operations when the machine is stationary. Risk due to inhalation of poison gases that can be produced by heating the varnishes during any welding. Warning Use work stations equipped with dust and fume discharging systems. Let the fumes disperse for at least 15 minutes, before welding or reheating, or working on the group again.

•

Risk of fire due to the solvents used and to the oil in the product. Warning Keep off any heat sources from the working area. When solvents or paint removers are used, they should be removed with soap and water, before welding. Remove any containers of solvent, paint remover or any other inflammable products from the working area.

•

Risk due to fall, drop or violent ejection of objects or oil from the product. Warning These residual risks and the suitable relative procedures to eliminate them completely are pointed out, in detail, in the assembly and disassembly procedures. During maintenance, follow carefully all the safety procedures indicated in the manual.

Mainframe/Crawlers

Final Drive Repair Manual

GENERAL SPECIFICATIONS C.1 Intended uses This slew drives has been designed and manufactured to be mounted on industrial machines. The slew drives is a component that transmits the power from the engine to the wheels. The slew drives, manufactured according to the customer’s technical specifications, allows: • increasing of tractive force, reducing the number of revolutions. Never mount this slew drives on machines different from the ones for which it has been designed and manufactured If the slew drives is used for any other purpose than the one foreseen, O&K Antriebstechnik GmbH & Co. KG declines any responsibility regarding damages or accidents caused by it. All consequences will be at the expense of the client. However, when used as foreseen, operational formalities as well as regular maintenance repair specifications given by O&K Antriebstechnik GmbH & Co. KG are to be observed strictly.

ung des Produktes

C.2 Product identification

s Getriebes

Tran

GETRIEBETYP TRANSMISSION TYPE

N° O&K ANTRIEBSTECHNIK UND FABRIKATIONSNUMMER O&K ANTRIEBSTECHNIK P/N AND S/N

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Final Drive Repair Manual 4 Dichtmittel und Kleber

C.4 Sealing compounds and adhesives

A1= LOCTITE® 510

B2= LOCTITE® 242

A2= LOCTITE® 573

C1= LOCTITE® 405

A3= LOCTITE® 518

C2= LOCTITE® 496

B1= LOCTITE® 542

C3= LOCTITE® 638

Auf der Kontaktfläche auftragen Apply on the contact surfaces Am Gewinde der Schrauben/Bolzen auftragen Apply on bolt screws / on pins

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Mainframe/Crawlers

Final Drive Repair Manual C.5 Füllmengen und Kontrollen

SCHMIERSTELLEN

C.5 Filling and checks

LUBRICATION POINTS

POSITION / POSITION

Einfüllverschluss und Ölstand epizykl. Untersetzungsgetriebe

Epicyclic reduction gear oil level and filling plug

Ölablassverschluss epizykl. Untersetzungsgetriebe

Drain plug of epicyclic reduction gear oil

Periodische Kontrollen:

Routine checks:

Der Schmiermittelstand des Fahrgetriebes muss genau auf Höhe des Kontrollverschlusses (1) stehen. Wenn dies nicht der Fall ist, ist Öl vom gleichen Typ nachzufüllen. Wenn ein Ölverlust oder ein anderer Schaden, der ein Absinken des Ölstandes verursacht, festgestellt wird, ist dieser sofort zu beheben, um mögliche Beschädigungen der mechanischen Teile zu verhindern. Um das Öl abzulassen, ist der Verschluss (2) aufzuschrauben.

If the final drive lubricant should be flush with control plug (1). If not, make up level with the same oil. If leakage or any other factor determining fall in the oil level is found, then it is advisable to check immediately, in order to avoid damages to the mechanical parts. Loosen and remove the drain plug for oil draining (2).

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Final Drive Repair Manual C.6 Service schedule

FIRST TIME

SEASONALLY OR EVERY 1000 OPERATING HOURS(1)

OPERATION

Slew drives oil change

50 Std./ hours

Lubrication works 50-100 Std./ hours 150-200 Std./ hours

monthly

Clean magnetic oil plugs every oil change monthly

150-200 Std./ hours

Check and in case adjust oil level

Clean oil breather Greasing

weekly

Remarks operation performed only by personnel authorized by the manufacturer operation performed only by trained personnel (1)

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which of both conditions comes first

Mainframe/Crawlers

Final Drive Repair Manual C.7 Lubrication / greasing: grades and application range

SAE 75 W Mainframe/Crawlers

50°C

122°F

40°C

104°F

30°C

86°F

20°C

66°F

10°C

50°F

0°C

32°F

-10°C

14°F

-20°C

-4°F

-30°C

-22°F

-40°C

-40°F

-55°C

-67°F

NLGI Number 2

GREASE SCHMIERE

NLGI Number 1

SAE 75 W -90

SAE 75 W-160

SAE 80 W

SAE 80 W-90

SAE 80 W-140

SAE 90 W

SAE 85 W-140

OIL ÖL

NLGI Number 0

7 Schmierung/Fettung: Temperaturbereich und relative Anwendungsbereiche

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Final Drive Repair Manual C.8 Anzugsmomente

C.8 Tightening torque

130 Nm

445 Nm

92 Nm

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Mainframe/Crawlers

Final Drive Repair Manual C.9 Allgemeine Kontrollen

C.9 General checks

Es wird vorausgesetzt, dass die Gruppe vor der Demontage und Montage schon vom Fahrzeug ausgebaut und auf einer geeigneten Werkbank abgelegt worden ist. Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

The disassembly/assembly instructions presume that the unit has been removed from the vehicle and positioned on a suitable workbench. Some of the following pictures may not show exactly your transmission, but the procedure is the same.

1 Die Kontrolle der Ölstandlinie mit eventueller Nachfüllung vom Fahrgetriebe, wird mit Entfernung des Verschlusses (1) durchgeführt. Der Ölablass erfolgt durch die Lockerung des Verschlusses (2). Fongende Arbeiten durchführen: Verschluss (1) und (2) auf das vorgeschriebene Anzugsmoment festziehen (Abschnitt C.8). 1

2 The oil level and its eventual topping up from gear box is carried out by removing plug (1). The oil drain is carried out by loosing the plug (2). Carry out following operations:screw plug (1) and (2) tightening them at the prescribed torque (Sec. C.8 ).

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Final Drive Repair Manual

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DISASSEMBLY AND ASSEMBLY OPERATIONS

Mainframe/Crawlers

Final Drive Repair Manual D.1

Motor

D.1.1 Demontage

D.1.1 Disassembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Die Schrauben (2) lockern und entfernen. Den Motor (1) demontieren. 1 2

Untighten and remove screws (2). Disassemble motor (1).

2 3

Den O-Ring (3) entfernen.

Remove O-Ring (3).

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Final Drive Repair Manual D.1.2 Montage

D.1.2 Assembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Den O-Ring (3) montieren.

Assemble O-Ring (3). 2 Den Motor (1) montieren. Loctite® 242 an die Schrauben (2) auftragen. 1 2

Assemble motor (1). Apply Loctite®242 on screws (2). 3 Die Schrauben schrauben (2). Mit dem vorgeschriebenen Drehmoment befestigen ( Abschnitt C.8). 2

Screw in the screws (2) and tighten to the prescribed torque (Sec. C.8).

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Mainframe/Crawlers

Final Drive Repair Manual D.2

Ring und Lager

D.2

Ring nut and bearings

D.2.1 Demontage

D.2.1 Disassembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Die Verstemmung vom Ring (1) entfernen. 1

Remove the punching on ring nut (1).

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Final Drive Repair Manual 2 Den Ring (1) entblocken und entfernen.

Unlock and remove ring nut (1). 3 Die Zwischenringe (2),(3),(4) entfernen. 3

Remove shims (2),(3),(4). 4 Die komplette Nabe (6) entfernen.

Remove hub (6) assembly. 5 Den Dichtung (10) aus der Nabe (6) entfernen.

6 Remove gasket (10) from hub (6).

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Mainframe/Crawlers

Final Drive Repair Manual 6 Die Halbdichtung (9) aus der Nabe (6) entfernen. 9

Remove half gasket (9) from hub (6).

7 Den Ring des Lagers (5) von der Nabe (6) entfernen. 6

Remove bearing cup (5) from hub (6). 8 Den Ring des Lagers (7) von der Nabe (6) entfernen.

Remove bearing cup (7) from hub (6).

9 Die Halbdichtung (8) vom Tragrohr (11) entfernen.

8 11

Remove half gasket (8) from beam (11).

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Final Drive Repair Manual 10 Das Lager (7) aus dem Tragrohr (11) entfernen.

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Remove bearing (7) from beam (9).

Mainframe/Crawlers

Final Drive Repair Manual D.2.2 Montage

D.2.2 Assembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

11 Das Lager auf 110 °C erwärmen. Das Lager (7) auf das Tragrohr (11) montieren. 7

Heat the bearing at 110°C. Assemble the bearing (7) on beam (11).

12 Die Halbdichtung (8) auf das Tragrohr (9) montieren. 8

Assemble half gasket (8) on beam (9).

13 Den Ring des Lagers (7) auf die Nabe (6) montieren.

7 6

Assemble bearing cup (7) on hub (6).

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Final Drive Repair Manual 14 Den Ring des Lagers (5) auf die Nabe (6) montieren. 5

Assemble bearing cup (5) on hub (6). 15 Die Halbdichtung (9) auf das Nabe (6) montieren. 9 6

Assemble half gasket (9) on hub (6). 16 Die Dichtung (10) auf die Nabe (6) montieren.

6 Assemble gasket (10) on hub (6). 17 Die komplette Nabe (6) auf das komplette Tragrohr (11) montieren.

Assemble hub assembly (6) on beam assembly (11).

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Mainframe/Crawlers

Final Drive Repair Manual 18 Das Lager (5) montieren. 5

Assemble bearing (5). 19 Ermittlung von Wert (Y) an einem neuen Ring.

Measure the value (Y) on a new ring nut. 20 Den neuen Ring ohne Zwischenringe völlig einschrauben und eine Anhaltslinie zwischen Nabeträger und Ring ziehen. Den Ring lösen.

Screw completely the new ring nut without shims and draw a line of reference between the wheel hub carrier and the ring nut. Unscrew the ring nut. 21 Das Mass (Z) und das Lager unter einer Druckkraft von 100.000 N einpressen.

Check the measure (Z) and press the bearing under a force of 100.000 N, measurable through a charge gauge.

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Final Drive Repair Manual 22 Um das Mass des Zwischenringes zu ermitteln, die unter den Ring zu montieren ist: X=Y-Z Anmerkung: wenn (X) weniger als 0,1 ist, könnten die Zwischenringe brechen. Um diesen Problem zu vermeiden, ist der Ring leicht zu schleifen und die Vorgänge zu wiederholen. In order to determine the measure of the shim to be fitted under the ring nut: X=Y-Z Notes: if (X) is less than 0.1 mm, shims may brake. To avoid this possibility, slightly reface the ring nut and repeat the operations. 23 Die Zwischenringe (2),(3),(4) montieren. 2 4

Assemble shims (2),(3),(4). 24 Den Ring (1) montieren und blockieren. Mit dem vorgeschriebenen Anzugsmoment befestigen (Abschnitt C.8).

Assemble and fasten ring nut (1) at the prescribed torque wrench (Sec. C.8).

25 Einstellmutter (1) mit Verstemmung sichern.

Punch for ring nut safety (1).

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Mainframe/Crawlers

Final Drive Repair Manual D.3

Planetenzahnrad

D.3

Planetary gears

D.3.1 Demontage

D.3.1 Disassembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Die Schrauben (4) lösen und entfernen.

Unscrew and remove screws (4).

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Final Drive Repair Manual 2 Den Deckel (3) entfernen.

Remove cover (3). 3 Die Anlaufscheibe (6) vom Deckel (3) entfernen. 3

Remove washer (6) from cover (3). 4 Die Dichtung O-Ring (5) vom Deckel (3) abnehmen.

5 3

Remove O-Ring (5) from cover (3). 5 Den ganzen Planetenträger (7) entfernen. 7

Remove side gear carrier assembly (7).

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Mainframe/Crawlers

Final Drive Repair Manual 6 Die Welle (8) entfernen. 8

Remove shaft (8). 7 Das Zahnrad (9) abnehmen. 9

Remove the gear (9). 8 Den ganzen Planetenträger (10) entfernen.

Remove side gear carrier assembly (10). 9 Das Zahnrad (11) abnehmen.

Remove the gear (11) .

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Final Drive Repair Manual 10 Den ganzen Planetenträger (12) entfernen.

Remove side gear carrier assembly (12). 11 Die Schrauben (13) lösen und abnehmen.

Untighten and remove screws (13). 12 Das Hohlrad (14) entfernen. 14

Remove hollow wheel (14). 13 Den O-Ring (5) entfernen.

Remove O-Ring (5).

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Mainframe/Crawlers

Final Drive Repair Manual 14 Seinen Zustand prüfen. Die Aufwölbungen der Bolzen mit einem Meissel vorsichtig zurückstemmen.

Check its wear conditions. Recaulk warily pins convexities by means of a chisel. 15 Im Mittelpunkt der Bolzen (7.3) schlagen, um sie aus ihren Sitz herauszutreiben. Die Planetenzahnräder (7.2) vom Planetenradträger (7) ausbauen.

7 7.3

7.2

Strike on pins center (7.3) in order to let them come out of their seat. Take the planetary gears (7.2) out of the side gears carrier (7). 16 Den Springring (10.4) abnehmen.

10.4

Remove snap ring (10.4). 17 Durch ein Ausziehwerkzeug die Planetenräder (10.2) vom Planetenradträger (10.1) entfernen. 10.2

10.1

By means of an extractor remove planetary gears (10.2) from side gear carrier (10.1).

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Final Drive Repair Manual

18 Die Einlagscheibe (10.3) entfernen. 10.3

Remove washer (10.3). 19 Den Sprengring (12.4) abnehmen.

12.4

Remove snap ring (12.4). 20 Mit Abziehwerkzeug die Planetenräder (12.2) vom Planetenradträger (12.1) entfernen.

12.1

12.2

By means of an extractor remove planetary gears (12.2) from side gear carrier (12.1).

21 Die Anlaufscheibe (12.3) entfernen. 12.3

Remove washer (12.3).

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Mainframe/Crawlers

Final Drive Repair Manual

D.3.2 Montage

D.3.2 Assembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Die Einlagscheibe (12.3) montieren.

12.3

Assemble washer (12.3). 2

12.2

Die Planetezahnräder (12.2) auf den Planetenradträger (12.1) montieren und durch den Sprengring (12.4) blockieren.

12.4

12.1

Assemble the planetary gears (12.2) on the side gears carrier (12.1) and lock them with snap ring (12.4). 3 Die Einlagscheibe (10.3) montieren. 10.3

Assemble washer (10.3).

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Final Drive Repair Manual

4 Die Planetezahnräder (10.2) auf den Planetenradträger (10.1) montieren Den Sprengring (10.4) montieren.

10.2

10.4

Assemble the planetary gears (10.2) on the side gears carrier (10.1) Assemble snap rings (10.4).

10.1

5 Die Planetenzahnräder (7.2) in den Planetenradträger (7.1) montieren. Die Bolzen (7.3) in die Bohrungen montieren und blockieren, indem 3 Verstemmungen am Bolzenrand einzubringen sind. 7.3

7.1

7.2

Assemble the planetary gears (7.2) in the planetary gears carrier (7.1). Fit pins (7.3) in the holes and lock them fitting 3 punchings in pin border. 6 Den O-Ring (5) montieren.

Assemble O-Ring (5). 7 Das Hohlrad (14) montieren. 14

Assemble hollow wheel (14).

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Mainframe/Crawlers

Final Drive Repair Manual

8 Loctite®242 an die Schrauben (13) auftragen.

Apply Loctite®242 on screws (13). 9 Die Schrauben (13) einschrauben und mit dem vorgeschriebenen Anzugsmoment befestigen (Abschnitt C.8).

13 Screw in the screws (13) and tighten at the prescribed torque wrench (Sec. C.8). 10 Den kompletten Planetenradträger (12) montieren. 12

Assemble side gear carrier assembly (12). 11 Das Zahnrad (11) montieren.

Assemble gear (11).

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Final Drive Repair Manual

12 Den kompletten Planetenradträger (10) montieren.

Assemble side gear carrier assembly (10). 13 Das Zahnrad (9) montieren. 9

Assemble gear (9). 14 Die Welle (8) montieren. 8

Assemble shaft (8). 15 Den kompletten Planetenradträger (7) montieren. 7

Assemble side gear carrier assembly (7).

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Mainframe/Crawlers

Final Drive Repair Manual

16 Die Anlaufscheibe (6) auf den Deckel (3) montieren. 6

Assemble the washer (6) on the cover (3). 17 Den O-Ring (5) auf den Deckel (3) montieren.

5 3

Assemble O-Ring (5) on cover (3). 18 Loctite®510 auf das Hohlrad auftragen.

Apply Loctite®510 on hollow wheel. 19 Den Deckel (3) montieren. Loctite®242 auf die Schrauben (4) auftragen.

3 4

Assemble cover (3). Apply some Loctite®242 to screws (4).

Mainframe/Crawlers

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Final Drive Repair Manual

20 Die Schrauben (4) einschrauben und mit dem vorgeschriebenen Anzugsmoment befestigen (Abschnitt C.8). 4

Screw in the screws (4) and tighten at the prescribed torque wrench (Sec. C.8).

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Mainframe/Crawlers

Final Drive Repair Manual

D.4

Bremse

D.4

Brake

D.4.1 Demontage

D.4.1 Disassembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Die komplette Bremseeinheit entfernen

Remove brake unit assembly.

Mainframe/Crawlers

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Final Drive Repair Manual

2 Zwei Schrauben einschrauben um Sprengring zu entfernen. 16

Screw in two screws to remove the snap ring. 3 Den Sprengring (17) entfernen. 17

Remove snap ring (17). 4 Die Dichtung (19) entfernen. 19

Remove the gasket (19). 5 Die Dichtung (18) entfernen.

Remove the gasket (18).

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Mainframe/Crawlers

Final Drive Repair Manual

6 Die zwei Schrauben entfernen.

Remove the two screws. 7 Die Scheibe (16) entfernen. 16

Remove the disk (16). 8 Die Feder (14),(15) entfernen.

14 15

Remove spring (14),(15). 9 Den Kolben (13) entfernen. 13

Remove piston (13).

Mainframe/Crawlers

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Final Drive Repair Manual

10 Die Dichtung (12) entfernen.

Remove the gasket (12). 11 Die Dichtung (10) entfernen.

Remove the gasket (10).

12 Außenscheibe (8) entfernen. 8

Remove outer disc (8). 13 Innenscheibe (7) entfernen. 7

Remove inner discs (7).

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Mainframe/Crawlers

Final Drive Repair Manual 14 Den Sprengring (1) entfernen. Den Buchse (2) entfernen.

Remove snap ring (1). Remove bushing (2). 15 Das Distanzstück (3) entfernen. 3

Remove spacer (3). 16 Die Welleeinheit (6) mit dem Lager (5) entfernen.

6 Remove shaft assembly (6) with the bearing (5). 17 Das Distanzstück (3) entfernen.

Remover spacer (3).

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3-149

Final Drive Repair Manual 18 Den Sprengring (4) entfernen.

Remove snap ring (4). 19 Die Welle (6) und das Lager (5) demontieren.

5 Disassemble shaft (6) and bearing (5).

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Mainframe/Crawlers

Final Drive Repair Manual D.4.2 Montage

D.4.2 Assembly

Einige Abbildungen könnten sich auf ein anderes Getriebe beziehen. Die Arbeitsvorgänge sind aber identisch.

Some of the following pictures could not show exactly your transmission, but the procedure is the same.

1 Die Welle (6) und das Lager (5) montieren. 6

Assemble shaft (6) and bearing (5). 2 Den Sprengring (4) montieren.

Assemble snap ring (4). 3 Das Distanzstück (3) montieren.

Assemble spacer (3).

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Final Drive Repair Manual 4 Die Welle (6) mit dem Lager (5) auf die Nabe montieren.

Assemble shaft (6) with bearing (5) on hub.

5 Das äußere Distanzstück (3) montieren. Das äußere Buchse (2) montieren. 3

Assemble outer spacer (3). Assemble bushing (2). 6 Den Sprengring (1) montieren. 1

Assemble snap ring (1). 7 Außere Scheibe (8) montieren. 8

Assemble outer disc (8).

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Mainframe/Crawlers

Final Drive Repair Manual 8 Innere Scheibe (7) montieren. 7

Assemble inner disc (7). 9 Die Dichtung (10) montieren.

Assemble the gasket (10). 10 Die Dichtung (12) montieren.

Assemble the gasket (12). 11 Den Kolben (13) montieren. 13

Assemble piston (13).

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Final Drive Repair Manual 12 Die Feder (15),(14) montieren.

14 15

Assemble spring (15),(14). 13 Die Scheibe (16) montieren. 16

Assemble the disk (16). 14 Auf die Scheibe drücken und zwei Schrauben einschrauben.

Press on disc and screw in the two screws. 15 Den Sprengring (17) montieren. 17

Assemble snap ring (17).

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Mainframe/Crawlers

Final Drive Repair Manual 16 Die Dichtung (18) montieren.

Assemble the gasket (18). 17 Die Dichtung (19) montieren. 19

Assemble the gasket (19). 18 Die zwei Schrauben entfernen

Remove the two screws. 19 Die Gesamte Bremseeinheit montieren.

Assemble the brake unit complete.

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Final Drive Repair Manual

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TROUBLESHOOTING

Mainframe/Crawlers

Final Drive Repair Manual PROBLEMS

- Uneven wear of tyre. - Brake noise. - Vibration during forward drive, intermittent noise.

POSSIBLE CAUSES

1 Falscher Einbau/Defektes Fahrgetriebe Den Einbau kontrollieren oder Fahrgetriebe, wenn dieses die Testverfahren nicht besteht, reparieren/ ersetzen.

1 Incorrect installation / defective final drive. Correct installation or repair or replace the final drive in case it does not survive any one of the test phases.

2 Überladung und/oder schlechte Verteilung der Last Übergewicht ablegen und die Last, den Fahrzeugbestimmungen entsprechend neu verteilen.

2 Overloading/ incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.

3 Radius der Reifen verschieden Ein kleinerer Radius verursacht ein teilweises Durchrutschen des Rades bei Krafteinwirkung. Der andere Reifen mit grösserem Radius muss daher die gesamte Arbeit leisten. Reifen ersetzen oder den Druck beider Reifen kontrollieren und anpassen, bis ein gleicher Radius für beide Reifen erzielt wird.

3 Different rotation radius of the tyres If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied.The other tyre with bigger radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both tyre.

4 Bruch des Fahrgetriebes Es wird davon abgeraten ein Fahrzeug mit einerm gebrochenen Fahrgetriebe zu verwenden. Ein Verschieben der nicht beladenen Maschine um einige Meter ist jedoch möglich. (Mit blockiertem Fahrgetriebe.)

4 Broken final drive It is not advisable to operate the vehicle with a broken final drive. It is acceptable to move the vehicle (final drive off unloaded) a few meters away only.

5 Fahrgetriebe verbogen Fahrgetriebe ersetzen.

5 Bent final drive Replace final drive.

6 Falscher Gebrauch des Produktes Die Gebrauchsanweisungen des Herstellers der

6 Incorrect use of the product See the vehicle producer‘s instructions once again. 7 Incorrect wheel adjustment Verify group integrity and wheel side bearings. Adjusting according. 8 Spoiled or worn out final drive parts Check the condition of ring gear, pinion gear, bearings etc. Replace when ever necessary. 9 Contamination in the final drive box or incorrect assembly of parts Look for foreign particles. Check assembly of the various parts of the final drive.

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Notes

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Mainframe/Crawlers

Section 4

Drive Train / Compressor

4-1

Engine and Drive Train Service Procedures

Fig. 4-1 Engine Air Filter - Right Side

Fig. 4-1a Compressor Air Filter - Left Side

2 4

5 6

7 8

19 9 18

14 15

Fig. 4-2 Engine and Compressor Air Cleaner Assembly 1. Cap 8. Gasket 2. Body Assembly 9. Nut 3. Flange Assembly (Outlet) 10. Clip 4. Safety Element 11. Washer Gasket 5. Washer Gasket 12. Primary Element 6. Nut 13. Body Assembly 7. Nut 4-2

14. 15. 16. 17. 18. 19.

O-Ring Clamp Assembly Cup Nut Gaskets Bolt

Drive Train / Compressor

Engine and Drive Train Service Procedures Service procedures outlined in this section include: 1. 2. 3. 4. 5. 6.

Diesel Engine Air Cleaners Drive Shaft Pump Drive and Pumps Compressor Drive Coupling Air Compressor System

For hydraulic pump adjustment see Section 7.

Engine Service Procedures Lubrication requirements, fluid levels, and general service requirements are covered in Section 9. Refer to the engine manufacturer's manual on the specific engine for more detailed service requirements.

Engine Fault Codes:

Caterpillar Engines - see Caterpillar operator/maintenance manual. Cummins Engines - see end of electrical section 8.

Engine and Compressor Air Cleaner Service Service for the disposable-filter type air cleaner includes general inspection and replacing the elements as required. A. Inspection and General Service 1.

Inspect air transfer duct between air cleaner and engine to be sure all clamps and joints are tight and there are no cracks in ducting.

Verify that air cleaner mounting bolts and clamps are tight, holding air cleaner securely.

Check dust cup to make sure it is sealing completely around air cleaner body.

Be sure vacuator valve is in place (if so equipped), not inverted or damaged, and free from obstruction.

Check body of air cleaner for dents and damage which could cause a leak or damage the elements.

Make sure all inlet accessories are free from obstruction and securely mounted.

Check pre-cleaner tubes for plugging.

Drive Train / Compressor

4-3

Engine and Compressor Air Cleaners Engine and Compressor Air Cleaner Service (continued) B. Air Cleaner Service Proper air cleaner servicing will result in maximum engine protection against the ravages of dust, and can also save time and money by increasing filter life and dust cleaning efficiency. Two of the most common servicing problems are: 1) Over-Servicing - New filter elements increase in dust cleaning efficiency as dust builds up on the media. Don't be fooled by filter appearance, it should look dirty. By using proper filter restriction measurement tools, you will use the full life of the filter at maximum efficiency. 2) Improper Servicing - Your engine is highly vulnerable to abrasive dust contaminants during the servicing process. The most common cause of engine damage is careless servicing procedures. By following the steps shown, unnecessary dust contamination to the engine can be avoided. 1.

A filter indicator is used to measure the filter restriction. There are two indicators mounted on the operator control console to monitor the right and left filters.

Dust cups should be dumped when 2/3 full. Make sure it seals 360o around the air cleaner body. On Vacuator Valve equipped models, 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.

Light dust plugging of tubes can be removed with a stiff fiber brush. If heavy plugging with fibrous material is evident, remove lower body section for cleaning with compressed air or water not exceeding 160o F (71.7o C).

CAUTION:

NEVER clean tubes with compressed air unless both the primary and safety elements are installed in the air cleaner. DO NOT steam-clean tubes. C. Element Servicing

4-4

When restriction indicates that element servicing is required, loosen wing nut and remove primary element. Before installing new element, inspect the element and gasket for shipping or storage damage. Carefully install element and wing nut. Reset the restriction indicator to green. For minimum downtime, replace dirty filter with new or properly cleaned XLP filter element. If element is to be serviced for immediate re-use, reinstall outer cover to protect induction system while cleaning element.

Inspect and tighten all air cleaner induction system connection.

Inspect all gaskets. Replace if worn or damaged. Annual replacement of all gaskets is recommended.

Drive Train / Compressor

Engine and Compressor Air Cleaners Engine and Compressor Air Cleaner Service (continued) D. Safety Element Service The safety element is not intended to be cleaned. For maximum engine protection and air cleaner service life, replace the safety element with a new safety element every third primary element change or cleaning, or as indicated by the Safety Signal Service Indicator (this is the special nut that holds the safety element in place). E. Element Replacement To replace the elements refer to Figure 4-1 or 4-2 (depending upon how your machine is equipped) and proceed according to the steps below. Anytime the elements are replaced or cleaned, the dust cup and the lower body assembly should also be cleaned. 1.

Release clamp assembly and remove dust cup. Remove and wash lower body and dust cup.

Release catches (STG Type) and remove cover and o-ring from upper body assembly.

Remove wing nut and gasket securing outer (primary) element.

Remove primary element.

Remove inside nut and gasket and remove small (safety) element.

To replace elements with new components, obtain correct replacement elements, with o-ring and two gaskets, and replace them in reverse order of disassembly.

When replacing elements, gaskets, and o-rings, it is a good idea to replace two o-rings (STG Type) on lower element, also.

F. Element Cleaning Methods Clean the Duralife element either by using compressed air or by washing. Compressed Air is recommended when element will be re-used immediately because a washed element must be dried before re-use. However, washing does a better job and must be used when exhaust soot has lodged in fine pores of the filter media. Use Donaldson D-1400 detergent which contains a special additive for removing soot and carbon. Replace element after 6 cleanings or annually, whichever occurs first. Do not remove plastic fin assembly - back-flowing with compressed air or washing will remove dust from beneath the fin assembly. Compressed Air - Direct air through element in the direction opposite to normal air flow through the element. Move nozzle up and down while rotating element. Keep nozzle at least one inch from pleated paper. Maximum air pressure to prevent damage of element is 100 PSI. Washing - Soak element 15 minutes or more in Donaldson D-1400 and water solution. See carton for instructions. Rinse until water is clear (Maximum water pressure - 40 PSI). Air dry or use warm flowing air, max. 160o F (71.7o C). Do not use compressed air or light bulbs. Inspection - Place bright light inside element and rotate element slowly. If any rupture, holes or damaged gaskets are discovered - replace.

Drive Train / Compressor

4-5

Flexible Drive Coupling Flexible Drive Coupling Service

Normally the flexible drive coupling requires no maintenance, however it may be necessary to remove the flexible drive coupling to service another component such as pump drive or engine. Follow the steps below for repair or removal and installation of flexible drive coupling.

Removal 1.

Remove flex drive cover.

Remove the socket head capscrews (items 5, 7 & 10) and slide the flexible flanges (4 & 9) back far enough to be able to move the inner plate (3) back away from the outer plate (2). When the lip of the inner plate clears the outer plate, you can lift the complete assembly out.

Installation NOTE

Use a torque wrench when installing the radial and axial capscrews. DO NOT use anaerobic adhesives, such as LoctiteTM as they have a detrimental effect of the bond between the rubber and the inserts. Pre-coated capscrews provided can be used up to three (3) times. Recommended adhesives are 3MTM 2353 or Nylok Precote 80.

Mounting Screws and Adhesive The axial and radial mounting screws are treated for corrosion resistance (minimum grade DIN 8.8, SAE Grade 8). The threads are coated with micro-encapsulated adhesive. The adhesive is released at assembly and further enhances the performance and safety of the coupling. For adequate effect, the adhesive should be allowed to harden for 4 to 5 hours prior to installation.

Fig. 4-3a Flex Drive Coupling (ref. 419519) 2. Outer Plate (2) 3. Inner Plate (2) 4. Flexible Flange 5. Axial Socket Head Capscrew (4) 6. Tube 4-6

7. 8. 9. 10.

Axial Socket Head Capscrew (4) Sleeve (4) Flexible Flange Radial Socket Head Capscrew (8 per side) Drive Train / Compressor

Flexible Drive Coupling Installation - continued

Fig. 4-3b Correct and Incorrect installation of axial and radial capscrews.

Be sure the flange hubs on the engine and pump drive are not damaged. Be sure they are free of nicks and burrs and that all mounting bolts are tight.

Place a small amount of grease under the head of each capscrew. This reduces the possibility of twisting the rubber element (see fig. 4-3b). Install all pre-coated axial capscrews (longer) finger tight. Be sure the flexible flange with the steel sleeves is on the engine side (fig. 4-3a).

Rotate the tube (item 6, fig. 4-3a) so all radial capscrews (shorter) can be installed finger tight. Use caution when tightening capscrews to prevent twisting of the flexible flange, see fig. 4-3b. This is particularly important for the radial capscrews. If the part is twisted, the cylindrical surface between the insert and the hub does not carry the load with the whole surface, but with the two corners only. If this happens the other radial bolts can loosen and the coupling will be destroyed. Tighten all axial capscrews first, torque to 370 ft. lbs. (503 Nm), then tighten all radial capscrews to same torque value.

NOTE

4. 5.

Install flex drive cover.

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4-7

Notes

4-8

Drive Train / Compressor

Pump Drive Pump Drive Assembly - Removal and Replacement WARNING:

Be sure to relieve pressure from hydraulic and pneumatic systems before loosening connections or parts. Two types of pump drives are used, they are Cotta and Funk Mfg. Removal and replacement is similar both. Repair procedures are discussed separately for each. 1.

Remove drive shaft cover.

Disconnect drive shaft or flex drive coupling from pump drive unit.

Drain oil from pump drive gearbox before removing pumps. Oil capacity for the Cotta pump drive is 3.5 gal. (13 L). Oil capacity for the Funk pump drive is 9 qts. (8.5 L). Support hydraulic pumps with a suitable lifting device. Remove mounting bolts and separate from pump drive.

For pump drive service only, it is not necessary to remove hoses from hydraulic pumps. Move pumps back far enough to clear pump drive unit for removal. Provide adequate support for hydraulic pumps. DO NOT let pumps hang from hydraulic hoses. Support pump drive assembly with a suitable lifting device.

Remove the four mounting bolts from each side and lift out pump drive assembly.

NOTE

Refer to parts manual for pump drive repair parts. Replacement is reverse of removal.

Fig. 4-4 Pump Drive Assembly 1. Pump Drive 2. Mounting Bolts (8) 3. Drive Shaft Cover Drive Train / Compressor

4-9

Pump Drive Gearbox (Cotta)

Fig. 4-5 Pump Drive Gearbox with Disconnect (ref. 0095133) 1. End Rod 9. Oil Splash Disc 2. Spring 10. Lifting Plate (2) 3. Dowel Pin (2) 11. Spline Adapter (2) 4. Clutch 12. Shift Rod 5. Spacer 13. Gear, 40T 6. Spacer 14. Gear, 40T (2) 7. Fork 15. Case 8. Shaft 16. Cover 4-10

17. 18. 19. 20. 21. 22. 23. 24.

Capscrew, Hex (18) Capscrew, Hex (2) Nut, Hex Nut, Flexlock (20) Nut, Stop Ball Bearing Ball Bearing (4) Ball Bearing (2) Drive Train / Compressor

Pump Drive Gearbox (Cotta)

Fig. 4-5a

Fig. 4-5b

25. 26. 27. 28. 29. 30. 31.

Bushing Plug Steel Ball, 1/2" dia. Setscrew, Hex Expansion Plug Washer Snap Ring (2)

Drive Train / Compressor

32. 33. 34. 35. 36. 37. 38.

Snap Ring Snap Ring Snap Ring (2) Snap Ring Seal Seal (2) Nameplate

39. 40. 43. 44. 45. 46.

Plug Window, Oil Level Companion Flange Breather Bearing Spacer

4-11

Notes

4-12

Drive Train / Compressor

Pump Drive Gearbox (Cotta) Pump Drive Gearbox - Repair Disassembly: 1.

After removing pump drive from machine as outlined previously, place unit on a workbench or on the machine deck if space and conditions permit. It is best to work in a clean sheltered environment whenever possible.

Remove the companion flange with a gear puller. Disassemble the disconnect assembly if equipped. Remove capscrews and separate the gearcase halves.

Remove the driven gears and their bearings from the gearbox.

Inspection and Repair: 1.

Check gears and bearings for damage, look for metal particles or flaking from bearings.

Check splines on output shafts for excessive wear.

Check bearing bores, the O.D. of the ball bearings are a slip fit. If there is excessive play, the bearing bores will have to be built up and re-machined.

Check condition of input shaft oil seal. Replace all seals when overhauling the unit.

Clean mounting surfaces of old sealant, clean and remove any debris from inside of gearcase.

Assembly: 1.

Assembly is basically the reverse of disassembly procedure. Remember to follow the notes with the assembly drawing.

If bearings need to be replaced, press them onto both sides of gears as far as they will go. There is no bearing pre-load on units with ball bearings, as the O.D. of the bearings are a slip fit. On units with tapered roller bearings add shims to obtain correct shaft end play (see fig. 4-5)

Apply anti-seize compound or a good grade of wheel bearing grease to the splines of the output shafts.

Apply silicone sealant at all split lines of gearcase.

Installation: 1.

Refer to "Removal and Replacement" procedures as outlined previously.

Lubrication: 1.

After installing pumps, fill gearbox with proper lubricant (see section 9). Oil level should be to midpoint of oil level window. DO NOT OVERFILL, this will result in overheating and possible malfunction of the unit.

Maximum operating oil temperature is 225o F (107.2o C).

Drive Train / Compressor

4-13

Pump Drive Gearbox (Funk)

Fig. 4-5c Funk Pump Drive Gearbox with 5" input shaft (ref.414347). Gearbox with 3" input shaft (ref. 421997) 1. Housing 9. Washer, Lock (24) 17. Screw, Drive (2) 25. Drive Shaft D/E, 19T (2) 2. Gasket, Housing 10. Elbow, 90 Deg. 18. Shaft, Input Assembly 26. O Ring 3. Oil Trough 11. Bushing, Reducing 19. Adapter, SAE C 27. O Ring (4) 4. Capscrew (2) 12. Breather 20. Ring, Adapter 28. Pin, Dowel (2) 5. Gear, 30T (3) 13. Plug, Magnetic 21. Adapter, Pump, SAE B 29. Plate, Cover 6. Bearing (6) 14. Plug, Pipe (3) 22. O Ring 30. O Ring 7. Capscrew (24) 15. Plug, Pipe (2) 23. Drive Shaft C, 19T 31. Capscrew (4) 8. Nut, Hex (24) 16. Plate, I.D. 24. Sleeve, Adapter

Fig. 4-5d 5" Input Shaft Assembly (item 18, fig. 4-5c) (see fig. 3-5e for 3" Input Shaft Assembly) 1. Retainer, Bearing 2. Shaft, Drive 3. Bearing 4. Ring, Snap 5. Seal, Oil 8. Capscrew (4) 10. Flange, Companion 11. Washer, Retainer 12. Capscrew (2)

4-14

Drive Train / Compressor

Pump Drive Gearbox (Funk) Pump Drive Gearbox - Repair Disassembly: 1.

Drive out the two dowel pins (28). Drive out pins toward input side of case.

If air breather (12) is damaged, replace with a new one. Be sure elbow (10) is not plugged.

Lay gearbox on bench with input shaft facing up. Remove input shaft assembly (18) from gearbox.

Remove the 24 capscrews, nuts, and lock washers (7, 8, & 9). Lift the upper half of the housing straight up and lay aside. Remove housing gasket (2) from lower half of housing.

Remove the two capscrews (4) that hold the oil trough (3) in place, and remove oil trough. If though cannot be tipped and pulled out from under gears, it will be necessary to lift each gear and bearing assembly from the output housing until trough can be removed.

With oil trough removed, lift gears and their bearings from the output housing. This can be done by hand since bearings are slip fitted to the housing bores and press fitted to gear hubs.

To remove bearings from gear hubs, use a gear puller or arbor press.

Disassemble input shaft assembly, refer to fig. 4-5d (see fig. 4-5e for alternate construction). A.

Remove the two capscrews (12) and retainer washer (11). Remove companion flange (10).

Remove oil seal (5) and snap ring (4).

Remove bearing (3) by pressing shaft out from the rear using an arbor press. Then press bearing off of shaft (2), or use a gear puller.

Inspection and Repair: 1.

Check gears and bearings for damage, look for metal particles or flaking from bearings.

Check splines on output shafts for excessive wear.

Check bearing bores, the O.D. of the ball bearings are a slip fit. If there is excessive play, the bearing bores will have to be built up and re-machined.

Replace all seals, o-rings, and gaskets when overhauling the unit.

Clean mounting surfaces of old sealant, clean and remove any debris from inside of gearcase.

Assembly: 1.

Assembly is basically the reverse of disassembly procedure.

If bearings need to be replaced, press them onto both sides of gears as far as they will go. There is no bearing pre-load on units with ball bearings, as the O.D. of the bearings are a slip fit.

Apply anti-seize compound or a good grade of wheel bearing grease to the splines of the output shafts.

Install new housing gasket (2) and assemble the two housing halves (1) together with the 24 capscrews, nuts, and lock washers (7, 8, & 9). Torque capscrews to 75 ft. lbs. (102 Nm).

Refer to fig 4-5d or 4-5e. Reassemble input shaft assembly (18) and install to housing with new oring (6). Install four new capscrews (8) using Loctite 262.

Drive Train / Compressor

4-15

Pump Drive Gearbox (Funk)

Fig. 4-5e 3" Input Shaft Assembly (item 18, fig. 4-5c) used on Pump Drive 421997 2. Flange 5. Ring, Retaining 8. Capscrew (4) 3. Spacer 6. Shaft, Input 9. Ring, Retaining 4. Seal, Oil 7. Bearing 10. O Ring

Fig. 4-5f Funk Pump Drive Gearbox (ref. 414347)

4-16

Drive Train / Compressor

Pump Drive Gearbox (Funk) 3" Input Shaft Assembly

Two different input shaft assemblies are used. One is 5" in length (fig. 4-5d) and the other is 3" in length (fig. 4-5e). Measure from the face of the gearbox to the face of the driveline flange. Assembly and disassembly procedures are outlined on the previous page for the 5" input shaft. The following instructions are for the 3" input shaft. Refer to fig. 4-5e.

Disassembly 1.

Remove retaining ring (5) and spacer (3) from input shaft (6).

Press input shaft out of flange (2) using an arbor press or remove with a gear puller.

Remove and discard oil seal (4).

Remove retaining ring (9), then remove bearing (7).

Assembly 1.

Install bearing (7) into flange bore, then install retaining ring (9). Be sure bearing is seated all the way in the bore and retaining ring is fully seated into groove.

Install oil seal (4) with the lip facing out as shown in fig. 4-5e. Coat seal lip with oil before installing input shaft.

Coat input shaft shoulder with oil where it will contact the oil seal, then press the input shaft into place using an arbor press. Be sure shaft is seated against the bearing.

Install spacer (3) and retaining ring (5). Be sure retaining ring is seated into the groove all the way.

Lubricate and install new o-ring (10) onto flange (2). Install input shaft assembly to pump drive housing. Use four new capscrews (8) and install with Loctite 262. Torque bolts to standard torque values.

Installation of Pump Drive Gearbox: 1.

Refer to "Removal and Replacement" procedures as outlined previously.

Lubrication: 1.

After installing pumps, fill gearbox with proper lubricant (see below). Oil level should be to bottom edge of oil level check plug (fig. 4-5f). DO NOT OVERFILL, this will result in overheating and possible malfunction of the unit.

If operating oil temperature is above 180o F (82o C) a synthetic oil is recommended. Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C.

Lubricant Grades: Below -10o F (-23o C) ambient use 75W. Above -10o F (-23o C) and up to 100o F (37.8o C) ambient use 80W-90 or EP90. Above 100o F (37.8o C) ambient use 85W-140. Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges).

Drive Train / Compressor

4-17

Hydraulic Piston Pumps Hydraulic Piston Pumps - Removal and Replacement WARNING:

Be sure to relieve pressure from hydraulic and pneumatic systems before removing hoses, or loosening parts or connections. 1.

Tag and remove hoses from pump unit.

Cap or plug all connections.

Support pump with a suitable lifting device.

Remove mounting bolts and lift pump out.

Be sure to fill case of pump with oil before starting.

Replacement is the reverse of removal.

Hydraulic Piston Pumps - Repair

Right Track & Pulldown Pump - Model AA4VG180HD Left Track & Rotary Pump Model AA4VG180HD

Overhaul of hydraulic piston pumps in the field is not recommended. Special tools, expert knowledge and absolute cleanliness are essential. It is usually best to exchange the pump for a new or factory rebuilt unit. However, if you choose to do the work yourself, the following service manuals will be of help to you.

Fig. 4-8 Shaft Seal Replacement 4-18

Drive Train / Compressor

4-19

4-20

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4-21

4-22

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4-23

4-24

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4-25

4-26

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4-27

4-28

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4-29

4-30

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4-31

4-32

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4-33

4-34

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4-35

4-36

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4-37

4-38

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4-39

4-40

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4-41

4-42

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4-43

4-44

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4-45

4-46

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4-47

4-48

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4-49

4-50

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4-51

4-52

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4-53

4-54

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4-55

4-56

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4-57

4-58

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4-59

4-60

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4-61

4-62

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4-63

4-64

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4-65

4-66

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4-67

4-68

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4-69

4-70

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4-71

4-72

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4-73

4-74

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4-75

4-76

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4-77

4-78

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4-79

4-80

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4-81

4-82

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4-83

4-84

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4-85

4-86

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4-87

4-88

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Notes

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4-89

Hydraulic Gear Pumps Hydraulic Gear Pumps - Removal and Replacement WARNING:

Be sure to relieve pressure from hydraulic and pneumatic systems before loosening parts or connections. 1.

Tag and remove hoses from pump unit.

Cap or plug all connections.

Support pump with a suitable lifting device.

Remove mounting bolts and lift pump out.

Replacement is the reverse of removal.

Hydraulic Gear Pumps - Repair Refer to the following service manual for repair of gear pumps. Cooler Fan Pump Auxiliary Functions Double Pump -

4-90

Model 350 Model 330

Drive Train / Compressor

4-91

4-92

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4-93

4-94

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4-95

4-96

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4-97

4-98

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4-99

4-100

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4-101

4-102

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4-103

4-104

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4-105

Notes

4-106

Drive Train / Compressor

Compressor Drive Coupling Compressor Drive Coupling - Removal and Replacement The compressor is driven off the rear of the engine via a Torsional Drive Coupling (fig 4-4). The coupling consists of a rubber element, flange, and taper lock bushing. Usually no service is required other than replacement when the rubber element is worn out. You can inspect the coupling through the opening in the side of the bell housing / adapter plate (fig. 4-10).

WARNING:

Be sure to relieve pressure from hydraulic and pneumatic systems before loosening parts or connections. Compressor Unit - Removal: 1.

Support the compressor unit with a suitable lifting device.

Remove bolts that attach compressor to engine and lower compressor mounting bolts (fig's. 4-10, 4-11 and 4-11a).

NOTE

Be sure not to lose shims at lower mounting.

NOTE

Some couplings have a negative reaction to thread lock chemicals.

Loosen main air connection so compressor unit can be moved back far enough to allow access to drive coupling.

Inspect drive coupling and taper lock bushing. Normally the rubber element is the only part that requires replacement. Refer to parts manual for part numbers.

Repair or replace as required.

Fig. 4-9 Torsional Drive Coupling 1. Rubber Element 2. Flange 3. Taper Lock Bushing Drive Train / Compressor

4-107

Compressor Installation Before Installation and Start-Up of New or Rebuilt Compressor: 1.

Drain all lubricant from receiver tank and system.

Replace compressor oil filter element.

Remove separator and check receiver tank for foreign material, metal cuttings, varnish and sludge. The system must be completely cleaned out.

Flush out compressor oil cooler.

Check all valves for foreign material and proper operation.

Install new filter elements and separator element. Install compressor unit (see "Compressor Unit Installation" below).

Reconnect all hoses and valves that were removed.

Fill system with new, clean lubricant (see section 9 for lubricant specifications) and pour 2 quarts (1.9 liters) of lubricant down the inlet.

Start compressor and set the full load RPM and the idle RPM (refer to Sullair service manuals in this section).

10.

Set the controls at the rated pressure and RPM.

11. Checks engine and compressor operating temperature. The engine water temperature should not be above 200o F (93.3o C) in radiator top tank. Compressor discharge temperature should not be above 210o F (98.9o C). 12. Check all shutdown devices for proper operation and temperature range.

Compressor Unit - Installation: 1.

Move compressor unit back into place with a suitable lifting device. Keep weight of compressor suspended with lifting device until all bolts and shims are installed.

Tighten mounting bolts to engine flywheel housing (fig. 4-10).

Be sure to install the same number of shims that were removed from the rear compressor mounts and install bolts (fig.4-11). If a new or rebuilt compressor is being installed, install as many shims that will fit between the rear compressor mount and frame pads. This must be done to keep weight of compressor off the engine flywheel housing, which can lead to premature bearing and seal failure. Tighten all bolts according to standard torque specifications listed in section 9 of this manual.

Reconnect any hoses or fittings that were removed.

4-108

Drive Train / Compressor

Compressor Installation Fig. 4-10 Compressor Mounting Bolts (engine adapter) and Inspection hole

Fig. 4-11 Rear Compressor Mounting Bolts and Shims.

Fig. 4-11a Front Compressor Mounting Bolts and Shims. Drive Train / Compressor

4-109

Main and Auxiliary Air The physical and functional aspects of the compressed air system are described briefly in the following paragraphs. However, you should refer to the parts manual for installation details and to the Sullair manual for technical information and troubleshooting.

Compressed Air Subsystem Components (low pressure)

Fig. 4-12 Low Pressure Compressor Cooling and Lubrication System Functional Diagram.

The compressed air subsystem consists of an engine driven air compressor, a separator tank, and the miscellaneous control and plumbing elements required to control the operation of the subsystem and to direct the air flow as desired. Figure 4-12 illustrates the compressor lubrication and cooling functions. Although the following topics briefly describe the functions of the compressor and separator tank, you should refer to the Sullair manual for functional details of these units. 1.

Air Compressor - A single-stage, positive-displacement, oil-flood-lubricated type air compressor is located behind the engine. The compressor operates in association with the separator tank to provide compressed air at a given CFM to the rotary drill and to other air operated components as required. The air compressor is engine driven by means of a torsional drive coupling. In operation, the compressor unit receives oil from the separator tank sump. Besides acting as a coolant for the compressor, the oil seals the leakage paths between the rotor and stator and between the rotor meshes. Forming a lubricating film between the rotors, the oil allows one rotor to directly drive the other. As the air is compressed, it becomes mixed with oil which must be separated out before the air is used.

4-110

Separator Tank - The separator tank is both a sump for the compressor oil and a reservoir for the compressed air. The tank serves to separate the cooling and lubricating oil from the air in the air/oil mixture delivered by the compressor. A built-in filter in the separator tank filters the oil from the air, and the recovered oil is returned to the compressor. A sight gauge in the return line enables the operator to see that oil is flowing in the line. A blow-down valve is located in a common line between the compressor and tank.

Drive Train / Compressor

Main and Auxiliary Air Compressed Air Functions The main function of the compressed air system is to provide air to the drill bit to propel the particles out of the hole. A secondary function of the system is to provide auxiliary air for control functions and for operation of air tools, etc. An air cleaner assembly on the intake to the air compressor cleans the air before it goes into the compressor. Similar to the air cleaner for the diesel engine, the unit has the same type of filter elements. The lower element traps the larger particles and a double filter unit that filters out the fine particles. Both the safety (inner) element and the primary (outer) element are disposable. The lower permanent element is designed to be removed for cleaning, while the upper safety (inner) element and the primary (outer) element are disposable. Although cleaning of these elements is possible, replacement is recommended. Refer to the parts manual for installation and assembly details and to the beginning of this section for service instructions. 1.

Main Air System - Filtered air to the drill bit passes through a check valve and the butterfly control valve, then through the main air header to an air hose that connects with a stand pipe. From the stand pipe the air is applied through a hose and swivel connector to the rotary element where it passes into the drill stem to emerge from the drill bit, blowing out the particles from the blast hole. Water is injected into the main air manifold by means of an air loop to the water injection system.

Auxiliary Air - The auxiliary air is used to control the main air butterfly valve, and is also available for special tool applications such as indexing the optional pipe rack and operating the automatic tool wrench.

Air subsystem Control Functions - The main air control valve, controlled by a switch on the control console, can be operated in two directions.

Air System Indicators - Three pressure gauges indicate the various air pressures in the system. The air "T" tank pressure gauge indicates the pressure in the tank itself, while the filter pressure gauge indicates the air pressure on the delivery side of the filter. The difference between the filter pressure gauge and the "T" pressure gauge readings indicates the condition of the filter. A pressure differential greater than ten PSI indicates incomplete air/oil separation, and thus indicates the need to service the air compressor. The bit pressure gauge indicates the pressure at the main air header, and hence the air pressure of the air delivered to the drill bit. A pressure switch on the main air header completes the circuit to the drill hour meter. Thus, when air is applied for drill operation the hour meter begins to count, measuring the time of operation. When the air is cut-off, the hour meter ceases to run, thereby indicating the number of hours the engine has operated (as indicated on the engine hour meter).

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4-111

Sulliscrew Compressor Unit Functional Description This unit provides continuous pulse-free compression to meet your needs. With a Sullair Compressor, no internal inspection of the compressor unit is required. Fluid is injected into the compressor unit and mixes directly with the air as the rotors turn, compressing the air. As a coolant, it controls the rise of air temperatures normally associated with the heat of compression. The fluid also seals the leakage paths between the rotors and the stator and also between the rotors themselves. It acts as a lubricating film between the rotors allowing one rotor to directly drive the other, which acts as an idler. After the air/fluid mixture is discharged from the compressor unit, the fluid is separated from the air. At this time, the air flows to your service line and the fluid is cooled in preparation for reinjection.

Control System The purpose of the compressor control system is to regulate the compressor air intake to match the amount of compressed air being used. The inlet valve consists of a butterfly valve controlled by an air cylinder as shown in fig. 4-13. For high pressure machines refer to Sullair Drill Compressor manual for high pressure units in this section. Fig. 4-12a shows the high pressure control circuit.

Fig. 4-12a High Pressure Compressor Control System.

4-112

Drive Train / Compressor

Butterfly Inlet Control System (high pressure) Refer to Sullair Drill Compressor Model 20/12 500 - 1350 CFM (high pressure 250 500 PSIG) Operator's Manual #02250136-659 in this section. This manual covers instructions for compressor set-up and inlet valve adjustment.

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4-113

Butterfly Inlet Control System (low pressure) Butterfly System Initial Set-up Procedure Perform steps 1 - 6 with machine shutdown and pressure relieved. 1.

Align air cylinder (item 1, fig. 4-13). Be sure cylinder is in line and rods are not bent or damaged.

Using shop air at the base of the cylinder, extend the large rod all the way out.

With cylinder extended place a wrench on the butterfly lever and move back to fully closed position (the small cylinder rod has a spring behind it). You should be able to close the butterfly valve before the spring bottoms out. If not, adjust cylinder base or stop screw (2).

Shut off shop air supply and remove hose from cylinder. Push the butterfly lever all the way back so large cylinder rod is fully retracted and butterfly valve is closed. Install hose from return manifold to base of cylinder.

Using the stop screw (2), adjust butterfly inlet so it is just barely open, just enough to build 50 - 60 PSI (3.5 to 4.1 bar) after starting machine.

Back out the reducing regulator, and the system regulator (fig. 4-13a).

Place compressor Start/Run valve in START position, and start machine and leave in low idle and watch pressure build. Loosen running blowdown outlet to muffler (fig. 4-13a) and verify when blowdown opens. Pressure should build to approx. 50 to 60 PSI (3.5 to 4.1 bar). This should be a steady pressure. If not, adjust butterfly open or closed to get 50 to 60 PSI (3.5 to 4.1 bar). Check at high idle and re-adjust if necessary.

Return to low idle and turn compressor vStart/Run valve to RUN position.

Adjust the system regulator to approx. 90 to 100 PSI (6.2 to 6.9 bar).

10. Shift to high idle and check, re-adjust if necessary.

Fig. 4-13 Butterfly Inlet Valve 1. Air Cylinder 2. Stop Screw 4-114

3. Butterfly Valve

4. Return Manifold

5. Grease Fitting (2) Drive Train / Compressor

Butterfly Inlet Control System (low pressure) 11. Open main air partially and let the butterfly open and close. 12. Adjust reducing regulator (fig. 4-13a) to 20 PSI (1.4 bar).

Maintenance 1.

Keep linkage and area around inlet clean.

Be sure clamps are tight and rubber inlet boot has no tears or holes.

Grease the butterfly valve weekly at the grease fittings (5) located at each end of the shaft.

Fig. 4-13a Low Pressure Air Control Piping (ref. 425365) Drive Train / Compressor

4-115

Compressor Maintenance Please refer to the following Sullair manuals for proper operation and maintenance of the compressor: 250 to 2000 CFM Single Stage Low Pressure Manual No. 02250150-154 or 500 to 1350 CFM High Pressure (250 - 500 PSI) Manual No. 02250136-569

4-116

Drive Train / Compressor

Notes

Drive Train / Compressor

4-117

Compressor Oil Filter

Fig. 4-14 Compressor Oil Filter Assembly 1. Visual Service Indicator 2. O-Ring 3. Locking Screw 4. Cannister Assembly 5. Filter Element 6. Filter Bowl 7. Filter Head

4-118

Drive Train / Compressor

Compressor Oil Filter Routine Maintenance Compressor Filters do not normally require special attention except for periodic monitoring of the differential pressure warning device. 1.

If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (2). If leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.

Differential pressure devices actuate when the element needs changing or because of high fluid viscosity in "cold start" conditions. If visual indicator is fitted and actuates during "cold start", reset by depressing the rubber button when the normal operating temperature is reached. If indicator actuates after resetting, replace element.

Changing Filter Elements WARNING:

Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts. Failure to depressurize system before proceeding could result in explosive loss of fluid, damage to equipment, or possible personal injury. 1.

Turn off and depressurize the system. Open bleed plug (if fitted) one and one half turns.

Unscrew and remove filter cover bowl (6) from head assembly (7), counterclockwise when viewed from above. It may be necessary to use a lever on the "Rotolok Ring" of the filter bowl (6) to loosen the bowl initially.

Remove filter element (5) and carefully inspect the surface for visible contamination. Normally no dirt should show, but visible dirt or particles can be an early warning of system component breakdown and can indicate potential failure. Discard both the filter element and its o-ring. The filter element is not cleanable. Any attempt to clean the filter element can cause degradation of the filter medium and allow contaminated fluid to pass through the filter element.

CAUTION:

DO NOT attempt to clean or reuse element.

Drive Train / Compressor

4-119

Compressor Oil Filter

Fig. 4-14 Compressor Oil Filter Assembly 1. Visual Service Indicator 2. O-Ring 3. Locking Screw 4. Cannister Assembly 5. Filter Element 6. Filter Bowl 7. Filter Head

Fig. 4-15 Compressor Oil Filter Assembly - may be mounted on either side. 1. Compressor Oil Filter 4-120

Drive Train / Compressor

Compressor Oil Filter Changing Filter Elements (continued) 4.

DO NOT run the system without a filter element (5) installed. Check that the o-ring (2) on the head assembly (7) is not damaged. Use replacement filter element part number called for on the element change label or in the parts book.

Lubricate element o-ring (2) with clean system fluid and push open end of filter element (5) straight onto the nipple in the head assembly (7). Clean out filter bowl (6) and lightly lubricate threads of filter cover assembly with clean system fluid. Screw cover assembly onto head assembly until it bottoms. O-ring sealing in not improved by overtightening.

CAUTION:

DO NOT use pipe wrench, hammer , or any other tool to tighten bowl.

Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one half turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system fully and check for leaks; if leaks occur, check o-rings and sealing surfaces.

After element change, ensure differential pressure device is reset by pushing in the button; electrical switches reset automatically. When system reaches normal operating temperature, check that the electrical switch has not actuated and/or the visual warning button has remained depressed. If visual indicator rises due to a cold start condition, reset again as outlined in "Routine Maintenance".

Fig. 4-15a Compressor Oil Filter Assembly - may be mounted on either side depending on compressor installation. 1. Compressor Oil Filter Drive Train / Compressor

4-121

Compressor Oil Filter Service Bulletin

4-122

Drive Train / Compressor

Radiator/Oil Cooler Assembly Unauthorized service will void the warranty. Read the service information carefully before performing any repair work. Refer to parts manual for your particular machine for correct parts ordering.

Fig. 4-16 Radiator/Oil Cooler Assembly with Single Fan (ref. dwg. 419821)

Drive Train / Compressor

4-123

Radiator/Oil Cooler Assembly

Fig. 4-17 Radiator/Oil Cooler Assembly with Two Fans (ref. dwg. 419914)

4-124

Drive Train / Compressor

Radiator/Oil Cooler Assembly

Fig. 4-18 Dual Fan Motor Hydraulic Circuit (ref. 420107)

Drive Train / Compressor

4-125

Radiator/Oil Cooler Assembly Square Tube Installation Tools - L&M Radiator (Mesabi) Use of proper tools makes radiator/oil cooler repair faster and reduces risk of damage to tubes. Following is a list of installation tools for square and round tubes, other special tools are available, if needed. Refer to the L&M Radiator service information at the end of this section.

Fig. 4-19 Square Tube Installation Tools (L&M Radiator)

4-126

Drive Train / Compressor

Radiator/Oil Cooler Assembly Round Tube Installation Tool - L&M Radiator (Mesabi)

Fig. 4-20 Round Tube Installation Tool (L&M Radiator)

Drive Train / Compressor

4-127

Radiator/Oil Cooler Assembly Maintenance and Repair Refer to the following pages for detailed maintenance and repair information on the L&M Radiator (Mesabi) units: Mesabi Radiators & Cores Mesabi Aluminum Tube Air To Oil Coolers Mesabi Copper Tube Air To Oil Coolers NOTE

4-128

Be sure to check whether your machine has copper or aluminum tube oil coolers. Copper tube units are good to 150 PSI (10.3 bar). Aluminum tube units are good to 350 PSI (24.1 bar).

Drive Train / Compressor

Radiator & Core Assembly

Drive Train / Compressor

4-129

Radiator & Core Assembly

4-130

Drive Train / Compressor

Radiator & Core Assembly

Drive Train / Compressor

4-131

Radiator & Core Assembly

4-132

Drive Train / Compressor

Radiator & Core Assembly

Drive Train / Compressor

4-133

Radiator & Core Assembly

4-134

Drive Train / Compressor

Radiator & Core Assembly

Drive Train / Compressor

4-135

Notes

4-136

Drive Train / Compressor

Aluminum Tube Oil Cooler

Drive Train / Compressor

4-137

Aluminum Tube Oil Cooler

4-138

Drive Train / Compressor

Aluminum Tube Oil Cooler

Drive Train / Compressor

4-139

Aluminum Tube Oil Cooler

4-140

Drive Train / Compressor

Aluminum Tube Oil Cooler

Drive Train / Compressor

4-141

Aluminum Tube Oil Cooler

4-142

Drive Train / Compressor

Aluminum Tube Oil Cooler

Drive Train / Compressor

4-143

Notes

4-144

Drive Train / Compressor

Copper Tube Oil Cooler

Drive Train / Compressor

4-145

Copper Tube Oil Cooler

4-146

Drive Train / Compressor

Copper Tube Oil Cooler

Drive Train / Compressor

4-147

Copper Tube Oil Cooler

4-148

Drive Train / Compressor

Copper Tube Oil Cooler

Drive Train / Compressor

4-149

Copper Tube Oil Cooler

4-150

Drive Train / Compressor

Copper Tube Oil Cooler

Drive Train / Compressor

4-151

Notes

4-152

Drive Train / Compressor

Section 5

WARNING:

HEALTH HAZARD Always use dust collector or water suppression to control dust when drilling. Avoid breathing airborne dust particles. Prolonged inhalation of silica dust can cause silicosis, a serious and sometimes fatal disease.

Dust Control Systems

5-1

Dust Control System Functions The dust control system includes a dust curtain around the drilling platform and a blower type dust collector which acts as a vacuum to gather the dust trapped within the dust curtain. The dust control system also contains a water injection system that injects water into the main air stream to help control dust accumulation. The general functions of the dust control subsystem units are described below.

Dust Curtains

The dust curtains are attached to a framework underneath the drilling platform. Part of the drilling platform forms the base for the mast assembly.

Dust Collector Subsystem Function

The dust collector subsystem consists of a dust collector assembly connected by a hose to an outlet of the enclosure formed by the dust curtains. The dry filter type dust collector uses a series of filters and retention rod elements to entrap and dump the dust into the bottom of the unit to be funneled to the outside. Significant to the effectiveness of this unit is a compressed air filter-cleaning system that automatically blows reverse flow air through the filters during operation. This reverse flow cleaning is facilitated through use of manifold system and a timer box. Auxiliary compressed air is applied to the manifold which routes compressed air through each filter in an endless sequence. Sequence control is a function of the timer, which sequentially operates control valves at the individual filter elements. Compressed air for dust collector operation is plumbed in from the auxiliary air system.

Water Injection Subsystem Function

Water is injected into the main air stream to control dust from the drilling operation. The water injection system consists of a water tank and a hydraulically driven water pump that injects water into the main air header. The pump provides water from the tank at a flow rate controlled by an adjustable flow control valve on the control console. The water is directed to an air control valve which meters the water into the air stream at the main air header.

Dust Control System Control Functions

The operator controls for the dust control system consist of a switch and a water flow control valve on the control console. Because the water injection system and the dry dust control system are not operated at the same time, a single switch operates the water pump hydraulic motor and the dust collector hydraulic motor. Pushing the switch up engages the water pump motor, and pushing the switch down engages the dust collector motor. The water flow control operates a needle valve that controls the amount of water being injected into the main air stream.

5-2

Dust Control Systems

Dust Collector Introduction The Filter/Clone Dust Collector is an advanced design utilizing a system of barrier filters located in the vortex of a cyclone. The use of the cyclone to centrifugally separate the heavier material from the fine dust has demonstrated a significant reduction in loading of the filter elements while at the same time allowing for an increase in volume of material collected. In order to maintain the level of performance that is designed into each Filter/Clone Dust Collector, one should fully understand how the unit operates, so that periodic inspections and repairs can be performed. This section is intended to explain to the user proper servicing techniques and offers special troubleshooting suggestions.

Basic Specifications These series of blasthole drills are equipped with the FC-4500 dust collector. Specifications are listed below.

TECHNICAL DATA Air Capacity (suction) No. Filters / Area (sq ft) Hydraulic Power Reqd. Suction Hose Dia. (in.) Cross Section (in. x in.) Height (in.) Shipping Weight (lbs)

FC-4500 4500 SCFM 6 / 822 23 GPM @ 1500 PSI 10.0 28.0 x 75.0 89.4 1600

Fig. 5-1 FC-4500 Dust Collector Dust Control Systems

5-3

Dust Collector

Fig. 5-2 Dust Collector (Model FC-3000) 1. Filter Access Doors 2. Air Valve Access Doors 3. Timer Box 4. Blower Housing 5. Flow Control Valve 6. Hydraulic Motor 7. Air Pressure Regulator/Filter

Fig. 5-3 Manometer Connections 1. Upper Tap 2. Lower Tap

5-4

Dust Control Systems

Dust Collector Initial Startup If the Filter/Clone dust system was installed on your drill at the factory, the unit should be set up ready to run. However, to make yourself familiar with the operation of the unit, it is advisable for you to go through the following setup procedures. The dust system is divided functionally into two separate subsystems: A. The blower assembly which provides the vacuum source. B. The compressed air supply which cleans the filter elements. Blower Assembly - The blower assembly consists of an aluminum blower wheel, an aluminum blower housing, and a hydraulic motor (fig. 5-2). For the unit to operate as it was designed, the blower wheel must turn at both the right speed and the right direction to produce the level of vacuum required.

Fan Speed Adjustment -

The proper speed of the blower wheel is: 3000 RPM (12-13 inches of water) - without precleaner 3300 RPM (12-13 inches of water) - with precleaner Although this speed can be set directly by use of a tachometer, the preferred method is to set the speed to give the desired vacuum as measured with a water manometer. A water manometer is a very simple device consisting of a clear plastic tube bent into a "U" shape. The tube is partially filled with water so that two columns appear side by side and extend approximately half way up the length of the manometer (fig. 5-4). If both ends of the tube are open to the atmosphere, then the water level in each leg of the manometer will be equal. However, if one leg is connected to a vacuum source, the air pressure in the other leg will be greater and will push the water column down on the side connected to atmosphere. At the same time, the column connected to the vacuum will rise. The distance in inches between the two water columns is the measurement of the vacuum in inches of water. There are two places on the dust collector to measure the vacuum produced by the blower system (fig. 5-3). 1.

The upper tap is connected to the clean air side of the filter element.

The lower tap is connected to the dirty air side of the filter element.

Dust Control Systems

5-5

Dust Collector Setting The Fan Speed - continued Figure 5-4 shows the manometer connected to both taps at the same time. This measurement would reflect the pressure drop across the filter element. To measure the clean air vacuum, connect one side of the manometer to the upper tap and the other side to atmosphere (fig. 5-4). Likewise, to measure the dirty air side of the filter, connect one hose to the lower tap and the other hose to atmosphere. Normal readings (in inches of water) for the various configurations are shown at the top of fig. 5-4. Using clean filters, adjust the fan speed by using the flow control valve (item 5, fig. 5-2) to achieve these readings.

Direction of Fan Rotation WARNING:

ALWAYS wear safety glasses when working on or around equipment. NEVER look directly into blower housing exhaust as small particles could fly out at high speed, causing personal injury. The blower wheel rotates in a clockwise direction when viewing the unit from the top. It is imperative that the blower turn in the right direction. It will not always be immediately obvious when the blower is turning backwards because the unit will still pull a vacuum of 2-3 inches of water. There are two methods to ensure that the fan is turning clockwise. The first is to make the measurements above. However, the easiest method is to physically view the fan as it is either starting or stopping and note the direction it is turning. Always stand to one side of the blower housing exhaust and wear safety glasses, as small particles could fly out at high speed causing personal injury. NORMAL MANOMETER READINGS: MODEL FC4500

UPPER TAP 12-13 inches

LOWER TAP 9-10 inches

PRESSURE DROP 2-3 inches

Fig. 5-4 Manometer Setup 5-6

Dust Control Systems

Dust Collector Air System

The compressed air supply is used to back blow the filter elements to clean the filter material. The outside section of the top of the dust collector is a compressed air reservoir. This air tank is connected directly to the impulse valves which supply the air pulse to clean the filter. The lines should be drained daily using the petcock next to the timer (fig. 5-7).

Air Regulator/Filter

Adjust the air regulator/filter to 40 PSI (2.8 bar). Lift up the cap and turn to adjust, then push back down to lock. If air pressure is too high the filter elements will be damaged. The air regulator/filter is located on the side of the dust collector opposite the timer (fig. 5-6). The air regulator/filter is equipped with a water separator which automatically drains the water off as it accumulates in the bowl.

Fig. 5-6 Air Regulator/Filter

Fig. 5-5 FC3000 Dust Collector 1. Air Impulse Valves (4) 2. Filters (4)

Fig. 5-7 FC3000 Dust Collector 1. Relief Valve 2. Water Drain Petcock Dust Control Systems

5-7

Dust Collector

Fig. 5-8 Electric Timer and Air Impulse Valve

Fig. 5-9 Electric Timer 1. Off Time Switch 2. Last Out Switch 3. First Out Switch 4. Reset Button 5-8

5. Power Light 6. Pulse Sequence Lights (for number of filters) 7. Fuse, 3 amp Dust Control Systems

Dust Collector Air System (continued) The impulse valve is connected directly to the air tank through a short threaded pipe nipple. Pressure builds in the air tank and the impulse valve is held closed as long as the port on top of the valve is closed. Under this condition, air from the tank is allowed to flow to both the top and bottom of a rubber diaphragm. A light weight spring is used to ensure that the diaphragm stays seated in the closed position. When air is exhausted from the top of the valve, the pressure from air on the bottom of the diaphragm causes it to be lifted momentarily. A small orifice connecting the air tank supply to the top of the diaphragm causes the diaphragm to re-seat within approximately 0.1 second. There is one impulse valve for each filter and these valves are made to sequentially pulse approximately every four seconds. The pulse rate is controlled by an electric timer.

Electric Timer

The electric timer (fig. 5-9) is a 24 Volt controller designed to sequentially activate 24V solenoid directional air valves shown in Figure 5-8. The solenoid valve, when activated, exhausts to atmosphere the air from the top of the impulse valve. Exhausting this air causes the impulse valve to pulse. The electric timer is set up at the factory and should need no adjustment. However, to suit your particular drilling situation you may wish to increase or decrease the interval between pulses. The numbers on the FIRST OUT and LAST OUT dials indicate the order in which the impulse valves fire. Do not change these settings. The red sequence lights indicate which impulse valve is firing. If only four filters are used, then only four lights will flash. Always check that the green POWER ON light is on and that the fuse is not blown. Push the RESET BUTTON if power has been interrupted.

Setting Time Interval Between Pulses

Use the OFF TIME switch (item 1, fig. 5-9) to set time between pulses. Each number on the dial represents 0.5 seconds, so 1 equals 0.5 seconds, 2 equals 1 second and so on. The factory setting is 18 pulses per minute (about 3.2 seconds between pulses).

Filter Maintenance If dust appears at blower housing, this indicates a filter has ruptured. Shutdown machine and change filters immediately. To check filter performance, connect manometer to upper and lower taps. With dust collector running, the difference between the two legs of the manometer should be about 3 in. (76.2 mm) of water for a clean filter. When the water difference is more than 4 in. (101.6 mm), filters need to be changed.

Ground Water Shut off dust collector if ground water is encountered, so filter will not plug up.

Dust Control Systems

5-9

Dust Collector Routine Maintenance In order to insure that your Filter/Clone Dust Control system is operating to its design specifications, the following visual inspections should be performed on a periodic basis. 1.

Verify that the dropout hose located at the bottom of the dust collector is securely fastened to the dropout cone. 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.

The suction hose leading from the deck to the collector should be clear of obstructions such as buildup of dirt or mud. There should be no kinks or extremely sharp bends in the suction hose.

Inspect the dust curtains surrounding the hole to be sure there are no holes or gaps.

Listen to the back-pulsing of 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 collector, verify that the air is pulsed at a peak pressure of approximately 40 PSI (2.8 bar).

Observe the discharge of the blower assembly. NEVER look directly into the discharge of the blower, as small particles could come out at high speed, causing personal injury. 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.

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 pipe sections, and possibly between each hole.

MANOMETER READING: UPPER LOWER

INDICATION

CAUSE

CURE

High

Low

Loss of suction. High reading across filter.

Plugged Filter.

Check Pulse Air (faulty timer, impulse valves or low pressure).

High

Loss of suction. Reading of zero across filter. Poor filter life.

Plugged Hose.

Clear obstruction

Fan speed too high.

Reduce hydraulic flow to fan motor.

Loss of suction.

Fan speed too low.

Adjust hydraulic flow to fan motor. Check hydraulic hookup. Replace dump hose.

Low

Fan runs backwards. Dump hose missing.

5-10

Dust Control Systems

Dust Collector Troubleshooting Guide 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. All the problems with the Filter/Clone Dust Control System can be isolated through the use of a single test instrument, namely the water manometer discussed earlier. Measurements should be made separately on the upper and lower vacuum taps located on the dust collector housing (see fig. 5-3). Typical readings for proper operation are listed in fig. 5-4. Depending on whether your readings are higher or lower than the normal values, the following explanations will apply. 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 compressed air. Three probable causes are: 1. The incoming air pressure is too low. This pressure should be maintained at approximately 40 PSI. Insert a gauge at the point where air enters the collector to make your measurement. 2. The timer could be malfunctioning. Check the timer to see that each station is being fired at the set timer interval of about 2-3 seconds between stations. 3. The 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, the electric-air solenoid valve operating the impulse valve may be faulty. Upper Tap HIGH - Lower Tap HIGH This condition 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. 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 start-up or shut-down. NEVER look directly into the blower discharge, as small particles could come out at high speed causing personal injury. The blower wheels on all Filter/Clone units should turn clockwise when viewed from the top looking down at the 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.

Dust Control Systems

5-11

Water Pump Item No.

Description

Qty.

1 2 3 4 5 6 7 8 9 10 10A 10B 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Hex Capscrew, 1/2"-13 x 1-1/2 Clamp, Valve Cover Valve Cover O-Ring, 1-3/16" OD Spring & Disc Valve Cage Valve Seat Hex Capscrew, 3/8"-16 x 5" Valve Chamber Gasket Cylinder Ring Seal O-Ring Cylinder Capscrew, 5/16"-18 Packing Washer Packing Packing Holder O-Ring, 3/4" OD Umbrella Washer, Umbrella Sleeve, Crosshead Case, Pump Pipe Plug, 3/4" Crosshead Wrist Pin Connecting Rod Assembly Bearing Insert, Con. Rod Machine Screw, #10-24 x 1/2" Speed Nut Oil Slinger Crankshaft Bearing Oil Seal Snap Ring Gasket, Pump Base Mounting Base, Pump Cup Washer, 3/8" Capscrew, 3/8"-16 x 3/4" Pipe Plug, 1/4" Valve Seat Remover

1 1 2 6 4 4 4 3 1 4 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 4 2 1 1 1 2 2 2 1 1 6 1 1

Fig. 5-10 5-12

Dust Control Systems

Water Pump Servicing Instructions WARNING:

Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts. General Care of the Pump a.

Drain and refill the pump crankcase with clean SAE 30 API service classification MM or better oil after the first 100 hours of operation. Following the first 100 hours of operation, for best results always change the oil every 750 hours of operation.

Keep all piping and mounting bolts tight.

Replace all worn parts promptly with Bean exact replacement parts.

The water relief valve mounted on the discharge of the water pump should be set 50 PSI higher than air pressure in order to inject water into the air stream (e.g.: Low Pressure = 150-200 PSI, High Pressure = 400-450 PSI).

Care in Freezing Weather NOTE

Precautions must be taken to avoid damage to the pump from liquid allowed to freeze in the valve chamber.

Drain all connecting piping.

Remove Capscrew (1), Clamp (2), Valve Cover (3) and Valve Disc and Spring (5) to drain the Valve Chamber (9) when freezing temperatures are expected (See Fig. 5-8). Remove "top" Discharge Valves or raise them to be sure that no liquid is trapped under the "inner" Suction Valves.

Servicing the Plunger Packings 1.

Release the Valve Chamber (9) from the Pump case by removing the three capscrews (8).

Lift the chamber free of the cylinders (11). Remove the capscrews (12), cup washers (14), and plunger packings (15).

Lift the cylinders (11) from the pump case (21).

Inspect the o-rings (17) and the umbrellas (18). If either of these parts are damaged, they should be replaced. A pocket knife can be used for easiest removal of the umbrellas. Clean all parts thoroughly - replace worn parts with exact replacement parts.

Dust Control Systems

5-13

Water Pump Item No.

Description

Qty.

1 2 3 4 5 6 7 8 9 10 10A 10B 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 2 6 4 4 4 3 1 4 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 4 2 1 1 1 2 2 2 1 1 6 1 1

Fig. 5-10 5-14

Dust Control Systems

Water Pump Reassembling Plunger Packings 1.

Inspect bottom gasket (10) and replace if necessary. (Torque capscrews to 15 to 20 lb-ft).

NOTE

If it is necessary to replace one gasket at either top or bottom of the cylinders, then both bottom and top cylinder gaskets should be replaced. For easier installation of the Umbrella, immerse in hot water for approximately two to three minutes to soften.

Fold the plastic Umbrellas (18) to insert them through openings and over ends of Crosshead Rods.

Press tops of Umbrellas to place Pilot Washers (19) over ends of rods with groove up.

Place O-Rings (17) and Packing Holders (16) in position on ends of crosshead rods.

Place cylinders (11) in position in the mounting plate recess.

Oil the plunger packings (15) and place them in the open end of the cylinders, with the cup "up". Use the thumb to press the packings into each cylinder, firmly and squarely on the plunger rod end.

Turn the pump by hand to raise each plunger rod to the top of the stroke, as needed.

Place the cup washers (14), with the ribbed side against the plunger packing inside the cups of the packing.

Secure packing and washers to plunger rods with capscrews (12), tightening them until the washers and cups seat firmly on the plunger rods.

10. Inspect top cylinder gaskets (10) and replace both if either shows defect, holding them in place in the valve chamber by using heavy oil or grease if necessary. 11. Return the valve chamber to position over the cylinder, making sure that gaskets (10) and cylinders (11) are properly positioned in the recesses top and bottom. 12. Retighten capscrews (8) alternately and evenly until the parts are snugly seated. Torque capscrews to 20-25 lb-ft.

Servicing the Pump Valves 1.

Remove the Capscrew (1) and Clamp Bar (2) from the rear of the Valve Chamber (9) and lift out Valve Covers (3) and O-Rings (4) attached.

Remove the Discharge Valve Springs and Seat Assemblies (5) and Valve Cages (6).

Insert the round end of Valve Seat Puller (tool 39) through the opening at the center of the Valve Seats (7) and loosen the Seats from the Valve Chamber (9) with a "rocking" motion of the tool (39).

Remove the Valve Seats from the recesses with the opposite end (curved end) if Tool (39).

Repeat the four preceding steps to remove the suction valve parts which are identical to the Discharge Valve Parts and are located immediately under them in the Valve Chamber.

Clean all parts and inspect them - replace all worn parts as needed.

Dust Control Systems

5-15

Water Pump Item No.

Description

Qty.

1 2 3 4 5 6 7 8 9 10 10A 10B 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 2 6 4 4 4 3 1 4 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 4 2 1 1 1 2 2 2 1 1 6 1 1

Fig. 5-10 5-16

Dust Control Systems

Water Pump Pump Specifications Stroke Oil Type Direction of Rotation Number of Pistons Crankcase Material

-----------

1" SAE 30 either 2 Cast iron

Oil Capacity GPM Maximum Pressure RPM

---------

1 quart 9 550 PSI 500

Torque Requirements Valve Chamber Studs Rear Cover HHCS

--- 15 ft-lb. --- 15 ft-lb.

Conn Rod Nuts --- 7 ft-lb. Packing Assembly Nut --- 10 ft-lb.

Reassembling Valve Parts NOTE

Valve seats are used with the thin seating area pointing toward the valve disc.

With the O-Ring (4) in place on each Valve Seat (7), place a few drops of light oil on the ring and seat and place each squarely in the bottom of the recess in the Valve Chamber.

Place the Valve Cages (6) on the Valve Seats (7) and the Spring and Disc (5) inside each Cage.

Repeat steps 1 and 2 to install the outer discharge valve parts.

Place the Valve Covers (3) (with O-Rings on bottom groove) over each Valve Assembly.

Replace Clamp Bar (2) and Capscrew (1), tightening Capscrew (1) only snugly. Overtightening Capscrew (1) can damage Valve Parts. Torque to 30 lb-ft.

Servicing the Crankshaft 1.

Remove Pipe Plug (38) and drain oil from Pump Case.

Disconnect piping and remove Pump from mounting.

Remove Capscrews (37), Cup Washers (36) and Mounting Base (35) carefully to protect Gasket (34).

Remove Capscrews from Rod Assemblies (25). Use a center punch or other suitable instrument to mark caps and rods for proper matching when they are reassembled.

Remove Oil Slinger (29) from the Crankshaft (30).

Push the Connecting Rods and Crosshead Assemblies into the Pump Case to clear the Crankshaft (30).

Remove the driven sheave from the Crankshaft extension.

Remove the Snap Rings (33).

Dust Control Systems

5-17

Water Pump Item No.

Description

Qty.

1 2 3 4 5 6 7 8 9 10 10A 10B 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 2 6 4 4 4 3 1 4 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 4 2 1 1 1 2 2 2 1 1 6 1 1

Fig. 5-10 5-18

Dust Control Systems

Water Pump Servicing the Crankshaft (continued) CAUTION:

NEVER pound directly on bearings (31) when removing or replacing them on the crankshaft. 9.

Place a wood block against either end of the Crankshaft and drive the shaft from the Pump Case (21). A block of wood, with a suitable sized opening or block supports to assure reasonably equal support around the bearing, in a press is best for this important work.

10. After inspecting and replacing all worn parts, press new Bearings (if needed) against the shoulders of the Crankshaft. 11. With the Crankshaft and Bearings assembly in place in the Pump Case, carefully place the Oil Seals (32) over the ends of the Crankshaft with the "lip" of the Seals facing the inside of the Pump Case. 12. Seat the Snap Rings (33) in the grooves in the bearing housings against the Oil Seals and tap the Crankshaft to allow a Slight end play in the Crankshaft. 13. Reassemble the Connecting Rods and Crossheads, being sure to match the Rod and Cap properly as marked when disassembled. Use 6 to 8 lb-ft on Capscrews. 14. Complete the reassembly by reversing steps 1-8, being sure to replace Drain Plug (33). Torque mounting base capscrews 20-25 lb-ft. Remove Plug (22) and fill the Crankcase with clean SAE 30 API service classification MM or better oil, to the Filler plug level. Turn the Pump a few revolutions by hand, to be sure all parts are running freely before using the Pump.

Servicing the Crossheads 1.

Remove the Valve Chamber, Cylinders, and Plunger Packings.

Remove O-Ring Seal (17), Back-up Washer (19), and the Crosshead Umbrellas (18).

Remove the Mounting Base and the Connecting Rods as described in "Servicing the Crankshaft".

Turn the Crankshaft by hand to allow removal of the Crossheads through the Pump Case Opening.

Reverse steps 1-3 when reassembling the Crossheads, be sure that all parts are reassembled in their EXACT former positions.

Dust Control Systems

5-19

Hydraulic Motor for vertical pump Refer to the following Char-Lynn H - Series Service Manual for repair information on the hydraulic drive motor for the vertical water pump.

5-20

Dust Control Systems

5-21

5-22

Dust Control Systems

5-23

5-24

Dust Control Systems

5-25

5-26

Dust Control Systems

5-27

5-28

Dust Control Systems

Notes

Dust Control Systems

5-29

Water Injection Pump (horizontal) Water Pump Repair:

Refer to the following CAT Pumps Service Manual which covers the Model 1050 for repair and maintenance information. Refer to machine parts manual for parts ordering.

Water Pump Drive Motor Repair:

Refer to the Char-Lynn 2000 Series Repair Manual which covers the Model 104-1002 Hydraulic Motor for repair. Shuttle Valve Option and Speed Sensor are not used on this model. Refer to machine parts manual for parts ordering.

5-30

Dust Control Systems

5-31

5-32

Dust Control Systems

5-33

5-34

Dust Control Systems

5-35

5-36

Dust Control Systems

5-37

5-38

Dust Control Systems

5-39

5-40

Dust Control Systems

5-41

5-42

Dust Control Systems

5-43

5-44

Dust Control Systems

Section 6

Mast / Rotary Drive / Pipe Rack

Mast/Rotary Drive/Pipe Rack

6-1

Mast Assembly WELD CHOCK BAR AGAINST NUT FLAT THIS SIDE ONLY AFTER TIGHTENING NUT

SHEAVES

PULLDOWN CABLE

HOIST/PULLDOWN CYLINDER

CYLINDER SHEAVE MOUNT

HOIST CABLE

CHOCK BAR SHEAVE

SHEAVE CYLINDER SPACER DUST HOOD SHEAVE

CHOCK BAR

PULLDOWN CABLE

SHEAVES

SHEAVE MOUNTING BOLTS (4 PER SIDE)

WELD CHOCK BAR AGAINST NUT FLAT THIS SIDE ONLY AFTER TIGHTENING NUT

16 GA SAFETY WIRE

AIR SWIVEL 16 GA SAFETY WIRE

SHEAVE

HOIST CABLE

BEARING ADJUSTMENT BUSHING

SHEAVE RETAINER PIN STOP NUT

GREASE FITTING

SHEAVE PIN

TYPICAL SHEAVE ASSEMBLY

CYLINDER GUIDE MOUNTING PLATE

CYLINDER GUIDE PAD (6) CYLINDER GUIDE RETAINER (6) CYLINDER GUIDE SPACER (6)

HOIST/PULLDOWN CYLINDER SHEAVE

SHEAVE CYLINDER MOUNT

CYLINDER

CYLINDER MOUNT

CYLINDER GUIDE

TOP OF MAST

Fig. 6-1 Mast Sections 35' Mast (ref. 1490377 rev. 01)

6-2

Mast/Rotary Drive/Pipe Rack

Hoist and Pulldown Cylinder Removal from Mast Assembly DO NOT climb on mast, serious injury or death can occur. BE SURE to relieve pressure on hydraulic or pneumatic systems before loosening connections or parts. 1.

Place mast in horizontal position and remove chock bars that hold cylinder end nuts at top and bottom of mast. Raise mast back up to vertical position and lock in place.

Remove drill pipe from top sub-adapter and rack in carousel. Extend auto tool wrench and place hardwood block on top of tool wrench. Place a steel plate on top of the hardwood block.

Bring rotary head with sub-adapter down on top of steel plate and wood block.

Switch Drill/Propel switch to Drill mode, switch pulldown system switch to Engage pulldown. Set pulldown system pressure to 4000 psi (275 bar) with pulldown system pressure control. Lower mast to horizontal position. NOTE

Be careful not to damage threads on cylinder rod when removing nuts. Record number of threads showing from top of nut.

With mast in horizontal position and pulldown still engaged, loosen lower cylinder nut using a chain wrench or a wrench made to fit nut. Nut may have to be broken loose with a sledge hammer. If nut does not break loose, increase pulldown pressure to 5000 psi (345 bar) and apply heat to nut. Once lower nut is loose, decrease pulldown pressure and switch pulldown switch to Disengage pulldown.

Run rotary head to top of mast. Secure rotary head to mast crown with chain, so it can not move. Remove the 8 bolts that hold the sheave mounts to the cylinder - 4 per side. Move the cylinder so the rods are centered on both ends. This is done to balance the cylinder for safer and easier removal.

Shut off engine and relieve pressure from system by opening vent on top of hydraulic tank. Remove the hydraulic hoses and fittings from both ends of the cylinder rods. Plug ports with cap plugs (not shop rags.)

Make a note of how many threads are showing above the cylinder rod nuts. When cylinder is installed, you will need to have the same amount of thread showing as before removal.

Support cylinder barrel (do not lift cylinder by the cylinder rods) with lifting straps and using an adequate lifting device, place slight tension on the cylinder barrel. Remove the lower and upper cylinder rod nuts. Remove the two lower cylinder guide bolts and the four upper cylinder guide mounting bolts.

10.

Protect chrome finish on exposed cylinder rods before lifting cylinder out of mast. Gently lift cylinder and move forward enough to clear the lower mount them move opposite to clear upper mount. Now carefully move cylinder out from under mast. Repair cylinder in an enclosed shop if possible. Use caution not to damage threaded ends of cylinder rods or chrome surface of rods.

Mast/Rotary Drive/Pipe Rack

6-3

Hoist and Pulldown Cylinders APPLY LOCTITE 242 TORQUE 350-360 FT LBS ALTERNATING FROM SIDE TO SIDE INSTALL LOCK-WIRE BETWEEN PAIRS OF CAPSCREWS

13.50 RETRACTED 240.00 STROKE 252.50 EXTENDED

APPROXIMATE CYLINDER DRY WEIGHT=3,629 LBS

Fig. 6-2a Hoist and Pulldown Cylinder - 35 Ft Mast (ref. 424739 rev. A)

TRANSFER TUBE W/SUPPORT BLOCKS

385.38 RETRACTED ± .13 360.00 STROKE ± .13 745.38 EXTENDED

Fig. 6-2b Hoist and Pulldown Cylinder - 13 & 16 Meter Masts with Auto Tensioning (ref. 426765 rev. A)

6-4

Mast/Rotary Drive/Pipe Rack

Hoist and Pulldown Cylinder Repair Refer to parts manual for specific cylinder and repair part numbers. Refer to cylinder repair information in Section 7 of this manual for type of cylinder on machine. Follow the instructions on the "General Information" page, then follow the detailed instructions for the type of head and type of piston that matches what is in the cylinder. For this particular cylinder, follow the procedures for "N" Type Head and "Z" Type Piston. This cylinder is somewhat different, due to the double ended rod. Pay particular attention to the notes and differences on the drawing.

Installation 1.

Protect the chrome surface of the exposed cylinder rods by wrapping with cloth or several layers of paper. Wrap the threaded ends of the cylinder rods with tape to protect threads from damage. With cylinder rods centered (equal length of rod exposed on both ends of cylinder body), lift cylinder barrel (do not lift by the cylinder rods) and position under mast with the lower cylinder guide mounts toward bottom of mast.

Position lower rod end through hole in mast base, then position upper rod end through hole in crown block. Install spacers and thread nut on rod ends so same length of rod extends beyond nut as before removal.

Install lower nut and tighten with chain wrench or special made wrench and a "cheater" pipe.

Remove cap plugs from rod ends and install fittings and hoses.

Install the four upper and two lower guide mounts and bolts on cylinder.

Start engine and using pulldown control lever, move cylinder to align bolt holes with sheave mounting brackets. Install 8 bolts using loctite on threads.

Remove chain from rotary head and mast crown.

Raise mast and run rotary head up and down mast ten to twelve times to work air out of the cylinder.

Place hardwood block and steel plate used previously on auto tool wrench jaw. Bring rotary head sub down against steel plate and block. Switch drill/propel switch to Drill mode and pulldown switch to Engage pulldown. Set pulldown pressure to 4000 psi (275 bar) using pulldown system pressure control.

10.

Lower mast with pulldown pressure still at 4000 psi (275 bar), tighten lower hoist/pulldown cylinder nut using chain wrench or special wrench and cheater pipe. Tighten nut as much as possible. Decrease pulldown pressure and switch pulldown switch to Disengage pulldown.

11.

Weld chock bars back in place against hoist/pulldown cylinder nut on top and bottom of mast.

12.

Raise mast and install bit sub, table bushing and bit. Install drill pipe.

13.

Shut machine down and check the fluid level in the hydraulic reservoir and add as required.

Mast/Rotary Drive/Pipe Rack

6-5

Hoist/Pulldown Cables HOIST CABLE ADJUSTMENT

HOIST CABLES ATTACHED PULLDOWN CABLES ATTACHED HOIST CABLES (2)

PULLDOWN CABLES (2)

PULLDOWN CABLE ADJUSTMENT

Fig. 6-3 Hoist/Pulldown Cables - 35' Mast (ref. 1490377 rev. 01) 6-6

Mast/Rotary Drive/Pipe Rack

Hoist/Pulldown Cable Adjustment DO NOT climb on mast, serious injury or death can occur.

Cable Adjustment (without auto tensioner) The following procedure is used to adjust the tension in the hoist/pulldown cable system. Frequency of adjustment varies according to drilling methods and operational requirements. Proper and equal cable tension is required to prevent misalignment of the rotary head, as well as, limiting any undesired stress forces in the mast assembly. 1.

Ensure the drill is jacked correctly and level.

Stow all drill pipes in the pipe rack and lower rotary head to engage with bit sub then feed up slightly without disengaging the deck wrench to ensure the feed cable slack is in the lower cables.

Lower the mast to the horizontal position. Check the lay/hang of the bottom cables. If the cables do not hang exactly the same, adjust the most loose cable to match the tighter cable using the two pulldown adjustment nuts (fig. 6-4). Ensure that the drill bit is clear of the rear deck if the pipe in hole lockout has to be activated to lower the mast.

Once the bottom cables are hanging exactly the same, apply minimal feed pressure (approx. 500–600 PSI) to bring the cable slack onto the hoist cables, then activate the auto feed to maintain the determined pressure. Check the lay/hang of the top cables. If the cables do not hang exactly the same, adjust the most loose cable to match the tighter cable using the two hoist adjustment nuts (fig. 6-4).

Disengage auto pulldown and hoist very slightly to bring the cable slack back to the lower cables. DO NOT hoist far enough to damage the deck wrench assembly.

Apply 100 PSI pulldown pressure and engage the auto feed switch. Check the lay/hang of the top cables and adjust both cables to exactly the same hang, but also so that both hang approximately 1 in. (25 mm) below the bottom of the mast rail.

Release hydraulic pressure on the system. Ensure all lock nuts are tightened. The cables are now adjusted. NOTE

Over time, as the cables are adjusted, it will be noticed that the rotary head does not travel all the way to the bottom of the mast, potentially causing non-engagement of the breakout wrench on the flats of the drill stem. At this point it will be necessary to loosen the top cable adjustment nuts and then tighten the lower cable adjustment nuts. Be sure to do this in equal amounts, i.e. one turn at the top for one turn at the bottom. Once this is done, the normal cable adjustment procedure is to be followed.

Mast/Rotary Drive/Pipe Rack

6-7

Hoist/Pulldown Cable Replacement

Fig. 6-4 Lower & Upper Mast Sections 24. Hex Nut (8) 25. Flat Washer (4) 31. Adapter 52. Spacer 53. Chock Bar

NOTE

Always replace cables in sets. Do not install a new cable on one side and a used one on the other side.

Cable Replacement (without auto tensioner) 1.

This process can be accomplished by using either one (1) piece of drill pipe and the bit sub on the rotary head, or just the bit sub screwed directly on to the top sub on the rotary head. If using a drill rod, raise the rotary head to the top of the mast. Extend the auto tool wrench, and engage the jaw over the bit sub slats.

Using the high-speed pulldown lever (or auto feed switch), apply sufficient (max. 1500 PSI) hydraulic pressure down on the breakout jaw (this will slacken the hoist upper cables.) If drill bit is screwed to bit sub, ensure it will clear the drill deck when lowering the mast. • If replacing the hoist cables, apply pressure downward. This will put some slack in the hoist cables so the top adjusting nuts can be loosened. • If replacing the pulldown cables, apply pressure downward and loosen hoist cable nuts, then feed upward slightly to slacken the pulldown cables. DO NOT feed up enough to damage deck wrench assembly. Hoist pressure is not controlled by the feed pressure relief.

Turn machine off and isolate (LOCKOUT), then remove locknuts and adjusting nuts.

Remove all sheaves that the cable passes through. Check all sheave bearings and seals and replace if necessary. Remove cable.

Install new cable. Attach clevis to rotary head first, then install threaded end to mast. Grease and install sheaves.

Install adjusting nuts and tighten until cable feels tight enough to be tested.

Follow procedure for cable adjustment as previously outlined.

6-8

Mast/Rotary Drive/Pipe Rack

Hoist/Pulldown Cables Auto Tensioning–Operating Principle The auto tensioning system consists of hydraulic cylinders anchored to the feed cylinder(s) and attached to a slider block with guide grooves that cable sheaves move up and down in. A separate cylinder is used for each sheave. Cable stretch is taken up at a 2:1 ratio, i.e. for every unit of cylinder movement, two units of cable stretch are taken up. Hydraulic valves are used to limit cable tension maximum and minimum values. The system operates in balanced tension, so that, if one cable wears or stretches more than another there will still be equal tension on all cables. Some systems use two cylinders for hoist cable tension and two cylinders for pulldown cable tension. Other arrangements have only two cylinders for pulldown cable tension. Regardless which system is on a particular machine, the operating and service procedures are basically the same.

Fig. 6-5a Auto Tensioning System–Two Tensioning Cylinder System

Mast/Rotary Drive/Pipe Rack

6-9

Hoist/Pulldown Cables

Fig. 6-5b Auto Tension–Four Tensioning Cylinder System

Fig. 6-5c Tensioner Manifold Port Identification (ref. 416113)

6-10

Mast/Rotary Drive/Pipe Rack

Hoist/Pulldown Cables Cable Installation and Adjustment (with auto tensioner) 1.

With one piece of pipe attached to the rotary head, raise the rotary drive up and engage the flats of the bit sub with the deck wrench. If using a down-the-hole hammer, remove it from the drill pipe to enable the mast to be lowered.

Lower the mast and shutdown and isolate the machine.

Connect a drain hose to port "CR2" on the tensioner manifold and the place drain hose into a container to catch hydraulic oil.

Open the needle valves connected to the rod side of the cable tensioning cylinders to drain via the tensioner manifold. The hoist and pulldown cables will immediately loose tension.

If the cables do not loosen enough to remove the cable nuts then the hose at port "P1" can be removed and capped off. Start machine and feed up and down slightly and the cable will fully loosen. DO NOT hoist far enough to damage the deck wrench assembly.

Shutdown and isolate machine.

Remove the cable nuts and disconnect the clevis ends from the rotary head. Remove all sheaves that the cable passes through. Check all sheave bearings and seals and replace as necessary. Remove cable.

Install new cable and existing sheaves. Install clevis on rotary head guide first, then install cable end and adjusting nut.

The cables are now installed loose and sagging. Adjust the nuts so the hoist cables are sagging about 1 1/2 in. at the midpoint. Do the same for the pulldown cables. Start machine.

10.

Install a 6000 PSI (414 bar) gauge in the "GA" port of the tensioner manifold, on the lower side of the manifold. Pressurize the "P" port of the manifold. Set the pressure reducing valve between 600–1250 PSI (41–86 bar). Set the pressure on the relief valve to 3000 PSI (207 bar).

11.

There should be equal pressure in the tensioning cylinders and equal tension of the cables. Shutdown and isolate machine. Reconnect the plumbing to port "P1" and cap off port "CR2".

12.

Start machine. The tensioning cylinders should be extended the same amount.

13.

If tensioning cylinders are not extended the same, move the feed up or down to transfer oil from one pair of cylinders to the other (four cylinder system).

14.

When the cylinder travel is even, fully close the needle valves and tighten the locking screw.

Mast/Rotary Drive/Pipe Rack

6-11

Rotary Head Guide Alignment

SEE TORQUE CHART IN SERVICE MANUAL FOR TORQUE VALUES.

Fig. 6-6 Rotary Drive Assembly (ref. 439029 rev.11) 1. Rotary Gear Case 14. Capscrew, Hexhead (12) 3. L.H. Rotary Guide 15. Nord Lock Washer (12) 4. R.H. Rotary Guide 16. Capscrew, Brass (8) 5. Wear Pad (8) 30. Bushing (2) 6. Shim, Wear Pad (8) 32. Chock Bar (2)

6-12

34. 35. 36. 37.

Shim, Wear Pad (2) Wear Pad (2) Capscrew, Brass (16) Nord Lock Washer (24)

Mast/Rotary Drive/Pipe Rack

Rotary Head Guide Alignment The following method is used to align the rotary head in relationship to the travel rails in the mast assembly: Spot and level the machine and raise the mast as in preparation for normal drilling operations. Before drilling the hole, check to be sure pipe is plumb with a level on the pipe. Check this reading against level in cab to be sure they are the same. Drill one pipe into the ground. At the completion of this pass, raise the rotary head just enough to suspend the drill pipe in the hole, approximately 2 ft. Check alignment of the pipe in the drill bushing. It should be hanging in the center without touching the sides of the bushing. If it is touching, loosen the hex head screws attaching the wear pads to the rotary guide assembly (fig. 6-6). If shimming of the rotary head guide is necessary, add or subtract the necessary amount of shims between the pads and guides until the drill stem hangs freely within the drill bushing. Retighten the guide / pad screws. Follow the sequence below: 1.

Shim the inside wear pad first.

Shim the front wear pad (towards the radiator end of the machine).

Shim the rear wear pad (cab end of machine).

Mast/Rotary Drive/Pipe Rack

6-13

Rotary Drive Assembly

SEE TORQUE CHART IN SERVICE MANUAL FOR TORQUE VALUES.

6-14

34. 35. 36. 37.

Shim, Wear Pad (2) Wear Pad (2) Capscrew, Brass (16) Nord Lock Washer (24)

Mast/Rotary Drive/Pipe Rack

Rotary Drive Assembly Rotary Drive - Removal from Mast DO NOT climb on mast, serious injury or death can occur. BE SURE to relieve pressure on hydraulic or pneumatic systems before loosening connections or parts. 1.

Remove pipe from sub-adapter and lower mast to horizontal position. Be sure machine is on level ground and position rotary head in an accessible working position. Grind the weld from the two chock bars that secure the sub-adapter to the rotary drive shaft and remove sub-adapter.

Remove air hose from swivel.

Remove the two hydraulic motors and suspend with wire. Do not let motors hang by their hoses. NOTE

You must remove the center gear case cover bolt on each outer edge of the gear case, so it will clear the upper stop blocks when lifting out.

Grind the welds from the two chock bars on the bottom of the rotary gear case so you can lift the gear case out of the mast.

Support the rotary gear case with suitable lifting device in two places. Remove capscrews that hold gear case to guides. Carefully slide gear case up and out of the mast and take to shop for repair.

Rotary Drive - Installation 1.

Hoist rotary drive into position with suitable lifting device. Align unit between upper and lower stop blocks and slide into guides. Align the six bolt holes in the rotary drive with the holes in the right and left guides.

Install the six capscrews and washers on each side and torque to 282 ft. lbs. (384 Nm).

Set main shaft bearing preload.

Install seal housing, air swivel and rotation motors along with all hoses and any other connections that were removed, don't forget the two gear case cover bolts at the outer edges.

Start machine and check that rotary drive functions properly and there are no leaks. Shut down machine and install sub adapter or shock sub and tighten joint. Weld new chock bars in place on the sub-adapter according to fig. 6-6. Also weld new chock bars in place under gear case that were removed earlier.

Mast/Rotary Drive/Pipe Rack

6-15

Rotary Drive Gear Case

Fig. 6-7a Rotary Drive Gear Case (ref. 4260824 rev. B) NOTES: 1.

Set preload to 0.002 to 0.004 by placing an 8 X 8 wood block under rotary head and load pulldown to 1500 PSI (103 bar). Turn locknut (11) until it contacts bearing cone (26), then turn locknut another 15o . Tighten setscrews (50) in locknut to 50 ft.lb. min. Tighten screws evenly and opposite to one another, gradually increasing the torque. Do Not tighten screws prior to assembling locknut to shaft.

Install silicone rubber sealant at all split lines unless shim or gasket is used.

6-16

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Rotary Drive Gear Case - Item Listing ITEM

QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

2 4 1 2 2 2 1 2 1 1 2 1 1 1 1 1 8 13 8 6 14 19 8 4 4 1 2 1 2 1 2 1 1 2 1 1 2 2 2 1 1 1 1 1 1 2

DESCRIPTION ADAPTER, SPLINE KEY SHAFT SHAFT, 24T GEAR, 84T SHAFT, 24T GEAR, 110T COVER, END SPACER SPACER LOCKNUT PLATE, SEAL CARRIER, BEARING HOUSING, SEAL CASE COVER CAPSCREW, HEX HEAD CAPSCREW, HEX HEAD CAPSCREW, HEX HEAD CAPSCREW, SOCKET HEAD WASHER, LOCK - 3/8 WASHER, LOCK - 1/2 WASHER, LOCK - 5/8 BEARING CONE BEARING CUP BEARING CONE BEARING CUP BEARING CONE BEARING, BALL PIN, ROLL PIN, DOWEL BUSHING PLUG, MAGNETIC PLUG, COUNTERSUNK HEX PLUG/O-RING PLUG, MAGNETIC SNAP RING ADAPTER SNAP RING SNAP RING SNAP RING PLUG SEAL, SPECIAL NAMEPLATE WINDOW, OIL LEVEL TAG, OIL EMPTY PLUG, PLASTIC (SHIPPING)

Mast/Rotary Drive/Pipe Rack

ITEM

QTY.

48 49 50 51 52 53 54 55 57 58 59 60 61 62 63 64 65

1 2 8 1 1 5 5 6 1 1 2 6 1 2 1 1 6

DESCRIPTION FITTING, BREATHER SHIM SET SETSCREW PLUG, SQUARE HEAD HOUSING, SEAL SHIM, .005 SHIM, .007 SHIM, .020 SEAL, FACE SEAL SPACER SEAL CAPSCREW, HEX HEAD FITTING, GREASE BEARING, BALL CAPSCREW, HEX HEAD WASHER (5/8") CAPSCREW, HEX HEAD

Fig. 6-7b Rotary Drive Gear Case (ref. 4260824 rev. B)

6-17

Rotary Drive Gear Case Repair 1.

Repair of the gear case is limited to the replacement of damaged or worn parts.

Inspect gear teeth for galling or heat discoloration and replace as necessary.

Inspect gear teeth for uneven wear patterns.

Inspect bearings and replace as necessary.

Replace seals and gaskets.

If further disassembly and repair are necessary, refer to the following Cotta TM2116-7 Repair Manual. Refer to parts manual for specific gear case and part numbers.

Main Shaft Bearing Preload After repairs are made to rotary drive gear case, the main shaft bearing preload of 0.002 to 0.004 in. must be set as follows: 1.

Do not install seal housing until after setting main shaft bearing preload.

With rotary gear case installed on the mast, place an 8 X 8 wood block on top of the deck wrench and lower rotary gear case so it is against the block.

Apply 3000 PSI (207 bar) pulldown pressure.

Tighten locknut by hand enough to achieve 0.000 end play, then tighten 1/64 to 1/32 turn (5 to 11 ).

Tighten the setscrews in the locknut evenly and opposite one another, gradually increasing torque to 50 ft. lbs. (68 Nm) minimum.

Do not tighten screws prior to assembling locknut to shaft. Apply Loctite 242 to setscrews.

After correct setting of main shaft bearing preload, install the seal housing, air swivel (if equipped), hydraulic motors and all connections that were removed.

Rotary Head Bull Shaft Bearing Nut

NOTE:

6-18

Locknut is Left hand thread

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Seal Installation In order to get maximum service life out of heavy duty face seals, they must be seated in their housings symmetrically, resulting in a stable running position. If the seal halves are not installed accurately, misalignment or cocking of the seal set can occur during the assembly procedure, resulting in non-uniform face loading and wobbling of the seals in their housings. This is the leading cause of leakage and premature failure. To avoid this, always follow these instructions. 1.

Clean all sealing components, seal rings (metal rings), load rings (bellevilles) and the housings with denatured alcohol. Check to make sure that there is no nicks or burrs in the housing area that could damage the load ring during installation.

After components have dried, the load rings should be placed back on the seal rings in their proper position. Make sure that the load rings are seated completely and tightly on the seal ring. Do not place the seal rings face down on any hard or abrasive surface to accomplish this.

Quickly swab out the housing with a clean lint free cloth generously soaked with denatured alcohol. This is to temporarily lubricate the installation bore. then, with the same cloth, quickly swab the outside (load ring area) of the seal half to temporarily lubricate the load ring.

With both hands, quickly center the load ring in the housing and firmly and evenly press the seal into the housing bore. It is important for the load ring as well as the housing bore to be wet with alcohol during this process.

Visually inspect the positioning of the load ring and seal ring relative to each other, as well as relative to the housing. Make sure that everything is seated symmetrically. Misaligned seals and improperly seated load rings can cause leakage or premature failure.

The seal may be adjusted by gently pushing the load ring into position with your fingers from the outside. Never use sharp instruments such as screwdrivers. They can cause permanent damage to the load ring and/or seal ring, which may lead to rapid failure. Also, the seal ring may need to be adjusted in the load ring. This can also be done with your fingers. For twists or obvious bulges in the load ring or if the seal ring is "riding up" on the load ring can not be adjusted, remove the seal half and repeat the procedure, beginning with the cleaning process.

After successful installation in housings, wait a few minutes for the alcohol to completely evaporate, before assembling. The alcohol is necessary as a lubricant during the installation process, but for assembly the area must be clean and dry in order for the load ring to properly "crush" into its final position.

Mast/Rotary Drive/Pipe Rack

6-19

Rotary Drive Gear Case Never install seals with oil, grease or any solvent that can leave a residue.

Assembly Instructions 1.

After both seal halves have been installed in the case and seal plate housings and just prior to assembly, thoroughly clean the faces with denatured alcohol. Apply a thin film of oil (the same oil that will be used in the drive unit) to the faces of the seal rings with a clean lint free cloth. Be careful not to get oil on the load rings.

Pick up the seal plate (with the half seal installed) with both hands and turn it over using your fingers to hold the seal ring in place, while it is inverted. Line the plate up over the shaft and slide on until the case seal face come in contact with your fingers. Slowly slide your fingers out at the gap and let the faces come together.

Place both hands on the seal plate and apply even pressure to the top of it to make sure that the seal is completely seated in the housings. Turn the plate slightly in both directions while applying pressure. At this time it is not important to line up the bolt holes.

Visually inspect the gap between the plate and the case to see that it is the same size all of the way around the circumference. If it is not, repeat step 3. If further adjustments are necessary, remove the seal plate and the seal halves from their housings and repeat the installation procedure again starting with step 1 (cleaning process).

Line up the bolt holes, and slowly and evenly draw the plate down to the case using the specified torque.

Run-In Period The run-in period is the amount of running time necessary for the faces to mate to each other to form a perfect seal. One hour in each direction is normally sufficient. It is common for seals to "weep" a little during this period. Continuous dripping and/or running oil is a signal that something is wrong.

Maintenance For trouble free function of the seal, adequate lubrication of the sealing faces is necessary at all times. A small amount of oil may be visible on the outer diameter of the seal when it is working. This is not a leak, but only the seal faces being properly lubricated. If a seal is removed or the faces are separated after it has been run-in, it should be replaced with a new set.

6-20

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case

Mast/Rotary Drive/Pipe Rack

6-21

Rotary Drive Gear Case Repair

6-22

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-23

Rotary Drive Gear Case Repair

6-24

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-25

Rotary Drive Gear Case Repair

6-26

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-27

Rotary Drive Gear Case Repair

6-28

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-29

Rotary Drive Gear Case Repair

6-30

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-31

Rotary Drive Gear Case Repair

6-32

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-33

Rotary Drive Gear Case Repair

6-34

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-35

Rotary Drive Gear Case Repair

6-36

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-37

Rotary Drive Gear Case Repair

6-38

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-39

Rotary Drive Gear Case Repair

6-40

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-41

Rotary Drive Gear Case Repair

6-42

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-43

Rotary Drive Gear Case Repair

6-44

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-45

Rotary Drive Gear Case Repair

6-46

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-47

Rotary Drive Gear Case Repair

6-48

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-49

Rotary Drive Gear Case Repair

6-50

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-51

Rotary Drive Gear Case Repair

6-52

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-53

Rotary Drive Gear Case Repair

6-54

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-55

Rotary Drive Gear Case Repair

6-56

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-57

Rotary Drive Gear Case Repair

6-58

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-59

Rotary Drive Gear Case Repair

6-60

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Repair

Mast/Rotary Drive/Pipe Rack

6-61

Notes

6-62

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Motor Rotary Drive Gearbox Motor - Repair Repair of hydraulic piston motors and pumps in this manual is limited to external controls (Refer to Section 7) and shaft seal replacement. Normally when a piston motor or pump is worn out or damaged internally it is more cost effective to replace it with a new or rebuilt unit.

Shaft Seal Replacement Removal - Refer to fig. 6-8 on next page. 1.

Remove four screws (33), gaskets (32), seal retainer (31), and o-ring (29).

Remove shaft seal (30) from shaft (27).

Remove screw (26) that secures cam (23) to housing.

Remove shaft and bearing assembly and cam (23) by grasping shaft and pulling out of housing from end of unit opposite mounting flange. When removing shaft from cam, use extreme care not to damage seal surface of shaft. Any scratches or marks on this surface will cause leaks around shaft seal.

Carefully remove shaft and bearing assembly from cam. NOTE

Do not remove bearing (18) from housing, unless damaged or worn.

Installation - Refer to fig. 6-8 on next page 1.

Insert barrel stop (14) into the spring assembly (15) through the shaft seal end of motor.

Insert the small end of drive shaft (27) and bearing through the bore of housing, bore of cam, and into the barrel spline until shaft rests against the springs (15) in the barrel.

Install o-rings (29) into counterbore of housing.

Press shaft seal (30) into seal retainer (31). Grease seal lips.

Install screws (33) through retainer (31). Install o-ring (32) over screw end protruding through retainer. O-ring to be trapped in retainer recess.

Install shaft seal (30) onto shaft using shaft seal assembly tool (see fig. 8a). NOTE

Use care not to scratch seal surface of shaft. Scratches will cause leakage around the seal.

Slide seal retainer over shaft and into housing, letting bolts go through housing to cam. Engage each screw 1-2 turns into cam.

Tighten each screw by no more than 1/4" in sequence so that each screw is advanced equally. Failure to do this may damage o-ring (32).

Pull screws down tight and torque evenly to 50 ft. lbs. (68 Nm).

Mast/Rotary Drive/Pipe Rack

6-63

Rotary Drive Gear Case Motor

Fig. 6-8 Rotary Gear Case Rotation Motor (ref. 95176)

6-64

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Motor Fig. 6-8 Rotary Gear Case Motor - Parts List 1. Plug, Hex Soc. (2) 14. Barrel Stop (10 2. O Ring (2) 15. Disc Spring (12) 3. Screw, Hex Hd. Cap (4) 16. Thrust Washer (12) 4. Port Block w/Shuttle (1) 17. Cylinder Barrel (1) 5. Gasket (1) 18. Barrel Bushing (1) 6. Port Plate, CW (1) 19. Retaining Ring (1) 7. Face Plate (1) 20. Thrust Washer (1) 8. Pin, Face Plate (5) 21. Piston, Shoes & Retainer (1) 9. O Ring (3) 22. Creep Plate (1) 10. Shuttle Valve (1) 23. Cam (1) 11. Screw, Hex Hd. (3) 24. Dowel Pin (2) 12. Retaining Ring (1) 25. Housing (1) 13. Spring Retainer (1)

26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

Screw, Soc. Hd. Cap (1) Shaft, Spined (1) Bearing Assembly (1) O Ring (1) Shaft Seal (1) Seal Retainer (1) Gasket (4) Screw, Hex Hd. Cap (4) O Ring (1) Plug, Hex Soc. (1)

Fig. 6-8a Shaft Seal Installation Tool

Mast/Rotary Drive/Pipe Rack

6-65

Rotary Drive Gear Case Motor Trouble Shooting Component problems and circuit problems are often interrelated. An improper circuit may operate with apparent success but will cause failure of a particular component within it. The component failure is the effect, not the cause of the problem. This general guide is offered to help in locating and eliminating the cause of the problems by studying their effects. Effect of Trouble Noisy pump / motor

6-66

Possible Cause

Fault Which Needs Remedy

Air in Fluid

Leak in suction line Leak at shaft seal Low fluid level Turbulent fluid Return lines above fluid level Gas leak from accumulator Excessive pressure drop in the inlet line from a pressurized reservoir Suction line strainer acting as air trap

Cavitation in rotating group

Fluid too cold Fluid too viscous Fluid too heavy Shaft speed too high Suction line too small Suction line collapsed Suction strainer too small Suction strainer too dirty Operating altitude too high Boost or replenishment pressure too low Replenishment flow too small for for dynamic conditions

Misaligned shaft

Faulty installation Distortion in mounting Axial interference Faulty coupling Excessive overhung loads

Mechanical fault in motor

Piston and shoe looseness or failure Bearing Failure

Erosion on barrel ports and port plate

Air in fluid Cavitation

See Above See Above

High wear in motor

Excessive loads

Reduce pressure settings Reduce speeds

Contaminant particles

Improper filter maintenance Filters too coarse Introduction of dirty fluid into system Reservoir openings Reservoir breather Improper line replacement

Mast/Rotary Drive/Pipe Rack

Rotary Drive Gear Case Motor Trouble Shooting (cont.) Effect of Trouble High wear

Pressure shocks

Possible Cause

Fault Which Needs Remedy

Improper fluid

Fluid too thin or thick for operating temperature range Breakdown of fluid with time/ temperature/shearing effects Incorrect additives in new fluid Destruction of additive effectiveness with chemical aging

Improper repair

Incorrect parts Incorrect procedures, dimensions, s finishes.

Unwanted water in fluid

Condensation Faulty breather / strainer Heat exchanger leakage Faulty cleanup, practice Water in make-up fluid

Cogging load

Mechanical considerations

Worn relief valve

Needed repairs

Slow response in check valves Replace or relocate

Heating of fluid

Mast/Rotary Drive/Pipe Rack

Excessive decompression energy rates

Improve decompression controls

Excessive line capacitance (line volume, line stretch, accumulator effects)

Reduce line size or lengths, eliminate hose Bleed air

Barrel blow-off

Recheck hold-down rotating group, drain pressure

Excessive motor leakage

Recheck case drain flow and repair required Fluid too thin Improper shaft assembly, port timing

Reservoir

Too little fluid Entrained air in fluid Improper baffles Insulating air blanket that prevents heat rejection Heat pickup from adjacent equipment

6-67

Winch Assembly Precautions on the Use of Winches Winch brakes may slip or not function if operated in cold weather before proper warmup. ALWAYS maintain a minimum five (5) wraps of wire rope on the drum. Before operating any winch, be absolutely sure that the drill hydraulic system is properly warmed up to 100oF (38oC). After proper hydraulic system warm-up "exercise" the winch without load for several up and down cycles to allow warm hydraulic fluid to circulate in the winch.

Wire Rope Regular wire rope inspection, maintenance and replacement is necessary on all drill rigs. Environmental drills may have five or more different winches; each with a different wire rope size, length, operating condition and load factor. Wear can occur rapidly on one winch and be negligible on another on the same drill rig. The point at which to discard a wire rope is after receiving maximum service but without sacrificing safety. This is achieved by visual inspection of the outside condition of the wire rope. Deterioration of wire rope occurs both internally and externally from abuse, wear and corrosion. Research by wire rope manufacturers has shown that internal failures are followed by external failures visible to an inspector. On this basis, careful examination of the outside of the wire rope is a satisfactory means of determining the condition of the rope. Since safety is dependent on the proper operation of the wire ropes in all operations, a visual inspection of the wire rope should be performed daily by appointed personnel by running the block to its lowest usable point, and slowly running the block up as all parts of the cable are observed for signs of wear and damage: A. Kinks or severe twists B. Broken wires and nicks C. Deformed, worn or flattened wires D. Corroded or pitted surfaces E. Shortened or lengthened rope lays

Fig. 6-11 Wire Rope

6-68

Mast/Rotary Drive/Pipe Rack

Winch Assembly Wire Rope (cont.) In addition, the following more detailed inspection should be performed monthly or at more frequent intervals dependent upon operating conditions and usage: When running out the wire rope, exercise care that the drum stops at the end of the rope run-out and does not begin rewinding in the reverse direction. Stop run-out before you reach the dead lays on the drum. 1.

Run out wire rope completely and note conditions such as the number of broken wires in one lay, the reduction in rope diameter, corrosion, shortening of the lay and lubrication.

Run a soft cloth (preferably cotton) over the entire length of wire rope and examine rope lays which pick up threads of cloth. Determine the extent of damage due to broken wires or nicks.

Examine sheaves and drums for abnormal wear, breakage or deterioration. Replace any sheave or drum contributing to rope wear.

Examine the wire rope closely at the equalizer sheave location. Where wear is noted, the rope can be shortened from the dead end to change the point of wear. (However, two dead wraps must be maintained on the drum and required lift or operating range not reduced.)

Examine socketed fittings; if one broken wire is noted adjacent to the socket, resocket the wire rope.

The length and type of service and the severity of operation must be taken into consideration before determining the disposition of a wire rope which shows signs of damage. Where failure might endanger life of equipment, the rope must be condemned and replaced if any of the following conditions are discovered: 1.

Six wires broken in one rope lay.

Three wires broken in one strand in one rope lay

Wear of 1/3 the original diameter of outside individual wires.

Rope severely kinked, crushed, cut, or unstranded, or any other damage resulting in distortion of rope structure.

Considerable corrosion in the valleys between strands.

Reduction from nominal rope diameter of more than 1/64" (0.3mm) for diameters up to and including 5/16" (3.1 mm); 1/32" (0.7mm) for diameters of 3/8" through 1/2" (9.5-12.7 mm); 3/64" (1.2 mm) for diameters of 9/16" through 3/4" (14.2-19.1 mm); 1/16" (1.6mm) for diameters of 7/8" through 1-1/8" (22.2-28.6mm); and 3/32" (2.4mm) for diameters of 1-1/4" through 1-1/2" (31.8-38.1mm). When any of the above conditions exist, the wire rope must be condemned and replaced.

Mast/Rotary Drive/Pipe Rack

6-69

Winch Assembly Wire Rope (cont.) Lubrication is also important in the life of wire ropes, and can be accomplished with little trouble and expense. Regular, frequent applications of lubricant are preferred to infrequent heavy applications. Brush, spray, or dip the wire rope with cable lubricant M-2C-10 as required, depending on service conditions. The lubricant must be applied properly to coat the entire cable, not just the portion in most frequent use. Wire rope subjected to high operating temperatures or corrosive atmosphere should be lubricated semi-monthly. Keep all wire ropes, including those infrequently used or those in storage, free of contaminants and well protected with lubricant. Dirty cables should be cleaned and flushed with M-99C30 penetrating oil; after one week, the entire surface should be brushed to remove all excess grease, accumulated dirt, metal rust, or other harmful contaminants. NOTE

NEVER subject a wire rope to shock loads or loads exceeding the safe load rating.

Wire Rope Clips Wire rope clips are widely used for attaching wire rope to thimbles, hoists and for joining two ropes. Clips are available in two basic designs; the U-bolt and fist grip. The efficiency of both types is the same. When using U-bolt clips, extreme care must be exercised to make certain that they are attached correctly, i.e., the U-bolt must be applied so that the "U" section is in contact with the dead end of the rope. Also, the tightening and re-tightening of the nuts must be accomplished as required.

How to Apply Wire Rope Clips 1.

U-Bolt Clips Turn back the specified amount of rope from the thimble. Apply the first clip one base width fro the dead end wire rope (U-bolt over dead end-live end rests in clip saddle). Tighten nuts evenly to recommended torque.

Apply the next clip as near the loop as possible. Turn on nuts firmly, but do not tighten.

Space additional clips, if required, equally between the first two. Turn on nuts, take up rope slack, tighten all nuts evenly on all clips to recommended torque.

Apply the initial load and retighten nuts to the recommended torque. New rope in particular and used rope will stretch and shrink in diameter when loads are applied. Inspect periodically and retighten. Failure to make proper terminations or to periodically retighten clips to the recommended torque will reduce the wire lines load rating, thus creating a hazardous condition.

6-70

Mast/Rotary Drive/Pipe Rack

Winch Assembly How to Apply Wire Rope Clips (cont.)

A termination made in accordance with the above 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 long lay wire rope, 6 x 19 class, or 6 x 37 class, fiber core or IWRC, IPS, or XIPS. If Seale construction or similar large outer wire type construction in the 6 x 19 class is to be used for sized 1" (25.4 mm) and larger, add one additional clip. The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2" (38.1mm) and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or XIPS, sizes 1-3/4" (44.5mm) and smaller. For other classes of wire rope not mentioned above, it may be necessary to add additional clips to the number shown. If a greater number of clips is used than shown in the table, the amount of rope turn-back should be increased proportionately.

Fig. 6-12 Wire Rope Clip Styles

Mast/Rotary Drive/Pipe Rack

Fig. 6-13 U-Bolt Wire Rope Clip Dimensions

6-71

Winch Assembly

Fig.6-14 Fist Grip Wire Rope Clip Dimensions

6-72

Mast/Rotary Drive/Pipe Rack

Winch Assembly How to Apply Wire Rope Clips (cont.) 1.

Fist Grip Clips Turn back the specified amount of rope from the thimble. Apply the fist clip one base width from the dead end of the wire rope. Tighten nuts evenly to recommended torque.

Apply the next clip as near the loop as possible. Turn on nuts firmly, but do not tighten.

Space additional clips if required equally between the first two. Turn on nuts, take up rope slack, and tighten all nuts evenly on all clips to recommended torque. Apply the initial load and retighten nuts to the recommended torque. New rope, in particular, and used rope will stretch and shrink in diameter when loads are applied. Inspect periodically and retighten.

A termination made in accordance with the above 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 long lay wire rope, 6 x 19 class, or 6 x 37 class, fiber core or IWRC, IPS, or XIPS. If Seale construction or similar large outer wire type construction in the 6 x 19 class is to be used for sized 1" (25.4 mm) and larger, add one additional clip. The number of clips shown also applies to right regular lay wire rope, 8 x 19 class, fiber core, IPS, sizes 1-1/2" (38.1mm) and smaller; and right regular lay wire rope, 18 x 7 class, fiber core, IPS or XIPS, sizes 1-1/2" (38.1mm) and smaller. For other classes of wire rope not mentioned above, it may be necessary to add additional clips to the number shown. If a greater number of clips is used than shown in the table, the amount of rope turn-back should be increased proportionately. The above is based on use of Fist Grip Clips on new wire rope. Failure to make proper terminations or to periodically retighten clips to the recommended torque will reduce the wire lines load rating, thus creating a hazardous condition.

Mast/Rotary Drive/Pipe Rack

6-73

Winch Assembly Wedge Sockets One of the more popular end attachments for wire rope is the wedge socket. For field, or on-the-job attachment, it is easily installed and quickly dismantled. 1.

Inspect the wedge and socket; all rough edges or burrs, that might damage the rope, should be removed.

If the rope is welded, the welded end should be cut off. This will allow the distortions of the ropes strands, caused by the sharp bend around the wedge, to adjust themselves at the end of the line. If the weld is not cut off, the distortions will be forced up the working line. This may result in the development of high strands of wavy rope.

Place the socket in an upright position and bring the rope around in a large, easy to handle loop. Care must be taken to make certain that the live-loaded side of the rope is in line with the ears.

The dead end of the rope should extend from the socket for a distance approximately nine times the rope diameter. The wedge is now placed in the socket, and a wire rope clip is placed around the dead end by clamping a short, extra piece or rope to the tail. (DO NOT clamp to the live part.) The U-bolt should bear against the tail; the saddle of the clip should bear against the short extra piece.

Secure the ears of the socket to a sturdy support and carefully take a strain on the live side of the rope. Full the wedge and rope into position with tension sufficiently tight to hold them in place.

After final pin connections are made, increase the loads gradually until the wedge is properly seated. Avoid sudden shock loads.

The foregoing is the recommended procedure. If variations are made to suit special conditions, they should be carefully evaluated beforehand.

Fig. 6-15

6-74

Mast/Rotary Drive/Pipe Rack

Winch Assembly Grooved Drums With grooved drums, the winding conditions should be closely supervised to assure adherence to the following recommended procedures. 1.

The end of the rope must be secure to the drum by such means as will give the end attachment at least as much strength as is specified by the equipment manufacturer.

Adequate tension must be maintained on the rope while it is being wound so that the winding proceeds under continuous tension.

The rope must follow the groove.

There should be at least three dead turns remaining on the drum when the rope is unwound during normal operation. Two dead turns are a mandatory requirement in many codes and standards.

If the sire rope is carelessly wound, and, as a result, jumps the grooves, it will be crushed and cut where it crosses from one groove to the other. Another, almost unavoidable problem is created at the drum flange; as the rope climbs to a second layer there is further crushing and the wires receive excessive abrasion. Riser and filler strips may help remedy this condition.

Plain (Smooth) Drums Installation of a wire rope on a smooth face drum requires a great deal of care. The starting position should be at the drum end so that each turn of the rope will wind tightly against the preceding turn. Here too, close supervision should be maintained during installation. This will help make certain that: 1.

the rope is properly attached to the drum;

appropriate tension on the rope is maintained as it is wound on the drum;

each turn is guided as close to the preceding turn as possible, so that there are no gaps between turns; and

there are at least two dead turns on the drum when the rope is fully unwound during normal operating cycles.

Loose and uneven winding on a smooth drum can, and usually does, create excessive wear, crushing and distortion of the rope. The results of such abuse are lower operating performance, and a reduction in the rope's effective strength. Also, for an operation that is sensitive in terms of moving and spotting a load, the operator will encounter control difficulties as the rope will pile up, pull into the pile and fall from the pile to the drum surface. The ensuing shock can break or otherwise damage the rope.

Mast/Rotary Drive/Pipe Rack

6-75

Winch Assembly

Fig. 6-16 Wire Rope Cross-Over

Fig. 6-17 Diagram showing how to determine wire rope "lay"

6-76

Mast/Rotary Drive/Pipe Rack

Winch Assembly Plain (Smooth) Drums (cont.) The proper direction of winding the first layer on a smooth drum can be determined by standing behind the drum and looking along the path the rope travels, and then following one of the procedures illustrated. The diagrams (Figs 6-16 and 6-17) show: the correct relationship that should be maintained between the direction of lay rope (right or left), the direction of rotation of the drum (overwind or underwind), winding from left to right, or right to left.

Drums - Multiple Layers Many installations are designed with requirements for winding more than one layer of wire rope on a drum, winding multiple layers presents some further problems. The first layer should wind in a smooth, tight helix which, if the drum is grooved, is all ready established. The grooves allow the operator to work off the face of the drum, and permit the minimum number of dead turns. A smooth drum presents an additional problem, initially, as the wire rope must be wound in such a manner that the first layer will be smooth and uniform, and will provide a firm foundation for the layers of rope that will be wound over it. The first layer of rope on the smooth drum should be wound with tension sufficient to assure a close helix, each turn being wound as close as possible to the preceding turn, and most, if not all, of the entire layer being used as dead turns. The first layer then acts as a helical groove which will guide the successive layers. Unlike wire ropes operating on groove drums, the first layer should not be unwound from a smooth-faced drum with multiple layers. After the rope has wound completely across the face of the drum (either smooth or grooved), it is forced up to a second layer at the flange. The rope then winds back across the drum in the opposite direction, lying in the depression between the turns of the rope on the first layer. Advancing across the drum on the second layer, the rope, following the "grooves" formed by the second layer, the rope, following the "grooves" formed by the rope on the first layer, actually winds back one turn in each revolution of the drum. The rope must then cross two rope "grooves" in order to advance across the drum for each turn. The point at which this occurs is known as the cross-over. Cross-over is unavoidable on the second, and all succeeding layers. At these cross-over points, the rope is subjected to severe abrasion and crushing as it is pushed over the two rope "grooves" and rides across the crown of the first rope layer. The scrubbing of the rope, as this is happening, can easily be heard. There is, however, a special drum grooving available that will greatly minimize the damage that can occur at crossover points. Severe abrasion can also be reduced by applying the rule for the correct rope lay (right or left-lay) to the second layer rather than to the first layer. It is for this reason that the first layer of a smooth drum should be wound tight and used as dead turns.

Winch Assembly Service Refer to the following Braden manual covering Model BG8A for service of the winch assembly.

Mast/Rotary Drive/Pipe Rack

6-77

Notes

6-78

Mast/Rotary Drive/Pipe Rack

6-79

Winch Service and Repair

CAUTION

BG BRADEN GEARMATIC

6-80

039

MAX RATING

DESIGN MODEL

GEAR

MOTOR SIZE

DRUM

RATIO

PERSONNEL HANDLING

SIZE

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-81

Winch Service and Repair

6-82

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

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Mast/Rotary Drive/Pipe Rack

6-83

Winch Service and Repair

9(17 3/8* $%29( &(17(5/,1(

6-84

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-85

Winch Service and Repair

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6-86

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-87

Winch Service and Repair

PREVAILING AMBIENT TEMPERATURE oF

-40

-30

-20

-10

100

110

120

130 oF

MOBILGEAR 600 XP 220 OR EQUIVALENT AGMA 5 EP, ISO VG 220 MOBILGEAR 600 XP 150 OR EQUIVALENT AGMA 4 EP, ISO VG 150 MOBILGEAR SHC 150 SYNTHETIC OR EQUIVALENT oC

-40

-30

-20

-10

NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.

Planetary hoists are factory filled with Mobilgear 600 XP 150, or equivalent. Consult your oil supplier for other equivalent oils if required.

Mobil

6-88

Shell

Chevron

Texaco

Mobilgear 600 XP 150

Omala 150

Gear Compounds EP 150

Meropa 150

Mobilgear 600 XP 220

Omala 220

Gear Compounds EP 220

Meropa 220

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-89

Winch Service and Repair

6-90

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-91

Winch Service and Repair

6-92

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-93

Winch Service and Repair

6-94

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-95

Winch Service and Repair

6-96

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-97

Winch Service and Repair

CAUTION

6-98

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-99

Winch Service and Repair

6-100

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-101

Winch Service and Repair

6-102

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

CAUTION

9(17 3/8* $%29( &(17(5/,1(

CAUTION

Mast/Rotary Drive/Pipe Rack

6-103

Winch Service and Repair

CAUTION

6-104

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair BRAKE VALVE ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 22

DESCRIPTION Valve Housing (NSS) Check Valve Retainer (NSS) Spring Retainer (NSS) Plug (NSS) Spool (NSS) Damper Piston (NSS) O-ring Check Valve Poppet (NSS) Pilot Orifice Check Valve Spring Spool Spring O-ring O-ring O-ring Back-up Ring Back-up Ring Check Ball (1/4 in.) Check Ball Spring Elbow Fitting Shim

QTY. 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 A.R.

NSS - NOT SERVICED SEPARATELY. REPLACE COMPLETE VALVE ASSEMBLY.

Mast/Rotary Drive/Pipe Rack

6-105

Winch Service and Repair

6-106

Mast/Rotary Drive/Pipe Rack

Winch Service and Repair

Mast/Rotary Drive/Pipe Rack

6-107

Winch Service and Repair

Bolt Dia. Thds Per Inches Inch 20 1/4 28 18 5/16 24 16 3/8 24 14 7/16 20 13 1/2 20 12 9/16 18 11 5/8 18

6-108

Torque (LB-FT) Grade 5 Grade 8 Dry Lubed Dry Lubed 8

110

150

110

150

115

210

160

Torque (LB-FT) Bolt Dia. Thds Per Grade 5 Grade 8 Dry Lubed Dry Lubed Inches Inch 10 3/4 265 200 380 280 16 9 420 325 600 450 7/8 14 8 485 910 1 640 680 14 7 790 590 1290 970 1 1/8 12 7 1 1/4 1120 835 1820 1360 12 6 1460 1095 2385 1790 1 3/8 12 6 1 1/2 1940 1460 3160 2370 12

Mast/Rotary Drive/Pipe Rack

H.O.B.O. Wrench BE SURE to relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.

Service procedures for the Hydraulically Operated Break Out (H.O.B.O.) Wrench are limited to replacing or repairing cylinders, and replacing the tong dies and holders. Refer to parts manual for specific repair part numbers, detailed drawings and cylinder repair kits. •

Refer to Section 3 of this manual for repair procedures on Texas Hydraulics cylinders. When repairing hydraulic cylinders follow the "General Information" instructions, then follow the specific instructions for the type of head and piston the cylinder you are working on has.

•

Refer to Section 7 of this manual for pressure relief valve settings, sequence valve adjustment and hydraulic schematic and piping diagrams.

Fig. 6-18 Hydraulically Operated Break Out (H.O.B.O.) Wrench 1. Swing Cylinder 5. Counterbalance Valve for Swing Cylinder 2. Telescoping Cylinder 6. Sequence Valves for Clamp and Rotate Cylinders 3. Rotate Cylinder 7. Cylinder Lock/Float Valve for Telescoping Cylinder 4. Clamp Cylinder

Mast/Rotary Drive/Pipe Rack

6-109

Pipe Positioner BE SURE to relieve pressure on hydraulic or pneumatic systems before loosening connections or parts.

Service procedures for the pipe positioner are limited to replacing or repairing cylinders, and replacing pins and bushings. Refer to parts manual for specific repair part numbers, detailed drawings and cylinder repair kits. •

•

Refer to Section 7 of this manual for sequence valve adjustment and hydraulic schematic and piping diagrams.

Fig. 6-19 Pipe Positioner 1. Swing Cylinder 2. Clamp Cylinder 3. Sequence Valves

6-110

Mast/Rotary Drive/Pipe Rack

Carousel Pipe Rack Major Components

Fig. 6-20 Lower Pipe Rack 1. Pipe Rack Support 2. Carousel Pipe 3. Bearing Cap - Lower Pipe Rack Support 7. Thrust Washer - Lower Pipe Rack Support 45. Swing Cylinder - Lower 61. Index Cylinder

Fig. 6-21 Mid-Section of Pipe Rack 24. Mid-Support - 2 places

Fig. 6-22 Upper Pipe Rack 3. Bearing Cap - Upper Pipe Rack Support 4. Bearing Cap - Carousel 45. Swing Cylinder - Upper Mast/Rotary Drive/Pipe Rack

6-111

Fig. 6-23 Pipe Rack Assembly (ref. 411495) 1. Pipe Rack Support 6. Bearing, Journal 2. Carousel Weldment 7. Thrust Washer (2) 3. Bearing Cap, Support (2) 24. Mid-Support (2) 4. Bearing Cap, Carousel 25. Capscrew (12) 5. Bearing, Journal (4) 26. Nut, Hex (12)

27. 30. 31. 32. 33.

Washer, Flat (24) Bushing (2) Nut, Elastic Stop (4) Washer, Flat (4) Capscrew (4)

34. 47. 57. 60. 61.

Grease Fitting (10) Shim Kit Index Plate End Cap Cylinder, Index

Carousel Pipe Rack

6-112

Mast/Rotary Drive/Pipe Rack

Carousel Pipe Rack General Information Service to the pipe rack assembly primarily consists of replacement of the hydraulic cylinders, replacement of the pipe rack support bearings, carousel bearings and pipe rack support roller. Replacement of hydraulic cylinders is a straightforward procedure that requires no detailed steps. Be sure the item is secure from movement before removing that cylinder. Be sure that lines are not pressurized before disconnecting fittings. Study the detail drawings of that cylinder in this manual or in the parts manual for removal and installation. Repair information for hydraulic cylinders is found in section 3 of this manual.

Pipe Rack Bearings - Removal If bearings are worn, it is best to replace both upper and lower bearings at the same time to avoid extra down time. Refer to photo's (fig's. 6-20 to 6-22) and drawings (fig's. 6-23 to 6-27) for disassembly and assembly. Read through entire procedure before starting and be sure you have all parts required on hand. 1. Remove pipe sections from carousel. Be sure machine is on level and stable ground. Lower mast to horizontal position, resting on mast rest. Pipe rack must be fully retracted and resting against the stop plate (item 35, fig. 6-27). Retract the index lock cylinders (8), so carousel is not locked. Extend index cylinder (61) so carousel is rotated counterclockwise all the way (as viewed from bottom). 2.

Remove pin (58) from index cylinder rod end. Retract cylinder and shut down machine.

Support pipe rack be means of chain or sling and a suitable lifting device. Place chain or sling around upper and lower portions of pipe rack support (1) and carousel weldment (2).

Remove the pins (53) from the upper and lower pipe rack swing cylinders (45).

Fig. 6-24 Pipe Rack Swing Cylinder Assembly 13. Washer, Flat 3/8 (2) 50. Capscrew, 1/2 (4) 34. Grease Fitting 51. Washer, Flat 1/2 (4) 45. Cylinder, Swing 52. Bushing (4) 49. Pin, Bolt Retained (2) 53. Pin, Bolt Retained Mast/Rotary Drive/Pipe Rack

54. Capscrew, 3/8 (2) 55. Bushing 56. Bushing

6-113

27. 30. 31. 32. 33.

Washer, Flat (24) Bushing (2) Nut, Elastic Stop (4) Washer, Flat (4) Capscrew (4)

34. 47. 57. 60. 61.

Grease Fitting (10) Shim Kit Index Plate End Cap Cylinder, Index

Carousel Pipe Rack

6-114

Mast/Rotary Drive/Pipe Rack

Carousel Pipe Rack Pipe Rack Bearings - Removal continued 5.

See fig. 6-23. Remove the four capscrews (25) from the upper bearing caps (3 & 4) and lower bearing cap (3).

Remove the caps from the mid-supports (24), by removing the four capscrews (33).

The pipe rack assembly is now free to move. Use caution and watch hoses to be sure they don't get stretched. Move pipe rack assembly far enough to remove bearing caps (3 & 4) and to gain access to the capscrews (62) that hold the end cap (60) to the bottom of the carousel.

See fig's. 6-23 & 6-25. Remove the eight capscrews (62) that hold the end cap (60) to the bottom of the carousel (2). Be careful not to lose the shims (47) under the cap. NOTE

Some units may not have any shims under the cap. They are only used if there is insufficient clearance between the outer flange of the end cap and base of carousel. There needs to be about 0.030 in (0.76mm) clearance so carousel will not bind when it is rotated.

Disconnect the index cylinder (61) from the index plate (57) and remove hoses from the index lock cylinder (8). Cap or plug all open hydraulic fittings and hose ends.

10.

Support the index plate (57) so it cannot fall when carousel pipe is removed. Slide the carousel pipe (2) out of the index plate (57) and carousel support (1).

11.

See fig. 6-26. Using a suitable lifting device, remove the index plate (57) to a convenient working area.

Fig. 6-25 Lower Pipe Rack Assembly (ref. 411495) 8. Hydraulic Cylinder, Index Lock (2) 34. Grease Fitting 9. Pin, Carousel Lock 44. Bushing (2) 10. Insert, Pin 47. Shim Kit 11. Pin, Dowel 51. Washer, Flat 1/2 12. Capscrew 3/8 57. Index Plate 13. Washer, Flat 3/8 58. Pin, Bolt Retained Mast/Rotary Drive/Pipe Rack

59. 60. 61. 62. 63.

End Cap, Cylinder (2) End Cap, Carousel Hydraulic Cylinder, Index Capscrew 1/2 (8) Capscrew 1/2 (8) 6-115

Carousel Pipe Rack Pipe Rack Components - Inspection 1.

Inspect journal bearings (5 & 6) for wear. The I.D. for a new pipe rack support or carousel base bearings (5) is 8.025" - 8.030" (203.8 - 204mm). The I.D. for a new upper carousel bearing (6) is 6.025" - 6.030" (153 - 153.2mm).

Inspect the two mid-point support bushings (30) for wear. These are split bushings, the I.D. should be 6.00" (152mm).

Inspect the two nylon thrust washers (7) for wear. Original thickness is 1/2" (12.7mm). Replace if wear is noticeable.

Inspect all weld areas for cracking. Check for damaged, misaligned or worn components. Repair any damage before reassembly of pipe rack.

Replace damaged or leaking hoses, repair leaking cylinders.

Inspect pipe rack roller (15) for wear. See separate repair instructions in this section.

Fig. 6-26 Lower Carousel Cross Section 1. Pipe Rack Support 13. Washer, Flat 3/8 2. Carousel Weldment 15. Pipe Rack Roller 5. Bearing, Journal (2) 44. Bushing (2) 7. Thrust Washer 47. Shim Kit 8. Index Lock Cylinder (2) 51. Washer, Flat 1/2 12. Capscrew 3/8 57. Index Plate 6-116

58. 59. 60. 61. 62. 63.

Pin, Bolt Retained End Cap, Cylinder (2) End Cap, Carousel Hydraulic Cylinder, Index Capscrew 1/2 (8) Capscrew 1/2 (8) Mast/Rotary Drive/Pipe Rack

Carousel Pipe Rack Pipe Rack - Assembly and Installation NOTE

Be sure to install the bearings so the grease groove is aligned with the grease fitting.

The journal bearings (5 & 6) are a slight press fit. Be sure to install the bearings so the grease groove is aligned with the grease fitting. Chill the bearings in a freezer for about 30 minutes before installing and they should drop right in. Clean old grease from tube ends, coat journal bearings with new grease.

See fig. 6-26. Install thrust washer (7) onto lower carousel pipe. Install other thrust washer (7) onto pipe rack support tube (1). Install lower carousel into bottom plate of pipe rack support (1). Install index plate (57) onto end of carousel tube.

See fig. 6-26. Install shims (47) and end cap (60) to bottom of carousel (2). Install 8 capscrews (62) and washers (51). Tighten capscrews and check for correct clearance between end cap and bottom of carousel pipe. You should have about .003" (.08mm). Add or subtract shims to get correct clearance.

See fig. 6-23. Grease and install the upper and lower pipe rack support bearing caps (3) onto the pipe rack support. Grease and install the upper carousel bearing cap (4) onto the upper carousel pipe. Grease mid-point support bushings (30). Install new bushings if required.

Hoist pipe rack assembly into position. Line up bearing cap bolt holes and install bearing cap bolts, nuts and washers (25, 26 & 27, fig. 6-23). Line up swing cylinder rod ends with clevises and install pins (53, fig. 6-24) and retaining bolts and washers (13 & 54). Tighten bearing cap bolts.

Grease and install mid-point support caps and bushings (30). Fasten with capscrews, washers and locknuts (33, 32, 31)

Line up index cylinder (61) with index plate clevis and install pin (58) and retaining bolt and washer (12 & 13).

Install hydraulic hoses to index lock cylinders (8).

Check all connections and all bolts for proper torque. Apply grease to all fittings at all pivot points. Start machine and check to see that pipe rack carousel functions correctly and there are no leaks.

Fig. 6-27 Pipe Rack Top View 13. Flat Washer 34. Grease Fitting 35. Stop Plate 45. Swing Cylinder (2) 49. Pin, Bolt Retained 50. Capscrew 51. Flat Washer 53. Pin, Bolt Retained 54. Capscrew

Mast/Rotary Drive/Pipe Rack

6-117

Carousel Pipe Rack Pipe Rack Roller Remove and Replace 1.

Lower mast to horizontal position, resting on mast rest.

Remove pipe rack roller from lower pipe rack support, by removing the two capscrews that hold the pipe rack roller shaft retainer plate (fig. 6-28). Then remove the retainer plate.

Remove grease fitting from end of roller shaft, and use a port-a-power to drive shaft out of lower pipe rack support. Repair or replace roller assembly.

Install roller shaft into bore far enough so retainer Fig. 6-28 Pipe Rack Roller 1. Capscrew (2) plate will fit into the slot.

Install the two capscrews and lockwashers and 3. Shaft, Pipe Rack Roller tighten.

Grease bearings through grease fitting at end of shaft. Grease once each shift.

2. Retainer Plate, Pipe Rack Roller Shaft

Fig. 6-29 Pipe Rack Roller (viewed from mast pivot end) 4. Roller, Pipe Rack 5. Stop, Roller

6-118

Mast/Rotary Drive/Pipe Rack

Carousel Pipe Rack Pipe Rack Roller Disassembly and Assembly 1.

Remove the two capscrews from the retainer plate (fig. 6-30) and remove retainer plate.

Turn roller over and remove the inner retaining ring as shown in fig. 6-31

Remove seal retainer (fig. 6-32) by pressing out shaft from opposite end using an arbor press. The inner bearing cup will come out with the seal retainer.

Fig. 6-30 Pipe Rack Roller Retainer Plate.

Fig. 6-31 Pipe Rack Roller Inner Retaining Ring.

Fig. 6-32 Pipe Rack Roller Seal Retainer. Mast/Rotary Drive/Pipe Rack

6-119

Carousel Pipe Rack Pipe Rack Roller Disassembly and Assembly 4.

Remove the outer retaining ring and outer bearing cup (fig. 6-33).

Clean and inspect inner and outer surfaces of roller. The I.D of the roller is 4.438" to 4.439". Check O.D. for any flat spots or cracks. Check roller shaft for damage and wear. The O.D. of the shaft on the bearing side is 2.438" ± .001". The O.D. of the shaft on the slot side is 2.498" + .002", -.000". Check to be sure the grease passage is not blocked.

Install outer bearing cup (fig. 6-33) so it is past Fig. 6-33 Outer Bearing Cup and Retaining Ring. the retaining ring groove.

Install outer retaining ring and seat outer bearing cup against retaining ring.

Pack dual bearing cone with grease and press onto roller shaft. Be sure bearing seats against shoulder of shaft. Install shaft into roller (fig. 6-34).

Press inner bearing cup (fig. 6-35) in place. Seat bearing cup against bearing cone. Be sure shaft rotates freely, but no excessive end play.

10. Install seal retainer (fig. 6-32) and seat below retaining ring groove. Install inner retaining ring (fig. 6-32). 11. Turn roller over and install retaining plate (fig. Fig. 6-34 Install Roller Shaft/Bearing Assembly into roller. 6-30) with two capscrews and washers. 12. Install grease fitting into end of shaft and pump full of grease until grease comes out of bearings.

Fig. 6-35 Install Inner Bearing Cup. 6-120

Mast/Rotary Drive/Pipe Rack

Section 7

Hydraulic Systems

7-1

Notes

7-2

Hydraulic Systems

Hydraulic System Hydraulic Reservoir and Return Filters

The hydraulic system consists of a hydraulic reservoir (tank) that supplies oil to hydraulic pumps. These hydraulic pumps provide hydraulic pressure to operate all machine functions outside of the electrical and compressed air circuits. From the pumps, oil is supplied to the levers and control valves which operate hydraulic motors or cylinders. Another important feature of hydraulic systems is the filters. All the oil returning to the tank flows through either the return manifold, the drain manifold, or the case manifold. Oil returning from the return manifold must pass through the return filter before entering the tank. Oil returning from the drain and case manifolds is first teed together before passing through the case return filter. Both these filters have by-pass check valves in case the filters become blocked. NOTE

It is important to remember that the pressure in the return, drain, and case manifolds is different. The pressure in the return manifold is around 20+ psi, and in the drain and case manifolds is only <7 psi. This is particularly important when connecting case drains from motors or pumps. If they are connected to the return manifold the increased pressure will prevent the case drain from draining, which will result in too much oil in the case and blowing out the shaft / oil seal.

Fig. 7-1 An important part of the hydraulic system is the filters. Hydraulic Reservoir Assembly 1. Main Return Filter 2. Case Drain Filter 3. Air Filter 4. Service Valve (open to relieve pressure after machine is shut down) 5. Hydraulic Pressure Test Station (optional)

Hydraulic Systems

7-3

Pressure Setting Sequence Pressure Setting Sequence

The following sequence is recommended for checking and setting pressures. Be sure to relieve all pressure in system prior to installing gauges. If machine is equipped with a hydraulic pressure test station (see fig's.7-2, & 7-2a) it will not be necessary to install gauges. The pressure setting procedures and locations are described fully in this section. FUNCTION

PRESSURE

PAGE

5500 PSI (380 bar)

7-27

HYDRAULIC SYSTEM 1.

Crossover Relief (High Pressure)

RH Tram & LH Tram/Rotation Pressure Override (P.O.R.)

5000 PSI (345 bar)

7-27

Charge Pressure

450 PSI (31 bar)

7-29

Mast Control Valves

2250 PSI (155 bar)

7-34

Main Control Valves

2700 PSI (190 bar)

7-44

Cooler Fan Speed (single) Cooler Fan Speed (dual)

2400 PSI (166 bar) 2000 PSI (138 bar)

7-56 7-56

Fig. 7-2 Hydraulic Pressure Test Station (ref. 426487) - optional - mounted on hydraulic tank

7-4

Hydraulic Systems

Hydraulic Pressure Test Station Circuit

Fig. 7-2a Hydraulic Pressure Test Station Circuit (ref. 426487) Hydraulic Systems

7-5

Hydraulic System Drill Tooling Circuit CAUTION:

Relieve pressure on hydraulic and pneumatic systems before loosening connections or parts. NOTE

When checking and setting relief valves, the engine should be operated at full governed RPM.

Open Service Valve on top of hydraulic tank to relieve any residual pressure in system. Open valve for about 30 seconds to let all air escape from tank, then close valve. Install a 3000 PSI (207 bar) test gauge in the inlet port or a work port of the valve. Start machine and engage one of the valve functions on the mast valve to deadhead the pressure. Correct relief valve pressure is 2250 PSI (155 bar). This indicates that the relief valve is set Fig. 7-1 Hydraulic Tank properly and that the pump will build pressure. To 1. Service Valve - open to relieve pressure after system is adjust the relief valve, loosen the jam nut using a shut down. 13mm wrench. Use a 4mm allen wrench to adjust relief valve adjusting screw. With the pressure deadheaded, turn the adjusting screw clockwise to increase relief pressure, or counter-clockwise to decrease the pressure. Tighten the jam nut while holding the adjusting screw. Recheck the pressure setting after the jam nut is tightened, to be sure 2250 PSI (155 bar) is showing on the gauge.

Fig. 7-3 Mast Valve Assembly (422873) Located above HOBO wrench, on left side of mast.

7-6

draulic Systems

Hydraulic System Open Loop System (Low Pressure) The open loop system consists of the necessary pumps, cylinders and controls to prepare and position the drill rig for operations: 30 / 17 GPM Tandem Gear Pump 36 GPM Gear Pump Mast Elevating Cylinders Leveling Jack Cylinders Carousel Swing & Rotation Cylinders Pipe Positioning Cylinder Tool Wrench Devices Mast Locks Dust Control System Cooling Fan Circuits Service Winch Filtration Pilot Pressure is initially filtered through one closed loop charge filter.

Fig. 7-3a Left Hand Pump

Fig. 7-4 Right Hand Pump

Return system pressure is filtered at the reservoir.

Hydraulic Systems

7-7

Hydraulic System Open Loop System (Low Pressure) NOTE

When checking and setting relief valves, engine should be operated at full governed RPM.

The valve bodies are located on the hydraulic tank in front of the operator's cab (fig. 7-5). Before checking pump and relief valve settings, ensure that the dust collector / water injection pump control switch is in the neutral position. Completely extend or retract the leveling jack cylinders. 2750 PSI (190 bar) should be shown on the hydraulic system pressure gauge in the cab. This indicates that the hydraulic pump is building pressure and the relief valves are set correctly. If not, adjust the relief valves as described below.

Adjustment Procedure 1.

This procedure is best done with two people. With machine running, have a helper in the cab hold one of the valve functions on the upper (5 bank) valve in the open or closed position to deadhead the flow. Adjust the relief valve on the upper (5 bank) valve until pressure on the hydraulic gauge in the cab reads 2750 PSI (190 bar).

Repeat this procedure in step 1 for the lower (4 bank) valve. You may have to back out the relief valve on the lower (4 bank) valve a couple of turns so the pressure will be lower than 2750 PSI (190 bar). If not, the pressure will relieve at the upper (5 bank) valve setting. Turn adjustment screw in until pressure on the hydraulic gauge in the cab reads 2750 PSI (190 bar).

Fig. 7-5 Deck Valve Assembly 1. Relief Valve Adjustment Screw 7-8

Hydraulic Systems

Hydraulic System Closed Loop System (High Pressure)

The closed loop system consists of two AA4VG180 piston pumps, controlling the tram and drill circuit. • Two AA4VG180 Piston Pumps •

Hoist / Pulldown Cylinder

•

Rotary Drive Motor

•

Propel Motors

•

Pilot Control Valves

Fig. 7-6 Closed Loop Portion of Hydraulic Schematic (ref. 426661) Hydraulic Systems

7-9

Main Hydraulic Pumps NOTE

The main hydraulic pumps discussed as follows are Rexroth pumps. Some series of drills use Linde main pumps. Refer to the parts manuals for your machine and if Linde equipped, refer to the Linde Pump Supplement at the end of this section.

Description The main hydraulic pumps used••are the Rextroth AA4VG180 variable displacement pump with built in charge pump. There are two types of pump controllers used, these are: 1. Electric Control (EP) - EP1 is 12VDC and EP2 is 24VDC. TEREX-Reedrill machines use 24VDC controllers. 2.

Hydraulic Pilot Control (HD). These control options are described below.

AA4VG EP2 (electric control) Main Hydraulic Pumps The two main pumps are AA4VG180EP2 Rexroth variable piston pumps. The left main pump supplies pressure to the left hand tram circuit and the rotation circuit. The right main pump supplies pressure to the right hand tram circuit and the pulldown (feed) circuit. The circuits are closed loop circuits. The internal charge pumps built into the back of each pump discharge through the Fe ports from which the oil is directed through a charge filter for each pump then back into the Fa ports to supply charge pressure to the piston pumps. The two charge circuits are tee’d together after the charge filter and pressure (450 psi) is controlled by a common charge relief. G ports are also looped together. Joining the charge circuit enables one side to assist the other so preventing ‘dips’ in the charge pressure which can cause cavitation and reduced pump life. The charge pressure is used as pilot pressure on the servo piston to stroke the pump as well as boosting the piston pump inlet. The standard integral charge relief in each pump is replaced by an orifice plug which allows a small amount of charge oil to flush the pump case, but the volume is reduced so pump case pressure is reduced and shaft seal life is increased. This particular pump configuration uses an electric proportional (EP) control to control the pump flow. For a complete description, see following pages under topic "EP (24VDC) Control".

AA4VG HD (hydraulic control) Main Hydraulic Pumps The two main pumps are AA4VG180HD Rexroth variable piston pumps. The left main pump supplies pressure to the left hand tram circuit and the rotation circuit. The right main pump supplies pressure to the right hand tram circuit and the pulldown (feed) circuit. The circuits are closed loop circuits. The internal charge pumps built into the back of each pump discharge through the Fe ports from which the oil is directed through a charge filter for each pump then back into the Fa ports to supply charge pressure to the piston pumps. The two charge circuits are tee’d together after the charge filter and pressure (450 psi) is controlled by a common charge relief. G ports are also looped together. Joining the charge circuit enables one side to assist the other so preventing ‘dips’ in the charge pressure which can cause cavitation and reduced pump life. The charge pressure is used as pilot pressure on the servo piston to stroke the pump as well as boosting the piston pump inlet. The standard integral charge relief in each pump is replaced with a charge cartridgeby an orifice plug which allows a small amount of charge oil to flush the pump case, but the volume is reduced so pump case pressure is reduced and shaft seal life is increased. Pilot pressure to control the pump direction and volume via the HD (hydraulic pilot) control is taken from the charge pressure. This pressure is supplied via the Drill/Tram solenoid valve, and then on to the control levers in the cab before reaching the "Y1" or "Y2" ports to enable the pump to stroke in either direction. 7-10

Hydraulic Systems

Main Hydraulic Pumps (HD)

Fig. 7-7 Standard AA4VG Pump Circuit

Hydraulic Systems

7-11

Main Hydraulic Pumps - Port Locations

Fig. 7-8 Main Hydraulic Pumps - AAVVG180 Port Locations Shown without Control Right Track/Pulldown (Feed), Left Track/Rotation

7-12

Hydraulic Systems

Main Hydraulic Pumps - Port Locations

Fig. 7-8a EP Control Option

Hydraulic Systems

Fig. 7-8b HD Control Option

7-13

Main Hydraulic Pumps (EP)

Relief Fig. 7-8c AA4VG Pump with electric controls (EP) 7-14

Hydraulic Systems

Main Hydraulic Pumps (EP)

Charge Pump

Fig. 7-8d AA4VG Pump with electric controls (EP) Hydraulic Systems

7-15

Main Hydraulic Pumps (EP)

Fig. 7-8e AA4VG Pump with electric controls (EP) 7-16

Hydraulic Systems

Main Hydraulic Pump Circuit (EP)

Fig. 7-8f AA4VG Pump Circuit with electric controls (EP)

Hydraulic Systems

7-17

Main Hydraulic Pump Circuit (EP) EP (24VDC) Control EP stands for Electrical Proportional control. Pump flow is infinitely varied from 0 to 100 percent, proportional to an electrical current in the range of 200 - 600 mA at 24VDC, supplied to solenoid A or B (see table 7-1). Electrical energy is converted to a force acting on the control spool. The spool then directs control oil in and out of the stroking piston to stroke the pump as required. A feedback lever, connected to the stroking piston, maintains the pump flow for any given current within the control range. The plugs to the solenoid valves are equipped with a green LED light (fig. 7-9). If the light is on, it indicates it is receiving power.

Table 7-1 Current vs. Flow Control Current (24 VDC): Begin of control: End of control:

I = 200 - 600 mA l = 200 mA (Vg0) l = 600 mA (Vg max)

Fig. 7-9 EP Control 24VDC Solenoids are receiving power if green LED is on. 7-18

Hydraulic Systems

Main Hydraulic Pumps (HD) AA4VG Pump - HD Control Module

Fig. 7-9a AA4VG Pump - HD Control Module

Fig. 7-9b AA4VG Pump - HD Control Module Hydraulic Systems

7-19

Main Hydraulic Pumps (HD) AA4VG Pump - Flow Diagram

Fig. 7-9c AA4VG Pump Flow Diagram

Fig. 7-9d AA4VG Pump Flow Diagram 7-20

Hydraulic Systems

Main Hydraulic Pumps (HD) Charge Pump - Flow Diagram

Fig. 7-9e AA4VG Charge Pump Flow Diagram

Hydraulic Systems

7-21

Main Hydraulic Pump Circuit (HD)

Fig. 7-10 AA4VG180HD Pump Schematic

7-22

Hydraulic Systems

Main Hydraulic Pumps Before Making Pump Adjustments Before the main pumps can be centered or the pressure relief and pressure cut off settings can be adjusted, a number of things have to be done; 1. Disconnect the tram brake release hose at the tee above the track equalizer bar (fig. 7-10c). This will set the brakes on and enable you to perform all main pump adjustments, and load the pump without the rig moving. 2.

Disconnect the rotation torque control line (if used) from the left track/rotation pump (port X3, fig. 7-10e) and plug the port.

Fig. 7-10c 1/4" Brake Release Line - located above axle pivot beam.

Fig. 7-10e AA4VG180EP Left Track & Rotation Pump. X3 Port for Rotary Torque Control Connection.

Fig. 7-10d 1/4" Brake Release Line at tram motor.

Hydraulic Systems

7-23

Main Hydraulic Pumps Adjustments Mechanical Centering With tram brakes set as described previously. 1.

Remove plugs at ports X1 and X2, and connect both control chambers with a hydraulic hose, no less than 1/4".

Disconnect and plug the X3 port for the rotation torque control (if used).

Install a 6000 PSI (414 bar) hydraulic pressure gauge to port MA and MB.

With pump running, adjust zero position so that at blocked drive both gauges indicate the same pressure. This pressure is approximately 440 PSI (30 bar).

Use a 24mm wrench to loosen locknut. Use an 8mm allen wrench to adjust centering screw. Turn allen wrench to the right and to the left and note the "dead band" (the area of the spool where no signal is received on either side, i.e., no pressure change on gauge) of the zero position of the valve spool.

Tighten locknut, shut off machine, and remove the hose connecting ports X1 and X2 and install the plugs.

Fig. 7-11 AA4VG180 Hydraulic Pump

7-24

Hydraulic Systems

Main Hydraulic Pumps Adjustments Hydraulic Centering

(Refer to fig. 7-11a for the following procedures) With tram brakes set as described previously. 1.

Install a 600 PSI (41 bar) hydraulic pressure gauge to ports X1 and X2.

Disconnect and plug the X3 port for the rotation torque control.

Loosen locking screw with a 4mm allen wrench. Turn adjusting screw with a 4mm allen wrench. Adjust zero position with allen wrench with pump in blocked drive so that both gauges read the same pressure. This pressure is approximately 40 PSI (2.8 bar). Then tighten locking screw.

NOTE

DO NOT turn adjustment more than 90o in either direction. The adjustment screw is an eccentric, therefore turning more than 90o will have no further effect, and could damage the eccentric pin.

Fig. 7-11a AA4VG180 Pump (EP Controls shown)

Fig. 7-11 AA4VG180 Hydraulic Pump

Hydraulic Systems

7-25

Main Hydraulic Pumps

Fig. 7-11b Pressure Cut-off (POR) adjustment.

Fig. 7-11c High Pressure adjustment.

7-26

Hydraulic Systems

Main Hydraulic Pumps High Pressure Valves and Pressure Cut-off (POR) Adjustments 1.

HP (high pressure) valves are always adjusted 10% higher than the pressure cut-off. If one setting is changed, always check both settings.

Make adjustments with system at normal operating temperature.

Install a 6000 PSI (414 bar) hydraulic pressure gauge to ports MA and MB .

WARNING:

BE SURE machine is on level ground and block tracks before removing brake lines. NOTE

High pressure valves must be checked in both directions. In order to load both pumps in both directions. Disconnect brake line to final drives at bulkhead fitting on the front axle. Plug line and cap fitting. This will prevent the brakes from releasing and you can now engage the propel levers in forward and reverse to load the pumps.

Pressure Cut-off (POR): 1.

Loosen locknut with a 13mm wrench, and with pump loaded (tram lever in forward or reverse), turn adjusting screw in with a 4mm allen wrench. Correct pressure reading is 5000 PSI (345 bar). Mark the setting of the adjusting screw. Then turn adjusting screw in until pressure is higher than HP valves (5500 PSI [379 bar]). This must be done BEFORE setting the High Pressure Reliefs. Now place tram lever in opposite direction.. Pressure should be equal on both sides of center.

High Pressure Valves: 1.

Operate tram valve with small pump flow volume (approximately 20%). Just enough to cause the relief valves to crack, thus preventing all the oil from washing over the relief valve.

Loosen locknut with a17mm wrench, and with pump loaded to 20% of full flow in one direction, turn adjustment screw in with a 5mm allen wrench. Set high pressure relief valves to 5500 PSI (379 bar). Now repeat procedure in opposite direction of flow.

NOTE

DO NOT take more than 10 seconds with this setting as excessive heat will be generated with fluid flowing over the high pressure relief valves.

Pressure Cut-off (POR): 1.

After checking/adjusting high pressure setting, turn pressure cut-off back to the mark you first made, or gauge reading of 5000 PSI (345 bar). The pressure cut-off must be 500 PSI (35 bar) below the high pressure relief setting.

••Hydraulic Systems

7-27

Main Hydraulic Pumps Stroking Orifices

Fig. 7-11d AA4VG180 Hydraulic Pump Stroking Orifices

7-28

Hydraulic Systems

Main Hydraulic Pumps Charge Pressure Circuit Charge pressure is the pressue supplied to the inlet side of a piston pump. The piston pump needs a positive charge to the inlet or it will cavitate and pump life will be reduced. The AA4VG180 piston pump has an internal charge pump. The charge pump is a fixed displacement gear pump. Oil comes from the tank in through the charge pump, and out of the Fe port. The oil goes through the charge filter and back into the main piston pump at the Fa port. Both of the AA4VG180 piston pumps are tee'd together and the charge circuit is regulated with one relief valve. This ensures that there is a constant pressure supplied to both the main piston pumps. If there is a pressure drop on one side, the other side will supply extra oil to compensate for it.

Charge Pressure Adjustment 1.

Install a 600 PSI (41 bar) hydraulic pressure gauge in the test port of relief valve.

Bring system up to normal operating temperature.

Loosen locknut and adjust pressure to 450 PSI (27.6 bar), tighten locknut.

Fig. 7-12 Main Pump Adjustments 1. Charge Pressure Adjustment 2. Relief Valve Test Port (Install gauge for Charge Pressure here) 3. Relief Valve

Hydraulic Systems

4. 5. 6. 7.

High Pressure Adjustment (for. & rev.) Pressure Cutoff (POR) Adjustment Mechanical Zero Adjustment Hydraulic Zero Adjustment

7-29

Main Hydraulic Pumps Specifications

Pressure Cut-Off The pressure cut-off valve varies the swashplate angle, as required, to limit the maximum pressure at port A or B. The pressure cut-off valve prevents continuous dumping of excessive flow, at load pressure, through the cross port relief valves in the pump. This eliminates unnecessary heating of the oil and protects the pump and motor during rapid acceleration or deceleration, or when the drive stalls, causing the pump to deadhead. The pressure peaks that occur with rapid swivel angle changes, and also the maximum system pressure, are further protected by the high pressure relief valves. The pressure cut-off valve should be set 20-30 bar (290-435 PSI) less than the high pressure relief valve settings. Standard Adjustment Range: 2175-6500 PSI (150-450 bar).

7-30

Hydraulic Systems

HD Pilot Control

Hydraulic Systems

7-31

Notes

7-32

Hydraulic Systems

EP Electric Pump Control

Hydraulic Systems

7-33

Mast Mounted Control Valve (SD8) Adjustment Procedure NOTE

When checking and setting relief valves, the engine should be operated at full governed RPM.

Open Service Valve on top of hydraulic tank to relieve any residual pressure in system. Open valve for about 30 seconds to let all air escape from tank, then close valve. Install a 3000 PSI (207 bar) test gauge in the inlet port or a work port of the valve. Start machine and engage one of the valve functions on the mast valve to deadhead the pressure. Correct relief valve pressure is 2250 PSI (155 bar). This indicates that the relief valve is set properly and that the pump will build pressure. To adjust the relief valve, loosen the jam nut using a 13mm wrench. Use a 4mm allen wrench to adjust relief valve adjusting screw. With the pressure deadheaded, turn the adjusting screw clockwise to increase relief pressure, or counter-clockwise to decrease the pressure. Tighten the jam nut while holding the adjusting screw. Recheck the pressure setting after the jam nut is tightened, to be sure 2250 PSI (155 bar) is showing on the gauge.

7-34

Fig. 7-13 Left Side (dust collector) of Mast 1. SD8 Mast Valve Bank 2. Relief Valve Setting 3. Counterbalance Valve - HOBO Swing 4. Sequence Valves (2) - HOBO Clamp/Rotate 5. Float Valve - connects to Telescoping (float) Cylinder

Hydraulic Systems

Mast Mounted Control Valve (SD8) Specifications

Spools All eight spools on the mast valve are motor spools as shown below:

Fig. 7-14 Mast Valve - Motor Spool Diagram (all 8 sections)

Hydraulic Systems

7-35

Mast Mounted Control Valve (SD8) Parallel Working Sections - Circuit Diagram

Fig. 7-15 Mast Valve - Work Section Diagram

7-36

Hydraulic Systems

Mast Mounted Control Valve (SD8)

Fig. 7-16 Mast Valve - Inlet Section with Relief Valve - set at 2250 PSI (155 bar).

Hydraulic Systems

7-37

Mast Mounted Control Valve (SD8) Electro - Hydraulic Kit (24VDC)

Fig. 7-16a Mast Valve - Electro-Hydraulic Circuit

7-38

Hydraulic Systems

Mast Mounted Control Valve (SD8) Electro - Hydraulic Kit (24VDC)

Fig. 7-16b Mast Valve - Electro-Hydraulic Circuit

Hydraulic Systems

7-39

Mast Mounted Control Valve (SD8)

Fig. 7-17 SD8 Mast Valve Assembly (ref. 422873)

Fig. 7-17a SD8 Mast Valve Assembly showing Feeder Kit option in gray (ref. 422873) 7-40

Hydraulic Systems

Mast Mounted Control Valve (SD8)

Fig. 7-17b SD8 Mast Valve - Inlet Section

Fig. 7-17c SD8 Mast Valve - Outlet Section

Fig. 7-17d SD8 Mast Valve - Work Section (1 - 8) Parts List for 8 Section Valve Assembly (ref. 422873) - Refer to fig's. 7-17 through 7-17d. 1. Body, Inlet Section 9. Plug 2. Valve, Relief 10. Tie Rod Kit - torque to 37 ft. lbs. (50 Nm) 3. Body, Work Section 1- 8 11. Bracket Kit 4. Spool, Motor 12. Feeder Kit - 8 Section 5. 24 VDC Electro Hydraulic Kit (sections 1 - 8)) 13. Seal Kit (includes o-rings for one working section and one 6. Plate, Dust Proof outlet section. Order 3 kits for complete valve assembly). 7. Plug, Work Port (2 per section) 8. Body, Outlet Section Hydraulic Systems

7-41

Mast Mounted Control Valve (SD8)

Fig. 7-18 SD8 Mast Valve - Torque Specifications

7-42

Hydraulic Systems

Mast Mounted Control Valve (SD8)

Fig. 7-18a SD8 Mast Valve - Troubleshooting Hydraulic Systems

7-43

Main Control Valves (SD25 & SD16) Deck Mounted Control Valves

There are two control valves that control the auxiliary functions (fig. 7-19). The upper (SD16) control valve is a 5 bank valve. Four sections are solenoid operated, and one section (mast elevate) is hydraulic pilot operated. The upper valve receives oil from the 30 GPM (114 lpm) gear pump. The power beyond port feeds excess oil to the lower (SD25) 4 bank control valve. The lower 4 bank valve has 3 hydraulic pilot operated sections for the jack functions, and one solenoid operated section for the service winch. The lower valve receives oil from the 17 GPM (64 lpm) gear pump, and from the power beyond port of the upper 5 bank valve.

Adjustment Procedure 1.

Fig. 7-19 Main Hydraulic Valves mounted on Hydraulic Tank (ref. 422952) 7-44

Hydraulic Systems

4 Section Valve (SD25) Specifications

Parallel Working Sections - Circuit Diagram

Fig. 7-19b Parallel Circuit with Two Sections

Hydraulic Systems

7-45

4 Section Valve (SD25)

Fig. 7-20 4 Section Valve Assembly (ref. 422875)

Fig. 7-20a Inlet Section (ref. 422875)

Fig. 7-20b Valve Section 1 Assembly (ref. 422875) 7-46

Hydraulic Systems

4 Section Valve (SD25)

Fig. 7-20c Valve Section 2 - 4 Assembly (ref. 422875)

Fig. 7-20d Outlet Section (ref. 422875)

Fig. 7-20e Feeder Kit - Electro-Hydraulic (ref. 422875) Parts List for 4 Section Valve Assembly (ref. 422875) - Refer to fig's. 7-20 through 7-20e. 1. Body, Inlet Section 9. Body, Section 2 through 4 2. Valve, Relief 10. Spool, Sections 2 through 4 3. Body, Section 1 11. Hydraulic Spool Control Kit, Sections 2 through 4 4. Spool 12. Body, Outlet Section 5. Plug (2 per work section) 14. Bracket Kit 6. 24 VDC Electro Hydraulic Kit (section 1 only) 15. Tie Rod Kit - torque to 37 ft. lbs. (50 Nm) 7. Plate, Dust Proof 17. Seal Kit (includes o-rings for one working section and one 8. Feeder Kit (section 1 only) outlet section. Order 3 kits for complete valve assembly). 8a. Plug, Power Beyond 8b. Valve, Backpressure

Hydraulic Systems

7-47

4 Section Valve (SD25) Torque Specifications

Fig. 7-21 4 Section Valve (SD25) Torque Specifications

Assembly 1.

Plug all openings to keep dirt out. Be sure all o-rings are in place between each section before assembly. There are five round o-rings and one square o-ring between each section. Place a little grease on the o-rings to hold them in place while assembling.

Be sure to assemble valve sections on a flat surface. Install the four tie rods, and be sure the valve assembly is perfectly flat. Install the four nuts on each end. Tighten nuts gradually in sequence to 37 ft. lbs. (50 Nm.).

DO NOT over-tighten tie rod nuts, as this can cause leakage and valve spool binding or sticking.

7-48

Hydraulic Systems

5 Section Valve (SD16) Specifications

Parallel Working Sections - Circuit Diagram

Fig. 7-22 Parallel Circuit with Two Sections

Hydraulic Systems

7-49

5 Section Valve (SD16)

Fig. 7-23 5 Section Valve Assembly (ref. 422874)

Fig. 7-23a Inlet Section (ref. 422874)

Fig. 7-23b Valve Section 1 - 4 Assembly (ref. 422874)

7-50

Hydraulic Systems

5 Section Valve (SD16)

Fig. 7-23c Valve Section 5 Assembly (ref. 422874)

Fig. 7-23d Outlet Section (ref. 422874)

Fig. 7-23e Feeder Kit - Electro-Hydraulic (ref. 422874) Parts List for 5 Section Valve Assembly (ref. 422874) - Refer to fig's. 7-23 through 7-23e. 1. Body, Inlet Section 9. Plate, Dust Proof 2. Valve, Relief 10. Plug, Sections 1 - 4 (2 per section) 3. Plug, Blanking 11. Body, Work Section 5 4. Plug, G 3/4 12. Spool, Cylinder (Work Section 5) 5. Feeder Kit, 4 Section 13. Spring Kit (not shown) use with Section 5 5a. Plug 14. Body, Outlet Section 5b. Valve, Backpressure 15. Tie Rod Kit - torque to 37 ft. lbs. (50 Nm) 6. Body, Work Sections 1 - 4 16. Mounting Bracket Kit 7. Spool, Motor (Sections 1 - 4) 17. Plug 8. 24 VDC Electro Hydraulic Kit (sections 1 - 4) 18. Seal Kit (includes o-rings for one working section and one outlet section. Order 3 kits for complete valve assembly).

Hydraulic Systems

7-51

5 Section Valve (SD16) Torque Specifications

Fig. 7-24 5 Section Valve (SD16) Torque Specifications

Assembly

7-52

DO NOT over-tighten tie rod nuts, as this can cause leakage and valve spool binding or sticking.

Hydraulic Systems

Counterbalance Valve Counterbalance Valve Adjustments CAUTION:

Over adjustment of a counterbalance valve, i.e. turning the adjusting screw in too far, could result in uncontrolled descent of the mast assembly. NOTE

Adjustment of the counterbalance valves is directly opposite of relief valves in this system, in that clockwise adjustment of relief valves increases pressure, whereas clockwise adjustment of the counterbalance valves decreases pressure. This must be remembered when performing any adjustments to the system.

Fig. 7-25 Counterbalance Valve

Hydraulic Systems

7-53

Mast Elevating Cylinders The hydraulic circuit of the mast elevating cylinders is protected by three counterbalance valves. There is one valve at the piston end of each cylinder, as well as, one that is tee'd into the rod end of both cylinders. The single valve on the rod ends is for controlling the mast when it breaks over center during setup. This is basically acting as a snubber valve to prevent the mast from running away when gravity overcomes the pivot support balance. The two valves on the piston ends are for controlling the descent of the mast when lowering back to tram position.

Fig. 7-26 Mast Elevating Circuit (ref. 405555)

Test and Adjustment 1. 2.

To determine if the valves are functioning correctly, the following procedure should be utilized: Lower the mast approximately one half of the way down to horizontal. Shut down the engine. If mast will move with engine shut down, then the valve on either or both piston ends is leaking by. To adjust the valve, raise the mast back up and lock in position. Loosen the jam nut and back out (counterclockwise) the adjusting screw in 1/4 turn increments. Tighten the jam nut and retest. If no difference is noted by the end of one full turn of the adjusting screw, then the valve must be replaced.

Another indication of a malfunctioning counterbalance valve is the mast assembly bouncing during the lowering of the assembly. If this is experienced, then the same adjustment procedure as above applies, except that the adjusting screw would be turned clockwise in 1/4 turn increments. Again, if no difference is noted by the end of one full turn, then the valve should be replaced.

7-54

Hydraulic Systems

Leveling Jack Cylinders 1.

The function of the dual counterbalance valves in the jack circuit is two-fold: To prevent the machine from drifting down after the jacks are set.

To prevent the jacks from drifting down when they are in the retracted position.

To check that the counterbalance valves are functioning properly: Extend jacks to raise machine off ground. Mark position of jacks, and let machine stand overnight. If machine has drifted down past mark, then counterbalance valve on rod end of cylinder needs adjustment or replacement. Retract jacks all the way up. Let machine stand overnight. If rod end of cylinder has drifted down, the counterbalance valve on piston end of cylinder needs adjustment or replacement.

Fig. 7-27 Leveling Jack Circuit with Dual Counterbalance Valves (ref. 423169)

Adjustment

While the valves are preset at the factory, they may be adjusted if drifting is encountered using the above test. Loosen the jam nut and back out (counterclockwise) the adjusting screw 1/4 turn increments, not to exceed one full turn. If drifting is still encountered, the valve must be replaced. NOTE

If in the above test, the unit does not start lowering, but does so during normal operations, then the jack cylinder most likely is bypassing or leaking internally, and further diagnostics and repair or replacement will be necessary.

Hydraulic Systems

7-55

Cooler Fan Circuit Setting Cooler Fan Speed Cooler fan pressure and flow is supplied by a open loop gear pump (fig. 7-27a).

Single Fan System •

Single fan speed is factory set at 1550 RPM. This results from the fan pump relief valve being set at approximately 2400 PSI (166 bar).

Dual Fan System •

Dual fan speed is factory set at 1700RPM. This results from the fan pump relief valve being set at approximately 2000 PSI (138 bar).

If you are operating in a hotter or colder environment, you may need to adjust fan speed accordingly. You do not want to waste horsepower by operating the fan at a higher speed than necessary. 1. Shutdown machine and relieve standing pressure. 2.

Install a 6000 PSI (414 bar) gauge in gauge port on back side of relief valve, opposite of relief valve adjustment screw (fig. 7-17). Or, if machine is equipped with a hydraulic pressure test station, turn the knob to FAN PUMP.

Start machine and allow system to warm up. Loosen lock nut and adjust screw (item 2, fig. 7-17) to desired pressure for fan R.P.M. Check fan speed with a strobe tachometer. When fan speed is correct, tighten lock nut. Shut down machine, relieve standing pressure, remove gauge and install plug in gauge port.

Fig. 7-27a Cooler Fan Pump 1. Relief Valve

7-56

Hydraulic Systems

Cooler Fan Circuit Hydraulic oil cooler

Hydraulic oil flows from the fan pump through the hydraulic fan motors then through a thermal by-pass valve then straight back to tank via the return filter until 140o F (60o C) is reached. The thermostat will then shift and redirect oil through the cooler pack before going back to tank. If the cooler becomes blocked oil will be redirected straight back to tank via the by-pass check valve. The by-pass check valve like all check valves is a differential check valve and opens at 45 psi differential between the secondary and primary lines . The thermostat by-pass is mounted at the bottom of the cooler pack. When the engine is shut down, in order to prevent the inertia from the fan draining the motor pressure line and causing the motor to cavitate, oil is diverted from the cooler discharge (to tank line) back through the motor via the wind down check valve, therefore ensuring positive charge on the inlet for the fan motor.

Fan motor

There are either one or two hydraulically operated fan motors on the cooling pack depending upon engine/compressor option. Each motor has a manifold mounted wind down check fitted across A and B ports. This enables fluid from the return side to circulate back through the motor as it slows down after the rig is shut down so preventing cavitation.

Fig.7-27b Dual Cooler Fans 1. Manifold 2. Wind Down (Anti-Cavitation) Check Valve 3. Thermal By-Pass Valve

Hydraulic Systems

7-57

Cooler Fan Circuit

Fig. 7-27c Dual Fan Circuit (ref. 420107)

7-58

Hydraulic Systems

Cooler Fan Circuit Thermal Bypass Valve Operation

Fig. 7-27d Thermal Bypass Valve

Hydraulic Systems

7-59

Hoist/Pulldown Cylinder Counterbalance Valve BI006785-04

The function of the counterbalance valve on the hoist / pulldown cylinder is to prevent the rotary head from dropping when the control is in neutral. It also stops creeping of the cylinder due to pump leakage when changing drill steel or tramming.

Fig. 7-28 Hoist Pulldown Cylinder

To determine if the counterbalance is functioning correctly, the following procedure should be used: Suspend a length of drill steel from the rotary drive; shut down the engine, and watch for creep over a period of several minutes. If it creeps down, then the counterbalance valve should be checked. Remove the acorn nut, loosen the jam nut and back out the adjusting screw in 1/4 turn increments. Do Not exceed one full turn of adjustment. NOTE

7-60

Prior to replacement of suspected defective counterbalance valve, the pump controller should be checked for neutral positioning (engine running). If controller is centered in neutral while running, and counterbalance valve replacement has no effect, then the hoist / pulldown cylinder is leaking and the cylinder should be repaired.

Hydraulic Systems

Hydraulic Operated Breakout Wrench Setting of Sequence Valves Adjustment Screw To Drain To Drain 3 Rotate Cylinder - Retract 2

Rotate Cylinder - Extend

“B” From Mast Valve to Clamp Cylinder - Retract

“B” Valve “A” From Mast Valve to Clamp Cylinder - Extend

1 “A” Valve

Fig. 7-28a Sequence Valves for Breakout Wrench.

Check setting of mast valve bank relief. It should be set at 2250 PSI (155 bar). See adjustment procedure on facing page.

Position H.O.B.O. wrench in open position.

Loosen and remove cap nut from adjustment screws (fig. 7-28a). Loosen locknut.

Screw both adjustments fully in, but not overly firm.

Operate breakout wrench to undo pipe. Pipe clamp cylinder will operate to full stroke, but rotate cylinder will not move.

While holding switch to clamp, adjust screw of the "A" (top) valve slowly outward until rotate cylinder actuates, adjust screw slightly more so that the cylinder operates freely. "A" valve is now correctly set - lock locknut. There should be about 200 PSI (14 bar) differential pressure between the clamp and rotate cylinders. This is to assure the clamp jaws are tight around the pipe before the rotate cylinder actuates, otherwise the jaws will slip on the pipe. Operate breakout to retract, clamp cylinder will release pipe but rotate cylinder will not move.

NOTE 7. 8.

While holding switch to retract, adjust screw on "B" (lower) valve slowly outward until actuation occurs. Adjust slightly more to achieve free movement.

Tighten adjustment locknut, install both protection caps.

10. Breakout sequencing now correctly set. See Figure 7-29 for breakout wrench schematic.

Hydraulic Systems

7-61

Fig. 7-29 ••• •ydraulic •• Operated Breakout Wrench (ref. 426769)

H.O.B.O. Wrench Ccuit

7-62

Hydraulic Systems

H.O.B.O. Wrench Operation 1.

First be sure the pipe has been secured with the deck wrench on the flats of the pipe.

Be sure the clamp jaws are all the way open before swinging the wrench in.

The SWING cylinder (1), swings the H.O.B.O. wrench into position on the pipe.

The ROTATE (2) and CLAMP cylinder (3) work together through the sequence valves (fig. 7-28a). When the clamp cylinder reaches the preset pressure, then the rotate cylinder operates to turn the pipe and break the joint.

NOTE There should be about 200 PSI (14 bar) differential pressure between the clamp and rotate cylinders. This is to assure the clamp jaws are tight around the pipe before the rotate cylinder actuates, otherwise the jaws will slip on the pipe.

Fig. 7-29a Hydraulically Operated Breakout Wrench (H.O.B.O.) 1. Swing Cylinder 2. Rotate Cylinder 3. Clamp Cylinder

Hydraulic Systems

7-63

Loop Filters (optional)

Fig. 7-30 Loop Filter Assembly (ref. 402263) 1. Bleed Plug 7. O Ring, Filter Element 2. O-Ring 7A. O Ring, Core Tube 3. Bowl 8. Backup Ring 4. Safety Grip 9. O-Ring 5. Label, Element Change 10. Retaining Ring 6. Filter Element 11. Reverse Flow Valve 6A. Core Tube 24. Bleed Plug 7-64

25. 26. 27. 28. 29. 32.

O-Ring Differential Pressure Device O-Ring O-Ring Dust Cover Head

Hydraulic Systems

Loop Filters (optional) Routine Maintenance The loop filters do not normally require special attention except for periodic monitoring of the dirty element warning device. See lubrication section for filter change intervals. Refer to Figure 7-40 for item numbers. 1.

If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (9) and backup ring (8), locating backup ring as shown in illustration (away from fluid, toward bowl (3) and the atmosphere). If leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.

Differential pressure indicators (26) act as a dirty element warning device and actuate when differential pressure across the element becomes excessive because of plugging by contaminant or because of high fluid viscosity under cold start conditions. If visual indicator actuates (red button extends 3/15" or 4.8 mm), reset by pushing button back after system reaches normal operating temperature at normal flow. If button stays in, element is still usable; if button will not stay in, change element (6).

Changing Filter Elements WARNING:

Turn off and depressurize system. Open bleed plug (1 or 24) at top of filter one and one-half turns. Remove plug (24 or 1) at bottom of filter and drain fluid into suitable container. Reinstall drain plug and tighten both plugs.

Remove bowl (3). Remove element (6) along with core (6A) and carefully inspect the surface for significant visible contamination. Normally, no dirt should show but visible dirt can be an early warning of system component breakdown and can indicate potential failure. Discard both the element and its o-ring, but do not discard the core (6A). The filter element is not cleanable. Any attempt to clean the filter element can cause degradation of the filter medium and allow contaminated fluid to pass through the filter.

NOTE Older model filters do not use the separate coreless filter and core assembly. The corless filter and core assembly can be fitted to the older models as a direct replacement for the filter with core. Core part number V011138. Filter Element part number V011136. The coreless filter elements provide longer service life and the core can be reused at each filter change.

Hydraulic Systems

7-65

Loop Filters (optional)

25. 26. 27. 28. 29. 32.

O-Ring Differential Pressure Device O-Ring O-Ring Dust Cover Head

Hydraulic Systems

Loop Filters (optional) Changing Filter Elements (continued) Refer to fig. 7-30 3.

Inspect filter housing and its bypass / reverse flow valve for possible damage or malfunction. Determine whether replacement of any components is necessary. Remove any accumulated dirt from filter, being careful to prevent contaminant from entering the outlet and washing downstream. Refer to element change instructions.

CAUTION:

Failure to replace damaged components, and operation without a properly functioning hydraulic filter can cause components downstream of the filter to fail or degrade in their performance.

Check that bowl seals; o-ring (9) and backup ring (8)) in head are not damaged. Use replacement filter element part number called for on assembly nameplate. Lubricate threads and sealing surfaces on bowl (3) and the o-ring (7) in element with clean system fluid. 4.

Push open end of filter element onto the core (6A). Lubricate the core o-ring (7A) and push the core and filter into the filter head (32). Screw bowl to head until bottomed. O-ring sealing not improved by overtightening; do not exceed 15 ft-lbs (20 Nm) torque. Bleed system. Reset visual warning device by pushing in the red button; electrical switch is reset automatically.

Pressurize system fully and check for external leaks; if leaks occur, check o-rings and sealing surfaces. After system reaches normal operating temperature, check that electrical switch has not actuated or that visual warning button remains down.

Fig. 7-31 Optional Charge Loop Filters (two per pump) Mounted adjacent to mast "A" frame, two each side) Hydraulic Systems

7-67

Charge Filters

Fig. 7-32 Charge Filter Assembly (ref. 58495) 1. Visual Service Indicator 2. Plug 3. O-Ring 4. O-Ring 5. Filter Element 6. Filter Bowl 7. Filter Head

7-68

Hydraulic Systems

Charge Filters Routine Maintenance The charge filters do not normally require special attention except for periodic monitoring of the dirty element warning device. See lubrication section for filter change intervals. Refer to figure 7-42 for item numbers. 1.

If external leakage is noted, replace o-ring at leak. For bowl seal leaks, replace o-ring (4). If leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.

Differential pressure devices actuate when the element needs changing or because of high fluid viscosity under cold start conditions. If visual indicator actuates (red button extends 3/15" or 4.8 mm), reset by pushing button back after system reaches normal operating temperature at normal flow. If button stays in, element is still usable; if button will not stay in, change element (6).

Changing Filter Elements WARNING:

Turn off and depressurize system. Open bleed plug (if fitted) one and one-half turns.

Unscrew and remove filter bole (6) from head assembly (7), counterclockwise when viewed from below. It may be necessary to use a lever on the "Rotolock Ring" of the filter bowl (6) to loosen the bowl initially.

Remove filter element (5) along with core, and carefully inspect the surface for visible contamination. Normally no dirt should show, but visible dirt or particles can be an early warning of system component breakdown and can indicate potential failure. Discard both the filter element and its o-ring, but do not discard the core. The filter element is not cleanable. Any attempt to clean the filter element can cause degradation of the filter medium and allow contaminated fluid to pass through the filter element.

CAUTION:

DO NOT attempt to clean or reuse element.

NOTE

Older model filters do not use the separate coreless filter and core assembly. The corless filter and core assembly can be fitted to the older models as a direct replacement for the filter with core. Core part number V011137. Filter Element part number V011135. The coreless filter elements provide longer service life and the core can be reused at each filter change.

Hydraulic Systems

7-69

Charge Filter

Fig. 7-33 Charge Filter Assembly - adjacent to pumps 1. Charge Filters (2)

Fig. 7-34 Right Side Charge Filter Assembly

7-70

Hydraulic Systems

Charge Filter Changing Filter Elements (continued) 4.

DO NOT run the system without a filter element (5) installed. Check that the o-ring (4) on the head assembly (7) is not damaged. Use replacement filter element part number called for on the element change label, or refer to the parts manual.

Lubricate element o-ring (4) with clean system fluid and push open end of filter element (5) onto the core. Lubricate o-ring on core and push core and filter into filter head (7). Clean out filter bowl (6) interior and lightly lubricate threads of filter bowl with clean system fluid. Screw filter bowl onto head assembly until it bottoms. O-ring sealing in not improved by overtightening.

CAUTION:

DO NOT use pipe wrench, hammer, or any other tool to tighten bowl. 6. Bleed the system and check for leaks. To bleed filter, open bleed plug, if fitted, one and one half turns. Jog system and fill filter until all air bleeds through plug, then tighten plug. Pressurize system fully and check for leaks; if leaks occur, check o-rings and sealing surfaces. 7.

Hydraulic Systems

7-71

Main Return and Case Drain Filter

Fig. 7-35 Main Return and Case Drain Filter 1. Head 2. Cover Assembly 3. Shell 4. Upper Cover O-Ring 5. Lower Cover O-Ring 6. Head to Reservoir O-Ring 7. Filter Element 8. Element O-Ring 9. Indicator 10. Indicator O-Ring 11. Indicator O-Ring 12. Anti-Backflow Assembly 13. Weldable Adapter Flange

7-72

Hydraulic Systems

Main Return and Case Drain Filter Routine Maintenance Main Return and Case Drain filters do not normally require special attention except for periodic monitoring of the differential pressure warning device. Schedule replacement of filter element every six months or sooner, and have ample supply of spare elements available. 1.

If external leaking is noted, replace o-ring at leak. For cover seal (4) and reservoir to head seal (6) leaks, replace o-rings. If leakage persists, check sealing surfaces for scratches or cracks; replace any defective parts.

Changing Filter Elements WARNING:

Turn off and depressurize the system. Open bleed plug (if fitted) one and one half turns.

Unscrew and remove filter cover assembly (2) from head assembly (1), counterclockwise when viewed from above. It may be necessary to use a correct sized wrench on the hexagon on the filter cover assembly (2) to loosen the cover initially.

Remove filter element (7) and carefully inspect the surface for visible contamination. Normally no dirt should show, but visible dirt or particles can be an early warning of system component breakdown and can indicate potential failure. Discard both the filter element and its o-ring. The filter element is not cleanable. Any attempt to clean the filter element can cause degradation of the filter medium and allow contaminated fluid to pass through the filter element.

CAUTION:

DO NOT attempt to clean or reuse element. NOTE The 'O' ring (item 5) is very easily dislodged. The filter will bypass if assembled without the ‘O’ring. It is therefore imperative that the 'O' ring is checked every time the filter is removed. It is recommended that the 'O' ring be replaced every time the filter is changed.

Hydraulic Systems

7-73

Main Return and Case Drain Filter

Fig. 7-36 Main Return and Case Drain Filter Assembly 1. Main Return Filter 2. Case Drain Filter 3. Air Filter 4. Service Valve (open to relieve pressure after machine is shut down)

Fig.7-37

7-74

Main Return and Case Drain Filters

Hydraulic Systems

Main Return and Case Drain Filter Changing Filter Elements (continued) 4.

DO NOT run the system without a filter element (7) installed. Check that the o-ring (4 and 5) on the head assembly (1) is not damaged. Use replacement filter element part number called for on the element change label.

Lubricate element o-ring (8) with clean system fluid and push open end of filter element (7) straight onto the nipple in the head assembly (1). Lightly lubricate threads of filter cover assembly with clean system fluid. Screw cover assembly onto head assembly until it bottoms. O-ring sealing in not improved by overtightening.

CAUTION:

DO NOT use pipe wrench, hammer , or any other tool to tighten bowl.

Hydraulic Systems

7-75

Hydraulic Cylinder Repair WARNING:

RELIEVE all pressure before attempting service or maintenance procedures to this machine. RELIEVE pressure in both hydraulic and pneumatic systems before loosening any connections or parts. The following pages provide information on hydraulic cylinder repair. Refer to your parts manual to identify and order replacement parts for the cylinder you are working on. Identify the specific type of head and piston in the cylinder and then follow the steps as outlined below:

7-76

Follow the General Information steps on the following pages.

Follow the Teardown steps.

Follow the Inspection steps.

Follow the specific Rebuild steps for head and piston type you are working on.

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-77

Hydraulic Cylinder Repair

7-78

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-79

Hydraulic Cylinder Repair

7-80

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-81

Hydraulic Cylinder Repair

7-82

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-83

Hydraulic Cylinder Repair

7-84

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-85

Hydraulic Cylinder Repair

7-86

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-87

Hydraulic Cylinder Repair

7-88

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-89

Hydraulic Cylinder Repair

7-90

Hydraulic Systems

Hydraulic Cylinder Repair

Hydraulic Systems

7-91

Hydraulic Cylinder Repair

7-92

Hydraulic Systems

2100 RPM

17 GPM

RET-2

30 GPM

350 PSI

60 GPM

2100 RPM

RET-1

350 PSI

100 GPM

435433

50 PSI BYPASS

AUTO TOOL

5000 PSI

RPM

5000 PSI

5510 PSI

RPM

1.0 mm

DRN-6

DRAIN 1600 MANIFOLD

HOBO SWING

DRN-8

45 PSI

25 bar 362 psi

407730

24.4 GPM

OIL COOLER

175 bar 2800 psi

ROTATE

HOBO

24.4 GPM

600 PSI

HOBO

CLAMP

GCH

437842

407730

600 PSI

RET-5

A C

PIPE

POSITIONER

(2250 PSI)

DRN-7

HOBO CLAMP

DRN-6

438977

50 PSI

HOBO SWING

SET ABOVE 5000 PSI

438004

THERMO VALVE

AUTO TOOL

(2250 PSI)

DRN-9

SPARE

A B

200 PSI

A C

DRN-7

FLUSHING SHUTTLE VALVE

PIPE RACK ROTATE

CAB

PIPE RACK SWING

PULLDOWN FORCE CONTROL

TO GAUGE IN CAB

PST

3 1

DRN-4

TO GAUGE IN CAB

PST

437842

DRN-12

DRN-11

PIPE RACK SWING

SET ABOVE 5000 PSI

PIPE RACK LOCK

CLAMP

PIPE POSITIONER

SWING

PIPE POSITIONER

RET-4

PIPE RACK ROTATE

P CAB

ROTATION TORQUE CONTROL

TO GAUGE IN CAB

DUST CURTAIN

TOP

R.H. TRAM

HOIST/PULLDOWN CYLINDER

L.H. TRAM

DRN-5

DRN-3

ROTATION TORQUE X PORT RELIEF

RET-6

RET-8

WATER PUMP MOTOR

RET-12

DRN-3

RET-9

25 bar 362 psi

MAST LOCK

DUST CURTAIN

BACK-UP ALARM PRESSURE SWITCH

ROTATION MOTORS

175 bar 2800 psi

DRN-1

A B

DRN-2

3 1

VALVE

MAST LOCK

MAIN AIR

VIEWING HATCH

DRILL/PROPEL

WATER INJECTION

MAIN AIR

A B

VIEWING HATCH

MAST ELEVATE

T V

RET-3

25 bar

DRN-6

DRN-5

RET-5

RET-4

DRN-7

RET-3

DRN-11

L.H. REAR JACK

RET-12

FRONT JACKS

RET-11

FRONT JACKS

L.H. FRONT

R.H. FRONT

RET-10

R.H. REAR JACK

DRN-2

DRN-1

DRN-12

DRAIN MANIFOLD

DRN-3

RET-9

DRN-10

RET-8

DRN-8

DRN-9

RET-6

RET-7

DRN-10

R.H. REAR

R.H. REAR JACK

MAIN RETURN FILTER

RETURN MANIFOLD

RET-1

L.H. REAR JACK

DRN-4

RET-2

WINCH

|A 1

WINCH ASSEMBLY W/BRAKE VALVE & STATIC BRAKE

MAST ELEVATE

175 bar 2800psi

BRAKE VALVE

WINCH BRAKE

L.H. REAR

RET-7

CASE DRAIN FILTER

5HI

RET-11

7-93

Hydraulic Schematic–(Wide Deck) (Linde Pumps)

8 bar

17 GPM

6.3 CU/IN

30 GPM

6.3 CU/IN

TO COOLER FAN MOTOR 2000 PSI

T1 T2

X1 X3

X4 X2

1700 RPM

Fa1

50 PSI

1700 RPM

175 bar 2538 psi

1.6mm (.063")

Fa1

A B

CHARGE 450 PSI

45 PSI

AUTO TOOL

50 PSI

ROTATION AND L.H. TRACK PUMP

1.6mm (.063")

FEED AND R.H. TRACK PUMP

25 bar 362 psi

ROTATE

CLAMP

B A

(2250 PSI)

HOBO CLAMP

PST

THERMO VALVE

HOBO SWING

PIPE POSITIONER

C2 V2

FLOAT/LOCK

C1 V1

3 2

SPARE

R.H. TRAM

L.H. TRAM

PIPE RACK LOCK PIPE RACK SWING

CLAMP

SWING

BACK-UP ALARM

PIPE RACK ROTATE

PULLDOWN VALVE

7-94

25 bar 362 psi

175 bar 2538 psi

DUST CURTAIN

A A

WATER INJECTION

MAST LOCK

MAIN AIR

MAST ELEVATE

L.H. REAR

25 bar

175 bar 2538 psi

|A 1

WINCH

MAST ELEVATE

TO BACK-UP ALARM

L.H. REAR JACK

R.H. REAR

FRONT JACKS

R.H. REAR JACK

Hydraulic Systems

5 HI

L.H. REAR JACK

L.H. FRONT

R.H. FRONT

Hydraulic Schematic–(Wide Deck) (Rexroth Pu

8 bar

Hydraulic Systems

16 15 14 13 12 11

HOLES SHOWN ARE REPRESENTED BY HEX BALLOONS ON SCHEMATIC

35 34 33

32 31 30 29 28 27 26 25 24 23 22 21

BRAKE BACKUP ALARM PRESSURE SWITCH

CAB MAST SIDE

WATER INJECTION OPTION

ROTARY TORQUE OPTION

PRESSURE FROM RH PUMP CHARGE FILTER

DRILL/HOUR METER SWITCH

DRAIN

LH AIR CLEANER INDICATOR

CAB WALL

C B

RH AIR CLEANER INDICATOR

CAB WALL

HYDRAULIC PLUMBING

REMOTE RELIEF VALVE

NOTE: PRESSURE 'B'TO'C'

3 WAY PILOT VALVE

PRESSURE FROM "B" PORT OF DRILL/PROPELL VALVE LOCATED OUTSTDE 5

TO MS PORT PULLDOWN PUMP 14

SHUTTLE VALVE LOOP FILTER 3

2 *1 2 *1

LR JACK FT JACK

RR 2 JACK *1 T P

2 *1 MAST

SHUTTLE VALVE LEFT LOOP FILTER 13

PULLDOWN

AIR GAUGE

5HI 7-95

Hydraulic Plumbing Cab–(Wide Deck)

LOWER VALVE

7-96

Hydraulic Systems

5HI UHY $ RI

VSOLW FRROHUV

Pressure and Return Plumbing–(Wide D

Hydraulic Systems

5HI UHY $ RI

VSOLW FRROHUV

7-97

Pressure and Return Plumbing–(Wide Deck)

PRESSURE "IN"

VALVE BANK

VALVE BANK A2 A2

"P"

PRESSURE

RETURN

A2 A1

B2 B2 B2 B2 B1

POWER BEYOND

GAUGE

PRESSURE P PORT

PUMP DRIVE GEARBOX

R.H. PUMP

MAIN RETURN

CASE DRAIN

HYD. TANK

SUCTION S PORT

7-98

SUCTION S PORT

L.H. PUMP

PUMP DRIVE GEARBOX

RETURN MANIFOLD

"P"

PRESSURE

MAST VALVE

POWER BEYOND

RETURN

Hydraulic Systems

5HI ZLWK /LQGH 3XPSV

Suction and Return Plumbing–(Wide Deck)

Hydraulic Systems

PRESSURE "IN"

VALVE BANK

"P"

PRESSURE

POWER BEYOND

A2 A2

RETURN

A2 A1

B2 B2 B2 B2 B1

GAUGE

MAIN RETURN

CASE DRAIN

HYD. TANK

SUCTION S PORT

PUMP DRIVE GEARBOX

S PORT

TI PORT

R.H. PUMP

PRESSURE P PORT

RETURN MANIFOLD

"P"

PRESSURE

L.H. PUMP

S PORT

TI PORT

SUCTION S PORT

MAST VALVE

5HI UHY &

POWER BEYOND

RETURN

7-99

Suction and Return Plumbing–(Wide Deck)

HYDRAULIC TANK

GCH

RH PUMP

1 2

7-100

OUT

5(/,() 9$/9(

RETURN MANIFOLD

LH PUMP GAUGE

LOOP FILTERS

"C" PORT PILOT OPERATED VALVE

Hydraulic Systems

5HI UHY % ZLWK /LQGH 3XPSV

CAB

TO "P" ON PULLDOWN REMOTE RELIEF

Charge and Pilot Plumbing–(Wide Deck)

Hydraulic Systems

HYDRAULIC TANK

OUT

LEFT PUMP

OUT IN

RIGHT PUMP

14 4 13 17 18

RIGHT PUMP

CAB

P. O. R. RELIEF PRESET TO 450 psi

5HI UHY '

RETURN MANIFOLD

7-101

Charge and Pilot Plumbing–(Wide Deck)

7-102

Fan Plumbing–(Wide Deck)

Hydraulic Systems

5HI UHY (

Hydraulic Systems

'867 &857$,1

5HI UHY $

:$7(5 ,1- '867 &2//(&725

0$67 /2&.

0$,1 $,5

0$67 (/(9$7(

7-103

Mast Lock Plumbing–(Wide Deck)

A2 A2 A2 A1

B2 B2 B2 B2 B1

RET.

EXT.

RET. A2 A2 A2 A1

B2 B2 B2 B2 B1

EXT.

DUST CURTAIN

7-104

RET.

WATER INJ.-DUST COLLECTOR

MAST LOCK

MAIN AIR

MAST ELEVATE

35 34 33

9 18

8 17

1 16 15 14 13 12 11

Hydraulic Systems

5HI

CAB MAST SIDE

WATER INJECTION OPTION

ROTARY TORQUE OPTION

LOCATED ON HYDRAULIC TANK

32 31 30 29 28 27 26 25 24 23 22 21

HOLES SHOWN ARE REPRESENTED BY HEX BALLOONS ON SCHEMATIC

Mast Elevating Plumbing–(Wide Deck)

Hydraulic Systems

A2 A2

:$7(5 ,1- '867 &2//(&725 '867 &857$,1

0$67 /2&.

0$,1 $,5

0$67 (/(9$7(

5HI UHY $ 7-105

Dust Curtain Plumbing–(Wide Deck)

A2 A1

B2 B2 B2 B2 B1

RETRACT

EXTEND

RETRACT

R.H. FRONT

L.H. REAR

LEFT REAR

MAST ELEVATE

EXTEND

FRONT

1 3

9 18

8 17

2 16 15 14 13 12 11

35 34 33

HOLES SHOWN ARE REPRESENTED BY HEX BALLOONS ON SCHEMATIC

EXTEND

7-106

RETRACT

EXTEND

L.H. FRONT

R.H. REAR

32 31 30 29 28 27 26 25 24 23 22 21

LEFT REAR

RIGHT REAR

RETRACT

CAB MAST SIDE

WATER INJECTION OPTION

ROTARY TORQUE OPTION

LOCATED ON HYDRAULIC TANK

Jack Plumbing–(Wide Deck)

Hydraulic Systems

5HI

L.H. LOOP

L.H. CONTROL

R.H. CONTROL

L.H. CHARGE

Hydraulic Systems

)5217 9,(: 2) 7(67 3$1(/

LOWER BANK

UPPER BANK

FAN PUMP

L T

2 1

L T

833(5 %$1.

/2:(5 %$1.

127( 5(7851 0$1,)2/' /2&$7(' ,1 0$67 3,927

5(7851 0$1,)2/'

R.H. CHARGE

R.H. LOOP

5HI UHY $

7-107

Hydraulic System Test Plumbing–(Wide Deck)

7-108

Notes

Hydraulic Systems

52 GPM

17 GPM

HIGH SPEED RELIEF

AUTO TOOL

52 GPM

2 1900 PSI

RPM

30 GPM

STANDARD SETTING 700 PSI

HOBO SWING

FEED AND R.H. TRACK PUMP

X4 X2

HOBO

SET AT 5500 PSI

RPM

PS Fa

Fa1

50 PSI

Fa1

50 PSI

SET AT 5000 PSI

A B

HOBO SWING

OIL COOLER

STANDARD SETTING 700 PSI

45 PSI

CHARGE 450 PSI

AUTO TOOL

PUMP COMPENSATOR

1.6mm (.063")

SET AT 5000 PSI

PUMP COMPENSATOR

1.6mm (.063")

155 bar 2250 PSI

2 1900 PSI

DRAIN 1700 MANIFOLD

25 bar 362 psi

ROTATE

CROSS PORT RELIEFS

SET AT 5500 PSI

HOBO

CLAMP

HIGH SPEED RELIEF

X4 X2 X1 X3 ROTATION AND L.H. TRACK PUMP CROSS PORT RELIEFS

2100 RPM

DRAIN 1700 MANIFOLD

B A

PST

THERMO VALVE

PIPE POSITIONER

(2250 PSI)

HOBO CLAMP

3 2

SPARE

L.H. TRAM

R.H. TRAM

HOIST/PULLDOWN CYLINDER

ROTATION MOTORS

PIPE RACK LOCK PIPE RACK SWING

PIPE RACK LOCK

CLAMP

PIPE POSITIONER

SWING

PIPE POSITIONER

BACK-UP ALARM PRESSURE SWITCH

PIPE RACK ROTATE

PIPE RACK SWING

600 PSI

3 1

4 2

DRILL/PROPEL VALVE

PULLDOWN VALVE

PIPE RACK ROTATE

A C

DUST CURTAIN

WATER PUMP MOTOR

DUST COLLECTOR MOTOR

25 bar 362 psi

MAST LOCK

175 bar 2800 psi

DUST CURTAIN

A A

MAST LOCK

MAIN AIR

VIEWING HATCH

MAIN AIR

MAIN RETURN FILTER

WATER INJECTION

DRAIN MANIFOLD

RETURN MANIFOLD

VIEWING HATCH

MAST ELEVATE

T V

L.H. REAR

25 bar

|A 1

WINCH

MAST ELEVATE

L.H. REAR JACK

L.H. FRONT

R.H. FRONT

R.H. REAR

FRONT JACKS

R.H. REAR JACK

SKS DUAL PUMP SEPARATE COOLERS

CASE DRAIN FILTER

175 bar 2800psi

7-109

Hydraulic Schematic–(13, 16 M)

8 bar

60 GPM

17 GPM

HIGH SPEED RELIEF

AUTO TOOL

2 1900 PSI

30 GPM

STANDARD SETTING 700 PSI

HOBO SWING

RPM

DRAIN 1700 MANIFOLD

2100 RPM

FEED AND R.H. TRACK PUMP

X4 X2

HOBO

SET AT 5500 PSI

RPM

PS Fa

Fa1

50 PSI

Fa1

50 PSI

SET AT 5000 PSI

A B

CHARGE 450 PSI

45 PSI

AUTO TOOL

PUMP COMPENSATOR

1.6mm (.063")

SET AT 5000 PSI

PUMP COMPENSATOR

1.6mm (.063")

155 bar 2250 PSI

DRAIN 1700 MANIFOLD

25 bar 362 psi

ROTATE

HOBO

CLAMP

CROSS PORT RELIEFS

SET AT 5500 PSI

X4 X2 X1 X3 ROTATION AND L.H. TRACK PUMP CROSS PORT RELIEFS

2100 RPM

OIL COOLER

HOBO SWING

B A

PST

THERMO VALVE

PIPE POSITIONER

(2250 PSI)

HOBO CLAMP

3 2

SPARE

L.H. TRAM

R.H. TRAM

HOIST/PULLDOWN CYLINDER

ROTATION MOTORS

PIPE RACK LOCK PIPE RACK SWING

PIPE RACK LOCK

CLAMP

PIPE POSITIONER

SWING

PIPE POSITIONER

BACK-UP ALARM PRESSURE SWITCH

PIPE RACK ROTATE

PIPE RACK SWING

600 PSI

3 1

4 2

DRILL/PROPEL VALVE

PULLDOWN VALVE

PIPE RACK ROTATE

A C

DUST CURTAIN

WATER PUMP MOTOR

DUST COLLECTOR MOTOR

25 bar 362 psi

175 bar 2800 psi

7-110

MAST LOCK

DUST CURTAIN

A A

MAST LOCK

MAIN AIR

VIEWING HATCH

MAIN AIR

MAIN RETURN FILTER

WATER INJECTION

DRAIN MANIFOLD

RETURN MANIFOLD

VIEWING HATCH

MAST ELEVATE

T V

L.H. REAR

25 bar

|A 1

WINCH

MAST ELEVATE

L.H. REAR JACK

L.H. FRONT

R.H. FRONT

R.H. REAR

FRONT JACKS

R.H. REAR JACK

Hydraulic Systems

SKS SINGLE PUMP DUAL COOLERS

CASE DRAIN FILTER

175 bar 2800psi

Hydraulic Schematic–(13, 16 M)

8 bar

Hydraulic Systems

Ref. 1704822 7-111

Hydraulic Schematic with Hold Back Control

0402263

MAX

0410663

M1 T1

0056385

0058495

MB B

0088595

419938

0088595

7.2 CIR

HYDRAULIC TANK

0088595

SUCTION MANIFOLD 0410672

ROTARY - PSI (IN CAB)

1.56 CIR

B 3.65 A CIR

A 3.65 B CIR

45 PSI (315 KPA)

0061684

419935

V02 57319

B C

COOLER

419943

PSI ADJUSTMENT (IN CAB)

PULLDOWN

60°C (140°F) CLOSE

PC2

P11

TP4

LS3

TP13

PC1 P4

TP11

LS2

TP3

LS5

DR3

V05

V15

424706

MAX PULLDOWN 18624 kPa (2700 psi) 3 4

1 3

TP1

V16

V10

V09 a

V08

TRAM/DRILL SEL ON = DRILL OFF = TRAM a

V07

DRILL/TRAM INTERLOCK a

7-112

TP10

34474 kPa (5000 psi)

V21

JACK MAST RAISE 18960 kPa (2750 psi)

AUX PRESS AUX PUMP RV 17500 kPa (2500 psi)

424706

V06

V04

TP12

3447 kPa (500 psi)

V14

Ø0.8 (mm)

1 3103 kPa (450 psi)

V22

V20

V19

33.16 IN2

TP8

DR5

V17

V18

V13

DRAIN

LS4

TP5

TP6

P13

TP9

PRESSURE SWITCH

BACK-UP ALARM

V12

AUTO-PULL DOWN

V11

SET-UP LOCK a

150 PSI

TP7

PILOT CONTROL BLOCK

MAST ELEVATE

JACK L.H. REAR

JACK R.H. REAR

JACK FRONT

R.H. FRONT

0436573

0095135

L.H. REAR

R.H. REAR

0095135

L.H. FRONT

0411027

.094

EXTEND

RETRACT

EXTEND

RETRACT

LS1

V03

AUX PUMP OFF - LS ON - HI a

V01 57319

ROTARY TORQUE PSI ADJUSTMENT (IN CAB)

TP2

1.6mm (.063")

416962

11.59 CIR

424015

20900kPa

(3000psi)

0070049 x 4.

-16

421241

280 psi

1930 kPa

LSC

AUX PUMP (psi)

GUAGE (IN CAB)

0411027

84885

.032" ORF

CASE DRAIN MANIFOLD 0401065

DRAIN MANIFOLD 0000000

0402263

FROM RECIEVER

0058495

84885

FA Fe

RETURN MANIFOLD 0402263

414277

3.19 CIR

3.2 CIR

1.6mm (.063")

0402263

AUX & FEED 190cc (11.59 CIR) @ 2100 R.P.M.

84885

-24

3100 kPa (450 psi) CHARGE

0407730

424015

0408549

ROTATE

CLAMP

RIGHT TRACK 180cc (10.98 CIR) @ 2100 R.P.M.

(2250 PSI)

-24

84885

-20

B P

(2250 PSI)

84885

PULLDOWN GAGE

GC2

HBP

HDR2

C2B

Ø.016

17.26 2 15.90 IN

C2A

V2B

V1B

A B

0402263

0413307 P

0413307 LS

A B

0084242

LEFT HAND DIVERTER VALVE

33.16 IN2

PRESSURE SWITCH

REGERATION SWITCH

-20 (TYP)

CB1

-06

0410091

MAST ELEVATE

JACK RH REAR

JACKS - FRONT

-16

410089

DUST COLLECTOR & WATER PUMP

JACK LH REAR

MAST LOCK

MAIN AIR

DUST CURTAIN

VIEWING HATCH

SPARE

BLANK PLATE

HOBO CLAMP ROTATE

HOBO SWING

AUTO TOOL WRENCH

CAROUSEL LOCK

CAROUSEL ROTATE

CAROUSEL SWING

LIFTING WINCH

SPARE

PIPE POSITIONER

2250 PSI

V1 T1

T2 P

B9 P

17.26 2 15.90 IN

A9 T

CA1

84885

BR B

ELECTRICAL

BRAKE VALVE

PULLDOWN

6.5 BORE x 4 1/2 ROD BORE AREA 1 CYL = 33.16 IN ROD AREA 1 CYL = 15.90 IN

A T

V2A

GC1

421240

CAIA-LHN

0410666

84885

V1A

WINCH ASSEMBLY W/BRAKE VALVE & STATIC BRAKE

WINCH BRAKE

CLAMP

SWING

DUST COLL.

GV1

HDR1

(2250 PSI)

81239

B6 A

0410665

MP22 FEED VALVE

WATER PUMP

Hydraulic Systems

Ref. 426498 rev. 02

Hydraulic Schematic–Open Loop –(13, 16 M) (Rexroth Pumps)

0408549

190cc/REV

A6 T B

FAN = 5.10, DC = 2.94

B A

LEFT TRACK & ROTATION 180cc (10.98 CIR) @ 2100 R.P.M.

25.5cc/REV

A P

AUXILIARY PUMP PRESSURE MANIFOLD 1412986

P B

DR4 DR8 DR1 DR6 DR7 DR2

A B

Hydraulic Systems

(P3)

(P2)

#9 AT CAB

CAP

RRJB

FJB

LRJA

LRJB

FJA

RRJA

#30 AT CAB (RIGHT REAR JACK)

CAP-BLANK

#24 AT CAB (MAST ELEV.)

#26 AT CAB (LEFT REAR JACK)

#28 AT CAB (FRONT JACK)

#29 AT CAB (RIGHT REAR JACK)

#27 AT CAB (FRONT JACK)

#25 AT CAB (LEFT REAR JACK)

#23 AT CAB (MAST ELEV.)

(P8)

(LS3)

(LS4)

(PC1)

CAP

Ref. 425185 rev. A

#18 AT CAB ALSO TEE DIVERTER VALVE PILOT PRESSURE

CAP

#34 AT CAB ROTARY TORQUE (CAP IF NO ROTARY TORQUE)

#14 AT CAB

REF.-VALVE STAND

LS3

LS4

PC1

(P9)

CAP-BLANK

7-113

Cab to Valve Stand Plumbing–(13, 16 M)

RELIEF VALVE

DR3

DR8

P5 P6

PC1

DR1

TP1

4 BS 1/

V18

SIZE C10 -8 -

FOR BULKHEAD PORT LOCATIONS - SEE CAB

HYDRAULIC MANIFOLD

V22

VALVE STAND ASSY

DR3

V05

V21

TP10

JACK MAST RAISE 18960 kPa (2750 psi)

AUX PRESS AUX PUMP RV 17500 kPa (2500 psi)

34474 kPa (5000 psi)

V06

V04

TP12

3447 kPa (500 psi)

V14

Ø0.8 (mm)

1 3103 kPa (450 psi)

V22

V20

V19

V03

7-114

PC2

P11

TP4

LS3

TP13

PC1 P4

TP11

LS2

TP3

LS5

LS1

TP2

AUX PUMP OFF - LS ON - HI a

SCHEMATIC

MAX PULLDOWN 18624 kPa (2700 psi) 4 3

V15

TP1

V16

V10

V09 a

V08

TRAM/DRILL SEL ON = DRILL OFF = TRAM a

V07

DRILL/TRAM INTERLOCK a

V12

DR5

LS4

TP5

TP6

P13

TP9

Hydraulic Systems

Ref. 428412 rev. A

TP8

V18

V17

V13

AUTO-PULL DOWN

V11

SET-UP LOCK a

PILOT CONTROL BLOCK

TP7

Rotary Torque Control–(13, 16 M)

DR4 DR8 DR1 DR6 DR7 DR2

Hydraulic Systems

TO FILTER 5 PORT "2"

TO RH PUMP PORT "F"

TO SUCTION MANIFILD AT HYDRAULIC TANK

"X" TO VALVE STAND PORT "LS1"

FILTER 1

FILTER 2

FILTER 3

FILTER 4

FILTER 5

SEE DETAIL D

"MB" TO VALVE STAND PORT "P4"

"G" TO CAB PORT "33"

"M" TO VAVE STAND PORT "P7"

TO FILTER 4 PORT "2"

FILTER 6 M G

TOP PORT "1' SIDE PORT "2"

TO FILTER 1 PORT "2"

TO VALVE STAND PORT "P1"

TO FILTER 3 PORT "2"

FILTER 8

FILTER 7

C TO DRAIN MANIFOLD ON VALVE STAND

TO DRAIN MANIFOLD ON VALVE STAND

VIEW B

TO LH PUMP PORT "F"

TO FILTER 2 PORT "2"

VIEW A

TO LH FILTER ON GEARBOX

TO FILTER 6 AT HYDRAULIC TANK

TO DRAIN MANIFOLD AT VALVE STAND

TO MANIFOLD ON HYDRAULIC TANK

VIEW C

TO RH FILTER ON GEARBOX

"X3" TO VALVE STAND PORT "P11"

TO FILTER 8 IN HYDRALUIC TANK

TO MANIFOLD ON HYDRAULIC TANK

7-115

Ref. 434610 rev. A (1 of 2)

Pressure and Return Plumbing–(13, 16 M)

CASE RETURN

V22

T-

V05

V15

T-

V06

T-2

4 BS 1/

TP3

V21

V20

DR6

LS4 P7 LS1

LS4 SIZE C10 -8 -

TP6

V08

V10

V14 T-

V09

T-

V12

P8 V07 C8-

V11

C8-

91-A20-222-003

4 BS 1/

DR7

SIZE C10 -8 -

PC1

P11

RCCHART SECTION

HOLE DISPLAY HOLEDIM

VERTEX VARS

SCREW DISPLAY

BOMVAR

P2 P1 LS2

C1A V2A

C2A

V2B

V1B

T C2B

TO "LS3" BULKHEAD PLATE AT VALVE STAND

TO FILTER 4 PORT "1"

TO FILTER 5 PORT "1"

TO RH PUMP

TO LH FRONT PUMP

TO LH PUMP

SEE DETAIL E

TO FILTER 6 IN HYDRAULIC TANK

P9 P6

HOLE CHART

PTDIM VARS

C83

DDIM VARS

TOOLBOX

V03

T-2

SIZE C10 -8 -

CASE RETURN

DR3

V18

4 BS 1/

TP1

CASE RETURN

DR3

PC1

DR1

DR8

DR4

P5 P6

LS1 P7

DR6 C-

LS3 PP

LS5

PP A 10

A 10

LS2

SIZE 10 3

DR2

LS5 DR4 LS2 DR2

SIZE 10 3

X M MB X3 FA

DR1

DR8

V1A

GV1

LS3

DR7

V2A

SIZE 10

PULLDOWN RET.

C1B

A 10

PULLDOWN RET.

PULLDOWN EXT.

LH REAR JACK

RH REAR JACK

FRONT JACK

MAST ELEVATE

DETAIL D

TO FILTER 7 AT HYD. TANK

7-116

LS3 TO SELECTOR VALVE

TO CAB

DETAIL {E} SCALE: {4}X

TO FILTER 3 PORT 1

PULLDOWN EXT.

Hydraulic Systems

Ref. 434610 rev. A (2 of 2)

Pressure and Return Plumbing–(13, 16 M)

RETRACT

TYP. AT ALL 4 JACKS

TO FRONT JACKS

FROM VALVE BANK PORT "A"

T-

V06

4 BS 1/

TP3

V21

V20

DR6 4

TP6

V08

LS4 SIZE C10 -8 -

V10

V14 T-

V09

T-

V12

V07 C8-

V11

C8-

P11

P1 P2

VIEW A

91-A20-222-003

4 BS 1/

DR7

SIZE C10 -8 -

A A

B B

CLAMPS ON ENGINE SKID

TO FRONT JACKS

FROM VALVE BANK PORT "B"

CAB SIDE

Hydraulic Systems

FROM VALVE BANK PORT "B"

VIEW B

EXTEND FROM VALVE BANK PORT "A"

T-

T-2

EXTEND

V15 V05

A 10

RETRACT

T-2

V22

SIZE 10 3

R.H. FRONT

C8-

SIZE C10 -8 -

LS3 4

ROUTE HOSES FOR FRONT JACKS THRU CLAMPS ON CAB SIDE OF ENGINE SKID

V03

TP1

4 BS 1/

V18

A 10

TO FRONT JACKS EXTEND PORT

A DR3

DR8

P5 P6

PC1

DR1

C-

TO FRONT JACKS RETRACT PORT

EXTEND PORT

SIZE 10 3

RETRACT PORT

SIZE 10

LS2

DR2

DR4

LS1 P7

LS5

A 10

TO LH REAR JACK

EXT. RET.

SEE DETAIL "A"

RETRACT PORT

EXTEND PORT

A A B

7-117

FRONT LH

Ref. 421450 rev. 06

DETAIL A

A B

Jack Plumbing–(13, 16 M)

11P

P1 P2

A1C

P11 P4

SIZE 10

1CP

3 1A

LS3 PP

2SL

DR6

7P 1SL

10 A

V11

A2V

V07 8C-

A2C T-

V12 8C-

B1V

DR7

V09

-8 SIZE C10

3 SIZE 10

LS4

91-A20-222-003

1/ 4 BS

B2C

-8 SIZE C10

TP6

V08

V10

V14 T-

V20

TP3

10 -

V21 1/ 4 BS

C-

T-2

T-

10 A T-

2P PP

LS1 P7

V22 V15 V05

3 SIZE 10

V06

B A

T-2

-8 SIZEC10

LS2

8C-

DR2

V18 1/ 4 BS

TP1

V03

10 A

LS5 DR4

PC1

DR1

DR8

4SL DR3

8P P5 P6

3SL PP

6P 5P

1P 3P 5SL

A1V 1VG

R B2V B1C

A2V

PORT A

PORT B

7-118

COUNTER BALANCE VALVE (#84885) REF

VALVE STAND CONTROL VALVE (422914) REF

Mast Lock Plumbing–(13, 16 M)

Hydraulic Systems

Ref. 421474 rev. B

Hydraulic Systems

TO BULKHEAD PLATE FOR COMPRESSOR FAN.

TO TEE FOR FAN DRAINS

1 1/4"

DR3

PC1

C8-

T-2

SIZE C10 -8 -

V22

T-

V05

V15

DR7

V18

4 BS 1/

TP1

V03 T-

V06

T-2

4 BS 1/

TP3

V21

DR6 C-

DR1

DR3

DR8

P5 P6

V20

DR6 4

LS4 P7 LS1

LS4 SIZE C10 -8 -

TP6

V08

V10

V14 T-

DR7

SIZEC10 -8 -

V09

T-

V12

P8 V07 C8-

V11

C8-

91-A20-222-003

4 BS 1/

P11

LS3

LS2

C1A V2A

C2A

LS3 PP

A 10

LS2

SIZE 10 3

DR2

LS1 P7

A 10

LS5 DR4

SIZE 10 3

DR8

V1A

LS5 DR4 LS2 DR2

FLOW

GV1

SIZE 10

DR1

V1B

T C2B

MAST ELEVATE

RH REAR JACK

LH REAR JACK FRONT JACK PULLDOWN EXT.

V2B

P9 P6

PC1 P5

Ref. 429977 rev. A 7-119

Fan Circuit Plumbing–(13, 16 M)

V2A

P1 X M MB X3 FA

C1B

A 10

PULLDOWN RET.

PULLDOWN EXT.

PULLDOWN RET.

MAST SUPPORT (DUST COLLECTOR SIDE)

DRAIN MANIFOLD

B Fa

OUT

Fa1

T1 Fe Fs

7-120

NOTE:

OUT

HEX BALLOONS INDICATE BULKHEAD LOCATION ON CAB WALL

Fa1

T1 Fe

Hydraulic Systems

Ref. 427523 rev. A

Hydraulic Charge Plumbing–(13, 16 M)

Hydraulic Systems 1 1/4" HOSE

ON MOTOR 1

F I L T E R

R.H. MOTOR

TO PORT B (TOP PORT)

1/4 HOSE TO PORT A ON MOTOR

1 1/4" HOSE

F I L T E R

3/4 HOSE

1/4 HOSE 9

BRAKE PRESSURE

CASE RETURN

RETURN MANIFOLD

3/4 HOSE

CAB

3/4 HOSE

TO PORT B ON MOTOR

1 1/4" HOSE

1/4 HOSE

L.H. MOTOR

1 1/4" HOSE

ON MOTOR B1 T

Ref. 421818 rev. 04 7-121

Propel Plumbing–(13, 16 M)

DIVERTER

TO PORT A (TOP PORT)

DR4

DR2

SELECTOR VALVE

PULLDOWN VALVE

DR3

DR8

P5 P6

P5/P6

PC1

P9 PC1

DR1

DR1 V18

4 BS 1/

V03

TP1 C8-

T-2

SIZE C10 -8 -

T-

V05

V15

V22

T-

V06

T-2

DR6 T-2

LS1

4 BS 1/

TP3

V21

DR6

DR4

V20

TP6

V08

SIZE C10 -8 -

V10

V14 T-

SIZE C10 -8 -

LS3

T-

V12

V07 C8-

C8-

V11 91-A20-222-003

4 BS 1/

V09

P8 P8

LS1 P7

C-

LS1 P7

LS3 DR7

LS4 LS4

LS5

PP A 10

LS2

A 10

LS5

DR2

3 3

LS5 DR4

DR7

DR2

LS2

P11 P4

P11

X M MB X3 FA

C1A V2A

C2A

LS5

PILOT CONTROL MANIFOLD

GV1

SIZE 10

V1B

C2B

JACK/MAST VALVE

HYDRAULIC MANIFOLD

LS2

FEED CONTROL VALVE

PULLDOWN EXT.

HYDRAULIC MANIFOLD

PULLDOWN RET.

PULLDOWN EXT.

V1A

PULLDOWN RET.

A 10

VALVE STAND ASSEMBLY

RETURN MANIFOLD

CONTROL VALVE

7-122

ITEM 2 ALTERNATE POSITION WHEN USING 600 GAL. TANK

Hydraulic Systems

Ref. 428443 rev. B

DRAIN MANIFOLD

REF. - MAST PIVOT

Valve Stand Assembly–(13, 16 M)

Service Supplement for Rotary Drills with Linde Hydraulic Pumps

Contents

General ........................................................................................................................... S-3 MD6420 Pump Arrangement ......................................................................................... S-4 MD6420 Hydraulic Hose Plumbing............................................................................... S-5 MD6290 Pump Arrangement ......................................................................................... S-6 MD6290 Hydraulic Hose Plumbing ............................................................................... S-7 HPV Pump Installation and Start-Up Instructions ...................................................... S-9 HPV Pump Repair Manual........................................................................................... S-17 HPR Pump Installation and Start-Up Instructions .................................................... S-77 HPR Pump Repair Manual .......................................................................................... S-83 MD6420 Hydraulic Schematic with Linde Pumps ....................................................S-129 MD6290 Hydraulic Schematic with Linde Pumps ................................................... S-130

S-2

September 10, 2008

General

Some late model rotary drills are supplied with hydraulic pumps manufactured by Linde. Others use hydraulic pumps manufactured by Rexroth. This supplement addresses the start-up and service of Linde pumps. Refer to the parts manual for your specific machine to determine the correct pump. A listing of Linde pumps used is shown below. Pump arrangement and functions are shown on the following pages.

P/N

Linde Model No.

Used On *

Seal Kit P/N

435433

HPV210

MD6420

V014525

435434

HPV135

MD6290

V014639

435435

HPV135

MD629

V014639

435436

HPR135

MD6290

V014559

435452

HPR210

MD6420

V014344

* Includes all variations of the machines.

S-3

MD6420 Pump Arrangement

Linde Pumps

S-4

MD6420 Hydraulic Hose Plumbing

S-5

MD6290 Pump Arrangement

Linde Pumps

S-6

MD6290 Hydraulic Hose Plumbing

S-7

Notes

S-8

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 1 of 7

Note: The oil level in the reservoir should always be at least 8 inches (~200mm) above the highest point of the pump as illustrated below:

Installation: •

Always cover or cap all HPV-02 case drain, control, and high pressure hydraulic lines during the installation of a new or replacement HPV-02 pump.

•

Always ensure all connections to the HPV-02 replacement pump are capped or covered during initial installation.

•

Connect and tighten each hydraulic line one at a time removing caps or covers just before each connection is made.

•

Installation must be carried out in accordance with the circuit or piping diagram.

•

It is recommended that the HPV-02 pumps be mounted with the pump control facing upward (as illustrated above).

S-9

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 2 of 7

•

The pump can optionally be mounted with the pump control facing to either side. During start-up, additonal care must be taken to vent entrapped air from the pump control via the highest flow stop adjustment (see the sketch above).

•

Avoid mounting the pump with the pump control facing down. Entrapped air is difficult to remove and any contaminants in the hydraulic oil will eventually settle into the control.

Venting: •

Positive venting is vital for the proper operation of the hydraulic system.

•

The highest case drain port on the pump housing must be connected to the reservoir. If the pump control is mounted on top (as illustrated above), then the vent port in the pump control should be connected to the reservoir as well.

•

All vent lines must be mounted continuously rising toward the reservoir. This allows any entrapped air to escape freely from the pump case.

Piping: •

Pipe work should be seamless drawn precision steel tube or hoses of suitable pressure rating.

•

During installation, attention should be paid to cleanliness. The pipes must be deburred, washed and blown through.

•

Scaled or rusted pipes must be scoured and then neutralized - Hoses must be brushed and flushed through when contaminated. IMPORTANT: The cleanliness of the circuit before commissioning has a crucial influence on the operation and life expectancy of the hydraulic components.

Filling the Hydrostatic Transmission: •

S-10

The initial filling of the system must be carried out in such a way that all of the air can escape from the high pressure circuit and from the pump/motor cases before the hydraulic units are operated.

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 3 of 7

•

The integral purge valve, which may be fitted as an option on the Linde hydraulic motors, assists in the venting of air from the high pressure circuit. This optional purge valve is illustrated in the schematic below. - With a pressure differential of about 350 psi (25 bar) across the hydraulic motor, the purge valve discharges a controlled amount of oil flow out of the high pressure circuit into the motor case. Therefore, any entrained air may escape freely to the reservoir. Again, refer to the schematic below.

•

The hydraulic motor(s) must be free to rotate under no load. For example, when a vehicle is chocked up with the wheels/tracks clear of the ground and free to rotate.

•

If already fitted, loosen the vent plugs on the cooler.

•

Manually fill the HPV-02 pump case at the most accessible case drain port with filtered oil. Manually fill the high-pressure (closed loop) lines with filterd oil if the lines are extremely long. Fill the oil reservoir to the maxmium level with filtered oil, and fill the motor case(s) to the maximum level via the most accessible case drain port with filtered oil.

•

Connect bleed lines or hoses to high pressure gauge ports "Mp" and "Ms". Connect a 1000 psi (70 bar) pressure gauge or transducer to gauge port "X".

S-11

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 4 of 7

•

Disconnect the prime mover's starting mechanism to insure that the prime mover will NOT start.

•

"Crank" the prime mover for at least ten seconds and stop while simultaneously monitoring the charge pressure at port "X". Continue this procedure at least 5 times or until the charge pressure at port "X" increases to the integrated boost relief valve setting in the pump (Consult Linde if unsure what boost relief valve setting is in the pump - The pump serial number is mandatory for this request). During this step, air in the closed loop should be discharged from the bleed lines. All air must be removed from the closed loop lines.

•

Check the hydraulic oil level in the reservoir and HPV-02 case. Add filtered oil to each as required.

•

Reconnect the prime mover's starting mechanism.

•

Start the prime mover and leave at low idle. Operate the prime mover at low idle for about 10 minutes while monitoring the charge pressure at port "X". The charge pressure at port "X" should remain at the boost relief valve setting.

•

Turn the prime mover OFF. Disconnect the bleed lines from gauge ports "Mp" and "Ms" and securely recap the ports.

WARNING: The wheels/tracks will turn during this next step.

S-12

•

Start the prime mover and set it at low idle, slowly stroke the pump 3 times to maximum displacement in both directions for about 30 seconds each time.

•

Warm the hydraulic oil by steadily increasing the prime mover speed and by increasing the load to the hydraulic motor(s). This will allow any air in the fluid to be released more easily.

•

Check the HPV-02 hydraulic neutral setting, regulation begin setting, and the maximum flow setting when the hydraulic oil reaches its normal operating temperature.

•

Check the oil level in the reservoir and fill with filtered oil if necessary before delivery of the machine.

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 5 of 7

Routine Maintenance: •

Maintenance of the hydraulic system is limited to changing the filter element of the HPV02 pump and changing the hydraulic fluid.

•

In order to gaurantee proper functions and efficiency of the hydraulic pumps, the purity of the hydraulic oil over the entire operating period must comply to at least class 18/13 according to ISO 4406.

•

With modern filtration technology, however, much better values can be achieved which contributes significantly to extending the life and durability of the hydraulic pumps and complete system.

Changing the Filter: •

The filter cartiridge fitted to the HPV-02 pump must be replaced for the first time after the initial start-up, but at least after 100 hours of operation.

•

Further filter changes should be made after every 500 hours of operation. If possible, these changes should be arranged to coincide with other routine maintenance work on the equipment, e.g., those on the prime mover.

S-13

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 6 of 7

Note: These recommendations are provided for guidance to insure long service life and proper operation of the HPV-02 pump. However, depending on the operating conditions of the HPV-02, it may not be necessary to adhere to these recommendations as long as the oil cleanliness level and oil vicosity specifications are strictly adhered to. Changing the Hydraulic Fluid: •

Oil changes are carried out by first draining the tank, cooler, pump, and motor housings. The high-pressure fluid must be changed after 1000-2000 hours of operation, according to the application.

•

High working temperatures and frequent cooling-down phases with low temperatures condense water and will shorten the life of the hydraulic fluid.

•

The oil remaining in the high-pressure circuit itself need not be changed. Do not open up the high pressure lines if possible. The instructions regarding initial filling must also be adhered to when changing the hydraulic fluid. In some applications, a complete oil change may not be necessary. The oil lost during each filter change must be replaced by fresh filtered oil.

Cleaning: •

Cleaning of the hydraulic system when chaning oil is normally not necessary. If the system becomes contaminated due to unusual circumstances (defect, etc.), then it must be thoroughly cleaned before recommissioning. Housings and pipelines must be flushed. If necessary, the pipelines and hydraulic units must be disassembled.

Service:

S-14

•

Maintenance and repairs should be undertaken only by skilled personnel who are familiar and trained with the equipment. Linde offers an excellent after-sales service capable of carrying out the work of repair and overhaul if required.

•

Only spare parts specified in the Linde spare parts catalogs should be used. The serial number stamped on the unit name tag is relevant to the configuration of the unit. Therefore, the serial number should be quoted when ordering spare parts.

HPV Pump Installation and Start-Up

Service Bulletin

HPV-02 Installation and Start-Up Instructions

HPV-startup.doc HPV-02, Section B Rev. 2, 3-30-00 Page 7 of 7

Oil Selection and Viscosity Recommendations: Suitable hydraulic oils are: • Mineral oil HLP to DIN 51524 • Biodegradeable fluids upon request • Other pressure fluids upon request Linde recommends only using hydraulic oils which are confirmed by the producer as suitable for use in high pressure hydraulic installations. For the correct choice of suitable hydraulic oils, it is necessary to know the working temperature in the hydraulic circuit (closed loop). The hydraulic oil chosen must allow the working viscosity to be within the optimum viscosity range (as shown below). Attention: Due to pressure and speed influences, the temperature of the leakage fluid is always higher than the circuit temperature. The temperature must not exceed 194°F (90°C) in any part of the system. Under special circumstances, if the stated conditions cannot be observed then please consult Linde. • • • •

Recommended viscosity range for optimum performance: 15 cSt to 30 cSt Maximum allowable working viscosity range: 10 cSt to 80 cSt Viscosity limitations: 6 cSt minimum viscosity 1000 cSt maximum viscosity (Intermittent for cold starts) Oil temperature limitations: (-68)°F to 194°F (-20) °C to 90°C

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Notes

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This Repair Manual is valid for all HPV-02 (55/75/105/135) pumps Tools/Equipment Required: • metric wrenches and Allen wrenches • vertical press • oven or hot plate (minimum temperature of 350°F required) • Green Loctite No. 648 (domestically available or Linde Part Number 7379200106) • Green Loctite No. 270 (domestically available or Linde Part Number 7379200108) • Blue Loctite No. 243 (domestically available or Linde Part Number 7379200104) • M8 socket head cap screws (qty 2, Linde Part Number 9048348183) • rubber mallet or soft metal rod • snap ring wrench (to squeeze/compress the snap ring) • snap ring wrench (to expand the snap ring) • torque wrench capable of setting between 25 N-m (18 ft-lb) and 180 N-m (133 ft-lb) • rear bearing shims (refer to Linde Spare Parts Catalog for required part numbers) • cylinder barrel shims (refer to Linde Spare Parts Catalog for required part numbers) • mechanical neutral shims (refer to Linde Spare Parts Catalog for required part numbers) • finger shims (refer to Linde Spare Parts Catalog for required part numbers) • commercially available bearing race remover • sanding stone and solvent • petroleum jelly • butane torch • Loctite 515, Gasket Eliminator (domestically available) • Locquic Primer "T" (domestically available) • Linde Conversion Bulletin "VARIABLE-PLATE" • bearing puller body: P/N (to be specified) - (HPV55) - (HPV75) P/N 0009419133 P/N 0009419138 - (HPV105 and 135) • bearing collet: P/N (to be specified) - (HPV55) - (HPV75) P/N 0009419110 - (HPV105) P/N 0009419146 P/N 0009419144 - (HPV135) • shaft seal assembly sleeve: - (HPV55) P/N (to be specified) - (HPV75) P/N 0009419746 P/N 0009419747 - (HPV105) P/N 0009419733 - (HPV135) • rear bearing race driver: P/N (to be specified) - (HPV55) - (HPV75) P/N 0009419743 P/N 0009419741 - (HPV105) - (HPV135) P/N 0009419742 • rear bearing driver: - (HPV55) P/N 8883036430 - (HPV75) P/N 8883036400 P/N 8883036410 - (HPV105) P/N 8883036420 - (HPV135)

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•

Repair Manual for HPV-02 Variable Displacement Pumps

cylinder barrel compression plate kit: - (HPV55) - (HPV75) - (HPV105) - (HPV135) shaft seal driver: - (HPV55) - (HPV75) - (HPV105) - (HPV135) driver for front bearing race: - (HPV55) - (HPV75) - (HPV105) - (HPV135) universal assembly fixture: - (HPV55) - (HPV75) - (HPV105) - (HPV135)

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P/N 8883035391 P/N 8883034481 P/N 8883034441 P/N 8883034491 P/N (to be specified) P/N 0009419748 P/N (to be specified) P/N 0009419750 P/N (to be specified) P/N 0009419751 P/N (to be specified) P/N 0009419753 P/N 0009419050 P/N 0009419051 P/N 0009419052 P/N 0009419053

The following sketches illustrate key items which will be referenced throughout this Repair Manual:

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Disassembly Procedure:

1. Remove the Filter and Filter Flange from the Rear Head.

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2. Remove the Charge Pump. 3. Remove the O-Ring from the Charge Pump and the O-Ring from the Rear Head. 4. Remove the Charge Pump Coupling.

5. Remove the pump control and all of the control o-rings.

6. Use the following steps to remove the Finger: a. With the butane torch, slowly heat the two mounting bolts. You only need to heat them enough to break the Blue Loctite No. 243 loose. b. Remove the two mounting bolts and discard them. c. Pull the Finger from the pump.

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7. Remove the Snap Ring from the Finger.

8. Remove all of the shims from the Finger.

9. Remove the seven mounting bolts from the Rear Head.

10. Remove the Rear Head from the pump.

11. Remove the Port Plate.

12. Remove the two Mechanical Neutral Shims.

13. Remove the three o-rings from the sealing area of the pump housing (for pump controls without the integrated POR feature). For pump controls with the integrated POR feature, there will be five o-rings.

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14. Use a sharp edge tool, sanding stone, and solvent to remove any remaining sealant from the sealing area of the pump housing.

15. Follow all steps in Linde Conversion Bulletin “VARIABLE-PLATE” to remove the Rear Bearing from the Drive Shaft.

16. Set the Rear Bearing aside.

17. Remove the Bearing Support Ring from the Drive Shaft.

18. Remove the two metal split pins from the swash plate.

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19. Pull the Cylinder Barrel out of the pump housing.

20. Pull the remaining rotating group out of the pump housing.

21. Pull the Drive Shaft out of the rotating group.

22. Remove the two Actuator Pistons from the HoldDown Clamp.

23. Disassemble the Swash Plate/Piston assembly as illustrated. Please note that the four mounting bolts that fasten the two Hold-Down Clamps to the Swash Plate have Green Loctite No. 648 on their threads. You must use heat to break the Loctite loose before the bolts can be removed.

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24. Remove the Snap Ring from the pump housing.

25. Press the Shaft Seal out of the pump housing.

26. Remove the Front Bearing Race from the pump housing.

27. Remove the two brass Bearing Strips from the pump housing.

28. There will be two brass pins (used to hold the Bearing Strips in place) remaining in the pump housing. If undamaged, leave them in the pump housing.

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29. Remove all plugs from the pump case drain ports.

30. Remove the two Lube Tubes and all Lube Tube Shims and Washers from the Rear Head.

31. Remove the Charge Relief Valve. 32. Remove the Main Relief Valve. 33. Remove the o-ring from the Rear Head in the Main Relief Valve cavity. 34. Remove the o-ring plug from the high pressure gauge port in the Rear Head.

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35. Remove the Main Relief Valve from the other side of the Rear Head. 36. Remove the o-ring from the Rear Head in the Main Relief Valve cavity. 37. Remove the o-ring plug from the high pressure gauge port in the Rear Head.

38. Remove the Rear Bearing Race and all of the Rear Bearing Shims from the Rear Head.

39. The Cylinder Barrel can be disassembled by compressing the Cylinder Barrel Spring, and then by removing the Snap Ring. Upon disassembly, there should be the Snap ring, Cylinder Barrel Shims, Washer, Cylinder Barrel Spring, and Bottom Washer.

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40. Position the drive shaft on a vertical press as illustrated to the left. Press the Front bearing and Shaft Seal Race off of the Drive Shaft.

41. The HPV-02 pump controls are non-serviceable items, hence no instructions will be provided for disassembly of the pump controls. 42. The HPV-02 charge pumps are serviceable, but the disassembly and assembly instructions are not provided in the main body of this Repair Manual. For instructions on how to disassemble and assemble the HPV-02 charge pumps, please refer to Appendix “G” located at the end of this Repair Manual.

This concludes the disassembly portion of this manual. At this point, all components of the HPV-02 pump should have been completely disassembled. Careful inspection of all parts is absolutely critical. Any parts showing signs of wear or damage should be discarded and replaced with genuine Linde parts. It is also strongly recommended that all sealant-type parts (o-rings, seal nuts, and shaft seal) be discarded and replaced with new genuine Linde parts. All parts that are going to be reused must be thoroughly cleaned and flushed free of all contaminants. Any remaining sealant material on the rear head and pump housing must be scraped clean. The mounting surfaces of the pump housing and rear head should be cleaned and deburred with a sanding stone and solvent.

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Assembly Procedure: 1. If reusing the Shaft Seal Race, the inside diametric surface must be scraped clean to remove all leftover Loctite material. Likewise, any remaining sealant material on the inside diametric surface of the Front Bearing and/or the bearing area of the Drive Shaft should be removed.

2. If using an oven, warm it to 350°F (If using a hot plate, adjust it to 350°F). Heat both the Front Bearing and Shaft Seal Race to 350°F. Install the Front Bearing onto the drive shaft.

3. Apply a narrow bead of Green Loctite No. 648 around the mounting surface of the new drive shaft. Then with a small brush or your finger, spread the Loctite into a thin, uniform layer around the mounting surface of the drive shaft.

4. Install the Shaft Seal Race onto the drive shaft. Make sure to properly orient the Shaft Seal Race with the tapered end positioned towards the drive shaft splines. Then wipe clean all excess Loctite.

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5. Install the o-ring plug into the high pressure gauge port in the Rear Head. Torque the plug to 47 N-m (35 ft-lb).

6. Repeat Step #5 for the other high pressure gauge port in the Rear Head.

7. Apply some petroleum jelly to the o-ring, then insert it into the o-ring groove in the Rear Head.

8. Repeat Step #7 for the other Main Relief Valve cavity in the Rear Head.

9. Verify that the o-ring on the Main Relief Valve is in good condition, then install it into the Rear Head. Torque the Main Relief Valve to 60 N-m (44 ft-lb) for HPV55, 75, and 105. For HPV135, torque to 170 N-m (125 ft-lb).

10. Repeat Step #9 for the other Main Relief Valve.

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11. Verify that the o-ring on the Charge Relief Valve is in good condition, then install it into the Rear Head. Torque the Charge Relief Valve to 30 N-m (22 ft-lb) for HPV55, 75, and 105. For HPV135, torque to 40 N-m (30 ft-lb).

12. Install the two brass Bearing Strips into the pump housing. Prior to installation, apply a thin layer of petroleum jelly to the bottom side of the Bearing Strips to help secure them. If reusing the original pins, press the Bearing Strips onto them. If new pins are needed, first install the Bearing Strips. Then install the new pins using a hammer and punch. IMPORTANT: The top surface of the pins must be lower than the top surface of the Bearing Strips

13. Place the Front Bearing Race into the cavity in the pump housing.

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14. Drive the Front Bearing Race into the pump housing using the proper race driver tool.

15. As illustrated, place the Drive Shaft into the pump housing.

16. Follow all steps outlined in Appendix “C” (located at the end of this repair manual) to measure for bearing end-play shimming.

17. Based on the measurement taken in Step #16, install the proper amount of Rear Bearing Shims into the Rear Head.

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18. Using the proper race driver tool, drive the Rear Bearing Race into the Rear Head.

19. Install the Snap Ring and Washer into the Cylinder Barrel. Do NOT install the Bottom Washer, Cylinder Barrel Spring, or Cylinder Barrel Shims at this time. When installing the Snap Ring, make sure to orient it so that the white mark is facing towards the bronze surface of the Cylinder Barrel. If using a new Snap Ring without a white mark, apply a white mark with paint on the snap ring and make sure to orient the Snap Ring as just described. 20. Follow all steps outlined in Appendix “A” (located at the end of this repair manual) to measure the Cylinder Barrel lift-off and for proper shim selection. 21. Assemble the Cylinder Barrel as illustrated below. Make sure that the tapered edge of the Bottom Washer is facing away from the Cylinder Barrel Spring. Addtionally, make sure the the Snap Ring is positioned with the white mark as illustrated.

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22. Follow all steps outlined in Appendix “B” (located at the end of this repair manual) to measure the Piston Slipper Lift-Off and for proper shim selection.

23. Install the proper shim combination onto the appropriate side of the Swash Plate.

24. Install the proper Hold-Down Clamp onto the Swash Plate. Apply Green Loctite No. 648 to the threads of the two new mounting bolts. Torque each mounting bolt to: [HPV55/75] [HPV105/135]

32 N-m (24 ft-lb) 64 N-m (47 ft-lb)

25. Install the nine Pistons into the Hold-Down Plate. As illustrated, make sure that the taper on the Hold-Down Plate is positioned correctly. Then set the entire assembly onto the Swash Plate.

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26. Install the proper shim combination onto the other side of the Swash Plate.

27. Install the proper Hold-Down Clamp onto the Swash Plate. Apply Green Loctite No. 648 to the threads of the two new mounting bolts. Torque each mounting bolt to: [HPV55/75] [HPV105/135]

32 N-m (24 ft-lb) 64 N-m (47 ft-lb)

28. Place the Cylinder Barrel on a non-abrasive surface as illustrated. Then insert the nine Pistons and the Swash Plate assembly into the Cylinder Barrel.

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29. Remove the Drive Shaft from the pump housing, then insert it into the Cylinder Barrel as illustrated.

30. Position the Drive Shaft onto a firm surface as illustrated. Place the Bearing Support Ring onto the Drive Shaft making sure to orient it correctly.

31. If using an oven, warm it to 350°F (If using a hot plate, adjust it to 350°F). Heat the Rear Bearing to 350°F. Install the Rear Bearing onto the drive shaft. Allow the Rear Bearing to cool for a moment. Then use the rear bearing driver tool to drive the Rear Bearing completely onto the Drive Shaft.

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32. Install the two Actuator Pistons into the HoldDown Clamp.

33. Slide the rotating group into the pump housing.

34. Follow all steps outlined in Appendix “E” to measure for and select the proper Lube Tube Shims. 35. Follow all steps outlined in Appendix “F” to measure for and select the proper Mechanical Neutral Shims. 36. Remove the rotating group from the pump housing and set it aside.

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37. With a brush, apply Locquic Primer “T” to the sealing area of the Rear Head. 38. Insert the two Lube Tubes and Shims into the Rear Head. Make sure that they are inserted into the correct cavities in the Rear Head. When inserting the Lube Tube Shims, make sure that the tapered edge faces away from the Lube Tube as illustrated below.

39. Pre-lubricate the running surface of the Port Plate (the surface with the dampening slots) with some mineral based oil or lubricant.

40. Install the Port Plate onto the Rear Head making sure to orient it with the dampening slots facing away from the Rear Head.

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41. Place the rotating group onto the Port Plate. You have to lift the Port Plate a little (as shown) to permit the two Actuator Pistons to fit into the cavities. Make sure that the two Lube Tubes are properly positioned into the spherical cavities in the two brass Hold-Down Clamps.

42. Apply Loctite 515 Gasket Eliminator to the sealing surface of the pump housing. Spread the sealant with your finger or with a clean brush over the entire sealing surface of the pump housing. The result should be a thin, uniform coat of sealant.

43. Install the o-rings into the sealing area of the pump housing.

44. Install the Mechanical Neutral Shims in the proper positions. Make sure that they are oriented properly with the rounded edge facing towards the pump housing (away from the Rear Head).

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45. Slowly lower the pump housing onto the Rear Head.

46. Torque each mounting bolt as follows: • •

HPV55 HPV75

• •

HPV105 HPV135

(M10 bolt) 64 N-m (47 ft-lb) (M8 bolt) 32 N-m (24 ft-lb) (M12 bolt) 110 N-m (81 ft-lb) (M12 bolt) 110 N-m (81 ft-lb) (M14 bolt) 180 N-m (133 ft-lb)

47. To help verify that the two Lube Tubes and the Swash Plate are properly positioned, use the photo to identify the two passages in which to supply air pressure (shop air through a nozzle will work). Supply air into the two passages and make sure that the Swash Plate moves and holds pressure by staying stroked. (Hint: As the Swash Plate moves, you can look through the open control cavity and the case drain port in the pump housing to visually verify that the Lube Tubes are in position)

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Clean This Surface

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48. Use cleaning solvent and a lintfree rag to thoroughly clean the surface indicated in the sketch. The old Shaft Seal had Loctite on its outside diametric surface and remnants of the Loctite may still be on the indicated surface of the housing.

Assembly Sleeve 49. Place the Assembly Sleeve Tool over the drive shaft as illustrated. Apply petroleum jelly to the outside surface of the Assembly Sleeve Tool.

Shaft Seal

Green Loctite No. 270 On This Surface

Petroleum Jelly On This Surface

50. As illustrated, apply petroleum jelly to the inside diametric surface of the new Shaft Seal. Then apply Green Loctite No. 270 to the outside diametric surface of the Shaft Seal, and spread it to a uniform thickness with your finger.

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51. Lightly press the Shaft Seal onto the Assembly Sleeve Tool as illustrated.

Shaft Seal

52. Using the proper shaft seal driver tool, drive the Shaft Seal into the pump housing.

Snap Ring 53. Reinstall the Snap Ring making sure that it is fully engaged into the snap ring groove.

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54. Install the Charge Pump Coupling onto the Drive Shaft.

55. Apply some petroleum jelly to the o-ring and place it in the o-ring groove in the Rear Head.

56. Apply some petroleum jelly to the o-ring and place it in the o-ring groove in the Charge Pump.

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57. Install the Charge Pump onto the pump.

58. Install the two Mounting Bolts and torque each one to 85 N-m (63 ft-lb).

59. Install the two metal split pins into the swash plate. Take care during the installation to avoid dropping the split pins into the pump housing.

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60. Insert the Finger onto the two metal spilt pins in the Swash Plate. Make sure to orient the Finger as illustrated.

61. Following the manufacturer's recommendations, apply Blue Loctite No. 243 to the threads of the two new Finger Mounting Bolts. 62. Install the two new mounting bolts into the pump and torque each one to 34 N-m (25 ft-lb). 63. Follow all steps outlined in Appendix “D” (located at the end of this Repair Manual) to properly measure and select shims for the Finger.

64. Based on the measurements from Step #63, install the Finger Shims.

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65. Install the Finger Snap Ring.

66. Apply petroleum jelly to each o-ring for the pump control and place all o-rings in the appropriate o-ring groove.

67. Install the control onto the pump making sure that: a. The Finger is properly positioned into the female linkage inside the control. b. The metal split pins in the pump control are aligned with the corresponding passage in the pump housing.

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68. Fasten the control with four Control Mounting Bolts. Torque each mounting bolt to: •

25 N-m (18 ft-lb) For HPV-02 Controls Without the integrated POR feature

•

34 N-m (25 ft-lb) For HPV-02 Controls With the integrated POR feature

69. Install the Filter and Filter Flange onto the Rear Head. Torque each mounting bolt to 25 N-m (18 ft-lb).

70. Make sure to install plugs in all open ports and cover the two pump workports.

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Appendix “A”: Procedure to Shim the Cylinder Barrel

Appendix “A” Rev. 1, 7-22-02 Page 1 of 3

Note: Refer to the Linde Spare Parts Catalog for the shim part numbers available for the pump size you are working on The parts and dimension shown in the following illustration will be used for this procedure:

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Appendix “A”: Procedure to Shim the Cylinder Barrel

Appendix “A” Rev. 1, 7-22-02 Page 2 of 3

4. As demonstrated during the training, remove the cylinder barrel spring and bottom washer from the cylinder barrel. Then reinstall the Washer and Snap Ring back into the cylinder barrel. Do NOT reinstall the cylinder barrel shims.

IMPORTANT: Make sure to reinstall the Snap Ring in the proper orientation as emphasized during the training. 5. Install the cylinder barrel onto the drive shaft as illustrated above. 6. Measure and record dimension “X” to the nearest 0.01mm. Dimension “X” =

7. As illustrated below, measure and record dimension “Y” to the nearest 0.01mm. Dimension “Y” =

8. Calculate Dimension “Z” and record the value below to the nearest 0.01mm: Dimension “Z” = (Dimension “X”) – (Dimension “Y”) Dimension “Z” =

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9. Based on the value for Dimension “Z”, select the quantity of cylinder barrel shims to acquire a clearance of 0.10mm to 0.30mm. Refer to the example below. Example: HPV105-02 Pump Dimension “X” = 4.75mm Dimension “Y” = 3.00mm Dimension “Z” = (4.75mm) – (3.00mm) = 1.75mm You must calculate a range for the cylinder barrel shims: (maximum clearance) = (1.75mm) – (0.30mm) = 1.45mm (minimum clearance) = (1.75mm) – (0.10mm) = 1.65mm You must select a shim (or combination of shims) that is between 1.45mm and 1.65mm

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Appendix “B”: Procedure to Shim For Piston Slipper Lift-Off

Appendix “B” Rev. 1, 8-13-02 Page 1 of 3

Refer to the Linde Spare Parts Catalog for the shim part numbers available for the pump size you are working on. The parts and dimensions shown in the following illustration will be used for this procedure:

IMPORTANT: Pump pistons must be replaced as a complete set. If one or more pistons are damaged, then discard all of them and replace them with a new set of pistons. 1. As illustrated on the following page, measure and record the following parts individually to the nearest 0.01mm:

• • •

Hold-Down Clamp Hold-Down Plate Piston Slipper [select any piston]

(Dimension “Q”) (Dimension “R”) (Dimension “S”)

Dimension “Q” =

Dimension “R” =

Dimension “S” =

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2. Do the following calculation and record the value below to the nearest 0.01mm: Dimension “Y” = (Dimension “R”) + (Dimension “S”) Dimension “Y” =

3. Do the following calculation and record the value below to the nearest 0.01mm: Dimension “Z” = (Dimension “Y”) – (Dimension “Q”) Dimension “Z” =

4. Based on the value for Dimension “Z”, select the proper Shims to acquire a clearance of 0.01mm to 0.03mm. Refer to the example below. 5. Repeat steps #1 through #4 for the Hold-Down Clamp on the other side of the pump.

IMPORTANT: There are two Hold-Down Clamps on each pump. The two Hold-Down Clamps are different from each other. Likewise, the Shims beneath them are different from each other. It is critical that each Hold-Down Clamp be measured and shimmed accordingly.

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Appendix “B”: Procedure to Shim For Piston Slipper Lift-Off

Appendix “B” Rev. 1, 8-13-02 Page 3 of 3

Example: HPV105-02 Pump Part #1: (For the first Hold-Down Clamp) Dimension “Q” = 10.39mm Dimension “R” = 5.50mm Dimension “S” = 5.99mm Dimension “Y” = (5.50mm) + (5.99mm) = 11.49mm Dimension “Z” = (11.49mm) – (10.39mm) = 1.10mm You must calculate a range for the Shims: (maximum clearance) = (1.10mm) + (0.03mm) = 1.13mm (minimum clearance) = (1.10mm) + (0.01mm) = 1.11mm Select a Shim (or combination of Shims) that is between 1.11mm and 1.13mm for the first Hold-Down Clamp. To compensate for measuring errors, it is recommended that you select a shim between the two extreme values – 1.12mm. Part #2: (For the second Hold-Down Clamp) Dimension “Q” = 10.42mm Dimension “R” = 5.50mm (same value as in Part #1) Dimension “S” = 5.99mm (same value as in Part #1) Dimension “Y” = (5.50mm) + (5.99mm) = 11.49mm Dimension “Z” = (11.49mm) – (10.42mm) = 1.07mm You must calculate a range for the Shims: (maximum clearance) = (1.07mm) + (0.03mm) = 1.10mm (minimum clearance) = (1.07mm) + (0.01mm) = 1.08mm Select a Shim (or combination of Shims) that is between 1.09mm and 1.10mm for the second Hold-Down Clamp. To compensate for measuring errors, it is recommended that you select a shim between the two extreme values – 1.09mm.

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Appendix “C”: Procedure to Shim for Bearing End-Play

Appendix “C” Rev. 0 Page 1 of 3

Refer to the Linde Spare Parts Catalog for the shim part numbers available for the pump size you are working on The parts and dimension shown in the following illustration will be used in this procedure:

1. Install the Bearing and Shaft Seal Race on the drive shaft. 2. Make sure to install the Bearing Race as illustrated above. 3. Use the proper race driver tool to ensure that the Bearing Race is installed completely into the housing. 4. Measure and record Dimension “A” as illustrated above to the nearest 0.01mm Dimension “A” =

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Appendix “C”: Procedure to Shim for Bearing End-Play

Appendix “C” Rev. 0 Page 2 of 3

5. As illustrated below, measure and record Dimension “B” and Dimension “C” to the nearest 0.01mm. Measure each component individually.

Dimension “B” =

Dimension “C” =

6. As illustrated below, measure and record Dimension “D” to the nearest 0.01mm. Make sure to remove ALL existing shims before taking the measurement for Dimension “D”. Dimension “D” =

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Appendix “C”: Procedure to Shim for Bearing End-Play

Appendix “C” Rev. 0 Page 3 of 3

7. Calculate and record Dimension “X” to the nearest 0.01mm: Dimension “X” = (Dimension “A”) + (Dimension “D”) Dimension “X” =

8. Calculate and record Dimension “Y” to the nearest 0.01mm: Dimension “Y” = (Dimension “B”) + (Dimension “C”) Dimension “Y” =

9. Calculate and record Dimension “Z” to the nearest 0.01mm: Dimension “Z” = (Dimension “X”) – (Dimension “Y”) Dimension “Z” =

10. Based on the value for Dimension “Z”, select the quantity of shims to get between an interference of 0.02mm and a clearance of 0.07mm. Refer to the example below.

Example: HPV105-02 Pump Dimension “A” = 8.70mm Dimension “B” = 3.50mm Dimension “C” = 22.23mm Dimension “D” = 19.70mm Dimension “X” = (8.70mm ) + (19.70mm) = 28.40mm Dimension “Y” = (3.50mm) + (22.23mm) = 25.73mm Dimension “Z” = (28.40mm) – (25.73mm) = 2.67mm You must calculate a range for the shims: (maximum clearance) = (2.67mm) – (0.07mm) = 2.60mm (minimum clearance) = (2.67mm) + (0.02mm) = 2.69mm You must select a shim (or combination of shims) that is between 2.60mm and 2.69mm.

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Appendix “D”: Procedure to Shim Control Finger

Appendix “D” Rev. 0 Page 1 of 2

Procedure “A”: For HPV-02 Cam Control 1. The new Finger for the Cam Control must be installed: a. As illustrated below, install the Finger into the pump by pressing it onto the two metal split pins. Refer to the illustration to insure the Finger is oriented correctly. b. Following the manufactorer's recommendations, apply Blue Loctite No. 243 to the threads of the two new M8 S.H.C.S. c. Install the two new M8 S.H.C.S. into the pump and torque each one to 34 N-m (25 ft-lb).

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Appendix “D”: Procedure to Shim Control Finger

Appendix “D” Rev. 0 Page 2 of 2

2. Using the digital depth calipers, measure from the designated edge of the Finger to the pump housing. 3. Select enough Shims so that the measurement adds up to 19.4mm (+0.1/-0.0mm) including the Snap Ring as illustrated above.

Procedure “B”: For All Other HPV-02 Controls 1. Repeat Step #1 from Procedure “A”. 2. As illustrated below, use digital depth calipers to measure from the designated edge of the Finger to the pump housing. 3. Select enough Shims so that the measurement adds up to 25.4mm (+0.1/-0.0mm) including the Snap Ring as illustrated below.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 1 of 5

Tools/Equipment Required: •

• • • • • •

Linde Universal Tool - For HPV55-02 pumps Part Number 0009419050 - For HPV75-02 pumps Part Number 0009419051 - For HPV105-02 pumps Part Number 0009419052 - For HPV135-02 pumps Part Number 0009419053 lube tube washers (as required) Part Number 9289003013 lube tube shims (refer to the appropriate Linde spare parts catalog for part numbers) digital depth calipers (capable of measuring to the nearest 0.01mm) sharp edge tool (to remove sealant from pump housing) sanding stone solvent

The illustration below can be used to identify some key parts of the Linde universal tool that will be referenced throughout this Appendix.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 2 of 5

1. Remove the Rear Head from the pump. 2. Remove and discard all of the o-rings on the sealing area of the pump housing. 3. Use the sharp edge tool to remove all sealant on the sealing area of the pump housing and the Rear Head. 4. Use the sanding stone and solvent to clean and debur the sealing area of the pump housing and the Rear Head. 5. As illustrated below, install the Linde universal tool onto the pump. Use the three fasteners to attach the Linde universal tool to the pump housing.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 3 of 5

6. Insert the two Lube Tubes into the Lube Tube Adjustments, as illustrated above, and make sure that both Lube Tubes are properly positioned into the Hold-Down Cavity. 7. With your fingers, lightly tighten both Lube Tube Adjustments. 8. As illustrated below, measure Dimensions “A” and “B” with digital depth calipers and record the measurements to the nearest 0.01mm.

Dimension “A” =

Dimension “B” =

(Note: Dimension “A” is for the Lube Tube between the two Actuator Pistons)

9. As illustrated on the following page, measure Dimensions “C” and “D” on the Rear Head with digital depth calipers and record the measurements to the nearest 0.01mm. (Note: Dimension “C” is for the Lube Tube between the two Actuator Pistons)

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Appendix “E”: Procedure to Shim Lube Tubes

Dimension “C” =

Dimension “D” =

Appendix “E” Rev. 0 Page 4 of 5

10. Do the following calculations and record the results to the nearest 0.01mm: Dimension “E” = (Dimension “C”) – (Dimension “A”) + (25.00) Dimension “E” =

Dimension “F” = (Dimension “D”) – (Dimension “B”) + (25.00) Dimension “F” =

(Note: Dimension “E” is for the Lube Tube between the two Actuator Pistons) Note: Dimensions “E” and “F” are the clearances between the end of the Lube Tubes and the cavities in the Rear Head. These clearances must be filled with Lube Tube Shims (and Washers as required) to provide a final clearance of 0.01mm to 0.15mm. Please refer to the illustration and the example on the following page.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 5 of 5

Example: HPV105-02 Pump Dimension “A” = 34.88mm Dimension “B” = 34.93mm Dimension “C” = 11.51mm Dimension “D” = 11.53mm Dimension “E” = (11.51mm) – (34.88mm) + (25.00mm) = 1.63mm Dimension “F” = (11.53mm) – (34.93mm) + (25.00mm) = 1.60mm You must calculate a shim range for each Lube Tube: -

For the Lube Tube between the two Actuator Pistons: (reference Dimension “E”) (maximum clearance) = (1.63mm) – (0.15mm) = 1.48mm (minimum clearance) = (1.63mm) – (0.01mm) = 1.62mm Select a Lube Tube Shim between 1.48mm and 1.62mm thick

For the other Lube Tube: (reference Dimension “F”) (maximum clearance) = (1.60mm) – (0.15mm) = 1.45mm (minimum clearance) = (1.60mm) – (0.01mm) = 1.59mm Select a Lube Tube Shim between 1.45mm and 1.59mm thick

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Appendix “F”: Procedure to Shim Mechanical Neutral

Appendix “F” Rev. 0 Page 1 of 5

Tools/Equipment Required: •

• • • • • •

Linde Universal Tool - For HPV55-02 pumps Part Number 0009419050 - For HPV75-02 pumps Part Number 0009419051 - For HPV105-02 pumps Part Number 0009419052 - For HPV135-02 pumps Part Number 0009419053 mechanical neutral shims (refer to the appropriate Linde spare parts catalog for the part numbers) digital calipers (capable of measuring to the nearest 0.01mm) digital depth calipers (capable of measuring to the nearest 0.01mm) sharp edge tool (to remove sealant from pump housing) sanding stone solvent

The illustration below can be used to identify some key parts of the universal tool that will be referenced throughout this Appendix.

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Appendix “F”: Procedure to Shim Mechanical Neutral

Appendix “F” Rev. 0 Page 2 of 5

Note: If you do NOT have the proper Lube Tube Shims, perform all steps in Appendix “E” before continuing with Appendix “F”. 1. If you are proceeding from Appendix “E”, then skip steps #2 through #7. 2. Remove the Rear Head from the pump. 3. Remove and discard all of the o-rings on the sealing area of the pump housing. 4. Use the sharp edge tool to remove all sealant on the sealing area of the pump housing and the Rear Head. 5. Use the sanding stone and solvent to clean and debur the sealing area of the pump housing and the Rear Head.

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Appendix “F”: Procedure to Shim Mechanical Neutral

Appendix “F” Rev. 0 Page 3 of 5

6. As illustrated on the previous page, install the universal tool onto the pump. Use the three fasteners to attach the universal tool to the pump housing. Insert the two Lube Tubes into the Lube Tube Adjustments and make sure that both Lube Tubes are properly positioned into the Hold-Down Cavity. 7. With your fingers, lightly tighten both Lube Tube Adjustments. 8. As illustrated below, use the Neutral Adjustments on the universal tool to make sure that Dimensions “G” and “H” are NOT different by more than 0.06mm (use the digital depth calipers to measure – this mechanically places the pump in neutral).

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Appendix “F”: Procedure to Shim Mechanical Neutral

Appendix “F” Rev. 0 Page 4 of 5

9. Measure and record Dimension “G” and “H” to the nearest 0.01mm: Dimension “G” =

Dimension “H” =

10. Remove the universal tool from the pump. 11. As illustrated below, measure and record Dimensions “I”, “J”, “K”, and “L” to the nearest 0.01mm: Dimension “I” = Dimension “K” =

mm mm

Dimension “J” =

Dimension “L” =

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Appendix “F”: Procedure to Shim Mechanical Neutral

Appendix “F” Rev. 0 Page 5 of 5

12. Do the following calculations and record the results to the nearest 0.01mm: Dimension “M” = (Dimension “I”) + (Dimension “J”) - (Dimension “G”) + 0.05 Dimension “M” =

Dimension “N” = (Dimension “K”) + (Dimension “L”) - (Dimension “H”) + 0.05 Dimension “N” =

13. Select mechanical neutral shims that have the same thickness as Dimension “M” and “N”. The allowable tolerance for the mechanical neutral shims is (+0.10mm)/(-0.00mm).

Example: HPV105-02 Pump Dimension “G” = 34.12mm Dimension “I” = 28.74mm Dimension “J” = 9.87mm

Dimension “H” = 34.14mm Dimension “K” = 28.73mm Dimension “L” = 10.03mm

Dimension “M” = (28.74mm) + (9.87mm) – (34.12mm) + (0.05mm) = 4.54mm

Select a mechanical neutral shim 4.54mm to 4.64mm thick Dimension “N” = (28.73mm) + (10.03mm) – (34.14mm) + (0.05mm) = 4.67mm

Select a mechanical neutral shim 4.67mm to 4.77mm thick

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 1 of 8

Note: The Charge Pump illustrated in this Appendix is an external feed charge pump. If you are working on an internal feed charge pump, contact the Linde Service Department if you have any specific questions about the repair instructions.

Disassembly Instructions:

1. Remove the Charge Pump from the HPV-02 pump.

2. Remove the Cold-Start Relief Valve. 3. Remove the tapered thread Plug (illustrated to the left) from the Charge Pump and discard it. On occasion, there may be a plug with an o-ring on it (not illustrated). If the charge pump you are working on has this type of plug, then you can reuse it.

4. Remove the Rear Cover Plate and O-Ring from the Charge Pump.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 2 of 8

5. Remove the seven Fastening Bolts and Washers.

6. Flip the Charge Pump over, then remove the Port Plate. 7. Remove the O-Ring that rests beneath the Port Plate.

8. Pull the Shaft/Inner Gear Assembly out of the Charge Pump.

9. Pull the Outer Gear from the Charge Pump.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 3 of 8

10. To disassemble the Shaft/Inner Gear Assembly: a. Remove one of the flat Snap Rings from the Shaft. b. Slide the Inner Gear off of the Shaft. c. Pull the Shear Key from the Shaft. d. Remove the other flat Snap Ring.

Assembly Instructions:

1. Install one flat Snap Ring onto the Shaft.

2. Apply some petroleum jelly onto the Shear Key. Then insert the Shear Key into the slot in the Shaft.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 4 of 8

3. Align the notch on the Inner Gear with the Shear Key, then slide the Inner Gear up to the flat Snap Ring on the Shaft. IMPORTANT: The Inner Gear has a sharp, flat edge on one side and a small taper on the other side. The edge with the small taper must be facing away from the external splines of the Shaft when installed. Failure to install the Inner Gear as described will lead to improper operation of the Charge Pump and/or permanent damage to the Charge Pump.

4. Install the other flat Snap Ring onto the Shaft. 5. (If reusing the original Needle Bearing in the Charge Pump housing, then skip this step) Apply a thin, uniform layer of Green Loctite No. 270 to the outer race of the new Needle Bearing. The orientation of the Needle Bearing is important. On one face of the Needle Bearing, there will be some stamping (bearing manufacturer's name, etc.) and the other side will be blank. The side of the Needle Bearing with the stamping must be facing away from the Charge Pump housing when installed. Install the new Needle Bearing into the Charge Pump housing and wipe away any excess Loctite.

6. Install the Shaft/Inner Gear Assembly into the Charge Pump housing as illustrated making sure to orient the assembly correctly. HINT: The small tapered edge on the Inner Gear should be facing downward.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 5 of 8

7. Install the Outer Gear into the Charge Pump Housing. IMPORTANT: The Outer Gear has a sharp, flat edge on one side and a small taper on the other side. The edge with the small taper must be facing downward (as illustrated to the left) when installed. Failure to install the Outer Gear as described will lead to improper operation of the Charge Pump and/or permanent damage to the Charge Pump.

8. Apply some petroleum jelly to the O-Ring, then install the O-Ring into the Charge Pump housing.

9. (If reusing the original Needle Bearing in the Port Plate, then skip this step) Apply a thin, uniform layer of Green Loctite No. 270 to the outer race of the new Needle Bearing. The orientation of the Needle Bearing is important. On one face of the Needle Bearing, there will be some stamping (bearing manufacturer's name, etc.) and the other side will be blank. The side of the Needle Bearing with the stamping must be facing away from the Port Plate when installed. Install the new Needle Bearing into the Port Plate and wipe away any excess Loctite.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 6 of 8

10. Install the Port Plate onto the Charge Pump. HINT: The seven holes on the Port Plate are NOT evenly spaced, hence the Port Plate can only be install in one position where all seven holes are aligned.

11. Install the seven Fastening Bolts and Washers to fasten the Port Plate to the Charge Pump. Torque each Fastening Bolt to 13 N-m (10 ft-lb).

12. Apply some petroleum jelly to the O-Ring, then install the O-Ring into the Charge Pump housing.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 7 of 8

13. Install the Cover Plate and fasten it to the Charge Pump with the two Hex Head Bolts. Torque each Hex Head Bolt to 46 N-m (34 ft-lb).

Note: For Steps #14 and #15, it is important to know the rotation for the pump. The positions for the Plug and Cold-Start Relief Valve are dependent on the pump rotation as illustrated below.

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Appendix “G”: Procedure to Repair Charge Pump

Appendix “G” Rev. 0 Page 8 of 8

14. Apply Blue Loctite No. 243 to the threads of a new Plug. Install the Plug into the Charge Pump. Torque the Plug to 60 N-m (44 ft-lb). For those special plugs with the o-ring, you do NOT need to apply Loctite.

15. Install the Cold-Start Relief Valve into the Charge Pump. Torque the Cold-Start Relief Valve to 30 N-m (22 ft-lb). 16. Install plastic shipping plugs into the two Charge Pump workports.

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Repair Manual for HPR-02 Variable Displacement Pumps

HPR-02 Rev. 1, 8-7-02 Page 1 of 28

This Repair Manual is valid for all single HPR-02 (55/75/105/135) pumps; For the HPR105-02 double pump, refer to Linde repair manual HPR-D-02. Tools/Equipment Required: • metric wrenches and Allen wrenches • vertical press • oven or hot plate (minimum temperature of 350°F required) • Green Loctite No. 648 (domestically available or Linde Part Number 7379200106) • Green Loctite No. 270 (domestically available or Linde Part Number 7379200108) • rubber mallet or soft metal rod • snap ring wrench (to squeeze/compress the snap ring) • torque wrench capable of setting between 2.7 N-m (2.0 ft-lb) and 180 N-m (133 ft-lb) • rear bearing shims (refer to Linde Spare Parts Catalog for required part numbers) • cylinder barrel shims (refer to Linde Spare Parts Catalog for required part numbers) • commercially available bearing race remover • steel sleeve or bushing (to press rear bearing onto drive shaft - no part number) • steel impact block (no part number) • sanding stone and solvent • petroleum jelly • Loctite 515, Gasket Eliminator (domestically available) • Locquic Primer "T" (domestically available) • bearing puller body: P/N (to be specified) - (HPR55) - (HPR75) P/N 0009419133 P/N 0009419138 - (HPR105 and 135) • bearing collet: - (HPR55) P/N (to be specified) - (HPR75) P/N 0009419110 - (HPR105) P/N 0009419146 - (HPR135) P/N 0009419144 • shaft seal assembly sleeve: P/N (to be specified) - (HPR55) - (HPR75) P/N 0009419745 - (HPR105) P/N (to be specified) - (HPR135) P/N (to be specified) • rear bearing race driver: P/N (to be specified) - (HPR55) - (HPR75) P/N 0009419743 P/N 0009419741 - (HPR105) - (HPR135) P/N 0009419742 • cylinder barrel compression plate kit: P/N 8883035391 - (HPR55) - (HPR75) P/N 8883034481 - (HPR105) P/N 8883034441 P/N 8883034491 - (HPR135)

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Repair Manual for HPR-02 Variable Displacement Pumps

shaft seal driver: - (HPR55) - (HPR75) - (HPR105) - (HPR135) driver for front bearing race: - (HPR55) - (HPR75) - (HPR105) - (HPR135) Linde Conversion Bulletin "VARIABLE-PLATE"

HPR-02 Rev. 1, 8-7-02 Page 2 of 28

P/N (to be specified) P/N 0009419748 P/N 0009419749 P/N 0009419750 P/N (to be specified) P/N 0009419751 P/N (to be specified) P/N (to be specified)

The following sketches illustrate an HPR-02 single pump and some key items which will be referenced throughout this Repair Manual:

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Disassembly Procedure: 1. Remove the two hex head bolts from the PTO Cover plate. 2. Remove the PTO Cover plate and PTO O-Ring from the back of the pump. 3. Remove the nine Mounting Bolts from the Rear Head.

4. Remove the Rear Head from the pump.

5. Remove the Port Plate from the pump.

6. Use a sharp edge tool, sanding stone, and solvent to remove any remaining sealant from the pump housing sealing area. 7. Follow all steps in Linde Conversion Bulletin “VARIABLE-PLATE” to remove the Rear Bearing from the Drive Shaft.

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8. Set the Rear Bearing aside.

9. Remove the Bearing Support Ring from the Drive Shaft.

10. Remove the entire rotating group from the pump housing.

11. Set the rotating group onto a soft, non-abrasive surface as illustrated.

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12. Pull the Drive Shaft straight up and out of the rotating group.

13. Pull the Swash Plate/Piston/Actuator assembly out of the Cylinder Barrel.

14. Disassemble the Swash Plate/Piston/Actuator assembly as illustrated. Please note that the four bolts that fasten the two Hold-Down Clamps to the Swash Plate have Green Loctite No. 648 on their threads. You must use heat to break the Loctite loose before the bolts can be removed.

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15. Remove the two brass Bearing Strips from the pump housing. 16. There will be two brass pins (used to hold the Bearing Strips in place) remaining in the pump housing. If undamaged, leave them in the pump housing.

17. Remove the Front Bearing Race from the pump housing.

18. Remove the Snap Ring. 19. Press the Shaft Seal out of the pump housing.

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20. If the pump has a side inspection cover on the housing, as illustrated, then remove it. If not, then disregard this step.

21. Remove all plugs from the pump case drain ports.

22. Remove the two Lube Tubes and all Lube Tube Shims from the Rear Head.

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23. Remove the Pump Control from the Rear Head by removing the three mounting bolts.

24. Remove the Displacement Adjustment Studs and Seal Nuts from the Rear Head.

25. Remove the Rear Bearing Race and all of the Rear Bearing Shims. 26. All other reusable metal and plastic plugs should be removed from the Rear Head.

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27. There are two types of Pump Controls for the HPR-02 pumps – The Load Sense/Pressure Compensator Control (illustrated to the left) and the Load Sense/Power Mode Control (illustrated below). Disassemble the Load Sense/Pressure Compensator control by removing the four mounting bolts from the side cover.

28. Finish disassembling the Load Sense/Pressure Compensator Control by removing the metal plugs and remaining spools.

29. Disassemble the Load Sense/Power Mode Control (illustrated to the left) by removing the four mounting bolts from the side cover. Remove the solenoid from the control by removing the four mounting bolts.

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30. Prior to disassembling the Cylinder Barrel, please note that there is a white mark on the Snap Ring. The white mark identifies the top surface of the Snap Ring. This will become important during the Assembly portion of this manual.

31. (For the HPR55-02 and HPR75-02 only) The Cylinder Barrel can be disassembled by compressing the Cylinder Barrel Spring, and then by removing the Snap Ring. Upon disassembly, there should be the Snap ring, Cylinder Barrel Shims, Washer, Cylinder Barrel Spring, and Bottom Washer.

32. (For the HPR105-02 and HPR135-02 only) The Cylinder Barrel can be disassembled by compressing the Cylinder Barrel Spring, and then by removing the Snap Ring. Then the remaining parts within the Cylinder Barrel can be removed – They are the Snap Ring, Outer Bushing, Inner Bushing (with two Piston Rings), Washer, Cylinder Barrel Spring, and Bottom Washer.

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33. Position the drive shaft on a vertical press as illustrated to the left. Press the Front bearing and Shaft Seal Race off of the Drive Shaft.

34. As illustrated, remove the Piston Rings from the two Actuator Pistons.

This concludes the disassembly portion of this manual. At this point, all components of the HPR-02 pump should have been completely disassembled. Careful inspection of all parts is absolutely critical. Any parts showing signs of wear or damage should be discarded and replaced with genuine Linde parts. It is also strongly recommended that all sealant-type parts (o-rings, seal nuts, and shaft seal) be discarded and replaced with new genuine Linde parts. All parts that are going to be reused must be thoroughly cleaned and flushed free of all contaminants. Any remaining sealant material on the rear head and pump housing must be scraped clean. The mounting surfaces of the pump housing and rear head should be cleaned and deburred with a sanding stone and solvent.

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Repair Manual for HPR-02 Variable Displacement Pumps

HPR-02 Rev. 1, 8-7-02 Page 14 of 28

Assembly Procedure:

1. If using the Load Sense/Pressure Compensator Pump Control (illustrated to the left), then reassemble it as shown. 2. Torque each of the mounting bolts on the side cover to 14 N-m (10 ft-lb).

3. If using the Load Sense/Power mode Pump Control (illustrated to the left), then reassemble it as shown. 4. Torque each of the mounting bolts on the side cover to 14 N-m (10 ft-lb) 5. Torque each of the solenoid mounting bolts to 2.7 N-m (2.0 ft-lb).

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6. Install the Displacement Adjustment Studs and new Seal Nuts into the Rear Head. There is no need to torque the Seal Nuts at this time since both maximum and minimum displacements will have to be adjusted during testing of the pump. Note: As illustrated on page 2, the longer Displacement Adjustment Stud should be installed in the larger Cavity of the Rear Head

7. If reusing the Shaft Seal Race, the inside diametric surface must be scraped clean to remove all leftover Loctite material. Likewise, any remaining sealant material on the inside diametric surface of the Front Bearing and/or the bearing area of the Drive Shaft should be removed. 8. If using an oven, warm it to 350°F (If using a hot plate, adjust it to 350°F). Heat both the Front Bearing and Shaft Seal Race to 350°F. Install the Front Bearing onto the drive shaft. 9. Apply a narrow bead of Green Loctite No. 648 around the mounting surface of the new drive shaft. Then with a small brush or your finger, spread the Loctite into a thin, uniform layer around the mounting surface of the drive shaft.

10. Install the Shaft Seal Race onto the drive shaft. Make sure to properly orient the Shaft Seal Race with the tapered end positioned towards the drive shaft splines. Then wipe clean all excess Loctite.

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11. If applicable, install the side inspection cover onto the pump housing. Make sure that the oring is in place prior to installing the cover. Torque each bolt to 23 N-m (17 ft-lb).

13. Place the Front Bearing Race into the cavity in the pump housing.

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14. Drive the Front Bearing Race into the pump housing using the proper race driver tool.

15. As illustrated, place the Drive Shaft into the pump housing. 16. Follow all steps outlined in Appendix “C” (located at the end of this repair manual) to measure for bearing end-play shimming for HPR55-02 and HPR75-02 pumps. For HPR105-02 and HPR135-02 pumps, follow all steps outlined in Appendix “D”.

17. Based on the measurement taken in Step #16, install the proper amount of Rear Bearing Shims into the Rear Head.

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18. Using the proper race driver tool, drive the Rear Bearing Race into the Rear Head.

19. Install the Piston Rings on the two Actuator Pistons. Be sure to orient the taper on each Piston Ring as illustrated below.

Steps #20, #21, and #22 are ONLY valid for the HPR55-02 and HPR75-02 pumps – If working on an HPR105-02 or HPR135-02 pump, then disregard these steps. 20. Install the Snap Ring and Washer into the Cylinder Barrel. Do NOT install the Bottom Washer, Cylinder Barrel Spring, or Cylinder Barrel Shims at this time. When installing the Snap Ring, make sure to orient it so that the white mark is facing towards the bronze surface of the Cylinder Barrel. If using a new Snap Ring without a white mark, apply a white mark with paint on the snap ring and make sure to orient the Snap Ring as just described. 21. Follow all steps outlined in Appendix “A” (located at the end of this repair manual) to measure the Cylinder Barrel lift-off and for proper shim selection. 22. Assemble the Cylinder Barrel as illustrated below. Make sure that the tapered edge of the Bottom Washer is facing away from the Cylinder Barrel Spring. Addtionally, make sure the the Snap Ring is positioned with the white mark as illustrated.

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23. (This step is ONLY valid for HPR105-02 and HPR135-02 pumps) Assemble the Cylinder Barrel as illustrated below. Make sure that the tapered edge of the Bottom Washer is facing away from the Cylinder Barrel Spring (Note: There is no shimming required for this Cylinder Barrel).

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24. Follow all steps outlined in Appendix “B” (located at the end of this repair manual) to measure the Piston Slipper Lift-Off and for proper shim selection.

25. Install the proper shim combination onto the appropriate side of the Swash Plate.

26. Install the proper Hold-Down Clamp onto the Swash Plate. Apply Green Loctite No. 648 to the threads of the two new mounting bolts. Torque each mounting bolt to: [HPR55/75] [HPR105/135]

32 N-m (24 ft-lb) 64 N-m (47 ft-lb)

27. Install the nine Pistons into the Hold-Down Plate. As illustrated below, make sure that the taper on the Hold-Down Plate is positioned correctly. Then set the entire assembly onto the Swash Plate.

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28. Install the proper shim combination onto the other side of the Swash Plate.

29. Position the two Actuator Pistons into the Swash Plate. Note that one piston is larger than the other. Position the Actuator Pistons such that when installed into the Rear Head, they fit into the appropriate cavity. 30. Install the proper Hold-Down Clamp onto the Swash Plate. Apply Green Loctite No. 648 to the threads of the two new mounting bolts. Torque each mounting bolt to: [HPR55/75] [HPR105/135]

32 N-m (24 ft-lb) 64 N-m (47 ft-lb)

31. Place the Cylinder Barrel on a non-abrasive surface as illustrated. Then insert the nine Pistons and the Swash Plate assembly into the Cylinder Barrel.

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32. Remove the Drive Shaft from the pump housing, then insert it into the Cylinder Barrel as illustrated.

33. Position the Drive Shaft onto a firm surface as illustrated. Place the Bearing Support Ring onto the Drive Shaft making sure to orient it correctly.

34. If using an oven, warm it to 350°F (If using a hot plate, adjust it to 350°F). Heat the Rear Bearing to 350°F. Install the Rear Bearing onto the drive shaft. Allow the Rear Bearing to cool for a moment. Then use the “steel sleeve” and “impact block” tools to drive the Rear Bearing completely onto the Drive Shaft.

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35. Insert the rotating group from Step #33 into the pump housing. Follow all steps outlined in Appendix “E” (located at the end of this repair manual) to measure for and select the proper Lube Tube Shims. It is absolutely critical that this measurement be done correctly. After the measurements have been done and the proper shims are selected, make sure that the Lube Tubes and Shims are properly labeled as to ensure that they are installed into the proper cavity in the Rear Head.

36. Insert the two Lube Tube and Shims into the Rear Head. Make sure that they are inserted into the correct cavities in the Rear Head. When inserting the Lube Tube Shims, make sure that the tapered edge faces away from the Lube Tube as illustrated below.

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37. Install the Port Plate onto the Rear Head making sure to orient it with the dampening slots facing away from the Rear Head. Additionally, the Port Plate must be positioned properly. The suction side of the Port Plate (the side with the long slot) must be oriented towards the suction port in the Rear Head. 38. Pre-lubricate the running surface of the Port Plate with some mineral based oil or lubricant.

39. Place the rotating group on the Rear Head as illustrated. Make sure that the two Lube Tubes are securely positioned in the Hold-Down Clamps. 40. With a brush, apply Locquic Primer “T” to the sealing area of the Rear Head.

41. Place the Drive Shaft Assembly Sleeve tool onto the splines of the drive shaft, then apply a layer of petroleum jelly on the tool.

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44. Carefully position the pump as illustrated to the left. Then turn in each Mounting Bolt with a hand tool until snug. 45. Torque each mounting bolt as follows: • • •

HPR55/75 (M8 bolt) 32 N-m (24 ft-lb) (M12 bolt) 110 N-m (81 ft-lb) HPR105 (M12 bolt) 110 N-m (81 ft-lb) HPR135 (M14 bolt) 180 N-m (133 ft-lb)

46. Install a new PTO O-Ring into the PTO cavity of the Rear Head. Use some petroleum jelly to help hold the o-ring in position.

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47. Install the PTO Cover onto the Rear Head. Torque each hex head bolt to 80 N-m (59 ft-lb).

48. Install the pump control onto the Rear Head making sure to replace all of the control o-rings with new o-rings. Torque each mounting bolt to 23 N-m (17 ft-lb).

49. Make sure to install plugs in all open ports and cover the two pump workports.

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Clean This Surface

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50. Use cleaning solvent and a lintfree rag to thoroughly clean the surface indicated in the sketch. The old Shaft Seal had Loctite on its outside diametric surface and remnants of the Loctite may still be on the indicated surface of the housing.

Assembly Sleeve 51. Place the Assembly Sleeve Tool over the drive shaft as illustrated. Apply petroleum jelly to the outside surface of the Assembly Sleeve Tool.

Shaft Seal

Green Loctite No. 270 On This Surface

Petroleum Jelly On This Surface

52. As illustrated, apply petroleum jelly to the inside diametric surface of the new Shaft Seal. Then apply Green Loctite No. 270 to the outside diametric surface of the Shaft Seal, and spread it to a uniform thickness with your finger.

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53. Lightly press the Shaft Seal onto the Assembly Sleeve Tool as illustrated.

54. Using the proper shaft seal driver tool, drive the Shaft Seal into the motor housing.

Snap Ring 55. Reinstall the Snap Ring making sure that it is fully engaged into the snap ring groove.

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Appendix “A”: Procedure to Shim the Cylinder Barrel

Appendix “A” Rev. 0 Page 1 of 3

Note: Refer to the Linde Spare Parts Catalog for the shim part numbers available for the pump size you are working on IMPORTANT: This Conversion Bulletin is ONLY valid for HPR55-02 and HPR75-02 pumps. HPR10502, HPR135-02, and HPR105D-02 pumps have cylinder barrels that DO NOT need to be shimmed. The parts and dimension shown in the following illustration will be used for this procedure:

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Appendix “A”: Procedure to Shim the Cylinder Barrel

Appendix “A” Rev. 0 Page 2 of 3

4. As demonstrated during the training, remove the spring and spring support ring from the cylinder barrel. Then reinstall the Washer and Snap Ring back into the cylinder barrel. Do NOT reinstall the cylinder barrel shims.

7. As illustrated below, measure and record dimension “Y” to the nearest 0.01mm. Dimension “Y” =

8. Calculate Dimension “Z” and record the value below to the nearest 0.01mm: Dimension “Z” = (Dimension “X”) – (Dimension “Y”) Dimension “Z” =

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Appendix “A”: Procedure to Shim the Cylinder Barrel

Appendix “A” Rev. 0 Page 3 of 3

9. Based on the value for Dimension “Z”, select the quantity of cylinder barrel shims to acquire a clearance of 0.05mm to 0.12mm. Refer to the example below. Example: HPR75-02 Pump Dimension “X” = 4.80mm Dimension “Y” = 3.00mm Dimension “Z” = (4.80mm) – (3.00mm) = 1.80mm You must calculate a range for the cylinder barrel shims: (maximum clearance) = (1.80mm) – (0.12mm) = 1.68mm (minimum clearance) = (1.80mm) – (0.05mm) = 1.75mm You must select a shim (or combination of shims) that is between 1.68mm and 1.75mm

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Appendix “B”: Procedure to Shim For Piston Slipper Lift-Off

Appendix “B” Rev. 1, 8-13-02 Page 1 of 3

• • •

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Hold-Down Clamp Hold-Down Plate Piston Slipper [select any piston]

(Dimension “Q”) (Dimension “R”) (Dimension “S”)

Dimension “Q” =

Dimension “R” =

Dimension “S” =

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Appendix “B”: Procedure to Shim For Piston Slipper Lift-Off

Appendix “B” Rev. 1, 8-13-02 Page 2 of 3

2. Do the following calculation and record the value below to the nearest 0.01mm: Dimension “Y” = (Dimension “R”) + (Dimension “S”) Dimension “Y” =

3. Do the following calculation and record the value below to the nearest 0.01mm: Dimension “Z” = (Dimension “Y”) – (Dimension “Q”) Dimension “Z” =

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Appendix “B”: Procedure to Shim For Piston Slipper Lift-Off

Appendix “B” Rev. 1, 8-13-02 Page 3 of 3

Example: HPR75-02 Part #1: (For the first Hold-Down Clamp) Dimension “Q” = 10.39mm Dimension “R” = 5.50mm Dimension “S” = 5.99mm Dimension “Y” = (5.50mm) + (5.99mm) = 11.49mm Dimension “Z” = (11.49mm) – (10.39mm) = 1.10mm You must calculate a range for the Shims: (maximum clearance) = (1.10mm) + (0.03mm) = 1.13mm (minimum clearance) = (1.10mm) + (0.01mm) = 1.11mm Select a Shim (or combination of Shims) that is between 1.11mm and 1.13mm for the first Hold-Down Clamp. To compensate for measuring errors, it is recommended that you select a shim between the two extreme values – 1.12mm. Part #2: (For the second Hold-Down Clamp) Dimension “Q” = 10.42mm Dimension “R” = 5.50mm (same value as in Part #1) Dimension “S” = 5.99mm (same value as in Part #1) Dimension “Y” = (5.50mm) + (5.99mm) = 11.49mm Dimension “Z” = (11.49mm) – (10.42mm) = 1.07mm You must calculate a range for the Shims: (maximum clearance) = (1.07mm) + (0.03mm) = 1.10mm (minimum clearance) = (1.07mm) + (0.01mm) = 1.08mm Select a Shim (or combination of Shims) that is between 1.08mm and 1.10mm for the second Hold-Down Clamp. To compensate for measuring errors, it is recommended that you select a shim between the two extreme values – 1.09mm.

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Appendix “C”: Procedure to Shim for Bearing End-Play

Appendix “C” Rev. 0 Page 1 of 3

IMPORTANT: Appendix “C” is ONLY valid for HPR55-02 and HPR75-02 pumps. For HPR105-02, HPR135-02 and HPR105D-02 pumps, refer to Appendix “D” for instructions to shim for bearing end-play. Refer to the Linde Spare Parts Catalog for the shim part numbers available for the pump size you are working on The parts and dimension shown in the following illustration will be used in this procedure:

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Appendix “C”: Procedure to Shim for Bearing End-Play

Appendix “C” Rev. 0 Page 2 of 3

5. As illustrated below, measure and record Dimension “B” and Dimension “C” to the nearest 0.01mm. Measure each component individually.

Dimension “B” =

Dimension “C” =

6. As illustrated below, measure and record Dimension “D” to the nearest 0.01mm. Make sure to remove ALL existing shims before taking the measurement for Dimension “D”. Dimension “D” =

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Appendix “C”: Procedure to Shim for Bearing End-Play

Appendix “C” Rev. 0 Page 3 of 3

7. Calculate and record Dimension “X” to the nearest 0.01mm: Dimension “X” = (Dimension “A”) + (Dimension “D”) Dimension “X” =

8. Calculate and record Dimension “Y” to the nearest 0.01mm: Dimension “Y” = (Dimension “B”) + (Dimension “C”) Dimension “Y” =

9. Calculate and record Dimension “Z” to the nearest 0.01mm: Dimension “Z” = (Dimension “X”) – (Dimension “Y”) Dimension “Z” =

10. Based on the value for Dimension “Z”, select the quantity of shims to get between an interference of 0.02mm and a clearance of 0.07mm. Refer to the example below.

Example: HPR75-02 Pump Dimension “A” = 7.95mm Dimension “B” = 3.50mm Dimension “C” = 17.03mm Dimension “D” = 15.19mm Dimension “X” = (7.95mm ) + (15.19mm) = 23.14mm Dimension “Y” = (3.50mm) + (17.03mm) = 20.53mm Dimension “Z” = (23.14mm) – (20.53mm) = 2.61mm You must calculate a range for the shims: (maximum clearance) = (2.61mm) – (0.07mm) = 2.54mm (minimum clearance) = (2.61mm) + (0.02mm) = 2.63mm You must select a shim (or combination of shims) that is between 2.54mm and 2.63mm.

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Appendix “D”: Procedure to Shim for Bearing End-Play

Appendix “D” Rev. 0 Page 1 of 4

IMPORTANT: Appendix “D” is ONLY valid for HPR105-02, HPR135-02, and HPR105D-02 pumps. For HPR55-02 and HPR75-02 pumps, refer to Appendix “C” for instructions to shim for bearing end-play. Refer to the Linde Spare Parts Catalog for the shim part numbers available for the pump size you are working on The parts and dimension shown in the following illustration will be used in this procedure:

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Appendix “D”: Procedure to Shim for Bearing End-Play

Appendix “D” Rev. 0 Page 2 of 4

5. The following sketch illustrates some key items which will be measured in the following steps:

6. As illustrated on the following page, measure and record Dimension “B”, Dimension “C”, and Dimension “D” to the nearest 0.01mm. Measure each component individually. Dimension “B” =

Dimension “C” =

Dimension “D” =

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Appendix “D”: Procedure to Shim for Bearing End-Play

Appendix “D” Rev. 0 Page 3 of 4

7. As illustrated below, measure and record Dimension “E” to the nearest 0.01mm. Make sure to remove ALL existing shims before taking the measurement for Dimension “E”. Dimension “E” =

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Appendix “D”: Procedure to Shim for Bearing End-Play

Appendix “D” Rev. 0 Page 4 of 4

8. Calculate and record Dimension “X” to the nearest 0.01mm: Dimension “X” = (Dimension “A”) + (Dimension “E”) Dimension “X” =

9. Calculate and record Dimension “Y” to the nearest 0.01mm: Dimension “Y” = (Dimension “B”) + (Dimension “C”) + (Dimension “D”) Dimension “Y” =

10. Calculate and record Dimension “Z” to the nearest 0.01mm: Dimension “Z” = (Dimension “X”) – (Dimension “Y”) Dimension “Z” =

11. Based on the value for Dimension “Z”, select the quantity of shims to get between an interference of 0.02mm and a clearance of 0.07mm. Refer to the example below. Example: HPR105-02 Pump Dimension “A” = 23.93mm Dimension “B” = 19.20mm Dimension “C” = 5.03mm Dimension “D” = 17.01mm Dimension “E” = 19.50mm Dimension “X” = (23.93mm ) + (19.50mm) = 43.43mm Dimension “Y” = (19.20mm) + (5.03mm) + (17.01mm) = 41.24mm Dimension “Z” = (43.43mm) – (41.24mm) = 2.19mm You must calculate a range for the shims: (maximum clearance) = (2.19mm) – (0.07mm) = 2.12mm (minimum clearance) = (2.19mm) + (0.02mm) = 2.21mm You must select a shim (or combination of shims) that is between 2.12mm and 2.21mm.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 1 of 5

Note: This procedure can be performed with or without the Rear Bearing on the drive shaft. The following illustrates how to measure the Lube Tube shimming without the Rear Bearing on the drive shaft. 1. As illustrated below, install the two Lube Tubes into the unit. Make sure that the two Lube Tubes are properly positioned into the Hold Down Clamp Cavity as shown.

2. Thoroughly clean all surfaces of the Cylinder Barrel Compression Plate. Then use a sanding stone and solvent to thoroughly clean the top mounting surface of the unit housing to ensure all sealant material is removed.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 2 of 5

3. Orient the Cylinder Barrel Compression Plate with the male pilot facing away from the cylinder barrel. Set the Cylinder Barrel Compression Plate on top of the unit housing. Match up the threaded holes in the unit housing with the four S.H.C.S. on the plate for alignment purposes.

IMPORTANT: Make sure to use the four Washers with the S.H.C.S. to avoid bottoming the S.H.C.S. in the threaded holes in the unit housing. 4. Fasten the Cylinder Barrel Compression Plate to the unit housing by tightening the four S.H.C.S. with a hand tool. 5. Center the swash plate (to the position of zero displacement) by moving the two actuator pistons. For best results, the swash plate should be at its zero displacement position. As illustrated below, use depth micrometers to measure dimensions "A" and "B". Measure dimensions "A" and "B" to the nearest 0.01mm and record the values below: Dimension "A" =

Dimension "B" =

Please note that there are two Lube Tubes designated Lube Tube "A" and Lube Tube "B". Make sure to keep each Lube Tube properly labeled to avoid mixing them up. Also make sure that dimension "A" corresponds with Lube Tube "A" (and the same for dimension "B" and Lube Tube "B")

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 3 of 5

6. As illustrated above, measure dimension "C" to the nearest 0.01mm and record the value below: Dimension "C" =

7. Do the following calculation and record the value to the nearest 0.01mm: Dimension "D" = (Dimension "C") - (Dimension "A") =

Dimension "E" = (Dimension "C") - (Dimension "B") =

8. Use a sanding stone and solvent to thoroughly clean the mounting surface of the Rear Head to ensure all sealant material is removed. 9. As illustrated below, use depth micrometers to measure dimensions "F" and "G". Measure dimensions "F" and "G" to the nearest 0.01mm and record the values below: Dimension "F" =

Dimension "G" =

Please note that there are two Lube Tube Cavities designated Cavity for Lube Tube "A" and Cavity for Lube Tube "B". These two cavities must correspond to the two Lube Tubes from step #5. Also make sure that dimension "F" corresponds with Lube Tube "A" (and the same for dimension "G" and Lube Tube "B")

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 4 of 5

10. Do the following calculations and record the value to the nearest 0.01mm: Dimension "H" = (Dimension "F") - (Dimension "D") = Dimension "I" = (Dimension "G") - (Dimension "E") =

mm mm

11. Refer to the illustration below for the following explanation: Dimension "H" is the clearance between the end of Lube Tube "A" and the Cavity for Lube Tube "A" in the Rear Head. This clearance must be filled with a Lube Tube Shim and/or Washer. The thickness of the Lube Tube Shim must be selected such that a clearance of 0.01mm to 0.15mm remains once the Washer and Lube Tube Shim is installed. Refer to the example. Dimension "I" is the clearance between the end of Lube Tube "B" and the Cavity for Lube Tube "B" in the Rear Head. This clearance must be filled with a Lube Tube Shim and/or Washer. The thickness of the Lube Tube Shim must be selected such that a clearance of 0.01mm to 0.15mm remains once the Washer and Lube Tube Shim is installed. Refer to the example. Use the Linde Spare Parts Catalog to select the correct Lube Tube Shims

IMPORTANT: When installing the Lube Tube Shim, be sure to orient it with the Tapered Edge facing towards the bottom of the cavity or downward as illustrated above.

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Appendix “E”: Procedure to Shim Lube Tubes

Appendix “E” Rev. 0 Page 5 of 5

Example: HPR105-02 Dimension “A” = 8.15mm Dimension “B” = 8.10mm Dimension “C” = 18.03mm Dimension “D” = (18.03mm) – (8.15mm) = 9.88mm Dimension “E” = (18.03mm) – (8.10mm) = 9.93mm Dimension “F” = 11.51mm Dimension “G” = 11.53mm Dimension “H” = (11.51mm) – (9.88mm) = 1.63mm Dimension “I” = (11.53mm) – (9.93mm) = 1.60mm You must calculate a shim range for each Lube Tube individually: Lube Tube “A”: (maximum clearance) = (1.63mm) – (0.15mm) = 1.48mm (minimum clearance) = (1.63mm) – (0.01mm) = 1.62mm You must select a shim between 1.48mm and 1.62mm thick for Lube Tube “A”. Lube Tube “B”: (maximum clearance) = (1.60mm) – (0.15mm) = 1.45mm (minimum clearance) = (1.60mm) – (0.01mm) = 1.59mm You must select a shim between 1.45mm and 1.59mm thick for Lube Tube “B”.

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Section 8

Fig. 8-0 Electronic Control Module - Cummins QST30 Electronic Engine - Left Side 1. Electronic Control Module (ECM) 2. Plug-Ins (shown disconnected) Disconnect from ECM BEFORE welding.

Fig. 8-0a Electronic Control Module - Cummins QST30 Electronic Engine - Right Side 1. Electronic Control Module (ECM) 2. Plug-Ins (shown disconnected) Disconnect from ECM BEFORE welding.

Electrical Components CAUTION:

Fig. 8-0b Cat C27 ECM

Electrical Components

8-1

Jump Starting

Fig. 8-1 Connection of Battery Cables

Jump Starting

8-2

DO NOT smoke or use open flame near batteries.

DO NOT jump start if the battery fluid is frozen or slushy as the battery may explode. The battery should be warmed to at least 40oF (4.4oC) before attempting a jump start.

Jump start only with an external power source, having an electrical system of the same voltage, ground polarity and equipped with battery or batteries of comparable size or larger.

DO NOT jump start using motor generator sets, welders or other sources of DC power.

DO NOT jump start 24V electrical systems with two 12V batteries connected in series. The current drain will be too high on the 12V batteries possibly causing an explosion.

DO NOT permit metal-to-metal contact between the machine and starting vehicle and do not allow jumper cable terminal clips to contact either vehicle as arcing may result in fire or explosion.

Use only jumper cables that are clean, in good condition, and are heavy enough to handle the starting current.

DO NOT use battery terminal for jump starting. Arcing at battery could result in explosion. Connect jumper cables as shown in Figure 8-1.

Stand as far away as possible from batteries before actual starting.

Electrical Components

Batteries and Circuit Breakers Batteries 1.

Acid burn, fire and explosion hazards exist when working around drill and vehicle batteries. Sulfuric acid in batteries will cause severe burns. Batteries emit hydrogen gas, which will burn or explode if sparks or flame are present.

Always add battery water before starting up, not after shutting down. Keep batteries filled and charged. A discharged battery will freeze at much higher temperatures than a fully charged battery.

Wear protective clothing, gloves, an acid-resistant apron and a face shield when servicing batteries.

Always loosen vent caps from the weak batteries and cover with a cloth before charging.

DO NOT short across battery terminals. The spark can ignite gases.

Be sure battery fluid is at the proper level.

When charging batteries, always disconnect battery charger from its power source or turn it off before connecting or disconnecting charger leads to battery terminals.

When removing a battery, disconnect ground (-) terminal FIRST.

When installing a battery, connect ground (-) terminal LAST.

Circuit Breakers Circuit breakers are located in the operator's cab on the side of the control console (fig. 8-2). They are disabled by pulling out on the knob and reset by pushing in on the knob. Before working on an electrical system, disable it at the circuit breaker or remove the positive battery terminal connector. Always place an "Out of Service" tag on the ignition switch to alert someone that the machine is being worked on.

Fig. 8-2 Cab Instrument Panel 62. 15 AMP–Cab Lights 63. 15 AMP–Ignition 24V 64. 10 AMP–Wipers 65. 50 AMP–Main Power 66. 15 AMP–Control Panel 67. 5 AMP–Heater & Drill Lights 68. 15 AMP–Starter 69. 5 AMP–12 Volt Circuit 70. 50 AMP–Drill Lights 71. 15 AMP–Additional Lights 72. 15 AMP–ECM 73. 10 AMP–Front Lights

Electrical Components

8-3

Welding Precautions

Fig. 8-3 Electronic Control Module - Cummins QST30 Electronic Engine - Left Side 1. Electronic Control Module (ECM) 2. Plug-Ins (shown disconnected) Disconnect from ECM BEFORE welding.

Fig. 8-4 Electronic Control Module - Cummins QST30 Electronic Engine - Right Side 1. Electronic Control Module (ECM) 2. Plug-Ins (shown disconnected) Disconnect from ECM BEFORE welding.

Fig. 8-5 Cat C27 ECM

8-4

Electrical Components

Welding Precautions CAUTION:

DO NOT weld on any part of the machine without first disconnecting the negative battery cable or place the battery disconnect switch in the open position. On machines equipped with electronic engine, disconnect the connections to the Electronic Control Module (ECM) on the engine before welding. Whenever possible, remove component to be welded from machine. If this is not possible or practical, then follow the steps below to provide minimum risk of damage to electrical components. 1.

Stop engine. Turn the switched power to the OFF position.

Disconnect negative battery cable from battery, or if equipped with a battery disconnect switch, place switch in OPEN position.

Disconnect the connectors from the ECM. Move the plug-ins so they can not accidently make contact with any of the ECM pins again.

Connect welder ground clamp directly to part being welded. If this is not done, any electronic components or bearings between the ground and the weld could be severely damaged by the current flow from the welder.

Protect wiring harness and wire rope from weld spatter.

Use standard welding practices to weld materials. All work is to be done by a certified welder.

Electrical Components

8-5

Heater & A/C Unit

BLU 14

RED 14 192

M 197

PRESSURIZER FAN MOTOR

194

159

RED 12

REF OPTIONS RELAY

RED 14 15

193

MED (RED)

HIGH (ORANGE)

RED 14

REF CAB JUNCTION BOX TERMINALS

OFF

LOW (YELLOW)

RESISTOR

RED 14 195

ROTARY SWITCH

A/C TOGGLE SHITCH

YLW 14

PWR TO AC CONDENSOR 192

YLW 14 GRN 14

PWR TO BINARY SW.

195

PWR TO AC CLUTCH 196

RED 14 YLW 14 GRN 14

196

THERMOSTAT

REF ENGINE JUNCTION BOX TERMINAL GRN 14 AC CLUTCH 196

A/C HEATER UNIT

196

A/C COMPRESSOR CLUTCH

GRN 14 196

RED 14 192 85 87

87a

85 87

87a

M 86

RELAY

YEL 14 195

LOW PRESS

HIGH PRESS

BINARY SWITCH

A/C CONDENSER LOW PRESSURE PROTECTION HIGH PRESSURE PROTECTION

OPENS 30-15 PSIG (FALLING PRESSURE) 270-330 PSIG (RISING PRESSURE)

CLOSES 40 PSIG MAXIMUM (RISING PRESSURE) 70-90 PSIG BELOW (OPENING PRESSURE)

Fig. 8-6 Heater & A/C/Unit (ref. 425136 rev. F)

8-6

Electrical Components

CONDENSER #942078 W/ #416970 SHOCK MOUNT KIT

CONDENSATE DRAIN HOSE

HEATER-A/C UNIT

A IR O W

Electrical Components

#8 90° OR STRAIGHT FEMALE FITTING #405852 90° #405859 STRAIGHT

#6 90° OR STRAIGHT FEMALE FITTING #405851 90° #405858 STRAIGHT

5/8" HEATER OUTLET

LOW PRESSURE SWITCH #404279 ATTACH TO FITTING #405924

13/32" I.D. DISCHARGE LINE

RECEIVER DRIER #402720 USE W/ MOUNTING BRACKET #510563

NOTE: DRYER FOUND INSIDE CONDENSER BOX.

BACK VIEW

1/2" I.D. SUCTION LINE

CAB WALL

5/8" HEATER INLET

SIDE VIEW

Fig. 8-6a Heater & A/C Unit (ref. 425136 rev. F)

FLOW

5/16" I.D. LIQUID LINE

#6 90° FEMALE FITTING #405851

5/16" I.D. LIQUID LINE

FRONT VIEW

A/C COMPRESSOR 402828

#10 90° FITTING WITH 134a ACCESS PORT #405900

#8 90° FITTING WITH 134a ACCESS PORT & SWITCH PORT #405903

HIGH PRESSURE SWITCH #404274 ATTACH TO FITTING #405903

3" FLEX HOSE FROM PRESSURIZER

Heater & A/C Unit

8-7

Filter Indicator Lights Wiring LOOP FILTER #1

LOOP FILTER #2

LOOP FILTER #3

LOOP FILTER #4

LOOP FILTER #5

CHARGE FILTER #1

CHARGE FILTER #2

MAIN FILTER #1

MAIN FILTER #2

CASE FILTER

2 3 4 5 6 7 8 9 10 11

LOOP #1 LOOP#2

LOOP#3

LOOP#4

LOOP#5

CASE

COMP

WHITE

BLACK

RED

WHITE-16 GA

GREEN-16 GA

RED GREEN-16 GA

BLACK-16 GA

WHITE

BLACK

GREEN-16 GA

WHITE-16 GA

RED

WHITE-16 GA

BLACK-16 GA

WHITE

BLACK

BLACK-16 GA

RED GREEN-16 GA

LOOP#1 LOOP#2 LOOP#3 LOOP#4 LOOP#5 CHARGE#1 CHARGE#2 MAIN #1 MAIN #2 CASE COMP

MAIN #2

NO C

CASE COMP

MAIN #1

LOOP#1

CHARGE#2

NO C

LOOP#2 LOOP#3 LOOP#4 LOOP#5 CHARGE#1 CHARGE#2 MAIN #1 MAIN #2

CHARGE#1

BLACK

WHITE 2

NO C

WHITE-16 GA

RED GREEN-16 GA

BLACK-16 GA

WHITE

BLACK WHITE-16 GA

RED GREEN-16 GA

1 1

NO C

BLACK-16 GA

WHITE

BLACK WHITE-16 GA

RED GREEN-16 GA

NO C

BLACK-16 GA

WHITE

WHITE-16 GA

BLACK

WHITE

BLACK

BLACK-16 GA

NO C

WHITE-16 GA

RED GREEN-16 GA

NO C

BLACK-16 GA

WHITE

BLACK WHITE-16 GA

RED GREEN-16 GA

NO C

BLACK-16 GA

WHITE

BLACK

GREEN-16 GA

WHITE-16 GA

RED

WHITE-16 GA

BLACK-16 GA

WHITE

BLACK

BLACK-16 GA

NO C

RED

NO C

GREEN-16 GA

NO C

COMPRESSOR FILTER

GRY/BLK-16 GA

GRY/GR-16 GA

WHITE-16 GA

TERMINAL BOX

KEY LOOP FILTER #1

LOOP FILTER #2

LOOP FILTER #3

LOOP FILTER #4

LOOP FILTER #5

CHARGE FILTER #1

CHARGE FILTER #2

MAIN FILTER #1

MAIN FILTER #2

CASE FILTER

COMPRESSOR FILTER

CAB CONSOLE

Fig. 8-7 Filter Indicator Lights Wiring (ref. 400346 rev. G) 8-8

Electrical Components

Engine Stop Wiring (optional)

Fig. 8-8 Emergency Kill Switch Wiring - Ground Level (ref. 409395)

Electrical Components

8-9

Jack Interlock Option

Fig. 8-9 Jack Interlock Option (ref. 426662)

8-10

Electrical Components

Drill Pipe in Hole Interlock Option

Fig. 8-10 Drill Pipe in Hole Interlock Option (ref. 426662)

Electrical Components

8-11

Tram Interlock Option

Fig. 8-11 Pipe in Hole & Jack Interlock Combination (ref. 426662)

8-12

Electrical Components

Joystick Adjustments (electric)

Fig. 8-12 Electric Joysticks 1. Hoist/Pulldown Control (426108) 2. Rotation Control (426109)

3. Left Track Control (426108) 4. Right Track Control (426108)

Fig. 8-13 Right Hand Cab Section Cutaway Items located under operator control panel, mounted to left cab wall.

Electrical Components

8-13

Joystick Adjustments (electric) GENERAL DESCRIPTION, ADJUSTMENT PROCEDURES & TROUBLESHOOTING Printed Circuit Board (P.C. Board) Terminal Board Connections (All terminals may not be present on your P.C. Board) (+)

Positive voltage 12VDC or 24VDC depending on the controller ordered.

(-)

Negative side of the supply voltage.

(X)

Auxiliary output: Supply voltage is present whenever the controller is turned on. Output current should not exceed 3 amps.

(A)

Output terminal to proportional coil when the control handle is moved in the "A" direction.

(B)

Output terminal to proportional coil when the controller handle is moved in the "B" direction.

(C)

Common return when high current P.C. Boards are used. The coil's ground or (-) connection must be return to the P.C. Board "C" terminal, not to ground.

(R)

Range terminal: See Dual Range Option.

Most P.C. Boards have LEDs (Light Emitting Diodes) which can be used for troubleshooting, or simply as an indication of output at a specific terminal. LEDs are located near the (A) and (B) terminals. Standard Coil Connections: Dual Coil: Two coils or solenoids, with each coil having at least 2 connections. One is connected to the P.C. Board (A) terminal, the other is connected to the negative (-) side of the supply voltage. The other coil is connected to the (B) terminal and the negative (-) side of the supply voltage. Two or more P.C. Boards can be paralleled to operate the same coil.

Fig. 8-14 Adjustment Detail and Dual Coil Connections

Adjustment Procedures: Adjustments are made by turning a trimpot adjustment screw. It may be necessary to turn the adjustment screw several turns (5 or more) to observe a change in output. Clockwise (CW) adjustment of the trimpot increases the output. Counterclockwise (CCW) adjustment of the trimpot decreases the output. Adjustment affects output current and voltage to the coil. The minimum and maximum output current is preset at the factory. However, for optimum performance, they must be adjusted while the equipment is operating. 8-14

Electrical Components

Joystick Adjustments (electric) Although the following adjustments affect the current/voltage or percentage of duty cycle, the best way to adjust the function is to observe the response or speed of the function. The following adjustments affect function response, or speed. There may be some interaction between adjustments. It may be necessary to repeat the adjustment in order to achieve the desired response. Threshold Adjustment: Adjusts the initial current flow, function response, or speed when the handle is first moved from the off position. Deflect the handle slowly to the position where the controller first turns on. Adjust the threshold trimpot screw for start-up or creep speed. If the speed is too fast, turn the trimpot screw CCW; if the speed is too slow, turn the trimpot screw CW. This adjustment should be done first. Maxout Adjustment: Adjusts the full stroke current, maximum function response, or speed when the handle is deflected to its full travel. Fully deflect the handle, and adjust the maxout trimpot for maximum desired function response or speed. To obtain proportional resolution, it is important that the function starts to slow down as soon as the handle is moved back from the fully deflected position. The ideal adjustment occurs when the function just begins to move when the handle is deflected, and the output increases until it reaches its maximum desired response or speed at the end of handle travel. Integrated Ramp System (IRS): Allows the input signal to come on and go off in a controlled manner. CW rotation of the trimpot increases ramp time and slows the response time. CCW rotation decreases ramp time and increases the response time. To increase ramp time, turn the adjusting screw CW a few turns, then move the controller handle abruptly. Continue to adjust until a smooth response is observed. Most controllers have on/off contacts which remove power from the PC board when the handle is returned to the "off" position. When the handle is abruptly returned to neutral, the output will not ramp down, and the function will stop. Ramp Thru Off: The P.C. board should be adjusted as outlined in the IRS adjustment procedure. If the handle is abruptly returned to neutral (OFF), the output will ramp down to off. Dual Range: When supply voltage is applied to the (R) terminal, the board is in "Hi Range". When voltage is not applied to the (R) terminal, the board is in "Lo Range". Hi Range Adjustment: With supply voltage applied to the (R) terminal, fully deflect the handle. Adjust the "Hi Range" trimpot for desired "Hi Range" response or speed. Refer to "Maxout" adjustment procedures. Whenever the dual range switch or contact is closed, the output should be adjusted for the maximum function response or speed. Lo Range Adjustment: With no voltage on the (R) terminal, fully deflect the handle. Adjust the "Lo Range" trimpot for the desired "Lo Range" response or speed. Again refer to "Maxout" adjustment procedures. Whenever the dual range switch or contact is open, you are in "Lo Range".

Electrical Components

8-15

Joystick Adjustments (electric) When changing from "Hi Range" to "Lo Range", a change in function speed should be observed. Dual Max: Allows for separate "Maxout" adjustments in each direction of the handle movement. "A Maxout" adjusts the maximum output when the handle is moved in the "A" direction, and "B Maxout" adjusts the maximum output in the "B" direction. Refer to Maxout Adjustment for adjustment procedures. Problem: 1.

The function will not operate when the handle is moved, The LEDs do not light. A.

Check that voltage is present at the positive (+) input terminal.

Check that ground is connected to the negative (-) terminal.

If there is an in-line fuse, check to see if it is good.

D. Check the controller on/off switch and the connectors. Voltage should be present at the (X) terminal when the controller is turned on.

Check that valve wiring is not shorted to ground. The LEDs will not light.

Check that valve wiring is not open. The LEDs will light, but the intensity will not vary.

Check trimpot settings. Fully CCW turns output off, CW turns output fully on.

The function jumps or lurches when turned on. A.

The functions reaches maximum speed before the handle is fully deflected. A.

Perform "Threshold" adjustment procedures. Perform "Maxout" adjustment procedures.

The function speed remains constant regardless of the degree of handle deflection. A.

Perform "Maxout" adjustment procedures.

IRS Option: 1.

Function speed reacts too slowly or too quickly in relation to handle deflection. A.

Check "IRS" (Ramp) trimpot adjustment. CW increases ramp time, CCW decreases ramp time.

Dual Range Option: 1.

8-16

Controller will not switch between "HI" and "LO" range. A.

Check to see that source voltage is present at the "R" terminal when in "HI" range, and absent when in "LO" range.

Check trimpot adjustments.

Electrical Components

NOTE: See Parts Manual to establish the correct drawings for your machine.

Ref. 437150 rev. 03 (1 of 6) 8-17

Electrical Schematic

8-18

Electrical Schematic

Electrical Components

Ref. 437150 rev. 03 (2 of 6)

Electrical Components

Ref. 437150 rev. 03 (3 of 6) 8-19

Electrical Schematic

8-20

Electrical Schematic

Electrical Components

Ref. 437150 rev. 03 (4 of 6)

Electrical Components

Ref. 437150 rev. 03 (5 of 6) 8-21

Electrical Schematic

8-22

Electrical Schematic

Electrical Components

Ref. 437150 rev. 03 (6 of 6)

Electrical Components

THREAD LUBE

&4+..

OIL 31945

RED 10

A GREEN/GRAY 16

DUST CURT

GRAY 16

VIOLET 16

DRILL LIGHT

WINCH

AUTO TOOL

CAROUSEL INDEX

DUST/WATER

MAST LOCK

GRAY 16

START

CONTROL PANNEL

BACK-UP 69499 12

DRILL LIGHT MAIN POWER

PIPE POSITIONER

PIPE RACK IN/OUT

12 VOLT

32189 DRILL HOUR

ECM DIAGNOSTIC LAMP

LIGHT 335245 TYP 6 PLACES

GREEN/WHITE 16

ETHER

SIGNAL + -

MAIN AIR

GREEN 10

DRILL HR

GREEN/GRAY 16

TACH 96194

THROTTLE POSITION SENSOR

96192

GREEN/BLACK 16

DOME LIGHT

18 18

88194 24V LIGHT BULB

OIL INJECTION LIGHT

START

RUN

319151

ENGINE HR

96192

OIL INJECT

VOLT

VIOLET 16

ORANGE 16

LIGHT SWITCH

GRAY 16

BLUE 12

KEY

SEE SHT 2

2412'.

SELECTOR SWITCH

TOP LIGHTS

RED 10

SEE SHT 2

IGNITION SOLENOID

FUEL 96193

% SEE DETAIL C -SHT 2 & SEE DETAIL D -SHT 2

LIGHT RELAY 47840

START

PIPE RACK LOCK

HOBO SWING

GRAY 16

GREEN/GRAY 16

HOBO CLAMP

319240 4 PLACES

319 14 33 6 52 45

COMP TEMP WATER TEMP 319146 319147

33 52 45

MAIN POWER

PIPE RACK IN

PIPE RACK OUT

WATER INJ

DUST COLL

MAIN AIR OPEN

MAIN AIR CLOSE

MAST LOCK

MAST UNLOCK

THROTTLE POS

FRONT LIGHTS

STARTER BUTTON

MAIN POWER

DRILL LIGHT POWER

A/C

BACKUP ALARM

ETHER

ENGINE HOUR

DIAGNOSTIC LAMP

RUN KEY

TACH

OIL PRESSURE

FUEL LEVEL

WATER TEMP

COMPRESSOR TEMP

THREAD LUBE

OIL INJECTION LIGHT

PIPE RACK UNLOCK

PIPE RACK LOCK

HOBO SWING IN

HOBO SWING OUT

HOBO CLAMP

HOBO RELEASE

OIL INJECTION

DUST CURTAIN UP

DUST CURTAIN DOWN

WINCH UP

WINCH DOWN

AUTO TOOL OUT

AUTO TOOL IN

PIPE POSITIONER OUT

PIPE POSITIONER IN

CAROUSEL INDEX CCW

CAROUSEL INDEX CW

THREAD LUBE SOLENOID

1410758

TAN 16

PINK/BLUE 16

GRAY/RED 16

BLACK/YELLOW 16

BLACK/WHITE 16

BLUE/WHITE 16

ORANGE/WHITE 16

ORANGE/BLACK 16

WHITE/BROWN 16

WHITE/RED 16

WHITE/YELLOW 16

YELLOW/BLUE 16

YELLOW/GRAY 16

YELLOW/ORANGE 16

YELLOW/GREEN 16

YELLOW/RED 16

YELLOW/BROWN 16

YELLOW/BLACK 16

YELLOW/WHITE 16

BLACK/PINK 16

PINK/BLACK 16

BROWN/WHITE 16

PINK/BROWN 16

BLUE/YELLOW 16

GRAY/BLUE 16

GRAY/WHITE 16

RED/WHITE 16

VIOLET 16

GREEN/GRAY 16

BLUE 12

RED 10

GREEN 10

ORANGE 16

GREEN/RED 16

MAST OPTIONS

GREEN/BROWN 16

WHITE/GREEN 16

GREEN 16

BLUE 16

RED 16

YELLOW 16

BLACK/ORANGE 16

BROWN 16

WHITE 16

GREEN/YELLOW 16

TIMER BOX

ENG BOX

LIGHT

TACH SENDER

BATTERIES

TIMER PUMP

OIL INJECTION

50 53

RED 6

GRAY 16

319153 WATER TEMP

RED 14

32189 ENGINE HOUR

/#56'4 &+5%100'%6 59+6%*

319152 OIL PRESS

FUEL

N.O.

PIPE POSITIONER

PIPE RACK LOCK

HOBO SWING

HOBO CLAMP

DUST CURTAIN

WINCH

AUTO TOOL

ETHER SOLENOID

ALTERNATOR

CAROUSEL INDEX

PIPE RACK

RED 14

&+#)0156+% .#/2 $#6 59+6%*'& 4'/16' 5*76&190 59

ORANGE 16

$#6 7059+6%*'&

RED 14

6*4166.' 215+6+10 5'0514

VIOLET 16

VIOLET/RED 16

STARTER

RED 6

COMP TEMP

319153

REAR

GRAY/YEL 16

P3/J3

CATERPILLAR

J2/P2

FRONT

DUST/ WATER

MAIN AIR

MAST LOCK

GREEN/GRAY 16

BLACK 16

NOTES: SEE CAB & ENGINE SUBASSEMBLIES FOR COMPONMENT PART NUMBERS. SEE 405306 FOR GUAGE PANEL LAYOUT. SEE 405413 FOR SWITCH PANEL LAYOUT.

FRONT LIGHTS

'.'%6410+%5 )4170& 567& %#6 5722.+'& '0)+0' 5'48+%' 611. %1000'%6+10 %#6 5722.+'& 6'4/+0#6+10 4'5+5614

J1/P1

CATERPILLAR 3412E ECM

WIRING HARNESS

+ TIMER D.C. -

Ref. 425138 rev. C (1 of 3)

BLACK 16

WHITE

WITH ENGINE HOURMETER

DUST COLLECTOR ENGINE O.P.

8-23

Wiring Diagram–(13, 16 M)

8-24

SEE SHT 3 FOR INTERLOCK OPTIONS INVOLVING THIS RELAY

RELAY #1 N.C.

-2

+10

WHT #7

BLK

R.H. PUMP

BLU #8

WHT #6 1

-2

WHT #6

BRN #8

GRN #8

PROPEL MODE

IGNITION

+10 11

POWER FROM IGNITION RELAY SEE SHT 1

-2

RELAY #2 N.C.

POWER FROM DRILL/PROPEL SW. SEE SHT 1

L.H. TRAM/ROTATE PUMP

+10 11

YEL #3

BRN #4

RELAY #3 N.C.

REF CAB JUNCTION BOX TERMINALS

YEL #9

+ BLK

BLU #4

BLU #8

BLU #4

WHT #7

YEL #3

YEL #9

GRN #4

DRILL MODE

IF PIPE RACK SWING INTERLOCK OPTION NOT USED, CONNECT PWR FROM ROTATE JOYSTICK TO HOIST/PULLDOWN JOYSITCK WITH WIRE #89

POWER FROM DRILL/PROPEL SW. SEE SHT 1

GRN #8

GRY #6

RELAY #4 N.C.

-2

153

+10 11

154

+ BLK

155

PRPL

ORG/GRN #16

OFF

OVERIDE

HOIST/PULLDOWN JOYSTICK

PNK #5

ROTATE JOYSTICK

PNK #2

L.H. JOYSTICK

WHT 16

GRN #4 BLK

YEL #9 WHT 16

GRY #6

PNK #6

R.H. JOYSTICK

BLK

YLW #9

156

Wiring Diagram–(13, 16 M)

GRN/BLK 16

WHT #7 WHT/BRN 16

ORG #5 BLK

ORG #7

BLK WHT/BRN 16

156

AUTO CARD

PNK #0

BLK

NC 2 3 NO

157

D POWER FROM IGNITION RELAY SEE SHT 1

IGNITION

157

Electrical Components

Ref. 425138 rev. C (2 of 3)

OPTIONAL PIPE RACK SWING INTERLOCK

PIPE RACK SWING LIMIT SWITCH N.O.

REF CAB JUNCTION BOX TERMINALS

DN. PULLDOWN CONTROL VALVE

REF CAB JUNCTION BOX TERMINALS

PRPL

PULLDOWN CONTROL VALVE

AUTO

GRN 16

Electrical Components

U BL BRN BL K

136

133

136

135

BRN U BL

BL K

RIGHT REAR JACK

TAN/RED

136

BLK 16

(-) 133

(+) 134

JACK INTERLOCK JACKS UP = GREEN LIGHT

133

PRPL/GRN 16

RIGHT FRONT JACK

K BL BRN BL U

-2

140

139

140

+10 11

137

138

WHT

RED/GRN 16

139

130

WHT 6

POWER FROM RELAY #2, TERMINAL #8 SEE SHT 2

REF R.H. JOYSTICK SHOWN ON SHT 2

130

POWER FROM RELAY #2, TERMINAL #8 SEE SHT 2

REF R.H. JOYSTICK SHOWN ON SHT 2

WHT 6

PROPEL INTERLOCK PIPE PRESENT = RED LIGHT

REF RELAY #1, N.C. SHOWN ON SHT 2

-2

+ 132

REF L.H. JOYSTICK SHOWN ON SHT 2

WHT 4 131

OPTIONAL DRILL STEEL INTERLOCK CIRCUIT WHEN USED INDEPENDANTLY

REF CAB JUNCTION BOX TERMINALS

LOAD

WHT 7

+10 11

132

REF RELAY #1, N.C. SHOWN ON SHT 2

131

WHT 4

OPTIONAL JACK INTERLOCK CIRCUIT WHEN USED INDEPENDANTLY

TAN/RED 16

PIPE PRESENT PROXIMITY SW.

REF CAB JUNCTION BOX TERMINALS

LEFT REAR JACK

133

PRPL/GRN 16

TAN/RED

LEFT FRONT JACK

PRPL/GRN 16

REF L.H. JOYSTICK SHOWN ON SHT 2

WHT 6

BRN K BL

BLK

WHT 4

BL U

WHT 6

WHT 7

PRPL/GRN 16

WHT 7

136

LEFT REAR JACK

140

(-)

139

136

133

TAN/RED 16

(+) 134

BL K

RIGHT REAR JACK

TAN/RED

132

+10 11

WHT 6

138

WHT

130

Ref. 425138 rev. C (3 of 3)

POWER FROM RELAY #2, TERMINAL #8 SEE SHT 2

REF R.H. JOYSTICK SHOWN ON SHT 2

PROPEL INTERLOCK PIPE PRESENT = RED LIGHT

REF RELAY #1, N.C. SHOWN ON SHT 2

-2

133

REF L.H. JOYSTICK SHOWN ON SHT 2

BRN U BL

WHT 4 131

RED/GRN 16

139

PRPL/GRN 16

140

BLK 16

135

JACK INTERLOCK JACKS UP = GREEN LIGHT

133

136

K BL BRN BL U

PRPL/GRN 16

RIGHT FRONT JACK

PRPL/GRN 16

136

OPTIONAL DRILL STEEL & JACK INTERLOCK CIRCUITS WHEN USED SIMILTANEOUSLY

LOAD

3 -

LOAD

1 +

136

U BL BRN BL K

136

REF CAB JUNCTION BOX TERMINALS

136

133

TAN/RED 16

LEFT FRONT JACK

133

PRPL/GRN 16

REF CAB JUNCTION BOX TERMINALS

PIPE PRESENT PROXIMITY SW.

BL U

BRN K BL

TAN/RED

BLK

PRPL/GRN 16

TAN/RED 16

BLK

WHT 6

TAN/RED 16

8-25

Wiring Diagram–(13, 16 M)

BLK

133

BLK

WHT 7

8-26

TOP OF CAB

-----------------------------------------------------------------------------------------------------------------

44089 44093 17816 17821 99329 17820 17819 17814 17817 88009 88010 88011 88012 88013 44090 17823 17824 35399 88015 99313 99353 99351 99333 99341 99362 99348 99330 88016 88017 88018 88019 88020 88021 88022 44092 88023 88024 88025 88026 17824 44090 88015 45259 45252 45257 78138 99320 99321 99331 99327 99328 99352 99339 99361 17818 44091

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

RDI P/N

ITEM 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 10 10 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 10 16 16 ----16 16 16 16 16 16 16 16 16 16

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------

GAUGE

GRAY --------------------GREEN/YELLOW STRIPE -----WHITE -------------------BROWN -------------------BLACK/ORANGE ------------YELLOW ------------------RED ---------------------BLUE --------------------GREEN -------------------WHITE/GREEN ------------GREEN/WHITE ------------GREEN/BROWN ------------GREEN/BLACK ------------GREEN/RED --------------ORANGE ------------------GREEN -------------------RED ---------------------BLUE --------------------GREEN/GRAY -------------RED/WHITE ---------------GRAY/WHITE --------------GRAY/BLUE ---------------BLUE/YELLOW -------------PINK/BROWN --------------BROWN/WHITE -------------PINK/BLACK --------------BLACK/PINK --------------YELLOW/WHITE -----------YELLOW/BLACK -----------YELLOW/BROWN -----------YELLOW/RED -------------YELLOW/GREEN -----------YELLOW/ORANGE ----------YELLOW/GRAY ------------YELLOW/BLUE ------------WHITE/YELLOW -----------WHITE/RED --------------WHITE/BLACK ------------WHITE/BROWN ------------RED ---------------------ORANGE ------------------GREEN/GRAY ------------TERMINAL 3/16 STUD 16/14-TERMINAL 1/4 EYE 12/10 --TERMINAL 3/16 EYE 16/14 -TERMINAL 1/4 STUD 16/14 -ORANGE/BLACK ------------ORANGE/WHITE ------------BLUE/WHITE --------------BLACK/WHITE -------------BLACK/YELLOW ------------GRAY/RED ----------------PINK/BLUE ---------------TAN ---------------------BLACK -------------------VIOLET -------------------

COLOR 47 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 16 14 18 ----39 40 41 42 43 44 45 46 51 99

TERMINAL

POWER-TEMP,FUEL,OIL,VOLT --COMPRESSOR TEMP -----------WATER TEMP ----------------FUEL ----------------------OIL PRESSURE --------------TACH ----------------------TACH ----------------------RUN-KEY -------------------ECM DIAGNOSTIC LAMP -------ENGINE HOUR ---------------DRILL HOUR ----------------ETHER ---------------------KEY DRILL HOUR ------------BACK-UP ALARM POWER -------A/C COMPRESSOR ------------DRILL LIGHT POWER --------MAIN POWER ---------------STARTER BUTTON ------------FRONT LIGHTS --------------MAST UNLOCK ---------------MAST LOCK -----------------MAIN AIR CLOSE -----------MAIN AIR OPEN ------------DUST COLLECTOR ------------WATER INJECTION ----------PIPE RACK OUT -------------PIPE RACK IN --------------PIPE RACK INDEX CW --------PIPE RACK INDEX CCW -------PIPE POSITIONER IN --------PIPE POSITIONER OUT -------AUTO TOOL IN --------------AUTO TOOL OUT -------------WINCH DOWN ----------------WINCH UP -----------------DUST CURTAIN DOWN ---------DUST CURTIAN UP -----------DRILL/PROPELL -------------OIL INJECTION -------------POWER TO AC ---------------AC COMPRESSOR -------------TOP LIGHTS ------------------------------------------------ -------------------------- -------------------------- ---------------------HOBO RELEASE --------------HOBO CLAMP ----------------HOBO SWING OUT ------------HOBO SWING IN -------------PIPE RACK LOCK ------------PIPE RACK UNLOCK ----------OIL INJECTION LIGHT -------THREAD LUBE ---------------GROUND --------------------THROTTLE POSITION SENSOR ---

DESCRIPTION

CAB WIRING QTY EACH

6'-0" -----6'-0" -----12'-0" 6'-0" 36'-0" 6'-0" 12'-0" -----12'-0" -----18'-0" 6'-0" 12'-0" 6'-0" 6'-0" 6'-0" 12'-0" 6'-0" 6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----26'-0" ----------- 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" 6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----6'-0" -----15'-0" -----15'-0" -----15'-0" -----65 EACH-----12 EACH-----110 EACH----3 EACH 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0" ------ 6'-0"

COMP QTY

Cab Wiring Harness–(13, 16 M)

Electrical Components

Ref. 419305

Electrical Components

-------- 12

---- -- ---- ---------------------------- --

37 --------- 344929 -- LOOM CRGTD SPLIT 1/4

12'-0" 2 EACH 2 EACH 1 EACH 12'-0" 2 EACH

--------------- ---------------- ---------------

EACH

24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" -----24'-0" 24'-0" 24'-0" 24'-0" 24'-0" 24'-0" -----24'-0" 24'-0" 24'-0" 24'-0" 8 EACH 26 EACH 22'-0" 2 EACH 12'-0"

-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-------- 12

1 2 3 4 5 6 7 8 9 11 13 -15 16 17 18 14 99 -----------------

QTY

-------- 12

COMPRESSOR TEMP -----------WATER TEMP ----------------FUEL ----------------------OIL PRESSURE --------------TACH ----------------------TACH ----------------------RUN-KEY -------------------DIAGNOSTIC LAMP -----------ENGINE HOUR ---------------ETHER ---------------------BACK-UP ALARM ----------------------------------------LIGHT POWER ---------------KEY POWER -----------------STARTER BUTTON POWER ------LIGHT ---------------------A/C COMPRESSOR ------------THROTTLE POSITION ------------------------------------EXTRA ---------------------EXTRA ---------------------EXTRA ---------------------EXTRA -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

TERMINAL

---- -- ---- ---------------------------- --

-------------------------------------------------------------------------------------------------------

DESCRIPTION

---- -- ---- ---------------------------- --

16 16 16 16 16 16 16 16 16 16 16 -10 10 12 16 16 16 -16 16 16 16 ------------

GAUGE

GREEN/YELLOW STRIPE -----WHITE -------------------BROWN -------------------BLACK/ORANGE-------------YELLOW ------------------RED ---------------------BLUE --------------------GREEN -------------------WHITE/GREEN STRIPE ------GREEN/BROWN STRIPE ------GREEN/RED STRIPE ---------------------------------GREEN -------------------RED ---------------------BLUE --------------------GREEN/GRAY STRIPE -------ORANGE ------------------VIOLET -------------------------------------------VIOLET/YELLOW STRIPE ----VIOLET/GREEN STRIPE -----VIOLET/BLUE STRIPE ------VIOLET/WHITE STRIPE -----TERMINAL-3/16 STUD-10/12 TERMINAL-3/16 STUD-16/14 CONDUIT-1" --------------CONNECTOR-CONDUIT-1" ----GROUND CABLE ------------POSITIVE CABLE ----------BATTERY ENDS-POSITIVE ---EYELETS -----------------TERMINAL STRIP-----------HEATER HOSE -------------BATTERY ENDS-NEGATIVE ----

COLOR

35 --------- 344931 -- LOOM CRGTD SPLIT 1/2 36 --------- 344930 -- LOOM CRGTD SPLIT 3/8

---------------------------------------------------------------------

44093 17816 17821 99329 17820 17819 17814 17817 88009 88011 88013 ----17823 17824 35399 88015 44090 44091 ----88058 88059 88060 88061 45258 45259 57860 57854 96331 96331 96332 17830 76582 30211 96333

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

RDI P/N

ITEM

WIRING-CAB/ENGINE SKID

Ref. 419306 8-27

Cab/Engine Skid Wiring–(13, 16 M)

8-28

RED/WHITE

GREEN/WHITE

A B

GREEN/BLACK

A B

GRAY/WHITE

BLACK/PINK YELLOW/BROWN BLACK/YELLOW YELLOW/ORANGE

YELLOW/WHITE YELLOW/GRAY BLUE/WHITE PINK/BLACK

MAST VALVE

ORANGE/BLACK YELLOW/BLACK YELLOW/RED YELLOW/BLUE

ORANGE/WHITE BLACK/WHITE YELLOW/GREEN GRAY/RED

COLOR 16 16 16 16 16 16 16 16 16 16

-------------------------------

GAUGE

GREEN/WHITE STRIPE ------GREEN/BLACK STRIPE ------RED/WHITE----------------GRAY/WHITE---------------PINK/BLACK---------------BLACK/PINK---------------YELLOW/WHITE ------------YELLOW/BLACK STRIPE -----YELLOW/BROWN STRIPE -----YELLOW/RED STRIPE --------

DESCRIPTION 10 12 19 20 25 26 27 28 29 30

A B

GREEN/BLACK RED/WHITE

MAST HARNESS

GRAY/WHITE

30 BLACK/PINK YELLOW/BROWN BLACK/YELLOW YELLOW/ORANGE

GREEN/WHITE

YELLOW/WHITE YELLOW/GRAY BLUE/WHITE PINK/BLACK

26'-0" 26'-0" 26'-0" 26'-0" 12 EACH 28 EACH 18'-0" 2 EACH 1 EACH 1 EACH 1 EACH 5 EACH 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 2 EACH 2 EACH 2 EACH 20 EACH 2 EACH 20 EACH

26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0"

QTY

-----------------------------------------------------------------------

TERMINAL

DRILL HOUR METER ----------DRILL HOUR METER ----------MAST LOCK -----------------MAST LOCK -----------------PIPE RACK IN/OUT ----------PIPE RACK IN/OUT ----------PIPE RACK CAROUSEL --------PIPE RACK CAROUSEL --------PIPE POSITIONER -----------PIPE POSITIONER ------------

88020 --- YELLOW/GREEN STRIPE ------ 16 ---- AUTO TOOL ------------------ 31 - -------88021 --- YELLOW/ORANGE STRIPE ----- 16 ---- AUTO TOOL------------------- 32 - -------88022 --- YELLOW/GRAY STRIPE ------- 16 ---- BREAKOUT ------------------- 33 - -------44092 --- YELLOW/BLUE STRIPE ------- 16 ---- BREAKOUT ------------------- 34 - -------45265 --- CONNECTOR-FEMALE-16/14 --- -- ---- ---------------------------- -- - -------45259 --- TREMINAL-3/16 STUD-16/14 - -- ---- ---------------------------- -- - -------35659 --- CONDUIT-3/4" ------------- -- ---- ---------------------------- 35 - -------56780 --- CONNECTOR-STR-CONDUIT-3/4" -- ---- ---------------------------- 36 - -------350477--- CONNECTOR-CROUSE HIN ----- -- ---- ---------------------------- -- - -------122227--- UNION-PIPE-3/4" ---------- -- ---- ---------------------------- -- - -------JB7201123-P CLAMP-TUBING-1.25" ---------- -- ---- ---------------------------- --------39999 --- P CLAMP-1.06--------------- -- ---- ---------------------------- -- - -------99320 --- ORANGE/BLACK ------------- 16 ---- HOBO CLAMP------------------ -- - -------99321 --- ORANGE/WHITE-------------- 16 ---- HOBO CLAMP------------------ -- - -------99331 --- BLUE/WHITE --------------- 16 ---- HOBO SWING------------------ -- - -------99327 --- BLACK/WHITE -------------- 16 ---- HOBO SWING------------------ -- - -------99328 --- BLACK/YELLOW-------------- 16 ---- PIPE RACK LOCK-------------- -- - -------99352 --- GRAY/RED------------------ 16 ---- PIPE RACK LOCK-------------- -- - -------95124 --- -------------------------- -- ---- CONNECTOR-8 WAY-MALE-------- -- - -------95126 --- -------------------------- -- ---- CONNECTOR-FEMALE-8 WAY------ -- - -------95129 --- -------------------------- -- ---- CONNECTOR-2 WAY-MALE-------- -- - -------95125 --- -------------------------- -- ---- TERMINAL- MALE-------------- -- - -------95128 --- -------------------------- -- ---- CONNECTOR-2 WAY-FEMALE------ -- - -------95127 --- -------------------------- -- ---- TERMINAL-FEMALE------------- -- - --------

---------------------

88010 88012 99313 99353 99348 99330 88016 88017 88018 88019

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

RDI P/N

ITEM

WIRING-MAST (SEE SCHEMATIC 95934)

Mast Wiring–(13, 16 M)

Electrical Components

Ref. 96330 rev. A

ORANGE/BLACK YELLOW/BLACK YELLOW/RED YELLOW/BLUE

ORANGE/WHITE BLACK/WHITE YELLOW/GREEN GRAY/RED

Electrical Components

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

COLOR

GAUGE

DESCRIPTION

TERMINAL

COMP QTY

44093 --- GREEN/YELLOW ------------ 16 ---- COMPRESSOR TEMP ------------ 1 --------- 18'-0" 17816 --- WHITE -------------------- 16 ---- WATER TEMP ----------------- 2 --------- 18'-0" 17821 --- BROWN -------------------- 16 ---- FUEL ----------------------- 3 --------- 18'-0" 99329 --- BLACK/ORANGE ------------- 16 ---- OIL PRESSURE --------------- 4 --------- 18'-0" 17820 --- YELLOW ------------------- 16 ---- TACH ----------------------- 5 --------- 18'-0" 17819 --- RED ---------------------- 16 ---- TACH ----------------------- 6 --------- 18'-0" 17814 --- BLUE --------------------- 16 ---- RUN-KEY -------------------- 7 --------- 18'-0" 17817 --- GREEN -------------------- 16 ---- ECM DIAGNOSTIC LAMP -------- 8 --------- 18'-0" 88009 --- WHITE/GREEN ------------- 16 ---- ENGINE HOUR ---------------- 9 --------- 18'-0" 88011 --- GREEN/BROWN ------------- 16 ---- ETHER ---------------------- 11 --------- 18'-0" 88013 --- GREEN/RED --------------- 16 ---- BACK-UP ALARM POWER -------- 13 --------- 18'-0" 44090 --- ORANGE ------------------- 16 ---- A/C COMPRESSOR ------------- 14 --------- 18'-0" 17823 --- GREEN -------------------- 10 ---- DRILL LIGHT POWER --------- 15 --------- 2'-0" 17824 --- RED ---------------------- 10 ---- MAIN POWER ---------------- 16 --------- 2'-0" 35399 --- BLUE --------------------- 12 ---- STARTER BUTTON ------------- 17 --------- 12'-0" 88015 --- GREEN/GRAY -------------- 16 ---- FRONT LIGHTS --------------- 18 --------- 26'-0" 44089 --- GRAY --------------------- 16 ---- POWER/ENGINE HOUR --------- 47 --------- 12'-0" 99333 --- BLACK -------------------- 16 ---- GROUND -------------------- 51 --------- 6'-0" 99355 --- GRAY/YELLOW -------------- 16 ---- DUST COLLECTOR ------------- 52 --------- 15'-0" 99380 --- RED ---------------------- 6 ---- STARTER 50 AMP ------------ 53 --------- 12'-0" 44091 --- VIOLET ------------------- 16 ---- THROTTLE POSITION SENSOR --- 99 --------- 18'-0" 88057 --- VIOLET/RED --------------- 16 ---- REMOTE SHUTDOWN ----------- -- --------- 12'-0" 346854--- RED ---------------------- 14 ---- BAT+/ECM P3 --------------- -- --------- 24'-0" 350477--- CONNECTOR, CABLE 1/2" ---- -- ---- ---------------------------- -- --------- 3 EACH 45249 --- TERMINAL 1/2 STUD 10/12 -- -- ---- ---------------------------- -- --------- 2 EACH 45252 --- TERMINAL 1/4 EYE 10/12 --- -- ---- ---------------------------- -- --------- 1 EACH 45253 --- TERMINAL 3/16 EYE 10/12 -- -- ---- ---------------------------- -- --------- 1 EACH 45257 --- TERMINAL 3/16 EYE 16/14 -- -- ---- ---------------------------- -- --------- 10 EACH 45261 --- CONNECTOR BUTT 16/14 ----- -- ---- ---------------------------- -- --------- 5 EACH 45258 --- TERMINAL 3/16 STUD 10/12 - -- ---- ---------------------------- -- --------- 2 EACH 45259 --- TERMINAL 3/16 STUD 16/14 - -- ---- ---------------------------- -- --------- 12 EACH 350398 --- TERMINAL #10 STUD 16/14 -- -- ---- ---------------------------- -- --------- 12 EACH 416809 -- 40 CONNECTOR PLUG ------- -- ---- ---------------------------- -- --------- 1 EACH 416811 -- PIN --------------------- -- ---- ---------------------------- -- --------- 6 EACH 416810 -- SEAL PLUG --------------- -- ---- ---------------------------- -- --------- 34 EACH 416808 -- 3 CONNECTOR RECEPTACLE -- -- ---- ---------------------------- -- --------- 1 EACH 416812 -- CONNECTOR SOCKET -------- -- ---- ---------------------------- -- --------- 3 EACH

RDI P/N

ITEM

WIRING-ENGINE SKID/ENGINE/AIR CONDITIONER

Ref. 419307 8-29

Engine Skid/Engine/AC Wiring–(13, 16 M)

8-30

319240 4 PLACES

GRAY 16

START

THREAD LUBE

PIPE RACK LOCK

HOBO SWING

HOBO CLAMP

DRILL

58496

BRAKE SOLENOID

(GREEN)

ENGINE PROTECTION

(AMBER)

ISC 2 2100

PROPEL

DIANOSTIC

(RED)

ISC 1 1800

SWITCH SHOWN ON SHEET 2

OIL 31945

STOP

ISC ON/OFF

DIANOSTIC ON/OFF

FUEL 96193

JOYSTICK SELECTOR

PRELUBE SOLENOID

319 14 33 6 52 45

COMP TEMP WATER TEMP 319146 319147

33 52 45

DUST CURT

GREEN/GRAY 16

OIL INJECT

VOLT 319151

TOP LIGHTS

47840

GRAY 16

10 AMP

GRAY 16

14 GA

WINCH

PIPE POSITIONER

PIPE RACK IN/OUT

MAIN AIR

MAIN POWER

START

12 VOLT

96192

DRILL HR

GREEN/WHITE 16

GREEN 10

32189

CONTROL PANEL

DRILL HOUR

OIL INJECTION LIGHT

AUTO TOOL

CAROUSEL INDEX

DUST/WATER

MAST LOCK

GREEN/GRAY 16

DRILL LIGHT

GREEN/BLACK 16

GREEN 10

A GREEN/GRAY

RED 10

ORANGE 16

BULB

DOME LIGHT

-'; 59+6%*

RED 10

FOR ENGINE STOP OPTION

CONTINUED ON SHEET 2- DETAIL B

FOR REMOTE TRAM OPTION

CONTINUED ON SHEET 2- DETAIL A

88194 24V LIGHT

LIGHT SWITCH

GREEN/BLACK 16

ALT/TACH

+)0+6+10 51.'01+&

12 GA

LIGHT RELAY

15 AMP

87a NC

87 NO

16 RED 10

MAIN POWER

BACK-UP 69499

96192

ENGINE HR

TAN 16

PINK/BLUE 16

GRAY/RED 16

BLACK/YELLOW 16

BLACK/WHITE 16

BLUE/WHITE 16

ORANGE/WHITE 16

ORANGE/BLACK 16

WHITE/BROWN 16

WHITE/BLACK 16

WHITE/RED 16

WHITE/YELLOW 16

YELLOW/BLUE 16

YELLOW/GRAY 16

YELLOW/ORANGE 16

YELLOW/GREEN 16

YELLOW/RED 16

YELLOW/BROWN 16

YELLOW/BLACK 16

YELLOW/WHITE 16

BLACK/PINK 16

PINK/BLACK 16

BROWN/WHITE 16

PINK/BROWN 16

BLUE/YELLOW 16

GRAY/BLUE 16

GRAY/WHITE 16

RED/WHITE 16

GREEN/GRAY 16

RED 10

GREEN 10

ORANGE 16

GREEN/RED 16

WHITE/GREEN 16

YELLOW 16

BLACK/ORANGE 16

BROWN 16

WHITE 16

GREEN/YELLOW 16

1410758

THREAD LUBE SOLENOID 46

THREAD LUBE

OIL INJECTION LIGHT

PIPE RACK UNLOCK

PIPE RACK LOCK

HOBO SWING IN

HOBO SWING OUT

HOBO CLAMP

HOBO RELEASE

OIL INJECTION

DRILL/PROPEL

DUST CURTAIN UP

DUST CURTAIN DOWN

WINCH UP

WINCH DOWN

AUTO TOOL OUT

AUTO TOOL IN

PIPE POSITIONER OUT

PIPE POSITIONER IN

CAROUSEL INDEX CCW

CAROUSEL INDEX CW

PIPE RACK IN

PIPE RACK OUT

WATER INJ

DUST COLL

MAIN AIR OPEN

MAIN AIR CLOSE

MAST LOCK

MAST UNLOCK

FRONT LIGHTS

MAIN POWER

DRILL LIGHT POWER

A/C

BACKUP ALARM

MICROWAVE OVEN

ENGINE HOUR

TACH

OIL PRESSURE

FUEL LEVEL

WATER TEMP

COMPRESSOR TEMP

LOCATED IN CAB ENCLOSURE

TIMER BOX

TIMER PUMP

A/C CONDENSER

LIGHT

DC\AC INVERTER

OIL INJECTION

135

24 VDC INPUT

THERMOSTAT

HEAT-A/C

24 VDC POWER SOLENOID

RED/BLUE

OPTIONAL GROUND KILL STOP BUTTON 426338

OUTPUT

RED 6

20 AMP

POWER ON DRILL

58496

DRILL/ PROPEL SOLENOID

MICROWAVE OVEN

ORANGE 16

LOCATED ON ENGINE

RED 12

KEY SWITCH

+V BATTERY

-V BATTERY

+V BATTERY

32189 ENGINE HOUR

21 PIN CONNECTOR

WHITE 12

HEATER-A/C UNIT

110 VAC

LOCATED IN ENGINE BOX ENCLOSURE

PIPE RACK LOCK

HOBO SWING

HOBO CLAMP

DUST CURTAIN

WINCH

AUTO TOOL

PIPE POSITIONER

CAROUSEL INDEX

PIPE RACK

BATTERIES

AC CLUTCH

REAR

GREEN/GRAY 16

FRONT

GRAY/YELLOW 16

MASTER DISCONNECT SWITCH

ISC 2 2100

ISC 1 1800

ISC ON/OFF

DIANOSTIC ON/OFF

ENGINE PROTECTION

DIANOSTIC

STOP

31 PIN CONNECTOR LOCATED ON ENGINE

YELLOW 16

BLACK 16

BLACK 4

STARTER

RED 4

N.O.

FRONT LIGHTS

+ TIMER D.C. -

BLACK 16

WHITE/GRN

319152

WATER TEMP

Electrical Components

Ref. 426662 rev. A (1 of 3) Cold Weather w/QST30

OIL PRESS

COMP TEMP

319153

DUST COLLECTOR ENGINE O.P. WITH ENGINE HOURMETER

ALTERNATOR

VIOLET/RED 16

NOTES: SEE CAB & ENGINE SUBASSEMBLIES FOR COMPONMENT PART NUMBERS. SEE 405306 FOR GUAGE PANEL LAYOUT. SEE 405413 FOR SWITCH PANEL LAYOUT.

DUST/ WATER

MAIN AIR

MAST LOCK

GRAY/YEL 16

COMP TEMP

50 PIN RIGHT BANK ECM ENGINE HARNESS CONNECTOR

FUEL

319153

Wiring Diagram–(Wide Deck) (QST30)

YELLOW 16

Electrical Components

PINK #2

BLK

WHT #6

-2

+10

WHT 16

BLU #8

JACK INTERLOCK SEE SHT 3

PINK #6

GRN #4

YEL #3

REF CAB JUNCTION BOX TERMINALS

-2

+10

GRN #8

RELAY #2 N.C.

+10 11

POWER FROM IGNITION RELAY

-2

TRAM INTERLOCK

POWER FROM DRILL/PROPEL SW.

WHT 16

BRN #8

BLK

R.H. PUMP

BRN #4

RELAY #3 N.C.

WHT #6 4

YEL #3

YEL #9

BLK

L.H. TRAM/ROTATE PUMP

BLU #4

RELAY #5 N.C.

WHT #7

YEL #9 WHT 16

BLK

GRN #4

POWER FROM DRILL/PROPEL SW.

GRN #8

GRY #6

HOIST/PULLDOWN JOYSTICK

GRY #6

ROTATE JOYSTICK

PNK #2

R.H. JOYSTICK

GRN/BLK 16

PNK #6

L.H. JOYSTICK

WHT #7 WHT/BRN 16

YLW #9 YEL #9

BLU #8

BLK

BLK WHT/BRN 16

BLK

PRPL

AUTO FEED

AUTO CARD

Ref. 426662 rev. A (2 of 3) Cold Weather w/QST30

PNK #0

PRPL

8-31

Wiring Diagram–(Wide Deck) (QST30)

BLK

8-32

U BL BRN BL K

TAN/RED 16

BRN U BL

BL K

BLK 16

(-)

TAN/RED 16 (+)

JACK INTERLOCK JACKS UP = GREEN LIGHT

RIGHT REAR JACK

TAN/RED

PRPL/GRN 16

+10 11

WHT 6

+ B

RED/GRN 16

WHT

+ B

POWER FROM RELAY #2, TERMINAL #8

WHT 6

REF R.H. JOYSTICK

PROPEL INTERLOCK PIPE PRESENT = RED LIGHT

REF RELAY #1, N.C.

-2

WHT 4

OPTIONAL DRILL STEEL INTERLOCK CIRCUIT WHEN USED INDEPENDANTLY

REF CAB JUNCTION BOX TERMINALS

LOAD

REF L.H. JOYSTICK

+10 11

REF RELAY #1, N.C.

-2

WHT 4

OPTIONAL JACK INTERLOCK CIRCUIT WHEN USED INDEPENDANTLY

PIPE PRESENT PROXIMITY SW.

REF CAB JUNCTION BOX TERMINALS

LEFT REAR JACK

TAN/RED

PRPL/GRN 16

RIGHT FRONT JACK

BLK

LEFT FRONT JACK

RED/BLK 16

BRN K BL

WHT 6

K BL BRN BL U

BLK

WHT 7

BL U

WHT 6

WHT 4

REF R.H. JOYSTICK

LEFT REAR JACK

LOAD

3 -

RED/BLK 16 1 +

TAN/RED 16

LEFT FRONT JACK

TAN/RED 16 TAN/RED 16

(+)

BL K

BRN U BL

+10 11

WHT 6

WHT

POWER FROM RELAY #2, TERMINAL #8

REF R.H. JOYSTICK

PROPEL INTERLOCK PIPE PRESENT = RED LIGHT

REF L.H. JOYSTICK

RIGHT REAR JACK

TAN/RED

REF RELAY #1, N.C.

-2

WHT 4

K BL BRN BL U

PRPL/GRN 16

RIGHT FRONT JACK

PRPL/GRN 16

Electrical Components

Ref. 426662 rev. A (3 of 3) Cold Weather w/QST30

OPTIONAL DRILL STEEL & JACK INTERLOCK CIRCUITS WHEN USED SIMILTANEOUSLY

RED/GRN 16

PRPL/GRN 16

BLK 16

(-)

JACK INTERLOCK JACKS UP = GREEN LIGHT

REF CAB JUNCTION BOX TERMINALS

U BL BRN BL K

PRPL/GRN 16

REF CAB JUNCTION BOX TERMINALS

PIPE PRESENT PROXIMITY SW.

BL U

BRN K BL

TAN/RED

BLK

PRPL/GRN 16

REF L.H. JOYSTICK

WHT 6

PRPL/GRN 16

WHT 7

Wiring Diagram–(Wide Deck) (QST30)

BLK

TAN/RED 16

BLK

WHT 7

Electrical Components

319240 4 PLACES

GRAY 16

START

THREAD LUBE

PIPE RACK LOCK

HOBO SWING

HOBO CLAMP

DRILL

(RED)

58496

BRAKE SOLENOID

(GREEN)

ENGINE PROTECTION

(AMBER)

ISC 2 2100

PROPEL

DIANOSTIC

ISC 1 1800

SWITCH SHOWN ON SHEET 2

OIL 31945

STOP

ISC ON/OFF

DIANOSTIC ON/OFF

FUEL 96193

JOYSTICK SELECTOR

PRELUBE SOLENOID

319 14 33 6 52 45

COMP TEMP WATER TEMP 319146 319147

33 52 45

DUST CURT

GREEN/GRAY 16

OIL INJECT

VOLT 319151

12 GA

TOP LIGHTS

47840

GRAY 16

10 AMP

GRAY 16

14 GA

WINCH

PIPE POSITIONER

PIPE RACK IN/OUT

MAIN AIR

MAIN POWER

START

12 VOLT

96192

DRILL HR

GREEN/WHITE 16

GREEN 10

32189

CONTROL PANEL

DRILL HOUR

OIL INJECTION LIGHT

AUTO TOOL

CAROUSEL INDEX

DUST/WATER

MAST LOCK

GREEN/GRAY 16

DRILL LIGHT

GREEN/BLACK 16

GREEN 10

A GREEN/GRAY

RED 10

ORANGE 16

BULB

DOME LIGHT

-'; 59+6%*

RED 10

FOR ENGINE STOP OPTION

CONTINUED ON SHEET 2- DETAIL B

FOR REMOTE TRAM OPTION

CONTINUED ON SHEET 2- DETAIL A

88194 24V LIGHT

LIGHT SWITCH

GREEN/BLACK 16

ALT/TACH

+)0+6+10 51.'01+&

LIGHT RELAY

15 AMP

87 NO

87a NC

16 RED 10

MAIN POWER

BACK-UP 69499

96192

ENGINE HR

TAN 16

PINK/BLUE 16

GRAY/RED 16

BLACK/YELLOW 16

BLACK/WHITE 16

BLUE/WHITE 16

ORANGE/WHITE 16

ORANGE/BLACK 16

WHITE/BROWN 16

WHITE/BLACK 16

WHITE/RED 16

WHITE/YELLOW 16

YELLOW/BLUE 16

YELLOW/GRAY 16

YELLOW/ORANGE 16

YELLOW/GREEN 16

YELLOW/RED 16

YELLOW/BROWN 16

YELLOW/BLACK 16

YELLOW/WHITE 16

BLACK/PINK 16

PINK/BLACK 16

BROWN/WHITE 16

PINK/BROWN 16

BLUE/YELLOW 16

GRAY/BLUE 16

GRAY/WHITE 16

RED/WHITE 16

GREEN/GRAY 16

RED 10

GREEN 10

ORANGE 16

GREEN/RED 16

WHITE/GREEN 16

YELLOW 16

BLACK/ORANGE 16

BROWN 16

WHITE 16

GREEN/YELLOW 16

1410758

THREAD LUBE SOLENOID 46

THREAD LUBE

OIL INJECTION LIGHT

PIPE RACK UNLOCK

PIPE RACK LOCK

HOBO SWING IN

HOBO SWING OUT

HOBO CLAMP

HOBO RELEASE

OIL INJECTION

DRILL/PROPEL

DUST CURTAIN UP

DUST CURTAIN DOWN

WINCH UP

WINCH DOWN

AUTO TOOL OUT

AUTO TOOL IN

PIPE POSITIONER OUT

PIPE POSITIONER IN

CAROUSEL INDEX CCW

CAROUSEL INDEX CW

PIPE RACK IN

PIPE RACK OUT

WATER INJ

DUST COLL

MAIN AIR OPEN

MAIN AIR CLOSE

MAST LOCK

MAST UNLOCK

FRONT LIGHTS

MAIN POWER

DRILL LIGHT POWER

A/C

BACKUP ALARM

MICROWAVE OVEN

ENGINE HOUR

TACH

OIL PRESSURE

FUEL LEVEL

WATER TEMP

COMPRESSOR TEMP

LOCATED IN CAB ENCLOSURE

TIMER BOX

TIMER PUMP

A/C CONDENSER

LIGHT

DC\AC INVERTER

OIL INJECTION

135

24 VDC INPUT

THERMOSTAT

HEAT-A/C

24 VDC POWER SOLENOID

RED/BLUE

OPTIONAL GROUND KILL STOP BUTTON 426338

OUTPUT

RED 6

20 AMP

DRILL/ PROPEL SOLENOID

POWER ON DRILL

MICROWAVE OVEN

ORANGE 16

LOCATED ON ENGINE

WHITE 12

58496

KEY SWITCH

+V BATTERY

G A

+V BATTERY

-V BATTERY

32189 ENGINE HOUR

21 PIN CONNECTOR

RED 12

HEATER-A/C UNIT

110 VAC

LOCATED IN ENGINE BOX ENCLOSURE

PIPE RACK LOCK

HOBO SWING

HOBO CLAMP

DUST CURTAIN

WINCH

AUTO TOOL

PIPE POSITIONER

CAROUSEL INDEX

PIPE RACK

BATTERIES

AC CLUTCH

REAR

FRONT

GRAY/YELLOW 16

MASTER DISCONNECT SWITCH

GREEN/GRAY 16

ISC 2 2100

ISC 1 1800

ISC ON/OFF

DIANOSTIC ON/OFF

ENGINE PROTECTION

DIANOSTIC

STOP

31 PIN CONNECTOR LOCATED ON ENGINE

YELLOW 16

BLACK 4

N.O.

+ TIMER D.C. -

FRONT LIGHTS

BLACK 16

WHITE/GRN

OIL PRESS

Ref. 440959 (1 of 3) Cold Weather w/C27

DUST COLLECTOR ENGINE O.P. WITH ENGINE HOURMETER

ALTERNATOR

VIOLET/RED 16

NOTES: SEE CAB & ENGINE SUBASSEMBLIES FOR COMPONMENT PART NUMBERS. SEE 405306 FOR GUAGE PANEL LAYOUT. SEE 405413 FOR SWITCH PANEL LAYOUT.

DUST/ WATER

MAIN AIR

MAST LOCK

GRAY/YEL 16

STARTER

RED 4

BLACK 16

COMP TEMP

WATER TEMP

319152

319153

50 PIN RIGHT BANK ECM ENGINE HARNESS CONNECTOR

FUEL

COMP TEMP

319153

8-33

Wiring Diagram–(Wide Deck) (C27)

YELLOW 16

8-34

PINK #2

BLK

WHT #6

-2

+10

WHT 16

BLU #8

JACK INTERLOCK SEE SHT 3

PINK #6

GRN #4

YEL #3

REF CAB JUNCTION BOX TERMINALS

-2

YEL #9

+10

GRN #8

RELAY #2 N.C. 1

+10 11

POWER FROM IGNITION RELAY

-2

TRAM INTERLOCK

POWER FROM DRILL/PROPEL SW.

WHT 16

BRN #8

A BLK

R.H. PUMP

BRN #4

RELAY #3 N.C.

WHT #6 4

YEL #3

GRN #4

POWER FROM DRILL/PROPEL SW.

GRN #8

GRY #6

HOIST/PULLDOWN JOYSTICK

GRY #6

ROTATE JOYSTICK

BLK WHT/BRN 16

BLK

L.H. TRAM/ROTATE PUMP

BLU #4

RELAY #5 N.C.

WHT #7

YEL #9 WHT 16

PNK #2

R.H. JOYSTICK

GRN/BLK 16

PNK #6

L.H. JOYSTICK

BLK

PRPL

AUTO FEED

AUTO CARD

Electrical Components

Ref. 440959 (2 of 3) Cold Weather w/C27

PNK #0

PRPL

Wiring Diagram–(Wide Deck) (C27)

WHT #7 WHT/BRN 16

YLW #9 YEL #9

BLU #8

BLK

Electrical Components

TAN/RED 16

BRN U BL

BL K

BLK 16

(-)

TAN/RED 16 (+)

JACK INTERLOCK JACKS UP = GREEN LIGHT

RIGHT REAR JACK

TAN/RED

PRPL/GRN 16

K BL BRN BL U

+10 11

WHT 6

+ B

RED/GRN 16

WHT

+ B

POWER FROM RELAY #2, TERMINAL #8

WHT 6

REF R.H. JOYSTICK

PROPEL INTERLOCK PIPE PRESENT = RED LIGHT

REF RELAY #1, N.C.

-2

WHT 4

OPTIONAL DRILL STEEL INTERLOCK CIRCUIT WHEN USED INDEPENDANTLY

REF CAB JUNCTION BOX TERMINALS

LOAD

REF L.H. JOYSTICK

+10 11

REF RELAY #1, N.C.

-2

WHT 4

OPTIONAL JACK INTERLOCK CIRCUIT WHEN USED INDEPENDANTLY

PIPE PRESENT PROXIMITY SW.

REF CAB JUNCTION BOX TERMINALS

LEFT REAR JACK

U BL BRN BL K

PRPL/GRN 16

TAN/RED

BLK

BRN K BL

RED/BLK 16

PRPL/GRN 16

RIGHT FRONT JACK

WHT 6

LEFT FRONT JACK

BLK

WHT 7

BL U

WHT 6

WHT 4

REF R.H. JOYSTICK

BL U

TAN/RED 16

(+)

RED/GRN 16

PRPL/GRN 16

BLK 16

(-)

JACK INTERLOCK JACKS UP = GREEN LIGHT

REF CAB JUNCTION BOX TERMINALS

TAN/RED 16

BL K BRN U BL

+10 11

WHT 6

WHT

Ref. 440959 (3 of 3) Cold Weather w/C27

POWER FROM RELAY #2, TERMINAL #8

REF R.H. JOYSTICK

PROPEL INTERLOCK PIPE PRESENT = RED LIGHT

REF L.H. JOYSTICK

RIGHT REAR JACK

TAN/RED

REF RELAY #1, N.C.

-2

WHT 4

K BL BRN BL U

PRPL/GRN 16

RIGHT FRONT JACK

PRPL/GRN 16

OPTIONAL DRILL STEEL & JACK INTERLOCK CIRCUITS WHEN USED SIMILTANEOUSLY

LOAD

3 -

LOAD

RED/BLK 16 +

PIPE PRESENT PROXIMITY SW.

REF CAB JUNCTION BOX TERMINALS

LEFT REAR JACK

TAN/RED 16

LEFT FRONT JACK

U BL BRN BL K

PRPL/GRN 16

BRN K BL

TAN/RED

BLK

PRPL/GRN 16

REF L.H. JOYSTICK

WHT 6

PRPL/GRN 16

WHT 7

8-35

Wiring Diagram–(Wide Deck) (C27)

BLK

TAN/RED 16

BLK

WHT 7

8-36

TOP OF CAB

99307 99311 99297 99302 99329 99301 99300 99296 99298 99284 99274 99275 99276 99277 99308 99303 99304 99306 99279 99313 99353 99351 99333 99341 99362 99348 99330 99280 99281 99282 99283 99284 99285 99286 99310 99287 99288 99289 99282 99304 99308 99279 45259 45252 45257 78138 99320 99321 99331 99327 99328 99352 99339 99361 99299 99309

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

-----------------------------------------------------------------------------------------------------------------

RDI P/N

ITEM 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 10 10 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 10 16 16 ----16 16 16 16 16 16 16 16 16 16

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------

GAUGE

COLOR 47 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 16 14 18 ----39 40 41 42 43 44 45 46 51 99

TERMINAL

DESCRIPTION

CAB WIRING

Cab Wiring–(Wide Deck) QTY EACH

COMP QTY

Electrical Components

Ref. 423992 Cold Weather

Electrical Components

GAUGE

DESCRIPTION

QTY

-------- 12

---- -- ---- ---------------------------- ----- -- ---- ---------------------------- --

37 --------- 344929 -- LOOM CRGTD SPLIT 1/4

-------- 12

---- -- ---- ---------------------------- --

EACH

1 - -------- 24'-0" 2 - -------- 24'-0" 3 - -------- 24'-0" 4 - -------- 24'-0" 5 - -------- 24'-0" 6 - -------- 24'-0" 7 - -------- 24'-0" 8 - -------- 24'-0" 9 -------- 24'-0" 11 - -------- 24'-0" 13 - -------- 24'-0" -- - -------- -----15 - -------- 24'-0" 16 - -------- 24'-0" 17 - -------- 24'-0" 18 - -------- 24'-0" 14 - -------- 24'-0" 99 - -------- 24'-0" -- - -------- ------- - -------- 24'-0" -- - -------- 24'-0" -- - -------- 24'-0" -- - -------- 24'-0" -- - -------- 8 EACH -- - -------- 26 EACH -- - -------- 22'-0" -- - -------- 2 EACH -- - -------- 12'-0" -- - -------- 12'-0" --------- 2 EACH -- - -------- 2 EACH ---------- 1 EACH -- - -------- 12'-0" --------- 2 EACH

TERMINAL

GREEN/YELLOW STRIPE ------ 16 ---- COMPRESSOR TEMP -----------WHITE -------------------- 16 ---- WATER TEMP ----------------BROWN -------------------- 16 ---- FUEL ----------------------BLACK/ORANGE-------------- 16 ---- OIL PRESSURE --------------YELLOW ------------------- 16 ---- TACH ----------------------RED ---------------------- 16 ---- TACH ----------------------BLUE --------------------- 16 ---- RUN-KEY -------------------GREEN -------------------- 16 ---- DIAGNOSTIC LAMP -----------GRAY/BLACK STRIPE ------- 16 ---- ENGINE HOUR ---------------GREEN/BROWN STRIPE ------- 16 ---- ETHER ---------------------GREEN/RED STRIPE --------- 16 ---- BACK-UP ALARM --------------------------------------- -- ---- ---------------------------GREEN -------------------- 10 ---- LIGHT POWER ---------------RED ---------------------- 10 ---- KEY POWER -----------------BLUE --------------------- 12 ---- STARTER BUTTON POWER ------GREEN/GRAY STRIPE -------- 16 ---- LIGHT ---------------------ORANGE ------------------- 16 ---- A/C COMPRESSOR ------------VIOLET ------------------- 16 ---- THROTTLE POSITION ----------------------------------- -- ---- ---------------------------VIOLET/YELLOW STRIPE ----- 16 ---- EXTRA ---------------------VIOLET/GREEN STRIPE ------ 16 ---- EXTRA ---------------------VIOLET/BLUE STRIPE ------- 16 ---- EXTRA ---------------------VIOLET/WHITE STRIPE ------ 16 ---- EXTRA ---------------------TERMINAL-3/16 STUD-10/12 - -- ---- ---------------------------TERMINAL-3/16 STUD-16/14 - -- ---- ---------------------------CONDUIT-1" --------------- -- ---- ---------------------------CONNECTOR-CONDUIT-1" ----- -- ---- ---------------------------GROUND CABLE ------------- -- ---- ---------------------------POSITIVE CABLE ----------- -- ---- ---------------------------BATTERY ENDS-POSITIVE ---- -- ---- ---------------------------EYELETS ------------------ -- ---- ---------------------------TERMINAL STRIP------------ -- ---- ---------------------------HEATER HOSE -------------- -- ---- ---------------------------BATTERY ENDS-NEGATIVE ---- -- ---- ----------------------------

COLOR

35 --------- 344931 -- LOOM CRGTD SPLIT 1/2 36 --------- 344930 -- LOOM CRGTD SPLIT 3/8

---------------------------------------------------------------------

99311 99297 99302 99329 99301 99300 99296 99298 99350 99275 99297 ----99303 99304 99306 99279 99308 99309 ----99292 99293 99294 99295 45258 45259 57860 57854 96331 96331 96332 17830 76582 30211 96333

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

RDI P/N

ITEM

WIRING-CAB/ENGINE SKID

Ref. 423997 Cold Weather

8-37

Engine Skid/Cab Wiring–(Wide Deck)

8-38

USE ITEM 10 & 19 ONLY IF MACHINE GETS OIL INJECTION

NOTE:

RED/WHITE GRAY/WHITE GRAY/BLUE BLUE/YELLOW PINK/BROWN BROWN/WHITE WHITE/YELLOW STRIPE WHITE/RED STRIP ------------BLACK CONDUIT-1/2" CONNECTOR-CONDUIT-1/2" CONNECTOR-CROUSE HIN UNION-PIPE-1/2" CLAMP-TUBING-1" CONNECTOR-FEMALE-16/14 TERMINAL-3/16 STUD-16/14 PINK/BLUE

99313 99353 99351 99333 99341 99361 99287 99288 ----99290 99299 424860 424866 350477 8304 46103 45265 45259 99339

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

COLOR

P/N

ITEM 16 16 16 16 16 16 16 16 -16 16 -------16

GAUGE MAST LOCK MAST LOCK MAIN AIR MAIN AIR DUST/WATER DUST/WATER DUST CURTAIN DUST CURTAIN -------OIL GROUND -------------------------------------------------OIL INJECTION LIGHT

DESCRIPTION

WIRING-CAB/VALVE BANK 19 20 21 22 23 24 35 36 -38 ----------

TERMINAL

Cab/Valve Bank Wiring–(Wide Deck)

Electrical Components

Ref. 424002 rev. A Cold Weather

15'0" 15'0" 15'0" 15'0" 15'0" 15'0" 15'0" 15'0" --15'0" 15'0" 9'0" 2 EA 1 EA 1 EA 1 EA 16 EA 8 EA 15'0"

QTY

Electrical Components

RED/WHITE

A B

GREEN/WHITE

A B

GREEN/BLACK

GRAY/WHITE

99274 99276 99313 99353 99348 99330 99280 99281 99282 99283

COLOR -------------------------------

DESCRIPTION 10 12 19 20 25 26 27 28 29 30

BLACK/PINK YELLOW/BROWN BLACK/YELLOW YELLOW/ORANGE

YELLOW/WHITE YELLOW/GRAY BLUE/WHITE PINK/BLACK

RED/WHITE

GREEN/BLACK

MAST HARNESS

GRAY/WHITE

A B

BLACK/PINK YELLOW/BROWN BLACK/YELLOW YELLOW/ORANGE

GREEN/WHITE

YELLOW/WHITE YELLOW/GRAY BLUE/WHITE PINK/BLACK

26'-0" 26'-0" 26'-0" 26'-0" 12 EACH 28 EACH 18'-0" 2 EACH 1 EACH 1 EACH 1 EACH 5 EACH 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 2 EACH 2 EACH 2 EACH 20 EACH 2 EACH 20 EACH

26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0" 26'-0"

QTY

-----------------------------------------------------------------------

TERMINAL

YELLOW/GREEN STRIPE ------ 16 ---- AUTO TOOL ------------------ 31 - -------YELLOW/ORANGE STRIPE ----- 16 ---- AUTO TOOL------------------- 32 - -------YELLOW/GRAY STRIPE ------- 16 ---- BREAKOUT ------------------- 33 - -------YELLOW/BLUE STRIPE ------- 16 ---- BREAKOUT ------------------- 34 - -------CONNECTOR-FEMALE-16/14 --- -- ---- ---------------------------- -- - -------TREMINAL-3/16 STUD-16/14 - -- ---- ---------------------------- -- - -------CONDUIT-3/4" ------------- -- ---- ---------------------------- 35 - -------CONNECTOR-STR-CONDUIT-3/4" -- ---- ---------------------------- 36 - -------CONNECTOR-CROUSE HIN ----- -- ---- ---------------------------- -- - -------UNION-PIPE-3/4" ---------- -- ---- ---------------------------- -- - -------P CLAMP-TUBING-1.25" ---------- -- ---- ---------------------------- --------P CLAMP-1.06--------------- -- ---- ---------------------------- -- - -------ORANGE/BLACK ------------- 16 ---- HOBO CLAMP------------------ -- - -------ORANGE/WHITE-------------- 16 ---- HOBO CLAMP------------------ -- - -------BLUE/WHITE --------------- 16 ---- HOBO SWING------------------ -- - -------BLACK/WHITE -------------- 16 ---- HOBO SWING------------------ -- - -------BLACK/YELLOW-------------- 16 ---- PIPE RACK LOCK-------------- -- - -------GRAY/RED------------------ 16 ---- PIPE RACK LOCK-------------- -- - --------------------------------- -- ---- CONNECTOR-8 WAY-MALE-------- -- - --------------------------------- -- ---- CONNECTOR-FEMALE-8 WAY------ -- - --------------------------------- -- ---- CONNECTOR-2 WAY-MALE-------- -- - --------------------------------- -- ---- TERMINAL- MALE-------------- -- - --------------------------------- -- ---- CONNECTOR-2 WAY-FEMALE------ -- - --------------------------------- -- ---- TERMINAL-FEMALE------------- -- - --------

16 16 16 16 16 16 16 16 16 16

GAUGE

MAST VALVE

ORANGE/BLACK YELLOW/BLACK YELLOW/RED YELLOW/BLUE

ORANGE/WHITE BLACK/WHITE YELLOW/GREEN GRAY/RED

99284 --99285 --99286 --99310 --45265 --45259 --35659 --56780 --350477--320167--306002--39999 --99320 --99321 --99331 --99327 --99328 --99352 --95124 --95126 --95129 --95125 --95128 --95127 ---

---------------------

RDI P/N

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

ITEM

WIRING-MAST (SEE SCHEMATIC 95934)

Ref. 424004 Cold Weather

ORANGE/BLACK YELLOW/BLACK YELLOW/RED YELLOW/BLUE

ORANGE/WHITE BLACK/WHITE YELLOW/GREEN GRAY/RED

8-39

Mast Wiring–(Wide Deck)

8-40

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

99311 --99297 --99302 --99329 --99301 --99300 --99296 --99298 --99350 --99275 --99277 --99308 --99303 --99304 --99306 --99279 --99307 --99333 --99355 --99380 --99309 --99291 --99304 --350477--45249 --45252 --45253 --45257 --45261 --45258 --45259 --350398 -416809 -416811 -416810 -416808 -416812 --

RDI P/N

ITEM GAUGE

DESCRIPTION

TERMINAL

COMP QTY

GREEN/YELLOW ------------ 16 ---- COMPRESSOR TEMP ------------ 1 --------- 18'-0" WHITE -------------------- 16 ---- WATER TEMP ----------------- 2 --------- 18'-0" BROWN -------------------- 16 ---- FUEL ----------------------- 3 --------- 18'-0" BLACK/ORANGE ------------- 16 ---- OIL PRESSURE --------------- 4 --------- 18'-0" YELLOW ------------------- 16 ---- TACH ----------------------- 5 --------- 18'-0" RED ---------------------- 16 ---- TACH ----------------------- 6 --------- 18'-0" BLUE --------------------- 16 ---- RUN-KEY -------------------- 7 --------- 18'-0" GREEN -------------------- 16 ---- ECM DIAGNOSTIC LAMP -------- 8 --------- 18'-0" GRAY/BLACK -------------- 16 ---- ENGINE HOUR ---------------- 9 --------- 18'-0" GREEN/BROWN ------------- 16 ---- ETHER ---------------------- 11 --------- 18'-0" GREEN/RED --------------- 16 ---- BACK-UP ALARM POWER -------- 13 --------- 18'-0" ORANGE ------------------- 16 ---- A/C COMPRESSOR ------------- 14 --------- 18'-0" GREEN -------------------- 10 ---- DRILL LIGHT POWER --------- 15 --------- 2'-0" RED ---------------------- 10 ---- MAIN POWER ---------------- 16 --------- 2'-0" BLUE --------------------- 12 ---- STARTER BUTTON ------------- 17 --------- 12'-0" GREEN/GRAY -------------- 16 ---- FRONT LIGHTS --------------- 18 --------- 26'-0" GRAY --------------------- 16 ---- POWER/ENGINE HOUR --------- 47 --------- 12'-0" BLACK -------------------- 16 ---- GROUND -------------------- 51 --------- 6'-0" GRAY/YELLOW -------------- 16 ---- DUST COLLECTOR ------------- 52 --------- 15'-0" RED ---------------------- 6 ---- STARTER 50 AMP ------------ 53 --------- 12'-0" VIOLET ------------------- 16 ---- THROTTLE POSITION SENSOR --- 99 --------- 18'-0" VIOLET/RED --------------- 16 ---- REMOTE SHUTDOWN ----------- -- --------- 12'-0" RED ---------------------- 10 ---- BAT+/ECM P3 --------------- -- --------- 24'-0" CONNECTOR, CABLE 1/2" ---- -- ---- ---------------------------- -- --------- 3 EACH TERMINAL 1/2 STUD 10/12 -- -- ---- ---------------------------- -- --------- 2 EACH TERMINAL 1/4 EYE 10/12 --- -- ---- ---------------------------- -- --------- 1 EACH TERMINAL 3/16 EYE 10/12 -- -- ---- ---------------------------- -- --------- 1 EACH TERMINAL 3/16 EYE 16/14 -- -- ---- ---------------------------- -- --------- 10 EACH CONNECTOR BUTT 16/14 ----- -- ---- ---------------------------- -- --------- 5 EACH TERMINAL 3/16 STUD 10/12 - -- ---- ---------------------------- -- --------- 2 EACH TERMINAL 3/16 STUD 16/14 - -- ---- ---------------------------- -- --------- 12 EACH TERMINAL #10 STUD 16/14 - -- ---- ---------------------------- -- --------- 12 EACH 40 CONNECTOR PLUG ------- -- ---- ---------------------------- -- --------- 1 EACH PIN --------------------- -- ---- ---------------------------- -- --------- 6 EACH SEAL PLUG --------------- -- ---- ---------------------------- -- --------- 34 EACH 3 CONNECTOR RECEPTACLE -- -- ---- ---------------------------- -- --------- 1 EACH CONNECTOR SOCKET -------- -- ---- ---------------------------- -- --------- 3 EACH

COLOR

WIRING-ENGINE SKID/ENGINE/AIR CONDITIONER

Electrical Components

Ref. 424010 Cold Weather

Engine Skid/Engine/AC Wiring–(Wide Deck)

Section 9

Lubrication and Preventative Maintenance NOTE

This section contains recommended procedures and instructions which personnel will need in order to properly perform necessary lubrication and preventive maintenance. This information should be considered as the manufacturer's recommendations only and are based upon normal operation. For severe or unusual conditions the recommended lubrication instructions should be varied in accordance with extended hours of operation, climate and drilling conditions.

Lubrication and Preventative Maintenance

9-1

Service Points The illustrations on the following pages show the location of the service points. In most cases these points will be connected to the auto lube system (if used), or will be connected to lubrication lines from a remote lube bulkhead.

Auto Lube System The auto lube system consists of an air powered pump assembly which is fitted to 120 lb. (54 kg.) grease container (Fig. 9-1). The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds containing injectors which supply grease to points required. A filter/regulator/lubricator supplies 90–100 PSI (6.2–7 bar) to the pump. The system is controlled by a lube & sensor controller mounted in the operator's cab. The controller controls the lubrication system and also will verify delivery of lubricant into a bearing.

Lincoln Lube System Description

Fig. 9-1 Auto Lube Pump and Grease Container

No. of Lube Points

Mast Crown Sheaves

Mast Lower Sheaves

Pipe Rack Bearing–Upper

Pipe Rack Bearing–Lower

Carousel–Upper

Carousel–Lower

Pipe Rack Roller

Mast Pivot

Mast Elevating Cylinders

Rear Axle

Front Axle–Center

Front Axle–Ends

Jacks–Rear

Jacks–Front

Pipe Rack Lock

Mast Lock

Pipe Positioner

Breakout Wrench

Pipe Rack Swing

Fig. 9-2 Auto Lube Pump Controller in Cab 9-2

Lubrication and Preventative Maintenance

Central (Auto) Lube System

Fig. 9-3 Lube Point Locations

Lubrication and Preventative Maintenance

9-3

Service Points–Main Frame

AIR RECEIVER TANK

ENGINE AIR FILTER COMPRESSOR AIR CLEANER LEFT FRONT REAR JACK

RIGHT HAND FRONT JACK CENTRAL LUBE TANK

HAMMER OIL TANK

ENGINE OIL RESERVE TANK COMPRESSOR OIL FILTER ENGINE

ENGINE RADIATOR

COMPRESSOR/HYD OIL COOLER

RETURN FILTERS PUMP DRIVE BOX

HYDRAULIC TANK

CHARGE FILTERS

MAST ELEVATING CYLINDERS LOOP FILTERS DUST COLLECTOR FILTERS (NOT SHOWN)

PIPE RACK RIGHT HAND REAR JACK LEFT HAND REAR JACK ROTARY HEAD AIR CONDITIONER AIR CLEANER

BREAKOUT WRENCH

AIR CONDITIONER

ARRANGEMENT WILL VARY ACCORDING TO CUSTOMER SPECIFICATIONS

Fig. 9-4 Main Frame 9-4

Lubrication and Preventative Maintenance

Service Points–Undercarriage MAST PIVOT BUSHING 2 PLCS

UPPER MAST RAISE CYLINDER PIN 2 PLCS

LOWER MAST RAISE CYLINDER PIN 2 PLCS

FRONT JACKS 2 PLCS BOTH SIDES

REAR JACKS 2 PLCS BOTH SIDES

FINAL DRIVE 2 PLCS REAR AXLE SHAFT

FRONT AXLE PIN

FRONT AXLE CENTER PIN

REAR AXLE SHAFT

FRONT AXLE PIN

TOP VIEW

Fig. 9-5 Undercarriage

Lubrication and Preventative Maintenance

9-5

Service Points–Mast UPPER SHEAVE

UPPER SHEAVE

ROTARY DRIVE GEARBOX

PIVOT WELDMENT

HOBO WRENCH

CLAMPING JAW PIPE POSITIONER PIN

SHEAVE CARRIAGE 2 PLACES

SHEAVE CARRIAGE PIN

PIPE POSITIONER PIN

SHEAVE CARRIAGE PIN

PIPE POSITIONER

SHEAVE CARRIAGE

MAST LOCK

SHEAVE CARRIAGE PIN

MAST

MAST LOCK PIN

Fig. 9-6 Mast

9-6

Lubrication and Preventative Maintenance

Service Points–Pipe Rack LOCK CYLINDER

SWING CYLINDER PIN

INDEX CYLINDER

TYPICAL SWING CYLINDER ASSEMBLY 2 PLCS - UPPER & LOWER VIEW A - A

CAROUSEL END CAP

B JOURNAL BEARING CAP

CAROUSEL END CAP

JOURNAL BEARING CAP

INDEX CYLINDER PIN

CAROUSEL LOCK PIN

SECTION B - B CAROUSEL OMITTED FOR CLARITY

SECTION D - D

SWING CYLINDER PIN

Fig. 9-7 Pipe Rack Lubrication and Preventative Maintenance

9-7

Lubrication–General Recommended lubrication instructions provided herein are based upon normal operation, and should be varied in accordance with other than normal operating conditions. After lubrication and filling, remove excess spills. Always keep fittings, caps and fill plugs clean of foreign matter.

Equipment Lubrication Determination of when oil changes are made, filters and filter elements are to be cleaned and/or replaced, and lubrication of equipment is required, should be based on the severity of operation. Equipment photo's and charts have been included to show the general location of points and equipment which require scheduled and periodic lubrication. The lubrication charts list the various lube and check points, filters and filter elements, and provides data such as quantities, types of lubricants recommended, and the recommended frequency of lubrication.

Care of Lubrication Points Before lubricating, or filling hydraulic fluids, the fittings, caps, and filler plugs should be thoroughly cleaned to prevent contamination.

NOTE

For additional lubrication information, refer to vendor manuals provided in this manual.

Lubrication Illustrations and Charts The machine illustrations on the preceding pages shows the location of lubrication points. The lubrication charts which follow provide information on the items to be lubricated, recommended lubricants, capacities, lubrication periods, and special instructions where required.

9-8

Lubrication and Preventative Maintenance

Lubrication and Maintenance Chart C/A = Check/Add if required Interval

Daily or Each Shift

Weekly or 50 Hrs

Lubricant Required See Note 7

Capacity

Charged Charged/Secure Check for correct function Report any leaks, damage, etc

15W-40 (factory fill) 15W-40 (factory fill) Diesel Fuel 1 ––––– 50/50 Anti-freeze/Water 50/50 Anti-freeze/Water Super Hyd AW ISO 46 3 Dexron III ATF Water/Anti-freeze 80W-90 Gear Oil ––––– ––––– ––––– ––––– NLGI No. 2 Grease ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– NLGI No. 1 Grease NLGI No. 2 Grease 6 ––––– ––––– ––––– –––––

35 gal. (133 L) 19 gal. (72 L) varies by model ––––– 23 gal. (85 L) 14.5 gal (55 L) 250 gal. (946 L)5 see 300 hours varies by model 9 qt. (8.5 L) ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– ––––– –––––

Cooler Fan Hydraulic Filters Coolant Filter (if equipped) Air/Oil Separator Tank Low Pressure High Pressure Compressor Oil Filter Rotary Drive Gearbox

Check/Torque mounting bolts Initial Change, then every 500 hrs Initial Change, then every 500 hrs Initial Change, then every 300 hrs

––––– ––––– ––––– Dexron III ATF

Initial Change, then every 250 hrs C/A

––––– GL-4 Full PAO-based ISO 50 Synthetic Gear Oil 10

––––– ––––– ––––– ––––– 44 gal. (167 L) 32 gal. (121 L) ––––– 13 gal. (49.2 L)

Water Pump (Bean) Water Pump (Cat)

SAE 40W Initial Change 12 Initial Change then every 300 hrs11 ISO 68

Service Point

Service Required

Engine Oil (Cummins QST30) Engine Oil (Cat C27) Fuel Tank Fuel/Water Separator Engine Coolant 2

C/A C/A C/A Drain water C/A (QST30 engine only) C/A (C27 engine only) C/A C/A C/A C/A Check Service Indicators 13

Hydraulic Oil Tank Air/Oil Separator Tank Water Tank (optional) Pump Drive Gearbox Engine Air Filters Compressor Air Filters Oil Filters Radiator & Coolers Shock Sub & Air Swivel Tracks, Rollers, Sprockets Track Frames, Axles, Mounts Mast & A-Frame Cab Mountings Deck & Surrounds Rotary Gearbox & Motor(s) Pulldown/Hoist Ropes Pulldown Sheaves Grease Pump Lubricator Pipe Thread Lubricator Fire Suppression System Fire Extinguisher Operating Controls Walk Around Inspection

Check Service Indicators 13 Check Service Indicators 4 Check/Clean Lubricate Check/Clean Inspect Integrity/Damage Inspect Integrity/Damage Inspect Integrity/Damage Inspect Integrity/Damage Check Inspect Check they are getting grease Top Up Top Up

1 qt. (.95 L) 42 oz. (1.26 L)

PLUS ALL ITEMS LISTED IN DAILY SERVICE

Lubrication and Preventative Maintenance

9-9

Lubrication and Maintenance Chart C/A = Check/Add if required Interval

100 Hrs

Service Point

Service Required

Winch (Braden BG8)

Initial Oil Change (then every 6 months) Initial Oil Change (then every 6 months)

Pump Drive Gearbox

Lubricant Required See Note 7

Capacity

80W-90 Gear Oil

4 pints (1.9 L)

80W-90 Gear Oil

9 qt. (8.5 L)

80W-90 Gear Oil 80W-90 Gear Oil

4.8 qt. (4.5 L) 1/2 to 2 pints (.24 to .95 L) ––––– see daily ––––– see daily ––––– ––––– ––––– ––––– ––––– ––––– ––––– 9 qt. (8.5 L) see daily 13 gal. (49.2 L) ––––– ––––– ––––– ––––– ––––– see 50 hrs ––––– ––––– ––––– ––––– ––––– ––––– –––––

PLUS ALL ITEMS LISTED IN DAILY & 50 HRS Track Final Drive 8 Winch

150 to 250 Hrs

Compressor Oil Filter Engine Oil & Filter Engine Fuel Filter(s) Engine Coolant Condition Engine Coolant Filter Radiator Cap Batteries Fuel Tank Comp. Receiver Tank Receiver Tank Oil Comp. Main Oil Filter Pump Drive Gearbox Track Final Drive Gearbox Rotary Drive Gearbox Rotary Drive Spindle Rotary Head Wearpads Water Pump Pressure Water Pump Oil Level Water Pump Strainer Water Pump Coupling Air Conditioner Belts Alternator Belts Mast Pivot Pins/Bushings 9 Hoist/Pulldown Ropes Track Chains

Initial Change, 200 hrs, then yearly Initial Change at 24 hours of winch operation Change Change at 250 hours Replace Check/Refill/Test Replace Check Condition Clean/Top Up Drain Water Drain Water C/A Replace C/A Check/Refill Drain & Replace Oil

––––– 15W-40 (factory fill) ––––– Water/Anti-Freeze 50/50 ––––– ––––– Distilled Water ––––– ––––– Dexron III ––––– 80W-90 Gear Oil 80W-90 Gear Oil GL-4 Full PAO-based ISO 50 Synthetic Gear Oil 10 Check Pre-Load (0.002–0.004 in.) – – – – – Check/Replace (shim as required) – – – – – ––––– Check, LP=150 PSI (10 bar) ––––– HP=375–400 PSI (26–28 bar) see 50 hrs C/A ––––– Clean ––––– Check ––––– Check/Adjust ––––– Check/Adjust NLGI No. 2 Grease Check/Lube Check/Adjust per Service Manual – – – – – Check/Adjust per Service Manual NLGI No. 2 Grease

PLUS ALL ITEMS LISTED IN DAILY, 50, & 100 HRS SERVICE 300 Hrs

9-10

Water Pump (Cat)

Change Oil

ISO 68

42 oz. (1.26 L)

Lubrication and Preventative Maintenance

Lubrication and Maintenance Chart C/A = Check/Add if required Interval Service Point Hydraulic Fluid Hydraulic Filters Hydraulic Tank Breather Engine Crankcase Breather Comp. Control Air Filter Air Filter Housings Pump Drive Gearbox Water Injection Pump Strainer Dust Collector

500 Hrs

Air Conditioner Filter Winch (Braden BG8) Rotary Drive Spindle

Service Required

Lubricant Required See Note 7

Capacity

Initial Change, then every 1000 hrs Replace Replace Check/Clean Replace Clean Drain/Replace Replace Check Timer Cycle/Air Pressure (3.2 sec. between pulses) (approx. 40 psi (2.8 bar) Replace Drain Gear Oil/Replace Check–adjust as necessary

Super Hyd AW ISO 46 ––––– ––––– ––––– ––––– ––––– 80W-90 Gear Oil ––––– ––––– ––––– ––––– ––––– 80W-90 Gear Oil –––––

250 gal. (946 L) 5 ––––– ––––– ––––– ––––– ––––– 9 qt. (8.5 L) ––––– ––––– ––––– ––––– ––––– 4 pints (1.9 L) –––––

80W-90 Gear Oil Super Hyd AW ISO 46

see daily 250 gal. (946 L)5

––––– ––––– Water/Anti-Freeze 50/50 ––––– –––––

––––– ––––– see daily ––––– –––––

PLUS ALL ITEMS LISTED IN DAILY/50/150–250/300 HRS 1000 Hrs or Yearly 2000 Hrs or Two Years

Track Final Drive Gearbox Hydraulic Tank

Drain/Replace Drain, Clean, Replace Oil

PLUS ALL ITEMS LISTED IN DAILY/50/150–250/300/500 HRS Comp. T -Tank Separator Comp. Return Strainer Engine Coolant All Pump Pressure Settings All Valve/Other Settings

Replace Replace Drain/Flush/Replace Check/Adjust per Service Manual Check/Adjust per Service Manual

PLUS ALL ITEMS IN DAILY/50/150–250/300/500/1000 HRS

NOTES: 1.

No. 1-D or No. 2-D diesel fuels as listed in ASTM D975 are acceptable fuels.

Distilled water or deionized water is recommended for use in engine cooling systems. Do not use hard water, softened water that has been conditioned with salt or sea water. Use a 1:1 mixture of water/glycol for optimum performance.

AW ISO 46 is the standard factory fill for hydraulic fluid. Other fluids may be used if they meet the specifications listed in this section.

Indicators may show change or by-pass when fluid is cold; reset and check again.

250 or 300 gal., depending on model.

Lithium Base with 3% Molybdenum Disulfide.

For severe operating conditions (extreme cold or tropical), use appropriate viscosity of lubricants or use fully synthetic lubricants as shown on the Cold Weather Lubricants chart in this section.

Tropical conditions require initial change at 50 hours then every 250 hours.

Replacement of the retaining pins is recommended whenever mast raise/lower cylinder is removed or replaced.

10.

No EP oil allowed.

11.

500 hours if using CAT PUMPS special multi-viscosity ISO 68 oil.

12.

After initial change, every 2000 hours or at least every 3 months. Lubricant type and change intervals may be modified depending on actual operating conditions.

13.

The replacement interval for the engine and compressor air filters is determined by the restriction indicator reading in the cab for the respective filters.

Lubrication and Preventative Maintenance

9-11

Lubricant Speci¿cations Hydraulic System Selection of Hydraulic Oil These selections assume "normal operating conditions" as expected in quarry or quarry-like operations. Hydraulic oils meeting the following specifications will be acceptable for use in the drill. Machines are factory filled with LUBSOIL Super Hydraulic AW ISO 46 oil, unless specified otherwise when ordered. Consult dealer before switching to an oil of different viscosity. Hydraulic Oil Speci¿cations ISO Grade

100

CPS Number

232953

255678

255679

232952

232950

API Gravity

27.3

32.6

31.9

30.9

30.7

15.8 4.0

30.4 6.1

43.7 8.0

64.6 10.6

95.0 13.5

210oF

85.3 39.7

155 46.6

222 53.0

329 62.3

487 73.4

Viscosity Index

159

153

157

154

143

-54 (-65)

-48 (-54)

-42 (-44)

-39 (-38)

150 (302)

190 (374)

186 (367)

212 (414)

232 (450)

3000+

2000+

Viscosity, Kinematic cSt at 40oC cSt at

100oC

Viscosity, Saybolt SUS at 100oF SUS at

Pour Point,

oC (oF) oC (oF),

Flash Point,

min.

Oxidation Life

ASTM D 943 hr.1

DO NOT use these products in high pressure systems in areas subject to fire hazard. 1 6000+ hours for IS0 32, 46 & 68 from the West Coast (Richmond, El Segundo and Willbridge).

NOTE

Diesel fuel or kerosene used as dilutants for cold weather operation are not recommended, as they are not suf¿ciently re¿ned products. Do not use any ¿re resistant Àuids or non-petroleum oils without consulting the manufacturer.

Hydraulic Tank Capacity Model

Capacity

Notes

MD6420 (10 M)

250 gal. (946 L)

MD6420 (13, 16 M)

300 gal. (1135 L)

Fluid level should be at the half-way point on the sight gauge on the tank, when all cylinders are fully extended. Fluid level should be near the top of the sight gauge, when all cylinders are fully retracted.

9-12

Lubrication and Preventative Maintenance

Lubricant Speci¿cations Compressor Lubrication The chart below lists manufacturer approved oils. Ambient Temperature Range oF (oC)

Lubricant

-20 to 120 (-29 to 49) 10 to 110 (-12 to 43) 0 to 100 (-18 to 38) 0 to 100 (-18 to 38)

Sullair AWF *D-A Torque Fluid SAE 10W SE, SF, SG, CD MIL-L-2104E 10W

Change Interval Hours 1200 300 300 300

* Product of D-A Lubricant® Company Inc.

Compressor Lubricant Speci¿cations Compressor oil should conform to the following specifications: A. Non-Detergent Turbine or Hydraulic Type Oil Viscosity @ 100oF o

160–200 SSU

Viscosity @ 0 F

11,000 SSU Maximum

Viscosity Index

90 Minimum

Pour Point oF

20o Lower than minimum starting temperature

Flash Point oF

400 Minimum

Rust Inhibitor

ASTM, D665-54 No Rust after 24 hours

Oxidation Inhibitor

ASTM, D949-54 Neutral No. 2.0 or less after 1000 hours

Anti-Foam Inhibitor

ASTM, D892-46T, 3 cycles stability nil.

B. Automatic Transmission Fluid (ATF) Viscosity @ 100oF

184.2 SSU

Viscosity @ 210oF

49.1 SSU

Viscosity Index

150

Pour Point F

-40

Flash Point

390

C. Premium quality heavy-duty engine oil which meets the performance classi¿cation, letter designation, SE or CD of SAE J183 or MIL-L-210. Ambient Temperature

Grade

-10o F to 90oF

SAE 10W

Above 90 F

Lubrication and Preventative Maintenance

SAE 20W, 20

9-13

Lubricant Speci¿cations Compressor Lubrication Procedure •

Drain Receiver Condensate: In periods of cold weather and/or high humidity, crack receiver drain valve prior to start-up to remove water. Close when oil appears.

•

Check oil level each shift: The level is checked at the upper sight glass with machine levelled. To check the oil level, the machine must be shut down long enough to permit oil foam to settle or check before start-up at the beginning of the shift. Oil level should cover the lower sight glass and be at the center of the center of the upper sight glass (see Fig. 9-8).

•

Change oil after first 50 hours, then change oil annually when using Dexron III ATF (Mobil SHC 1024 Synthetic optional), or as specified in compressor lubrication chart. Consult manufacturer for specific recommendations if extremely severe duty is encountered.

•

Change both main compressor oil filter (Fig. 9-9), and compressor bearing oil filter (Fig. 9-10, if equipped) elements every 250 hours of operation.

•

Lubricate control and linkage periodically.

Fig. 9-8 Air/Oil Receiver Tank Oil Level

Fig. 9-9 Main Compressor Oil Filter

Fig. 9-10 Compressor Bearing Oil Filter (optional)

9-14

Lubrication and Preventative Maintenance

Lubricant Speci¿cations Final Drive Oil Speci¿cations •

Use only the lubricants listed below or oil that meets the specifications in the chart on the next page. Unit is filled at factory with 80W-90 gear oil, unless special request is made.

•

Oil must meet the specification listed on the final drive label.

•

For ambient temperatures of 50o F to 86o F (10o C to 30o C) use oil with a viscosity of ISO-VG 150 or ISO-VG 220.

•

If ambient temperature is 14o F to 50o F (-10o C to +10o C) use an oil that is one viscosity class lower.

•

If ambient temperature is 86o F to 122o F (30o C to +50o C) use an oil that is one viscosity class higher.

Recommended Oils (per ISO Speci¿cations) ARAL

Degol BG 150

AVIA

Degol BG 220 Avilib RSX 150

Energol GR-XP 150

CASTROL

Energol GR-XP 220 Alpha SP 150

CHEVRON

Alpha SP 220 NL Gear Compound 150

DEUTSCHE SHELL

NL Gear Compound 220 Omala EP 150

ESSO

Omala EP 220 Spartan EP 150

FINA

Spartan EP 220 Giran 150

FUCHS GULF

Giran 220 Renep Compound 104 EP Lubricant Oil HP 150

MOBIL

EP Lubricant Oil HP 220 GF 629 (Mobilgear 629)

TEXACO TOTAL

GF 630 (Mobilgear 630) Meropa 150 Carter EP 150 Carter EP 220

Lubrication and Preventative Maintenance

9-15

Lubricant Speci¿cations Final Drive Oil (cont.) Recommended Oils (per API/MIL Speci¿cations)

For heavy duty gearbox operation use fully synthetic oils only.

Rotary Gearbox The following chart is a quick reference guide to oils which may be available for use in the rotary gearbox. The ISO viscosity grade may vary depending upon the operating temperature where the drill is operated. ISO VISCOSITY GRADE 150

LUBSOIL 4150 SYN GEAR OIL

CASTROL ALPHASYN EP 150

CONOCO

MOBIL

SHELL

SYNCON EP PLUS 150

MOBILGEAR SHC 150

OMALA HD 150

CHEVRON

EXXON

TEGRA SYN GEAR 150

SPARTAN SYN EP 150

Lubricating Grease Use SAE designation MPGM which contains 3–5% Molybdenum disulfide conforming to MIL-M-7866 and a suitable corrosion inhibitor. From 30 to 125oF (-1 to 51.6oC) ambient use NLGI No. 2 From 10 to 100oF (-12 to 37.7oC) ambient use NLGI No. 1 From -20 to 50oF (-289 to 10oC) ambient use NLGI No. 0 From -65 to 50oF (-54 to 10oC) ambient use Mobiltemp SHC 32 synthetic 9-16

Lubrication and Preventative Maintenance

Lubricant Speci¿cations Engine Oil (Cat) Cat® Diesel Engine Oil (DEO) is the preferred oil for use in Cat engines. If Cat DEO multigrade is not used, use only commercial oils that meet the following classifications: •

API CG-4 multigrade oils are acceptable for all Cat diesel engines. When API CG-4 oils are used, the oil drain interval should not exceed the standard oil drain interval for your engine.

•

API CH-4 multigrade oils and API CI-4 multigrade oils are acceptable if the requirements of Cat ECF-1 (Engine Crankcase Fluid-1 specification) are met. API CH-4 oils and API CI-4 oils that have not met the requirements of ECF-1 specification may cause reduced engine life.

Capacity for the Cat C27 engine is 19 gal. (72 L).

Engine Oil Viscosities for Ambient Temperatures Min. oC Max. Min. oF

Viscosity Grade

Max.

SAE 0W-20

-40

SAE 0W-30

-40

50 86

SAE 0W-40

-40

104

SAE 5W-30

-30

-22

SAE 5W-40

-30

-22

122

SAE 10W-30

-18

104

SAE 10W-40

-18

122

SAE 15W-40

-9.5

122

Engine Oil (Cummins) Cummins recommends the use of oil that meets American Petroleum Institute (API) performance categories of CF-4, CG-4, CF-4/SG, or CG-4/SH. Special break-in oils are not recommended for new or rebuilt Cummins engines. Synthetic or partially synthetic oils can not be used during break-in period. Use standard recommended petroleum based oil for the first drain interval. After that, synthetic oils may be used. Capacity for the Cummins QST30 engine is 35 gal. (133 L).

Gear Lubricant Use any oil which meets EP gear lubricant specification MIL-L-2105C or API-GL-5 of SAE J3083C. Lubricant Grades: Below -10oF (-23oC) ambient use 40W Above -10oF (-23oC) and up to 100oF (37.8oC) ambient use 80W-90 or EP90 Above 100oF (37.8oC) ambient use 85W-140 Optional: Mobil SHC 635 synthetic or equivalent (all temperature ranges) Lubrication and Preventative Maintenance

9-17

Lubricant Speci¿cations Braden BG8 Winch Lubrication •

Check oil level every 3 months or 500 operating hours whichever occurs first. Remove the large plug located in the center of the drum support. Oil level should be at the bottom of this opening.

•

Gear housing should be drained and filled with new oil after the first 100 hours of operation. Then oil should be changed every 1000 hours of winch operating time or every six (6) months, whichever occurs first.

•

Remove and clean vent plug in solvent every time oil is changed. Vent plug must be kept clean and free from obstructions.

•

The standard factory fill from Braden for the BG8 winch is Texaco Meropa150. Other oils may be used if they meet the following specifications: Do not mix different kinds of oil. AGMA 4EP or API GL-2 with ISO 150.

The following are recommended oils: Texaco

Exxon

Mobil

Shell

Chevron

Meropa 150

Spartan EP 150

Mobilgear 629

Omala 150

American Industrial Oils 150

Meropa 220

Spartan EP 220

Mobilgear 630

Omala 220

American Industrial Oils 220

NOTE: All gearcases are factory filled with Mobillube SCH 75W-90 Synthetic gear lube for cold weather operation.

Cat Water Pump (Model 1050) The Cat Pump, Model 1050 is factory filled with ISO 68. This is suitable for temperatures below 0oF (-17.8oC). Special oil is available from Cat Pump dealers. If another type oil is used, be sure it meets the specifications for Cat Pumps. •

Fill with oil to red dot in sight window on back of pump (Fig. 9-15).

•

Lubricate the wicks monthly with 2-3 drops of oil in each hole on top of the crankcase (Fig. 9-16). DO NOT lubricate the wicks at initial start-up. Operate pump for 10–15 minutes, then lubricate the wicks. Use crankcase oil as lubricant.

Fig. 9-15 Cat Pump Oil Level Sight Window (back of pump) Fig. 9-16 Cat Pump Oil Filler Cap and Wick Lubrication Points

9-18

Lubrication and Preventative Maintenance

Lubricant Speci¿cations FMC Water Pump (Bean Model A04/I04) Oil Changes •

Oil changes must be carried out after first 50 hours of operation, and subsequently after every 2000 hours or at least every 3 months. These intervals may be modified depending on actual operating conditions.

•

Oil should be changed when hot to prevent build up of sludge deposits.

•

It is advisable to check oil level daily. If more than 10% of the total capacity has to be added, check for oil leaks. Oil capacity for models A04 and I04 pumps is 1 qt. (0.95 L).

•

Do not mix oils of different types, even if produced by the same manufacturer. Never mix mineral and synthetic oils.

Lubricant temperatures should not exceed 170°F (77°C) for continuous duty or 180°F (82°C) for intermittent duty applications. Crankcase temperatures that exceed these limits will cause the lubricant to prematurely “break down.” The result will be poor lubrication and failure of power end components. Several products are listed by manufacturer name in the table below in order to aid the customer in locating suitable lubricants. The following listing is not exclusive, nor an endorsement of any particular product or manufacturer. RECOMMENDED LUBRICANT CHART Mineral Oil Lubricant

Type of Service General Service

High Ambient Temperature Service

Cold Ambient Temperature Service

Ambient Temp 0°F to 100°F (-18°C to 38°C)

100°F to 130°F (38°C to 54°C)

0°F to -30°F (-18°C to -34°C)

SAE Grade 30

ISO Viscosity (cSt @ 40 C) 100

250

Synthetic Lubricant*

SSU Viscosity 550

1165

350

Manufacturer Brand Name Texaco® Meropa 100 Shell® Omala 100 Shell® Rotella T SAE 30 Exxon® XD-3 30 wt Mobil® Trans HD-30 Texaco® Meropa 68 Shell® Omala 220 Shell® Rotella T SAE 50 Exxon® HD-3 50 wt Mobil® Trans HD-50 Texaco® Meropa 68 Shell® Omala 68 Shell® Rotella T SAE 20 Exxon® HD-3 20 wt Mobil® Trans HD-20

SAE Grade 5W-40 NA

ISO Viscosity (cSt @ 40 C) 90.0 @ 40 15.0 @ 100 99.1 @ 40 13.9 @ 100

Manufacturer Brand Name Shell® Rotella T Synthetic SAE 5W-40 Mobil® SCH 627

5W-40

90.0 @ 40 15.0 @ 100

217 @ 40 29.9 @ 100

Shell® Rotella T Synthetic SAE 5W-40 Mobil® SCH 630

5W-40

90.0 @ 40 15.0 @ 100

10W-30

12.0 @ 100

Shell® Rotella T Synthetic SAE 5W-40

69.9 @ 40 10.9 @ 100

BP® Vanellus E8 ULTRA 5W-30 Mobil® SCH 626

Frequent Start-Stop Operation

150

775

Texaco Meropa® 150

*Synthetic lubricants are suggested for high or low temperature service.

Lubrication and Preventative Maintenance

9-19

Lubricant Speci¿cations Down-the-Hole (DTH) Hammer Lubricants Just like any other piece of precision machinery, the DTH hammer must be lubricated and small quantities of oil should be injected into the air stream at regular interval whilst the hammer is working. Rock drill oils are recommended because these contain the emulsifying and viscosity additives necessary to deal with high pressure and high air flow conditions in which water is usually present, if only from condensation in the air line. Oil not only provides slip to prevent pick up and premature failure of components but it also acts as a seal on the surface of running parts to use air efficiently without pressure loss. It is therefore of paramount importance that the correct grade of oil is used at the appropriate consumption rate to suit volume and pressure, in line with the hammer manufacturers recommendation. Most modern valveless hammers, particularly when operating at high pressures need a heavy oil providing of course that ambient temperatures allow the oil to run through the airline. AMBIENT TEMPERATURE BELOW 10ºC

FROM 10ºC TO 32ºC

ABOVE 32ºC

HAMMER THREAD GREASE

HAMMER O-RING GREASE

HALCO

HS3

HS200

FAXENE CP COMPOUND

FAXANE H76

MOLYBOND

9-20

HAMMER GREASE

MAKE

GOG

---

ENERGOL RD-E-100

MOLYHAMMER 320 MACCURAT D220

MACCURAT D220

ENERGREASE AS11

---

CALTEX

CALTEX ARIES 100

CALTEX ARIES 320

THREADTEX

---

CASTROL

RD OIL 100

RD OIL 150

RD OIL 150 or MAGNA CF220

---

RED RUBBER GREASE

ELF

PERFORA 100

PERFORA 220

TIFORA CA

NATURELF GEP2

ESSO

AROX EP46

AROX EP150

AROX EP150 or FEBIS K220

---

GULF

GULFSTONE

GULFSTONE HEAVY

ANTI NO.2

---

MOBIL

ALMO 527

ALMO 529

VACTRA OIL NO.4

MOBILTEMP SCH460

---

SHELL

TORCULA 100

TONNA TX220

HIGH PRESS. THREAD

---

TEXICO

AIRES 100

WAY LUBRICANT X220

---

Lubrication and Preventative Maintenance

Lubricant Speci¿cations Pump Drive Gearbox The pump drive gearbox can use any oil which meets EP Gear Lubrication Spec MIL-L-2105C or API Classification GL-5. Oil capacity is 9 qt. (8.5 L).

Cold Weather Lubricants The following chart lists replacement lubricants that are recommended for the temperature ranges shown, typically in extreme cold weather operating conditions. Consult dealer for proper application.

Component Description

Operating Temperature Range (Ambient)

Lubricant Required

Compressor

Mobil SHC 1024 Synthetic

Below -20 to 100oF (-28.9 to 37.8oC)

Engine Crankcase Oil

SAE 15W-40

5 to 120oF (-15 to 48.9oC)

Hydraulic Tank

Mobil Synthetic ATF

Below -10 to 100oF (-23 to 37.8oC)

Pump Drive Gearbox

Mobil Delvac 75W-90 Synthetic

-67 to 100oF (-55 to 37.8oC)

Rotary Head

Mobil Delvac 75W-90 Synthetic

-67 to 100oF (-55 to 37.8oC)

Undercarriage Final Drive

Mobil Delvac 75W-90 Synthetic

-67 to 100oF (-55 to 37.8oC)

General Grease Lubrication Points

NLGI MobilTemp SHC32

10 to 100oF (-12 to 37.8oC) -65 to 50oF (-54 to 10oC)

Drill Rod Thread Grease

Mobil CM-L NLGI 1 Citgo Lithoplex CM1

-30 to 350oF (-34.4 to 177oC)

DTH Hammer Oiler

Rock Drill Oil

All

Note: These recommendations are based on each systems component manufacturer's recommendations, requirements and/or manufacturer's requirements for maximum and minimum oil viscosity values during start-up and continuous operation.

Lubrication and Preventative Maintenance

9-21

Preventive Maintenance In order for an operator to be sure his drill is ready for operation at any time, a regular program of preventive maintenance should be adopted. It is recommended that such a maintenance program be established on the basis of the operator and/or maintenance personnel performing specific maintenance work during various periods of equipment operations, at intervals during which the equipment will be idle, and during extended periods of time when the equipment will be in storage. When the drill is in continual, daily use, it is further recommended that a program of daily service requirements be established with preventive maintenance being performed on a "before operation", "during operation", and "after operation" schedule. NOTE

For additional preventive maintenance information, refer to vendor manuals provided herein.

Hydraulic System Maintenance The hydraulic components of the drill are built for many years of trouble-free operation. Only one preventive maintenance step is necessary to ensure the expected life of the system—CLEANLINESS. When dirty filters are indicated, change the filter as follows: •

Clean the area around the filter covers to prevent dirt entering the filter housings.

•

Pull filters from the housings. Install new filter and install the covers making sure the cover O-ring is in place.

Fig. 9-17 Hydraulic Tank Oil Level and Temperature Gauge

Sight gauges are provided on the sides of the tank for checking oil levels. • Oil level should be at the halfway point of the sight gauge when all cylinders are extended. •

A temperature gauge is also provided on the sight gauge.

CLEANLINESS cannot be overstressed. •

Use new oil only from previously unopened containers.

•

Clean all tank openings.

•

Fill tank through return filter.

Fig. 9-19 Hydraulic Pump Charge Filter–One filter mounted on each side of pump drive.

Fig. 9-18 Hydraulic Loop Filter–Two filters mounted on each side of mast "A" frame. 9-22

Lubrication and Preventative Maintenance

Preventive Maintenance Remove the radiator pressure cap slowly and only when the engine is cool or serious burns could result.

Cooling System Maintenance–Cummins The engine's cooling system is designed to provide adequate cooling during all normal operating conditions. Engine overheating can become the primary cause for extensive repair work, lost operating time, and possibly result in eventual complete engine failure. Cooling system maintenance should, therefore, hold an important place in the drill maintenance program. The engine cooling system is filled with a 50/50 mix of anti-freeze and water. Refer to Cummins engine manual for complete cooling system specifications and maintenance. The Cummins QST30 is equipped with two coolant filters (Fig. 9-20). These are to be changed every 250 hours of operation. Cooling system is to be drained, flushed, and refilled every 2 years, or 6000 hours of operation, whichever occurs first. Cummins recommends filling system with Fleetguard® Compleat, a fully formulated anti-freeze which contains supplemental coolant additive

Every 250 Hours: Change Coolant Filters 1.

Turn valve to OFF position, and remove filters.

Clean mounting base and be sure old gasket is not stuck to it.

Apply a thin film of oil to the gasket and install new filters. Screw filter on until gasket contacts base, then tighten 1/2 to 3/4 turn by hand. Turn valve to ON position.

Fig. 9-20 Cummins QST30 Engine–right side 1. On/Off Valve 2. Coolant Filters

Lubrication and Preventative Maintenance

Fig. 9-21 Engine Radiator–left side of machine

9-23

Preventive Maintenance Supplemental Coolant Additive (SCA) Cummins recommends DCA4 as the supplemental coolant additive. DCA4 is compatible with all type of coolant except Methoxy Propanol. Supplemental coolant additive prevents the buildup of corrosion and scale deposits in the cooling system. The correct concentration is 1.5 units for each gallon (3.8 L) of coolant. Concentration must never drop below 1.2 units, nor exceed 3 units per gallon (3.8 L). If coolant is added between drain intervals, the SCA concentration must be checked, and added, if required. A coolant test kit no. CC2626 is available from Cummins dealers. When the system is initially filled, the correct amount of liquid SCA is added to make 1.5 units of SCA per gallon (3.8 L) of coolant. In this case, total system capacity is 71 gallons (269 L), so 47.3 SCA units are required. When changing coolant filters at 250 hours, normally 4 SCA units will bring the system up to the required amount. Filters contain SCA in crystal form that dissolves in the system. Filters come in 2, 4, 6, 8, 12, 15, and 23 SCA units. A filter is also available with no SCA units. At each filter change, check the system with a Cummins coolant test kit. This kit contains strips, to dip in the coolant that will determine the SCA level. If additional SCA is required, add liquid SCA to bring up to correct concentration.

Air Cleaners The air cleaner should be inspected periodically to maintain engine and compressor protection and maximum service life. These inspections should include the following points: 1.

Inspect the air transfer duct between the air cleaner and the engine to be sure all clamps are tight, all flange joints are tight, and there are no cracks in the ducting.

Air cleaner mounting bolts and clamps must be tight to hold the air cleaner securely.

Check the dust cup to make sure it is sealing 360o around the air cleaner body.

Vacuator valve must be in place, not inverted, and free from obstruction.

Check for dents and damage to the air cleaner which could mean a leak.

Air Filter Elements Replace air filter elements as required per maintenance schedule, or when indicated by pressure differential indicator on filter. DO NOT clean ¿lter element with high pressure air (30 PSI maximum). Advise replacement of ¿lter element. DO NOT start engine when the ¿lter element(s) is removed from the air cleaner NEVER attempt to clean the element by rapping it. Rapping the element will dent the metal covering. The inner paper element will in turn rub this dent, causing the element to puncture.

9-24

Lubrication and Preventative Maintenance

Preventive Maintenance–Weld Inspection

Lubrication and Preventative Maintenance

9-25

Preventative Maintenance–Mast Pivot Mast Pivot Shaft Inspection and Repair Procedure A visual inspection should be performed with the mast in the horizontal position by removing the trunnion cap and bushing. Clean the shaft and shoulder radius free of lubricant and inspect visually for any indication of cracking in the radius. Perform visual inspection at the mid point of non-destructive test (NDT) interval #1 and #2. Intervals for magnetic particle inspection will be in accordance with AS1171 or a dye penetrant test, post repair. Same inspection intervals apply to new machines or replaced shafts. Intervals are operating hours on shaft.

SHAFT DETAIL

MD6240 Interval #1 <15,000 Hours Inspect every 3000 Hours

Interval #2 >15,000 Hours but <25,000 Hours Inspect every 1500 Hours

MD6290/MD6420 Interval #1

Interval #3

<15,000 Hours Inspect every 5000 Hours

>25,000 Hours Inspect every 1000 Hours

Interval #2 SHAFT DETAIL

RO.25 ORIGINAL RADIUS

>15,000 Hours but <30,000 Hours Inspect every 3000 Hours

Interval #3 RO.38 MAXIMUM RADIUS 30˚ MAX ANGLE

>30,000 Hours Inspect every 2000 Hours

Approved Pivot Shaft Repair Procedure Fatigue cracking in the A-Frame pivot shaft radius of any rotary drill may be repaired by completely grinding out cracks up to a maximum depth of 0.12 in. or 3mm. This approved repair method is intended only to extend the service life of a shaft that is in the first stages of fatigue where the cracking is not extensive and is just becoming visible. Shafts with more extensive cracking, i.e. crack depths exceeding 0.12 in. (3mm) should be replaced by removing the shaft from the A-Frame structure and rewelding a new shaft in place in accordance with the factory repair procedure.

Unapproved Repair No grinding that undercuts the diameter of the bearing surface is allowed. Cracking outside of the hatched area is not repairable by grinding and requires replacement of the shaft. All known fatigue cracking has occured in the hatched area. 9-26

NON-REPAIRABLE FATIGUE CRACK Lubrication and Preventative Maintenance

Preventative Maintenance–Bolted Joints Bolted Joint Maintenance for Rotary Drills Introduction To properly maintain bolted joints, some technical understanding of threaded fasteners will be helpful. Threaded fasteners are often taken for granted and are seldom viewed as the highly engineered items that they are. Their proper selection and proper joint design are critical to ensure structures and machine elements perform as intended. This is a detailed subject and what is intended here, is to present a few highlights to assist with good maintenance practices for rotary drills. This guide is not all inclusive. Proper Bolt Tension Proper “Preload” or residual tension in a tightened bolt means more to assembly strength than actual bolt strength. In a bolted joint, a bolt torqued to its proper load level can resist a maximum amount of external load without loosening. Ensuring that the intended preload is achieved and maintained is the objective of this guide. These rotary drills typically use SAE guidelines which are commonly recognized throughout most industries, for non-permanent connections. All bolted joints in the drills are non-permanent joints (bolted joints of a bridge or building structure would be considered permanent joints.) Standard SAE torque specifications for bolt tensioning recommends that bolts be pre-tensioned to 75% of yield strength or “Proof Load.” Bolts torqued to this level are re-useable if in good condition otherwise. There are a couple of exceptions in these drills where bolts are tightened beyond this value, and these will be identified. See the following chart for recommended torque values for different bolt sizes. Reasons Properly Tensioned Bolts Loose their Preload and Require Maintenance x Surface Degradation Surfaces under bolt heads can degrade due to creep failure, embedment, high bearing stress, corrosion or a combination of these. These rotary drills use hardened washers in many situations to help prevent surfaces from degrading. Critical joints may use “Nordlock” washers which are a hardened, zinc coated, two-piece serrated washer incorporating inclined planes at the mating boundary of the two pieces. To loosen a bolt using this locking device, the bolt must be significantly stretched. Critical bolted joints are identified in the “Critical Fastener ID & Inspection Schedule” drawing in this manual. Joints that are assembled with Nordlock washers and hardened washers are less likely to experience surface degradation, as the hardness of the washer is close to the hardness of the fastener and is harder than the surface of most nuts used in these drill assemblies. x Corrosion Most critical bolted joints on these rotary drills contain components that are made from steel. Most bolts used are also steel, and therefore susceptible to rusting. Water is a small molecule and can find its way into the smallest spaces to attack the surfaces of a bolted joint and the bolt head, body and threads. We recommend that all critical fasteners be lubricated using a lubricant that contains Molybdenum Disulfide (NLGI 2 Molycoat or Never-Seize are readily available Worldwide. Good quality NLGI 2 grease can be substituted if a Moly product is not available at the time of service.)

Lubrication and Preventative Maintenance

9-27

Preventive Maintenance–Bolted Joints x Vibratory Overload Abusive, unusual or unforeseen loads can cause bolted joint separation. This can result in the loosening of bolts, which in turn can cause bolt fatigue failure. Bolt fatigue will generally result in a fracture surface and ultimately failure at the first engaged thread of the bolt or sometimes in the fillet under the bolt head. Loose bolts can also fail quickly in fatigue. As an example, tests conducted by a bolt manufacturer indicated that a bolt tightened to 1420 lb tension and stressed cyclically to 9215 lb failed after 5960 load cycles. Identical bolts tightened to 8420 lb and stressed to the same 9215 lb survived 4.65 million cycles before failure. If the bolts had been tightened beyond 9215 lb, it would have been impractical to cycle them to failure. x Thermal Relaxation Bolted joints exposed to high temperatures or thermal cycling have a tendency relax or lose bolt tension over time, due to stress creep. Since pre-loading stretches bolts, and only stretches them a few thousandths of an inch. It is easy to imagine that a bolt heated to the operating temperature limits of an air compressor could increase the plasticity of the bolt material, allowing it to lose some of its initial loading. Bolted joints of a new machine that are subjected to high heat should be checked and re-torqued to specification after the first 500 hours of operation. Critical Bolted Joint Maintenance Critical bolted joints are those joints which hold major structures together or hold overhead loads. Failure of these joints could endanger personnel or seriously damage equipment. As stated earlier, these are identified in the drawing “Critical Fastener ID & Inspection Schedule. We recommend that critical bolted joints of drills should be checked for proper torque every 120 days or 2000 operating hours for machines that have less than 10,000 operating hours, and every 90 days or 1500 operating hours for machines that have greater than 10,000 operating hours. If a bolt is found to be loose (less than 90% of specified torque value), it should be removed and replaced. If the joint contains more than one bolt, all bolts in the joint should be replaced. The joint mating surfaces and bolts should be inspected for signs of corrosion, surface degradation, and the presence of hardened washers or Nordlock washers. Joints with Nordlock washers require the replacement of the washers as well. Hardened washers can generally be reused as long as the washer is undamaged. The new bolts should be lubricated with NLGI2 molycoat grease and torqued to the proper specification. Bolts should be replaced with the same grade bolt that was originally in the assembly. These drills primarily use SAE Grade 8 bolts. These are identified by the markings on the head of the bolt. Chart #1 of the drawing for each machine titled “Critical Fastener Torque Values” graphically depicts the standard indentifying bolt markings. Bolts in critical joint should also be removed and replaced every 2.5 years or 15,000 hours of operation, regardless of apparent condition.

Other Bolt Maintenance All bolts contained in these drills are subject to the same topics described above, but generally do not have the same degree of risk involved should a bolt failure occur. Every machine should have a “walk-around” inspection performed at the beginning of each operating shift, which includes looking for loose hardware. Other significant bolted joints include all pressurized fittings, flange connections and all bolted pin retainer/keeper plate bolts. All machine bolts should be inspected for proper torque specification annually at a minimum. 9-28

Lubrication and Preventative Maintenance

Preventative Maintenance–Bolted Joints SAE Recommended Torque Values SAE Grade 5 Tightening Torque

SAE Grade 8 Tightening Torque

Size

Dry K=.2 (Ft lb)

Lub K=.15 (Ft lb)

Dry K=.2 (Ft lb)

Lub K=.15 (Ft lb)

3/8-16 UNC 3/8-24 UNF

30 35

23 25

45 50

35 35

7/16-14 UNC 7/16-20 UNF

50 55

35 40

70 80

55 60

1/2-13 UNC 1/2-20 UNF

75 90

55 65

110 120

80 90

5/8-11 UNC 5/8-18 UNF

150 170

110 130

220 240

170 180

3/4-10 UNC 3/4-16 UNC

260 300

200 220

380 420

280 320

7/8-9 UNC 7/8-14 UNF

430 470

320 350

600 660

460 550

1-8 UNC 1-12 UNF

640 700

480 530

900 1000

680 740

1-1/8-7 UNC 1-1/812 UNF

800 880

600 660

1280 1440

960 1080

1-1/4-7 UNC 1-1/4-12 UNF

1120 1240

840 920

1820 2000

1360 1500

1-1/2-6 UNC 1-1/2-12 UNF

1940 2200

1460 1640

3160 3560

2360 2660

NORD-LOCK Washers This bolt securing system uses tension to make the bolt selflocking. The key is the difference in angles. Since the angle "a" is larger than the angle "b", the pair of washers expand more than the corresponding pitch of the thread. NORD-LOCK washers positively lock the fastener in a joint which is subjected to extreme vibration or dynamic loads.

Į>ȕ

ȕ Lubrication and Preventative Maintenance

9-29

9-30

RECOMMENDED INTERVALS FOR PRE-LOAD VALIDATION BY VERIFYING FASTENER TORQUE RECOMMENDED INTERVALS FOR VISUAL INSPECTION AND RE-LUBRICATION RECOMMENDED INTERVALS FOR REPLACEMENT

A CURSORY VISUAL INSPECTION SHOULD BE PERFORMED BY THE OPERATOR AT THE START OF EACH SHIFT.

LESS THAN 10,000 HOURS VERIFY EVERY 120 DAYS OR 2000 HRS

REPLACE BOLTS EVERY 2.5 YEARS OR 15000 HRS REGARDLESS OF CONDITION

GREATER THAN 10,000 HOURS VERIFY EVERY 90 DAYS OR 1500 HRS

MACHINE SERVICE HOURS:

WINCH MOUNTING FASTENERS

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

SEE MACHINE PARTS BOOK FOR PART NUMBERS OF SPECIFIC FASTNERS, WASHERS AND NUTS.

SEE BOLTED JOINT MAINTENANCE IN THIS MANUAL FOR ADDITIONAL INFORMATION CONCERNING BOTH GENERAL AND CRITICAL FASTENERS.

LEVELING JACK CAP FASTENERS

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS REPLACEMENT OF THE RETAINING PINS IS RECOMMENDED WHENEVER MAST RAISE/LOWER CYLINDER IS REMOVED OR REPLACED.

UNDERCARRIAGE MAIN AXLE FASTENERS

AFRAME PIVOT CAP FASTENERS MAST PIVOT CAP FASTENERS

CRITICAL FASTENER ID & INSPECTION SCHEDULE

Preventive Maintenance–Bolted Joints

Lubrication and Preventative Maintenance

WINCH MOUNTING FASTENERS

5/8 - 11UNC GRD5 150 FT LBS LUBRICATED

UNDERCARRIAGE MAIN AXLE FASTENERS

1 - 8UNC GRD8 680 FT LBS LUBRICATED

NOTE “NORDLOCK” WASHERS

MD6420 (SKSS)

SEE MACHINE PARTS BOOK FOR PART NUMBERS OF SPECIFIC DASTENERS, WASHERS AND NUTS.

LUBRICATE BOLTS WITH 3% MOLY NLGI2 EXTREME PRESSURE GREASE, P/N 966825 OR EQUIVALENT.

NOTES:

1 - 8UNC GRD8 -- 680 FT LBS LUBRICATED 1-1/4 - 7UNC GRD8 --1360 FT LBS LUBRICATED

NOTE HARDENED WASHERS AND SAFETY WIRE

1/2 - 13UNC GRD8 80 FT LBS LUBRICATED

NOTE HARDENED WASHERS AND SAFETY WIRE

REPLACEMENT OF THE RETAINING PINS IS RECOMMENDED WHENEVER MAST RAISE/LOWER CYLINDER IS REMOVED OR REPLACED.

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS

1-1/4 - 7UNC GRD5 -- 952 FT LBS LUBRICATED (.85 PROOF LOAD) (EARLIER MACHINES) 1-1/4 - 7UNC GRD8 -- 1545 FT LBS LUBRICATED (.85 PROOF LOAD)

NOTE “NORDLOCK” WASHERS

A FRAME PIVOT CAP FASTENERS MAST PIVOT CAP FASTENERS NOTE “NORDLOCK” WASHERS

7/8 - 9UNC 460 FT LBS LUBRICATED

NOTE HARDENED WASHERS

3/4 - 10UNC 226 FT LBS LUBRICATED (.85 PROOF LOAD)

LEVELING JACK CAP FASTENERS

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

1/2 - 13UNC BRASS 55 FT LBS DO NOT LUBRICATE USE LOCTITE

NOTE “NORDLOCK” WASHERS

Critical Fastener Torque Values

MD6420 (13, 16 M)

9-31

9-32

1 - 8UNC GRD8 680 FT LBS LUBRICATED

1-1/2 - 6UNC GRD8 2360 FT LBS LUBRICATED

MD6420 (SKSW)

SEE MACHINE PARTS BOOK FOR PART NUMBERS OF SPECIFIC DASTENERS, WASHERS AND NUTS.

LUBRICATE BOLTS WITH 3% MOLY NLGI2 EXTREME PRESSURE GREASE, P/N 966825 OR EQUIVALENT.

NOTES:

WINCH MOUNTING FASTENERS

5/8 - 11UNC GRD5 110 FT LBS LUBRICATED

UNDERCARRIAGE MAIN AXLE FASTENERS

NOTE “NORDLOCK” WASHERS

MAST PIVOT CAP FASTENERS

NOTE HARDENED WASHERS

3/4 - 10UNC GRD5 226 FT LBS LUBRICATED (.85 PROOF LOAD)

LEVELING JACK CAP FASTENERS

3/8 - 16UNC GRD8 23 FT LBS LUBRICATED

REPLACEMENT OF THE RETAINING PINS IS RECOMMENDED WHENEVER MAST RAISE/LOWER CYLINDER IS REMOVED OR REPLACED.

MAST RAISE/LOWER HYDRAULIC CYLINDER PIN RETAINER FASTENERS NOTE “NORDLOCK” WASHERS

7/8 - 9UNC GRD8 460 FT LBS LUBRICATED

ROTARY HEAD MOUNTING FASTENERS ROTARY HEAD WEAR PAD MOUNTING FASTENERS

1/2 - 13UNC BRASS 55 FT LBS DO NOT LUBRICATE USE LOCTITE

NOTE “NORDLOCK” WASHERS

Critical Fastener Torque Values MD6420 (10 M)

Lubrication and Preventative Maintenance

Preventive Maintenance Electrical System Be sure battery is filled and kept charged. A discharged battery will freeze at much higher temperatures than a fully-charged battery. Battery terminals should be kept clean and tight for dependable operation. See engine manual for engine electronics and diagnostic codes for electronic engines.

Extended Machine Shutdown If machine is to be shut down for a long period of time (more than 30 days), there are certain precautions that should be followed to minimize the possibility of damage to the machine. 1.

Position the machine in a safe place on level and solid ground. Do not park close to a high wall where the machine would be in danger of rock fall or slides. Do not park in an area prone to flooding. Extend the jacks to contact the ground, but the tracks should also be in contact with ground.

If freezing temperatures are expected, be sure cooling system has adequate anti-freeze to protect system from freezing temperatures.

Check all fluid levels, keep fuel tank full to avoid condensation.

Follow pre-start checks in section 4 before starting machine. Make walk around inspection of machine.

Start the machine at least once per month. Allow system to warm up and cycle all hydraulic cylinders to their full stroke and back. Follow proper shutdown procedures, allowing engine to idle for at least five minutes before shutdown.

Scheduled Oil Sampling Analysis The manufacturer recommends that scheduled oil sampling be taken at regular intervals. This will maintain all warranty requirements and monitor condition of component wear in the system. Oil sampling must be carried out at regular intervals to serve as an effective indicator for component wear. Intermittent oil sampling does not allow a wear pattern to be established. Samples should be taken from the following components. • Hydraulic Oil •

Compressor Oil

•

Engine Oil

•

Rotary Gearbox and Pump Drive Gearbox Oil

Sampling Criteria •

Recommended interval for oil samples is every 200 hours.

•

Take samples when oil is warm and well mixed to assure an accurate reading.

•

A proper oil analysis should include the following three elements: 1. Wear Analysis 2. Chemical and Physical Tests 3. Oil Condition Analysis

Lubrication and Preventative Maintenance

9-33

Drill Stem Thread Lubricator

GREASE AIR

LUBRICATOR

AIR MANIFOLD MAST PIVOT

GREASE

REGULATOR

AIR VALVE

AIR

Fig. 9-22 Drill Stem thread Lubricator System

Description and Adjustments The machine can be equipped with an optional automatic drill string thread greasing system. The system uses an air powered grease pump attached to a 35 lb. (15.9 kg.) grease container. The system is activated by a switch on the drill control console, and the pump delivers grease to the nozzle mounted adjacent to the drill stem. Air supply is filtered, lubricated and regulated by the filter/ regulator/lubricator mounted on the left rear jack housing (Fig. 9-23). Normal pressure setting is 80 PSI (5.5 bar). The following pages give maintenance and repair instructions. Refer to parts manual for repair part numbers and kits. Turning the knurled knob on the 3-way air valve (item 4, Fig. 9-23) increases or decreases the duration of the grease when the switch is activated. Fig. 9-23 Left Rear Jack Housing 1. Filter/Water Separator 2. Regulator 3. Lubricator 4. 3-Way Air Valve

9-34

Lubrication and Preventative Maintenance

Wiggins Rapid Fill The optional Wiggins Full Service System consolidates individual fluid fill spots on the machine, reducing daily maintenance time. Fig. 9-24 shows how the system is connected and functions served. The functions shown varies by model. Not all functions are present on each machine.

3/4 HOSE

HYDRAULIC RESERVOIR

2" HOSE 1/2 HOSE

3/4 HOSE

OIL PAN

FUEL TANK RADIATOR

WIGGINS RAPID FILL

Fig. 9-24 Wiggins Rapid Fill

Lubrication and Preventative Maintenance

9-35

Conversion Table METRIC CONVERSION TABLE En g l i s h to Me tr i c

Me tr i c to E n glish LINEAR

inches (in.) feet (ft.) miles (mi.)

X 25.4 X 0.3048 X 1.6093

= millimeters (mm) = meters (m) = kilometers (km)

millimeters (mm) meters (m) kilometers (km)

X 0.3937 X 3.281 X 0.6214

= inches (in.) = feet (ft.) = miles (mi.)

AREA inches 2 (s q.in. ) feet 2 (s q.ft.)

= millimeters 2 (mm 2) = meters 2 (m 2)

X 645.15 X 0.0929

millimeters 2 (mm 2) meters 2 (m 2)

X 0.000155 X 10.764

= inches 2 (s q.in. ) = feet 2 (s q.ft.)

VOLUME inches 3 (cu.in. ) qua rts ( qts . ) ga llons ( ga l. ) inches 3 (cu.in. ) feet 3 (cu.ft. ) feet 3 (cu.ft. ) fluid ounce (fl.oz.)

X 0.01639 = liters (l) X 0 . 9 4 6 3 5 = lite rs ( l) X 3. 7854 = lite rs ( l) = centimeters 3 (cc ) X 16.39 X 28.317 = liters (l) = meters 3 (m 3) X 0.02832 X 29.57 = millileters (ml)

liters (l) lite rs ( l) lite rs ( l) centimeters3 (cc ) liters (l) meters3 (m3) milliliters (ml)

= inches 3 (cu.in. ) X 61.024 X 1. 0567 = qua rts ( qts . ) X 0. 2642 = ga llon ( ga l. ) = inches 3 (cu.in. ) X 0.06102 = feet 3 (cu.ft. ) X 0.03531 = feet 3 (cu.ft. ) X 35.315 X 0.03381 = fluid ounce (fl.oz.)

MASS ounces (oz.) X 28.35 = grams (g) pounds (lbs.) X 0.4536 = kilograms (kg) tons (2000 lbs.) X 907.18 = kilograms (kg) tons (2000 lbs.) X 0.90718 = metric tons (t) tons (long) (2240 lbs.) X 1013.05 = kilograms (kg)

grams (g) kilograms (kg) kilograms (kg) metric tons (t) kilograms (kg)

X 0.03527 = ounces (oz.) X 2.2046 = pounds (lbs.) X 0.001102 = tons (2000 lbs.) X 1.1023 = tons (2000 lbs.) X 0.000984 = tons (long) (2240 lbs.)

PRESSURE o

inches H g (60 F ) pounds/sq.in. (PSI) pounds/sq.in. (PSI) pounds /s q. in. ( P S I ) o inches H 2O (60 F ) bars

kilopascals (kPa ) X X 3600 = kilo pascals (kPa ) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = kilograms/s q.cm. (kg/cm 2) X 0.0703 kilograms/s q.cm. (kg/cm2) X X 0. 069 = ba rs ba rs X X 0.2488 = kilo pascals (kPa ) kilopascals (kPa ) X X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01

= inches H g (60 oF ) 0.2961 = pounds/sq.in. (PSI) 14.22 = pounds/s q.in. (PSI ) 14. 5 = pounds /s q. in. ( P S I ) o 4.0193 = inches H 2O (60 F ) = bars

POWER horsepower (hp) ft.-lbs./min.

X 0.746 X 0.0226

= kilowatts (kW) = watts (W)

kilowatts (kW) watts (W)

X 1.34 = horsepower (hp) X 44.25 = ft.-lbs./min.

TORQUE pound-inches (in.-lbs.) X 0.11298 pound-feet (ft.-lbs.) X 1.3558 pound-feet (ft.-lbs.) X .1383

= newton-meters (N-m) = newton-meters (N-m) = kilograms/meter (kg-m)

newton-meters (N-m) newton-meters (N-m) kilogram/meter (kg-m)

X 8.851 X 0.7376 X 7.233

= pound-inches (in.lbs.) = pound-feet (ft.-lbs.) = pound-feet (ft.-lbs.)

VELOCITY miles/hour (m/h) feet/second (ft./sec.) feet/minute (ft./min.)

X 0.11298 = kilometers/hour (km/hr) X 0.3048 = meter/second (m/s) X 0.3048 = meter/minute (m/min)

kilometers/hour (km/hr) meters/second (m/s) meters/minute (m/min)

X 0.6214 = miles/hour (m/h) X 3.281 = feet/second (ft./sec.) X 3.281 = feet/minute (ft./min.)

TEMPERATURE o

Celsius = 0.556

(oF - 32 )

Fahrenheit = (1.8 oC ) + 32

COMMON METRIC PREFIXES me ga kilo hecto deka

9-36

( M) (k) (h) (da)

= = = =

1 , 0 0 0 , 0 0 0 or 1 0 6 1,000 or 10 3 100 or 10 2 10 or 10 1

de c i centi milli micro

( d) (c) (m) ( m)

= = = =

0.1 or 10 -1 0.01 or 10 -2 0.001 or 10 -3 0.000.001 or 10

-6

Lubrication and Preventative Maintenance

Torque Values for Split Flange Connections The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and fitting shoulders should fit squarely. Install all bolts, finger tight and then torque evenly. NOTE

Over-torquing bolts will damage the Àanges and/or bolts, which may cause leakage.

Bolt Torque Flange Size in Inches (*) 1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2

Bolt Size in Inches 5/16 3/8 3/8 7/16 1/2 1/2 1/2 5/8 5/8

Newton Meter (Nm) 20–24 30–37 37–47 47–61 62–79 75–88 107–123 187–203 159–180

Pound-Force/Foot (ft. lb.) 15–18 22–27 27–35 35–45 46–58 55–65 79–91 138–150 117–133

(*) Inside diameter of hydraulic tube or hose fitting.

Lubrication and Preventative Maintenance

9-37

Torque Values for Hydraulic Tubes & Fitt

O-Rings Boss Plugs and Swivel Nuts JIC 37o Seat

Tube Nuts for 37o Flared Fittings Torque

Torque

Size

Tubing O.D. in Inches

Thread Size in Inches

Newton Meter (Nm)

PoundForce/ Foot (ft. lb.)

Newton Meter (Nm)

PoundForce/Foot (ft. lb.)

1/4

7/16-20

14–27

10–20

8–14

6–10

5/16

1/2-20

20–34

15–25

14–20

10–15

3/8

9/16-18

34–47

25–35

20–27

15–20

1/2

3/4-16

54–75

40–55

34–41

25–30

5/8

7/8-14

75–102

55–75

47–54

35–40

3/4

1-1/16-12

102–129

75–95

81–95

60–70

7/8

1-3/16-12

129–156

95–115

95–108

70–80

1-5/16-12

156–197

115–145

108–122

80–90

1-1/4

1-5/8-12

203–244

150–180

129–156

95–115

1-1/2

1-7/8-12

271–339

200–250

163–190

120–140

2-1/2-12

407–475

300–350

339–407

250–300

NOTES: 1. Above Torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations. 2. Swivel nuts either swaged or braxed. 3. These torques are not recommended for tubes with wall thickness of 0.89 mm (0.035 in.) or less.

9-38

Lubrication and Preventative Maintenance

Maintenance Record DATE

HOUR METER

MAINTENANCE PERFORMED

Lubrication and Preventative Maintenance

WORK WORK PERFORMED AUTHORIZED BY BY

9-39

Maintenance Record DATE

9-40

HOUR METER

MAINTENANCE PERFORMED

WORK WORK PERFORMED AUTHORIZED BY BY

Lubrication and Preventative Maintenance

Section 10

Optional Equipment

10-1

Auto Lube System Description The auto lube system consists of an air powered pump assembly (fig. 10-1) which is fitted to 120 lb. (54 kg.) grease container. The pump supplies grease under pressure (2500 PSI [172 bar]) to manifolds containing injectors which supply grease to point required. A filter/regulator/lubricator supplies 90 - 100 PSI (6.2 - 7 bar) to the pump. The system is controlled by a lube and sensor controller mounted in the operator's cab (fig. 10-2). The controller will verify delivery of lubricant into a bearing and also controls the lubrication system. The lube points are as follows: Mast Crown Sheaves (4) Mast Lower Sheaves (4) Pipe Rack Bearing - Upper (1) Pipe Rack Bearing - Lower (1) Carousel - Upper (1) Carousel - Lower (1) Pipe Rack Roller (1) Pipe Rack Lock (1) Pipe Positioner (2) Pipe Rack Swing (6)

Fig. 10-1 Air Powered Lube Pump

10-2

Mast Pivot (2) Mast Elevating Cylinders (4) Rear Axle (2) Front Axle - Center (1) Front Axle - Ends (2) Jacks - Rear (2) Jacks - Front (2) Mast Lock (2) Breakout Wrench (3)

Fig. 10-2 Lube System Controller

Optional Equipment

Lube Pump Air Motor

Optional Equipment

10-3

Lube Pump Air Motor

10-4

Optional Equipment

Lube Pump Air Motor

Optional Equipment

10-5

Lube Pump Air Motor

10-6

Optional Equipment

Lube Pump Air Motor

Optional Equipment

10-7

Lube Pump Tube

10-8

Optional Equipment

Lube Pump Tube

Optional Equipment

10-9

Lube Pump Tube

10-10

Optional Equipment

Lube Pump Tube

Optional Equipment

10-11

Auto Lube Injectors SL-1 Injector Assembly Fig. 10-6 SL1 Injector Assembly 1. Adjusting Screw 2. Lock Nut 3. Piston Stop Plug 4. Gasket (2) 5. Washer 6. O Ring 7. Injector Body Assembly 8. Piston Assembly 9. Fitting Assembly 10. Plunger Spring 11. Spring Seat 12. Plunger 13. Packing 14. Inlet Disc 15. Packing 16. Washer 17. Gasket 18. Adapter Bolt 19. Adapter 20. Packing

SL-1 Injector Specifications •

DO NOT exceed N.L.G.I. No. 1 Grade Grease.

•

Minimum operating pressure 1850 PSI (128 bar).

•

Maximum operating pressure 3500 PSI (241 bar).

•

Normal operating pressure 2500 PSI (172 bar).

•

Maximum vent (recharge) pressure 600 PSI (41 bar).

•

Lubricant output is adjustable from .008 cu. in. to .08 cu. in. (.13 cu. cm. to 1.3 cu. cm.).

10-12

Optional Equipment

Auto Lube Injectors

Fig. 10-7 SL-1 Injector Operation Optional Equipment

10-13

Auto Lube System Filter/Regulator/Lubricator Refer to following pages for maintenance and repair of individual units.

Fig. 10-8 Filter/Regulator/Lubricator Combination

10-14

Optional Equipment

Auto Lube System Filter Maintenance and Repair

Optional Equipment

10-15

Auto Lube System Regulator Maintenance and Repair

10-16

Optional Equipment

Auto Lube System Lubricator Maintenance and Repair

Optional Equipment

10-17

Notes

10-18

Optional Equipment

Auto Lube System

Optional Equipment

10-19

Auto Lube System

10-20

Optional Equipment

Auto Lube System

Optional Equipment

10-21

Auto Lube System

10-22

Optional Equipment

Auto Lube System

Optional Equipment

10-23

Auto Lube System

10-24

Optional Equipment

Auto Lube System

Optional Equipment

10-25

Auto Lube System

10-26

Optional Equipment

Auto Lube System

Optional Equipment

10-27

Auto Lube System

10-28

Optional Equipment

Auto Lube System Lube Controller Components

Item 1 2 3 4 5 6 7 8 9 Optional Equipment

Qty. 1 1 1 1 4 1 1 1 1

Description Jumper Shunt (strip of 10) Green LED, Green Lens and Chrome Bezel Amber LED, Amber Lens and Chrome Bezel Red LED, Red Lens and Chrome Bezel Standoff & Screw Ribbon Cable Assembly Seal for Switches Processor Board Assembly Power Supply Board Assembly 10-29

Drill Stem Thread Lubricator

Drill Stem Lubricator System (ref. 401973)

Description and Adjustments The rotary drill can be equipped with an optional automatic drill string thread greasing system. The system uses an air powered grease pump attached to a 35 lb. (15.9 kg.) grease container. The system is activated by a switch on the drill control console, and the pump delivers grease to the nozzle mounted adjacent to the drill stem. Air supply is filtered, lubricated and regulated by the filter/regulator/ lubricator mounted on the left rear jack housing. Normal pressure setting is 80 PSI (5.5 bar). The following pages give maintenance and repair instructions. Refer to parts manual for repair part numbers and kits. Turning the knurled knob on the 3-way air valve increases or decreases the duration of the grease when the switch is activated.

Left Rear Jack Housing 1. Filter/Water Separator 2. Regulator 3. Lubricator 4. 3-Way Air Valve 10-30

Optional Equipment

Drill Stem Thread Lubricator

Optional Equipment

10-31

Drill Stem Thread Lubricator

10-32

Optional Equipment

Drill Stem Thread Lubricator

Optional Equipment

10-33

Drill Stem Thread Lubricator Grease Pump The grease pump is shown below. For operation and repair information, refer to the following Lincoln Owner/ Operator Manual for Model 82716 Series "F".

Grease Pump and Cover (ref. 1417103)

10-34

Optional Equipment

Drill Stem Thread Lubricator

Optional Equipment

10-35

Drill Stem Thread Lubricator

10-36

Optional Equipment

Drill Stem Thread Lubricator

Optional Equipment

10-37

Drill Stem Thread Lubricator

10-38

Optional Equipment

Drill Stem Thread Lubricator

Optional Equipment

10-39

Drill Stem Thread Lubricator

10-40

Optional Equipment

Drill Stem Thread Lubricator

Optional Equipment

10-41

Drill Stem Thread Lubricator

10-42

Optional Equipment

Cold Weather Operation Description For machines operating in arctic type conditions an optional cold weather package can be installed to preheat fluids and lubricants. With the cold weather option, the machine can operate down to temperatures of -40°F (-40°C). The cold weather option includes the appropriate lubricants (listed in this manual) in the compressor, engine, hydraulic system and gear cases. An optional diesel fired heater/pump unit, using fuel from the machine's diesel tank, circulates a water/antifreeze mixture through heat exchanger tubes located in the hydraulic tank, fuel tank, water tank, radiator and engine block. The heating system can also be powered by a generator (GenSet) mounted on the machine, or an external power source, to provide 120 or 240 VAC to the system to thermostatically control heating elements and silicone heating pads. A heater/controller supplies power to a distribution breaker box and pumps heated water/anti-freeze through the engine block. The heating elements for this type of system are installed in the hydraulic tank, fuel tank and engine while the heating pads are installed in the compressor control box, receiver tank, auto lube grease container and under the batteries in the battery tray. Additional measures included for extreme cold protection are: • Thermo-glass cab windows • Additional heater in cab • Spray-on insulating material under the cab, water and fuel tanks • Cold weather wiring for AC/DC systems including low temperature conduit • Ether injection for engine starting, if desired (cat engines only) There are no additional fluid additives required for cold weather operation.

NOTE

When cold weather operation is specified, the options discussed above may be used separately or in combination to suit a specific operating environment.

Heater/Pump Unit A heater/pump unit heats and circulates water and anti-freeze through the engine, radiator, hydraulic tank and fuel tank. A 24VDC motor operates the water pump. Diesel fuel is used to fuel the heating system.

Optional Equipment

10-43

Cold Weather Operation

10-44

Heater Installation

Optional Equipment

Cold Weather Operation

Heater Installation

Optional Equipment

10-45

Cold Weather Operation Operation The pre-heat system is energized prior to starting the machine in temperatures less than 32°F. (0°C) by a switch located on the front of the operator console. Warm up periods are in relation to outside temperatures, but normally sufficient warm up can be accomplished in approximately one hour prior to starting machine. If the machine is supplied by a GenSet, the GenSet is switched on to provide power for preheating. After the GenSet warms up to operating temperature, the heater/controller is switched on and the Operator can then select which system is to be energized via the distribution breaker box. If the heater/controller is supplied power from an external source, the Operator plugs in the system and then switches on the heater/controller.

Cooling System Freeze Protection In the late fall, before temperatures drop below 32oF. (0oC), the complete cooling system should be drained and flushed. The thermostat should be removed during flushing. Check for proper operation or replace before reinstalling. When refilling, add a sufficient amount of anti-freeze for your climate. A 50/50 mixture is recommended for maximum protection.

Water Injection System Freeze Protection To blow water out of the lines and pump before shutting machine down, the following steps need to be done with the machine in idle mode. 1. Turn the optional handle on the cab side crawler frame to open ball valve to drain water tank. After water tank is drained, leave ball valve on bottom of water tank open until time to add water to tank, then close valve. 2. After water tank is drained, open shut off valve on top of air receiver to release air into water system. With the water injection switch in the cab in OFF position, this will blow water through the pump and back to the tank. After 5 seconds, switch the water injection switch to ON. This will blow water into the main air line. 3. Turn main air ON to blow water out of standpipe and drill pipe. Let run for about 15 seconds. At this time all water is out of lines and pump. 4. Shut machine down. While the machine's air receiver is in blowdown mode, leave shut off valve on top of air receiver open to blow into water injection system. 5. After air receiver has blown down, close shut off valve on top of air receiver to close line. 6. Before starting machine, prime the water pump by pouring water into the pipe nipple on suction side of pump inlet.

Receiver Tank Drain water from the receiver tank daily or whenever the machine is shut down for more than one hour. NOTE

10-46

BE SURE to evacuate all the remaining water from the water injection pump to prevent the pump from freezing.

Optional Equipment

Cold Weather Operation–GenSets GenSets on the rotary blasthole drills include a diesel engine power pack, usually Deutz. Refer to the following Deutz operator manual for detailed operation and maintenance information.

Operation Manual

912 913

26 4

Safety guidelines / Accident prevention ● Please read and observe the information given in this Operation Manual. This will enable you to avoid accidents, preserve the manufacturer’s warranty and maintain the engine in peak operating condition. ● This engine has been built exclusively for the application specified in the scope of supply, as described by the equipment manufacturer and is to be used only for the intended purpose. Any use exceeding that scope is considered to be contrary to the intended purpose. The manufacturer will not assume responsibility for any damage resulting therefrom. The risks involved are to be borne solely by the user. ● Use in accordance with the intended purpose also implies compliance with the conditions laid down by the manufacturer for operation, maintenance and servicing. The engine should only be operated by personnel trained in its use and the hazards involved. ● The relevant accident prevention guidelines and other generally accepted safety and industrial hygiene regulations must be observed. ● When the engine is running, there is a risk of injury through: - turning/hot components - engines with positive ignition - ignition systems (high electrical voltage) You must avoid contact at all times!

Optional Equipment

● Unauthorized engine modifications will invalidate any liability claims against the manufacturer for resultant damage. Manipulations of the injection and regulating system may also influence the performance of the engine, and its emissions. Adherence to legislation on pollution cannot be guaranteed under such conditions. ● Do not change, convert or adjust the cooling air intake area to the blower. The manufacturer shall not be held responsible for any damage which results from such work. ● When carrying out maintenance/repair operations on the engine, the use of DEUTZ original parts is prescribed. These are specially designed for your engine and guarantee perfect operation. Non-compliance results in the expiry of the warranty! ● Maintenance and cleaning of the engine should only be carried out when the engine is switched off and has cooled down. You must ensure that the electrical systems have been switched off and the ignition key has been removed. Accident prevention guidelines concerning electrical systems (e.g. VDE-0100/-0101/0104/-0105 Electrical protective measures against dangerous touch voltage) are to be observed. When cleaning with fluids, all electrical components are to be covered impermeably.

10-47

GenSets–Deutz Engine Operation General DEUTZ Diesel Engines

Care and Maintenance

Service

are the product of many years of research and development. The resulting know-how, coupled with stringent quality standards, guarantee their long service life, high reliability and low fuel consumption. It goes without saying that DEUTZ Diesel Engines meet the highest standards for environmental protection.

Sound care and maintenance practices will ensure that the engine continues to meet the requirements placed on it. Recommended service intervals must be observed and service and maintenance work carried out conscientiously. Special care should be taken under abnormally demanding operating conditions.

Please contact one of our authorized service representatives in the event of breakdowns or for spare parts inquiries. Our trained specialists will carry out repairs quickly and professionally, using only genuine spare parts. Original parts from DEUTZ AG are always produced in accordance with state-of-the-art technology. Please turn to the end of this manual for further service information.

Beware of Running Engine

Safety

California Proposition 65 Warning

Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started. Risk of accidents. When the work is complete, be sure to refit any panels and guards that may have been removed. Never fill the fuel tank while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.

This symbol is used for all safety warnings. Please follow them carefully. The attention of operating personnel should be drawn to these safety instructions. General safety and accident prevention regulations laid down by law must also be observed.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Asbestos

DEUTZ original parts are asbestosfree.

Engine Description 2

2.1.1 Rating Plate

2.1.2 Rating Plate Location

25 611 2

The model A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.

10-48

2.1 Model 2.1.3 Engine Serial Number

24 587 1

The rating plate C is attached to the crankcase; depending on the design, a second rating plate may be attached to the air duct.

24 552 1

The engine serial number D is stamped on the crankcase as well as the rating plate.

Optional Equipment

GenSets–Deutz Engine Operation 2.1.6 Two-stage Combustion FL 912W

2.1.5 Direct Injection FL 912

2.1.4 Cylinder Numbering

21 878 3

24 858 1

Cylinders are numbered consecutively, beginning at the flywheel end.

Engines with direct injection are used where high performance is required.

26 045 0

Engines with two-stage combustion are used where it is particularly important to keep exhaust emissions to an absolute minimum.

Engine Description

2.2 Engine Illustrations

2.2.1 Service Side F4L 912

15 14

2 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fan V-belt (fan) Injection pump V-belt (alternator) V-belt pulley Tension roller Oil fill point Oil pan Oil drain plug Fuel pump Oil dipstick Lube oil filter Easy-change fuel filter Air duct cover Cylinder-head cover

12 4 5

6 11

Optional Equipment

24 856 2

10-49

GenSets–Deutz Engine Operation 2.2.2 Exhaust Side F4L 912

16 17

16 17 18 19 20 21 22 23

Air-intake pipe Exhaust manifold pipe Screen Alternator Starter Engine mounting Crankcase Crankcase ventilation

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Fan V-belt (fan) V-belt (alternator) V-belt pulley on crankshaft Tension roller Oil fill point Oil drain plug Fuel filter cartridge Fuel pump with fuel precleaner Injection pump Oil dipstick Lube oil filter cartridge Air duct cover Engine oil radiator cover

18 19 20 21 22 23 24 857 1

2.2.3 Service Side BF4L 913

2 13

12 4 11 10 10-50

30016 0

Optional Equipment

GenSets–Deutz Engine Operation 2.2.4 Exhaust Side BF4L 913

15 16 17 18 19 20 21 22 23

Exhaust manifold line Terminal housing Starter Crankcase ventilation Oil pan Alternator Exhaust turbocharger Air-intake pipe-exhaust turbocharger Charge-air line

30017 0

Engine Description

2.3 Lube Oil Circuit

2.3.1 Lube Oil Circuit FL 912 / 913

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

22 18 17 19 16 6 15 20 5

17 18 19 20 21 22 23 24 25

10 9 11 13 21 1 12 14 2 3 19 058 6

Optional Equipment

Oil pan Intake manifold Oil pump Oil pressure control valve Pressure-oil line Bypass line or selectively Finned pipe spiral or selectively Frame oil cooler Lube oil filter Safety valve Main oil gallery Crankshaft bearing Con-rod bearing Camshaft bearing Tappets Push rod (hollow, for oil feed to rocker arm lubrication) Rocker arm bearing Metering plug (r. arm lubrication)* Protective sleeve for push rod Throttle bore (for lubrication of the gear wheels) Injection jet for cooling the pistons Connection for oil pressure gauge Oil pressure gauge Injection pump connected to lube oil circuit Connection point for oil heating**

* only for inclined engines ** in this instance the filter holder must be replaced. Please contact our service representative for this alteration.

10-51

GenSets–Deutz Engine Operation 2.3.1 Lube Oil Circuit BF6L 913

21 17 16

18 15

23 25 22 14 19 5

24 10

20 1

12 11 2 1324 355 2

Engine Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Oil pan Intake manifold Oil pump Oil pressure control valve Pressure-oil line Connecting line to oil cooler Frame oil cooler Lube oil filter Safety valve Main oil gallery Crankshaft bearing Con-rod bearing Camshaft bearing Tappets (with impulse lubrication of the rocker arm) Push rod (hollow, for oil feed to r. arm lubrication) Rocker arm bearing Metering plug (r. arm lubrication)* Protective sleeve for push rod (oil return from cylinder head to crankcase) Throttle bore (for lubrication of the gear wheels) Injection jet for cooling the pistons Oil line for lub. of the exhaust turbocharger Oil ret. line from exhaust turboc. to the crankcase Oil pressure gauge Partial-flow lube oil filter Connection point for oil heating** Injection pump connected to lube oil circuit

* only for inclined engines ** in this instance the filter holder must be replaced. Please contact our service representative for this alteration.

2.4 Fuel System Schematic

2.4.1 Fuel Circuit

1 2 3 4 5 6 7 8 9 10 11 A

Fuel tank Fuel line from tank to fuel pump Fuel supply pump Easy-change fuel filter Injection pump Injection lines Injection valves Oil leakage line Fuel overflow pipe Overflow valve Fuel return line to tank Clearance: keep as far apart as possible

24 673 3

10-52

Optional Equipment

GenSets–Deutz Engine Operation Engine Description

2.5 Engine Cooling 2.5.1 Regulation of Coolant Flow using the Exhaust Thermostat

1 Pressure-oil line from engine to exhaust thermostat 2 Air line to exhaust thermostat 3 Exhaust manifold pipe 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive 9 Oil return line to crankcase 10 Ventilation line 11 Adjusting pin with special seal

26 120 1

2.5.2 Regulation of Coolant Flow using the Exhaust Thermostat and Solenoid

26 121 0

Optional Equipment

10-53

GenSets–Deutz Engine Operation Engine Operation 3

3.1 Commissioning

3.1.1 Adding Engine Oil

3.1.2 Filling Oil Bath Air Cleaner

3.1.3 Adding Fuel

FUEL

24 675 1

As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see 4.1

Fill oil cup 1 of the oil bath air cleaner with engine oil up to the arrow. For oil grade and viscosity, see 4.1

Use only commercial-grade diesel fuel. For fuel grade, see 4.2. Use summer or winter-grade fuel, depending on the ambient temperature.

Oil may not be filled into the dust collector of the precleaner, if this is fitted.

Never fill the tank while the engine is running. Keep the filler cap area clean and do not spill fuel.

! 3.1.4 Ventilation Model: “Bosch” fuel pump

Ventilation Model: “IMSA” fuel pump

24 593 1

● Loosen overflow valve 1 at the lower (larger) hexagon. ● Loosen hand pump 2 at the notched grip 3 by unscrewing by several turns to the left. ● Actuate hand pump 2 until bubble-free fuel is emitted at the loosened overflow valve 1. ● Tighten overflow valve 1, continuing to pump at the same time. ● Tighten grip 3.

10-54

26 398 0

24 980 2

24 592 1

● Loosen overflow valve 1 at the lower (larger) hexagon. ● Actuate preliminary pump lever 2 against the spring pressure until bubble-free fuel is emitted at the loosened overflow valve 1. ● Tighten overflow valve 1, continuing to pump at the same time.

Optional Equipment

GenSets–Deutz Engine Operation 3.1.5 Other Preparations

3.1.6 Additional Maintenance Work

● Check battery and cable connections, see 6.7.1

The following maintenance should be carried out after 50-150 operating hours:

● Transport hooks Remove if fitted (see 6.7.3). ● Trial run After the engine has been prepared, let it run for about 10 minutes without load.

● Change lube oil, see 6.1.2 ● Change oil filter cartridge, see 6.1.3

During and after trial run – Check the engine for leaks.

● Change fuel filter cartridge, see 6.2.1

After the engine has been turned off – Check the oil level, see 6.1.2 If necessary, top up oil, see 3.1.1 Retension V-belts, see 6.5

● Check V-belts and retension as necessary, see 6.5

● Breaking in During the break-in phase – about 200 operating hours – check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.

3.1.7 Selector Switch for Oil Heater

● Check valve clearance and adjust as necessary, see 6.6.1 ● Check the engine for leaks. ● Check the engine mount and adjust as necessary, see 9.2

30 027 0

Position of selector switch for oil filter console with oil heater connection: Pos. 1: open Pos. 2: closed

! Engine Operation

For engines without oil heating, the selector switch is always open Pos. 2: to lock closed.

3.2 Starting

3.2.1 Electric Starting Starting without Cold-Start Aid Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with flame glow system, do not use any other starter substance (e.g. injection with start pilot).

Caution: If the speed regulator has been removed, the engine must not be tested under any circumstances: Disconnect the battery.

24 627 2

● Where possible, disengage the clutch to separate the engine from any driven parts. ● Move speed control lever 1 into idle position.

Do not actuate the starter for more than 20 seconds. If the engine does not catch, wait a minute then try again. If the engine does not catch after two attempts, refer to the Diagnosis Chart (see 7.1).

Optional Equipment

25 746 2

● Insert key. – Position 0 = no operating voltage ● Turn key clockwise – Position 1 = operating voltage – Pilot lights come on. ● Push the key in and turn it further clockwise against spring pressure – Position 2 = no function – Position 3 = start ● Release key as soon as engine fires – Pilot lights go out.

10-55

GenSets–Deutz Engine Operation with Cold-Start Aid/Flame Glow Plug FR 60 = 9.5 and 19 volts

with Cold-Start Aid/Flame Glow Plug FR 20/30 = 11 and 23 volts

25 746 2

● Insert key. – Position 0 = no operating voltage. ● Turn key clockwise. – Position 1 = operating voltage – Pilot lights come on. ● Push key in and turn further clockwise against spring pressure. – Glow plug indicator comes on. – Position 2 = Preheat for approx. 60 seconds (hold key in position)*. – Glow plug indicator goes out. – Position 3 = start ● Release key as soon as engine fires. – Pilot lights go out. * By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.

with heating pipe

25 746 2

● Insert key. – Position 0 = no operating voltage ● Turn key clockwise. – Position 1 = operating voltage – Pilot lights come on. ● Push key in and turn further clockwise against spring pressure. – Glow plug indicator comes on. – Position 2 = Preheat for approx. 20 -30 seconds (hold key in position)*. – Glow plug indicator goes out – Position 3 = start ● Release key as soon as engine fires – Pilot lights go out. * By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.

Engine Operation

25 746 2

● Insert key. – Position 0 = no operating voltage. ● Turn key clockwise. – Position 1 = operating voltage – Pilot lights come on. ● Push key in and turn further clockwise against spring pressure. – Position 2 = Preheat for approx. 60 seconds (hold key in position)*. – Position 3 = start ● Release key as soon as engine fires – Pilot lights go out.

* By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.

3.3 Monitoring Systems

3.3.1 Engine Oil Pressure Oil Pressure Pilot Light

Oil Pressure Indicator

25 752 1

● The oil pressure pilot light comes on with operating voltage on and engine off. ● The oil pressure pilot light should go out when the engine is running.

10-56

Oil Pressure Gauge

25 753 0

● The pointer must remain in the green sector over the entire range.

25 754 0

● The pointer must indicate the minimum oil pressure (see 9.1).

Optional Equipment

GenSets–Deutz Engine Operation 3.3.2 Engine Temperature

3.3.3 Cooling Fan Drive

Temperature Gauge

24 590 1

24 985 0

● The engine temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn off and establish the cause from the Diagnosis Chart (see 7.1).

● If the V-belt rips, pressure pin 1 of the electrical switch is actuated by the tension roller and an acoustic or light signal is given. Switch off the engine immediately to prevent overheating.

Engine Operation

3.4 Stopping

3.4.1 Mechanical Shutdown

3.4.2 Electrical Shutdown Ignition Key

24 630 1

● Move speed control lever 1 to low idle. ● Operate shutdown lever 2 until the engine comes to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops. ● Turn key anticlockwise (to position 0) and remove. The pilot lights will go out.

25 746 2

● Turn key anticlockwise (to position 0) and remove. The pilot lights will go out.

If possible, do not suddenly switch off the engine when under full load.

Optional Equipment

10-57

GenSets–Deutz Engine Operation Engine Operation

3.5 Operating Conditions 3.5.1 Winter Operation

● Lube Oil Viscosity – Select the oil viscosity (SAE grade) according to the ambient temperature when the engine is started, see 4.1.2 – Increase oil change frequency when operating below -10 °C, see 6.1.1 ● Diesel Fuel – Use winter-grade diesel fuel for operation below 0 °C, see 4.2.2

● Battery – Efficient cold starting requires a healthy battery, see 6.7.1 – The starting limit temperatures can be lowered by 4-5 °C by heating the battery up to about +20 °C. (To do so, remove the battery and store in a warm place.)

● Additional Maintenance Work – Drain the sludge from the fuel tank once a week. (Unscrew the sludge drain plug.) – If necessary, allow the oil in the oil bath air cleaner and the engine oil to settle at the ambient temperature. – Below -20 °C, after removing the starter if necessary, smear the ring gear on the fly wheel via the pinion bore from time to time with coldresistant grease (e.g. Bosch grease FT 1 V 31).

26 248 0

● Cold-Start Aid – At temperatures near or below freezing point, use glow plugs if necessary, see 3.2.1. This not only lowers the starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid.

3.5.2 High Ambient Temperatures, High Altitude ● As the altitude and ambient temperature rise, the density of air tends to decrease, which affects the maximum power output of the engine, the exhaust gas quality and, in extreme cases, the starting behaviour. Under transient conditions, the engine can be used at altitudes up to 1000 m and temperatures up to 30 °C. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quantity and thus, engine power. ● If you have any doubts about engine operation under these or similar conditions, ask your engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.

10-58

25 901 1

Optional Equipment

GenSets–Deutz Engine Operation Operating Media

Approved ACEA Oils: At least:

E1-96

SAE 40

59 50

+ 10

41 32

23 14

- 10

5 -4

- 20

- 13 - 22

- 30

- 40

4.2.1 Quality Grade

4.2.2 Winter-Grade Fuel

Use commercially available diesel fuel with less than 0.5 % sulphur content. If the sulphur content is higher than 0.5 % oil change intervals should be reduced, see 6.1.1

Waxing may occur at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0 °C, wintergrade fuel (suitable down to -15 °C) should be used. (This fuel is usually available from the filling stations well in advance of the cold months). Diesel fuel containing additives (Super diesel) is often on sale as well, for use down to -20 °C.

● DIN EN 590 ● BS 2869: A1 and A2 (with A2, take note of the sulphur content!) ● ASTM D 975-88; 1-D and 2-D ● NATO Code F-54 and F-75 Any exhaust emission levels which may have been determined during type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test.

● Below -20 °C, petroleum must be added. For the required mixing ratios please refer to the adjacent diagram. ● For artic climate zones down to -44 °C special diesel fuels can be used. If summer-grade diesel fuel must be used at temperatures below 0 °C, up to 60% kerosene can be added (see diagram). In most cases, adequate resistance to cold can be obtained by adding a flow improver (additive). Please inquire at DEUTZ-PARTNER.

+32

+23

-5

+14 - 10 + 5 - 15 - 4 - 20 - 13 - 25 II - 22 - 30 °F

°C

60 %

B A

26441 1

Legend: I

Summer diesel fuel

Winter diesel fuel

Ambient

Proportion of Kerosene to be

! Optional Equipment

✳

Operating Media

4.2 Fuel

The following fuel specifications / standards are approved:

- 40

26021 0

-31

Oil change intervals, see 6.1.1 Oil capacities, see 9.1

✳ nur mitwith Motorvorwärmung *only engine oil preheating

+ 20

SAE 30

At least:

SAE 20W/20

Approved API Oils:

°C + 30

°F 86

SAE 15W/40

As the viscosity of the lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site. Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of SAE grade selected, cold starting may be affected but the engine will not be damaged. In order to keep wear to a minimum, do not exceed application limits for extended periods of time. Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. Multi-grade oils – particularly light-flowing oils – also reduce fuel consumption.

SAE 15W/30

Lube oils are differentiated according to their performance and quality class. In common use are specifications named after the API (American Petroleum Institute) and ACEA (European Engine Oil Sequences).

SAE 10W/40

4.1.2 Viscosity

SAE 10W/30

4.1.1 Quality grade

SAE 5W/30 (Synthetic)

4.1 Lube Oil

Mix in tank only. Fill with the appropriate amount of kerosene first, then add the diesel fuel.

10-59

GenSets–Deutz Engine Operation Routine Maintenance 5

check

Operating hours (OP)1) every

Once after

every 10 OH 2) or 50-150 daily

5.1 Maintenance Schedule

change 125

250

500

1000

2000

3000

5000

●

Operation ●

●

Oil level in engine / separate container Engine leaks Oil bath- and dry type air cleaners 3) 4) Battery and cable connectors Cooling system (depending on engine use) 3) 6) Engine oil (depending on engine use) 5) Oil filter cartridge Fuel filter cartridge Valve clearance (adjust if necessary) Engine mounts (retighten if necessary) V-belts (retension if necessary) Warning system Fuel precleaner Mountings Flame glow plugs 4) Partial-flow oil filter Sheathed element heater plugs Injection valve

● ●

●

● ●

●

● ●

●

● ●

See Section

clean

●

● ●

●

● ●

●

6.1.2 6.3/6.4 6.7.1 6.3.1/6.3.2 6.1.1/6.1.2 6.1.3 6.2.1 6.6.1 9.2 6.5 6.5.5 6.2.2 6.8.1 6.8.3 6.1.4

The specified engine maintenance times are maximum values. Depending on the operating environment, shorter maintenance intervals may be required. Please observe the operating instructions of the equipment manufacturer. 1) Recommended maximum 2) Commissioning new or reconditioned engines 3) Clean if needed, see Section 6.3 4) Change if necessary. If fitted, service after service indicator. 5) Oil change interval, see Section 6.1.1 6) Clean system / cooling fins.

Routine Maintenance

5.2 Maintenance Charts The maintenance charts shown here are supplied as self-adhesive labels with each engine. They should be affixed where they can be seen clearly on the engine or driven equipment.

FL 912/913

h Std.

AIR

a in.

Check that this is the case.

0,15 mm 0.006 in

1000 ca. 15 mm 0.6 in.

ex.

250

If necessary, ask your engine or equipment supplier for a fresh supply of labels. Routine work should be carried out according to the schedule in 5.1

1252000 250 FU EL

1000 OIL

500 500

500

OIL

0297 7224

1000

OIL max.

h Std.

0,15 mm 0.006 in

in.

AIR

500 ex.

ca. 15 mm 0.6 in.

1252000

250

250 500 OIL

1000

Stop the engine before carrying out any maintenance work.

OIL

500 10

OIL

max.

BF 4/6L 913/C/T 0297 4070

10-60

1000

Optional Equipment

GenSets–Deutz Engine Operation Routine Maintenance Hours

Date

Signature / Stamp

5.3 Completed Maintenance Jobs Hours

50-150*

–

125

250

375

500

625

750

875

1000

1125

1250

1375

1500

1625

1750

1875

2000

2115

2250

2375

2500

2625

2750

Date

Signature / Stamp

* Commissioning new and overhauled engines. The maintenance jobs duly completed can be recorded in the above table.

Hours

Date

Signature / Stamp

Hours

2875

3000

3125

3250

3375

3500

3625

3750

3875

4000

4125

4250

4375

4500

4625

4750

4875

5000

5125

5250

5375

5500

5625

5750

Date

Signature / Stamp

The maintenance jobs duly completed can be recorded in the above table.

Optional Equipment

10-61

GenSets–Deutz Engine Operation Routine Maintenance Hours

Date

5.3 Completed Maintenance Jobs

Signature / Stamp

Hours

5875

6000

6125

6250

6375

6500

6625

6750

6875

7000

7125

7250

7375

7500

7625

7750

7875

8000

8125

8250

8375

8500

8625

8750

Signature / Stamp

Date

The maintenance jobs duly completed can be recorded in the above table.

Service and Maintenance 6

6.1 Lubrication System

6.1.1 Oil Change Intervals

Lube oil intervals in OH Installed engines Naturally aspirated engines

● The oil change intervals are dependent on the engine application and the quality of the lube oil.

Lube oil quality

● If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year. ● The table refers to the following conditions: – For diesel fuel: sulphur content max. 0.5% by weight. – Continuous ambient temperatures down to -10 °C (+14 °F). ● If the sulphur content is > 0.5 to 1% or the continuous ambient temperature below -10 °C (+14 °F), the intervals between oil changes should be halved.

Turbocharged engines

API classification

CF-4/CH-4/CG-4

CF-4

CH-4/CG-4

ACEA classification

E1-E3/96+ E4-98

E1-E2/96

E3-96+ E4-98

500

250

500

250

125

250

Normal oil usage, e.g.: Road vehicles, cranes, construction machinery, ships, electrical units, pumps, rail-run vehicles Heavy-duty oil usage, e.g.: Combine harvesters, emergency pumps, underground equipment, sweeping machines, winter operation equipment, emergency power generating units

● In the case of fuels containing more than 1% sulphur, contact your service representative.

Lube oil intervals in km Vehicle engines Naturally aspirated engine

Turbocharged engine

API classification

CF-4/CH-4/CG-4

CF-4

CH-4/CG-4

ACEA classification

E1-E3/96+ E4-98

E1-E2/96

E3-96+ E4-98

Lube oil quality

Change the oil with the engine off but still warm (lube oil temperature approx. 80 °C).

10-62

Service group

Annual kilome trage km

average speed approx km/h

> 30 000

10 000

5 000

10 000

30 000 – 100 000

20 000

10 000

20 000

III

< 100 000

30 000

15 000

30 000

Optional Equipment

GenSets–Deutz Engine Operation Service and Maintenance

6.1 Lubrication System 6.1.2 6.1.2.1

Checking Oil Level / Changing Engine Oil Checking Oil Level

6.1.2.2

25 729 0

● Ensure that the engine or vehicle is in a horizontal position. ● – Warm engine: Switch off engine, wait 5 minutes and check the öil level. ● – Cold engine: Check oil level. To this end: ● Remove the oil dipstick. ● Wipe the dipstick with a non-fibrous, clean cloth. ● Insert it to the stop and remove again. ● Check the oil level, and if necessary, top up to the “MAX” mark. – If the oil level is only just above the “MIN” mark, more oil must be added. The oil level must not fall below the “MIN” marking.

Engine Oil Change

26 022 0

● Ensure that the engine or vehicle is on a level surface. ● Allow the engine to warm up – Lube oil temperature approx. 80°C. ● Switch off the engine.

26 023 0

● Place oil tray under the engine. ● Unscrew drain plug. ● Drain oil. ● Fit oil drain plug, with the new gasket and tighten firmly (for torque, see 9.2). ● Fill with lube oil. – For grade / viscosity, see 4.1 – For quantity, see 9.1 ● Check oil level, see 6.1.2.1

Be careful when draining hot oil – danger of scalds! Do not let used oil run into the soil but catch it in a container ready for proper disposal.

6.1.3 Changing Oil Filter

25880 0

● Undo the filter cartridge using a commercial tool and spin off. ● Catch any dripping oil.

● Clean any dirt from the filter carrier rim. ● Lightly oil the rubber gasket of the new oil filter cartridge. ● Screw in the new cartridge finger tight against the gasket.

Optional Equipment

25882 0

25881 0

● Tighten the oil filter cartridge with another halfturn. ● Check oil level, see 6.1.2 ● Check oil pressure, see 3.3.1 ● Check cartridge seal for leaks.

10-63

GenSets–Deutz Engine Operation 6.1.4 Changing the Partial-Flow Oil Filter Insert

24 511 1

● Unscrew oil drain plug 1 and drain off oil. ● Unscrew tension screw 2. Remove the cover. ● Unscrew the dirtied filter insert 3. Clean the filter housing. ● Check and if necessary replace cover seal 4. ● Screw in oil drain plug 1 with new seal 5. ● Fit new filter insert. ● Screw on cover with sealing ring 6. ● Check for leaks and check the oil pressure during a test run.

Service and Maintenance 6

6.2.1 Changing Fuel Filter

25880 0

● Close fuel stopcock. ● Undo fuel filter cartridge with commercial tool and spin off. ● Catch any fuel.

! 10-64

6.2 Fuel System

Keep naked flames away when working on the fuel system. Do not smoke.

25882 0

25881 0

● Clean any dirt from the filter cartridge with a final half-turn.

● Tighten the fuel filter cartridge with a final halfturn.

● Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.

● Open fuel stopcock.

● Screw in the new cartridge finger tight against the gasket.

● Check for leaks.

The fuel system does not need to be bled.

Optional Equipment

GenSets–Deutz Engine Operation 6.2.2 Fuel Precleaner Cleaning the Fuel Filter “Bosch” model

Cleaning the Fuel Filter “IMSA” model

1 2 3 4 19 725 2

● Close the fuel shut-off valve. ● Loosen tensioning nut 2. ● Swing wire clip 1 to the side. ● Remove filter cone 5 with strainer 4 and clean in fuel. ● Use a new seal 3 for filter cone 5. ● Bleed the fuel system, see 3.1.4 ● Check for leaks.

26 047 1

● Close the fuel shut-off valve. ● Loosen hexagonal nut 1 and unscrew with sealing ring 2. ● Remove cover 3. ● Remove fuel strainer 4.

● Clean the fuel strainer 4 in fuel. Replace if necessary. ● Refit in the reverse order. ● Bleed fuel system, see 3.1.4 ● Check for leaks.

No naked flames when working on the fuel system. No smoking!

Service and Maintenance

6.3 Cooling System

6.3.1 Cleaning Intervals

● The amount of contamination in the cooling system depends on the engine application. ● Spilled oil or fuel on the engine increases the risk of contamination. Be especially careful if the engine is used in dusty environments. ● Serious contamination can occur, for example: – on construction sites where there is a high level of air-borne dust. – in harvesting application where there are high concentrations of chaff and chopped straw in the vicinity of the machine. ● Because applications vary, cleaning intervals have to be determined from case to case. The cleaning intervals given in the table on the right can be used as a guide.

Optional Equipment

Inspection and cleaning intervals Engine application Recommended OH 2000

Ships, Electrical units in enclosed areas, pumps

1000

Vehicles on reinforced highways

500

Tractors, fork-lift trucks, mobile electrical units

250

Vehicles on construction sites and on roads with loose surfaces, constrution machinery, compressors, mining equipment

125

Agricultural machinery, tractors used for harvesting purposes

10-65

GenSets–Deutz Engine Operation 6.4 Combustion Air Filter

Service and Maintenance

6.4.1 Cleaning Intervals

● The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner. ● Cleaning intervals will have to be determined from case to case. ● If dry-type air cleaners are used, they should be cleaned only in accordance with the service indicator or the service switch. ● Air cleaner servicing is needed when: – Service indicator the red signal 1 is fully visible when the engine is off. – Service switch the yellow pilot light comes on when the engine is running.

25 885 1

● After carrying out service work, reset the signal by pressing the button on the service indicator.

6.4.2 Emptying Cyclone Type Precleaner

6.4.3 Cleaning Oil Bath Air Cleaner

25 886 0

● Undo wing nut 1 and remove cover 2. ● Remove collector bowl 3 from lower section 4 and empty. Clean leaves, straw and other foreign matter from lower section of precleaner. ● Reposition collector bowl 3 onto lower section 4, fasten cover 2 in place by tightening wing nut 1.

Never fill collector bowl with oil. Replace collector bowl if damaged.

10-66

25 887 0

● Turn engine off and wait about 10 minutes for the oil to drain from filter housing 1. ● Release snap clips 2 and remove oil cup 3 together with filter element 4. If necessary prise element out with a screwdriver, taking care not to damage the rubber gasket 5. ● Remove dirty oil and sludge. Clean oil cup. ● Clean filter element 4 in diesel fuel and allow to drip-dry.

● Clean filter housing 1 if very dirty. ● Inspect and replace rubber gasket 5 and 6 if necessary. ● Fill oil cup with engine oil up to the mark (arrow) (for viscosity, see 4.1.2). ● Refit oil cup and element to filter housing and secure with snap clips.

Never clean air cleaner with gasoline. Dispose of cold oil in accordance with environmental regulations!

Optional Equipment

GenSets–Deutz Engine Operation 6.4.4 Dry Type Air Cleaner Dust Discharge Valve

Filter Cartridges

25 888 1

● Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows. ● Clean discharge slot from time to time. ● Remove any caked dirt by pressing together the upper section of the valve.

25 889 0

● Undo clip fasteners 1. ● Take off hood 2 and remove cartridge 3. ● Clean cartridge (replace at least once a year). ● Clean cartridge 3. Blow out from inside out with dry compressed air (max. 5 bar), (or in difficult cases, tap out, taking care not to damage the cartridge, or wash according to manufacturer’s instructions). ● Through regular removal and replacement, the gaskets on the filter cartridge can become damaged. Check paper filter (light showing through) and gaskets for damage. Replace if necessary.

● After five cleaner services or after two years at the latest, replace safety cartridge 4 (never clean). To do so: – Undo hex. nut 5 and remove cartridge 4. – Install new cartridge, insert and tighten hex. nut. ● Install cartridge 3, replace hood 2 and do up clip fasteners 1.

Optional Equipment

Never clean filter cartridge with gasoline or hot fluids.

10-67

GenSets–Deutz Engine Operation Service and Maintenance

6.5 Belt Drives

6.5.1 Checking V-Belts

6.5.2 Changing the Fan V-Belt

25 890 2

● Inspect entire V-belt for damage. ● Replace damaged V-belts. ● After installing new belts, run engine for 15 minutes, then check belt tension. ● To check the tension of the V-belt, use a tension gauge (see 9.3). – Place indicator arm 1 into gauge. – Position gauge on V-belt 2, midway between the pulleys, with flange 3 on bottom of gauge against the edge of belt. – Push slowly on the black pad 4 at right angles to belt 2 until the spring is heard or felt to trigger.

24 684 1

– Carefully remove the gauge without altering the position of the indicator arm 1. Read off the value where the black indicator arm 1 intersects scale 5 (arrow). For settings, see 9.1 – If necessary, retension belt and measure again.

● To replace, press in tension roller 1 using a commercial tool and remove the V-belts.

Check tension and change belts only with the engine off. Refit belt guard, if provided.

When new V-belts are fitted, check the belt tension after ca. 15 minutes running time.

! 6.5.3 Tensioning Alternator Belts

26 051 1

● Loosen bolts 1, 2 and 3. ● Press alternator 4 outwards in direction of arrow A until correct belt tension is achieved. ● Retighten bolts 1, 2 and 3.

! 10-68

Only check/tension/replace V-belts when the engine is at a standstill. If necessary, replace V-belt cover.

24 684 1

6.5.4 Changing Alternator Belts

● Fit new V-belts.

6.5.5 Checking Warning System

26 052 0

24 590 1

● Remove fan V-belts as described under 6.5.2 ● Loosen bolts 1, 2 and 3. ● Swing alternator 4 inwards in direction of arrow B. ● Remove V-belts and place on new belt. ● Swing alternator 4 outwards in direction of arrow A until correct belt tension is achieved. ● Retighten bolts 1, 2 and 3. ● Fit fan V-belts.

● If the V-belt rips, pressure pin 1 of the electrical switch is actuated by the tension roller and an acoustic or light signal is given. ● Functional check by pressing in pin 1.

Retighten new V-belts after 15 minutes running time.

Only carry out a check when the engine is at a standstill.

Optional Equipment

GenSets–Deutz Engine Operation 6.5.6 Tensioning and Changing Air Compressor V-Belts

24 598 1

● Unscrew hexagonal bolts 1. ● Remove outer half of belt pulley 2. ● If necessary replace the V-belts.

24 599 1

● To tighten, remove one or more of the inner intermediate discs 3. Place the removed discs on the removed half of the V-belt pulley 2. ● Retighten bolt 1. Whilst tightening, simultaneously rotate the engine to prevent the V-belt from being crushed.

When new V-belts are fitted, check the belt tension after ca. 15 minutes running time.

6.5.7 Air Compressor Design with Double V-Belt

20 762 2

● Screw off hexagonal nut 1, remove V-belt pulley half 2, V-belt 3 and intermediate disc packet 7. ● Remove intermediate disc 4, rear V-belt 3, intermediate disc packet 6 and V-belt disc half 5. ● To tighten, remove one or more of the intermediate discs from packet 6 or 7. Place the removed discs in front of or behind V-belt pulley halves 2, so that the V-belt remains aligned. Always take the same number of discs from each packet.

Optional Equipment

● Fit in the reverse order. Whilst tightening nut 1, the engine must be rotated to prevent the V-belts from being crushed.

If a V-belt is worn or damaged, both belts in the set must be replaced. The difference in the length of the new V-belts may not exceed 0.15%.

Only check or replace the V-belts when the engine is at a standstill. If necessary, replace the V-belt cover. When new Vbelts are fitted, check the belt tension after approx. 15 minutes running time.

10-69

GenSets–Deutz Engine Operation Service and Maintenance

6.6 Adjustments

6.6.1 Checking / Adjusting Valve Clearances

19 691 2

● Remove the cylinder head cover. ● Position crankshaft as per schematic 6.6.1.1 ● Before adjusting valve clearance, allow engine to cool down for at least 30 minutes. The oil temperature should be below 80 °C. ● Check valve clearance 1 between rocker arm / tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1

26 053 1

● Adjust valve clearance if necessary: – Release locknut 4. – Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened. ● Check and adjust valve clearance on all remaining cylinders. ● Replace cylinder head cover (use new gasket if needed).

Only inclined engines are fitted with an additional oil jet for lubrication of the bearing. Any adjustments must be carried out in an authorised specialist workshop.

6.6.1.1

Valve Clearance Adjustments Schematic ● Crankshaft Position 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valves marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been done.

● Crankshaft Position 2: Turn crankshaft one full revolution (360°). Adjust clearance of valves marked in black on schematic.

26 055 1

10-70

Optional Equipment

GenSets–Deutz Engine Operation Service and Maintenance 6.7.1 6.7.1.1

Battery Checking Battery and Cable Connectors

6.7 Accessories

6.7.1.2

Checking Electrolyte Level

25 895 0

● Keep battery clean and dry. ● Undo dirty clamps. ● Clean terminal posts (+ and -) and clamps of the battery, and grease with acid-free and acidresistant grease. ● When reassembling, ensure that clamps make good contact. Do up clamp bolts finger tight.

in [kg/ l]

24 232 3

● Remove caps 1. ● If testers 2 are used, the electrolyte should come up to their base. ● If testers are not used, the electrolyte level should be 10-15 mm above the top of the plates. ● If necessary, top up with distilled water. ● Replace caps.

in[°Bé (Baumégrad)*]

6.7.1.3

Checking Electrolyte Density

25 896 0

● Measure the electrolyte density of individual cells with a commercial hydrometer. The hydrometer reading (see table on following page) indicates the state of charge. During measurement, the temperature of the electrolyte should preferably be +20 °C.

State of Charge

Normal

Tropics

Normal

Tropics

1,28

1,23

Fully charged

1,20

1,12

Half charged, recharge

1,12

1,08

Discharged, recharge immediately

* Measurement of electrolyte density in ° Bé (Baumégrad) is out of date and rarely used today.

The gases emitted by the battery are explosive! Keep sparks and naked flames away from the battery. Do not allow battery acid to come into contact with skin or clothing. Wear protective goggles. Do not rest tools on the battery.

Optional Equipment

10-71

GenSets–Deutz Engine Operation 6.7.2 Three-Phase Alternator

6.7.3 Lifting Tackle

Notes on the three-phase system: ● Never disconnect the cables between battery, alternator and regulator while the engine is running. ● If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting. ● Be sure not to confuse the battery terminals. ● Replace defective bulb of the charge pilot lamp immediately. ● When washing the engine, cover up the alternator and regulator. ● The habit of touching a lead against the frame to check whether it is live must under no circumstances be used with three-phase electrical systems. ● In case of electric welding, connect the ground terminal on the welder directly to the piece being welded.

26 056 0

26 057 0

● Always use proper lifting tackle 1 when transporting the engine. ● After transportation and before commissioning of the engine: Remove transport eyes 2.

Use only the correct lifting tackle.

Service and Maintenance

6.8 Engine Cleaning 6.8.1 Cleaning the Engine With Cold-Cleaning Compound

With Compressed Air

26 048 0

● Switch off the engine. ● Remove engine covers, cooling-air hoods. Replace following cleaning and before test run. ● Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). ● Pass compressed air through the engine, being careful with the cooler and cooling fins (start at the exhaust side) Remove dirt which has been blown into the inner compartment.

With High-Pressure Equipment

26 049 0

● Switch off the engine. ● Remove engine covers, cooling-air hoods. Replace following cleaning and before test run. ● Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). ● Spray engine with commercial cold-cleaning compound and leave to work for approx. 10 minutes. ● Spray engine clean with water jet and if necessary repeat procedure. ● Drive the engine warm so that remaining water evaporates.

26 050 0

● Switch off the engine. ● Remove engine covers, cooling-air hoods. Replace following cleaning and before test run. ● Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). ● Clean engine with steam jet (max. spray pressure 60 bar, max. steam temperature 90 °C) ● Drive the engine warm so that remaining water evaporates.

! 10-72

The engine may only be cleaned when it is at a standstill.

Optional Equipment

GenSets–Deutz Engine Operation Service and Maintenance

6.9 Additional Maintenance

6.9.1 Checking the Mountings

6.9.3 Checking the Function of the Flame Glowing System

6.9.2 Checking the Function of the Heating Pipe

26 111 0

● Cylinder head cover 1 ● Air-intake pipe 2 ● Coupling sleeves ● Exhaust line 3 ● Engine mounting 4

26 113 0

● When functioning correctly, the heating pipe heats up via the integrated heating coil when starting with preheating. – 1 heating pipe – 2 air intake pipe

25 746 2

24 717 1

● When functioning correctly, intake pipe 4 heats up in the vicinity of flame glow plug 2 when starting with preheating.

24 717 1

Test stage 1:

Test stage 2:

Test stage 3:

● Move speed adjustment lever and shut-off lever to “stop” position. ● Insert key – Position 0 = no operating voltage ● Turn key clockwise. – Position 1 = operating voltage – Pilot lights come on. ● Press in key and turn further clockwise against the spring pressure. – Position 2 = preheat, hold for approx. 1 minute. – Preheat lamp lights up. ● Otherwise flame glow plug defective or power interrupted.

● Loosen pipe connection 1. ● Rotate engine with starter, key on switch position 3. ● Fuel must be emitted at loosened pipe connection. Otherwise have the system, solenoid 3, checked by a specialist.

● Loosen pipe connection 1. ● Remove flame glow plug 2. ● Rotate engine with starter, key in switch position 3. ● Fuel must be emitted at flame glow plug 2, replace plug 2 as necessary. ● Use sealant DEUTZ DW 47 when fitting flame glow plug 2. ● Refit flame glow plug 2 on fuel line. Keep clear of rotating parts.

Optional Equipment

Collect any leaked fuel and dispose of in an environmentally friendly fashion.

10-73

GenSets–Deutz Engine Operation Faults, Causes and Remedies 7

10-74

Fault Engine fails or is difficult to start Engine starts but runs unevenly or stalls Engine overheats. Temperature monitor gives warning Engine gives poor performance Engine not firing on all cylinders Engine has little or no oil pressure Engine oil consumption excessive Engine smokes – blue – white – black Cause ● Not declutched (where possible) ● ● Below starting limit temperature ● ● Engine shut-off lever not in stop position (shut-off magnet defective) ● ● Oil level too low ● ● ● ● Oil level too high ● ● ● Excessive inclination of engine ● ● Engine predominantly operated at lower load ● ● ● ● ● ● Air cleaner clogged / turbocharger defective ● ● ● Air cleaner service switch / indicator defective ● LDA defective (leak in connecting line) only with charged engines ● ● ● Exhaust counter pressure too high ● ● Charge-air line leaking, only with charged engines ● Charge-air line leaking, only with charged engines ● ● ● Charge air cooler clogged ● ● Oil cooler air and/or oil side clogged ● Cooling fan or exhaust thermostat defective, V-belts ripped or loose ● Cooling air temperature rise / heating short circuit ● Cooling air fins loose, cracked or missing

7.1 Diagnosis Chart

Remedy Inspect Adjust Replace Clean Top up Lower level

I A R C T L

Section Operation

I I I T L I/A I Combustion air R I/R I/R I I/A Cooling system I/C I/C I/C I/R I I

Optional Equipment

GenSets–Deutz Engine Operation 7.1 Diagnosis Chart

Faults, Causes and Remedies

Fault Engine fails or is difficult to start Engine starts but runs unevenly or stalls Engine overheats. Temperature monitor gives warning Engine gives poor performance Engine not firing on all cylinders Engine has little or no oil pressure Engine oil consumption excessive Engine smokes – blue – white – black Cause ● Battery defective or discharged ● Electric cable connections to starter electrical system loose or oxidised ● Starter defective or pinion does not engage ● Oil pressure switch/oil pressure gauge defective ● ● ● ● ● ● ● Incorrect valve clearance ● ● ● ● Leaking injection line ● Vent line clogged ● ● ● Flame glow system/heating pipe defective ● ● ● ● ● ● ● Injection valve defective ● ● ● ● Air in fuel system ● ● ● ● Fuel filter/fuel precleaner clogged ● ● Oil filter defective ● ● ● Incorrect SAE class or grade of engine lube oil ● ● ● ● ● ● Compression pressure too low ● Oil in combustion chamber

Engine Preservation 8

Remedy Inspect Adjust Replace Clean Top up Lower level

Section Electrics

Engine

I A R C T L

I I I I/R A I/C I/C I/R I/R P/R I/C/R R R I I/C

8.1 Preservation

If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rust formation. The preservative measures described here will protect the engine for up to 6 month. The procedure will have to be reversed before the engine is recommissioned. ● Anti-corrosion oils to specification: – MIL-L-21260B – TL 9150-037/2 – Nato Code C 640 / 642 ● Recommended cleansing agent to remove preservatives when recommissioning engine: – Petroleum benzine (hazardous materials class A3)

Optional Equipment

8.1.1 Preserving Engine

8.1.2 Removing Engine Preservatives

● Clean engine (with cold cleansing agent if preferred) using high pressure equipment. ● Run engine until warm, then turn off. ● Drain engine oil, see 6.1.2, and fill with anticorrosion oil. ● If necessary, clean oil bath cleaner, see 6.4.3, and fill with anti-corrosion oil. ● Drain fuel from tank. ● Make up a mixture of 90% diesel fuel and 10% anti-corrosion oil, and refill fuel tank. ● Run engine for about 10 minutes. ● Turn engine off. ● Turn engine over manually several times to preserve the cylinders and combustion chamber. When rotating with starter, place shut-off lever in stop position. ● Remove V-belts and store dry in wrapped condition. ● Spray grooves on V-belt pulleys with anticorrosion spray. ● Close off intake ports and exhaust ports.

● Remove anti-corrosion agent from grooves in V-belt pulleys. ● Install V-belts. Retension after brief operation if necessary, see 6.5 ● Remove plugs from intake port and exhaust port. ● Set the engine in operation.

10-75

GenSets–Deutz Engine Operation Technical Specifications 9

9.1 Engine Specifications and Settings

Model Numbers of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle Combustion system Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) Engine power Speed Lubrication SAE oil Oil temperature in oil pan Min. oil pressure in warm condition (120 °C) at low idling speed / rated speed Oil change quantity without filter Oil change quantity with filter Valve clearance with cold engine Opening pressure of the injection valve Start of delivery Firing order V-belt pressure: pretension / tighten Alternator fan Compressor

[mm] [mm] [cm3] [ε]

F3L 912

F4L 912

F5L 912

F6L 912

4712

5655

380 5)

410 5)

13,5 3) 14,0 3)

14,5 3) 15,5 3)

vertical in line 100 120 2827

3770 19 4-stroke diesel induction engine direct injection counterclockwise

[ca. kg] [kW (PS)] [1/min]

270 5)

300 5) 1) 1) pressure lubrication 15W 40 125

[°C] [bar] [ca. ltr.] [ca. ltr.]

0,4 4) 9,0 3) 9,5 3)

[mm] [bar] [°crank angle b TDC] 1–2–3 [N] [N]

12,0 3) 12,5 3)

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05 250 +8 1) 1–3–4–2 1–2–4–5–3

1–5–3–6–2–4

preload / torquing load 2) 450 / 300 ± 20 550 / 400 ± 20

1) Engine power, speed, start of delivery are stamped on engine rating plate, see also 2.1 2) Tighten after 15 minutes, after the engine has been driven under load. 3) Ca. value can vary depending on model. The upper oil dipstick marking should always be taken as authoritative. 4) Values for engines without engine oil heating. 5) Ca. value can vary depending on oil pan design.

10-76

Optional Equipment

GenSets–Deutz Engine Operation Technical Specifications

9.1 Engine Specifications and Settings Model Numbers of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle Combustion system Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) Engine power Speed Lubrication SAE oil Oil temperature in oil pan Min. oil pressure in warm condition (120 °C) at low idling speed / rated speed Oil change quantity without filter Oil change quantity with filter Valve clearance with cold engine Opening pressure of the injection valve Start of delivery Firing order V-belt pressure: pretension / tighten Alternator fan Compressor

[mm] [mm] [cm3] [ε]

F3L 913

F4L 913

F6L 913

4 vertical in line 102 125 4086 19

3064

6128

4-stroke diesel induction engine direct injection counterclockwise [ca. kg] [kW (PS)] [1/min]

277 4)

8,0 3) 9,5 3)

0,4 4) 12 3) 13,5 3)

16,5 3) 18,5 3)

1–2–3

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05 250 + 8 1) 1–3–4–2

1–5–3–6–2–4

[mm] [bar] [°crank angle b TDC]

[N] [N]

420 4)

pressure lubrication 15W 40 125

[°C] [bar] [ca. ltr.] [ca. ltr.]

320 4) 1) 1)

preload / torquing load 2) 450 / 300 ± 20 550 / 400 ± 20

Optional Equipment

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GenSets–Deutz Engine Operation Technical Specifications 9

9.1 Engine Specifications and Settings

Model 913/C/CT Numbers of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle Combustion syst Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) Engine power Speed Lubrication SAE oil Oil temperature in oil pan Min. oil pressure in warm condition (120 °C) at low idling speed / rated speed Oil change quantity without filter Oil change quantity with filter Valve clearance with cold engine Opening pressure of the injection valve Start of delivery Firing order V-belt pressure: pretension / tighten Alternator fan Compressor

[mm] [mm] [cm3] [ε]

F3L 913W

F4L 912W

F6L 912W

4 vertical in line 102 125 4086 22

3064

6128

4-stroke diesel induction engine direct injection counterclockwise [ca. kg] [kW (PS)] [1/min]

270 4)

8,0 3) 9,5 3)

0,4 4) 12 3) 13,5 3)

16,5 3) 18,5 3)

1–2–3

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05 120 + 10 1) 1–3–4–2

1–5–3–6–2–4

[mm] [bar] [°crank angle b TDC]

[N] [N]

410 4)

pressure lubrication 15W 40 125

[°C] [bar] [ca. ltr.] [ca. ltr.]

300 4) 1) 1)

preload / torquing load 2) 450 / 300 ± 20 550 / 400 ± 20

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Optional Equipment

GenSets–Deutz Engine Operation Technical Specifications

9.1 Engine Specifications and Settings Model 913/C/CT Numbers of cylinders Cylinder arrangement Bore Stroke Total displacement Compression ratio Working cycle Combustion syst Direction of rotation Weight incl. integrated cooling system as per DIN 70020-A (without starter, with alternator) Engine power Speed Lubrication SAE oil Oil temperature in oil pan Min. oil pressure in warm condition (120 °C) at low idling speed / rated speed Oil change quantity without filter Oil change quantity with filter Valve clearance with cold engine Opening pressure of the injection valve Start of delivery Firing order V-belt pressure: pretension / tighten Alternator fan Compressor

[mm] [mm] [cm3] [ε]

BF4L 913

BF6L 913

BF6L 913 C

6 vertical in line 102 125 6128 18

4086 18

6128 17

supercharged 4-stroke diesel induction engine direct injection counterclockwise [ca. kg] [kW (PS)] [1/min]

360 5)

9,5 3) 11,5 3)

0,5 4) 16,0 3) 18,2 3)

16,0 3) 18,2 3)

1–3–4–2

inlet 0.15 + 0.05 / exhaust 0.15 + 0.05 250 + 8 1) 1–5–3–6–2–4

1–5–3–6–2–4

[mm] [bar] [°crank angle b TDC]

[N] [N]

510 5)

pressure lubrication 15W 40 125

[°C] [bar] [ca. ltr.] [ca. ltr.]

485 5) 1) 1)

preload / torquing load 2) 450 / 300 ± 20 550 / 400 ± 20

Optional Equipment

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GenSets–Deutz Engine Operation Technical Specifications

9.1 Engine Specifications and Settings

9 Location

Preload [Nm] 20

1st stage 180°

2nd stage –

180°

–

Cylinder head cover

–

12 ± 1,2 Nm

–

Rocker arm set screw

–

22 ± 2 Nm

–

Support foot

15°

60°

–

75°

M14 x 100

45°

60°

–

105°

M14 x 110

45°

60°

–

105°

M14 x 125

Air intake manifold

–

22 ± 2 Nm

–

Exhaust manifold

–

40 ± 4 Nm

–

Oil drain plug – cast iron oil pan

–

150 ± 10 Nm

M22 x 1,5

Oil drain plug – sheet metal oil pan

–

100 ± 10 Nm

M30 x 1,5

Injection valve mounting

–

25–30 Nm

–

Alternator mounting

10-80

Torquing load 3rd stage 4th stage – –

Total

Remarks

180°

M10 x 180

180°

M14 x 230

Optional Equipment

GenSets–Murphy Controller Operation

Cascade CD101 Auto-Start Controller Installation and Operations Manual

00-02-0594 09-07-11 Sections 40 & 75 Optional Equipment

10-81

GenSets–Murphy Controller Operation In order to consistently bring you the highest quality, full featured products, we reserve the right to change our specifications and designs at any time. The latest version of this manual can be found at www.fwmurphy.com.

Please read the following information before installing. BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT:

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Read and follow all installation instructions.

A visual inspection of this product for damage during shipping is recommended before mounting.

It is your responsibility to have a qualified person install this unit and make sure it conforms to NEC and local codes.

Disconnect all electrical power to the machine.

Make sure the machine cannot operate during installation.

Follow all safety warnings of the machine manufacturer.

Please contact FW MURPHY immediately if you have any questions.

Optional Equipment

GenSets–Murphy Controller Operation Operating the Cascade When power is first applied, all LEDs will flash indicating a Lamp Test function. x

To manually start the engine, press the “MAN” (Manual) button. The controller will initiate a normal start sequence.

In MANUAL MODE, operating the “UP/DOWN” arrow keys will activate Aux outputs 1-4 if they are configured for SPEED UP / SPEED DOWN.

To manually stop the engine (or turn off the controller), press the “OFF” button.

To place the controller in automatic mode, press the button labeled “AUTO”. The LED next to the “AUTO” button should come on to indicate that the controller is waiting for the remote start input to become active to initiate a start sequence.

If there is no activity (key presses or start signal) for 2 minutes, the controller will go into low-power sleep-mode. A start input will wake the controller.

To reset the controller, press the “OFF” button. Then correct the cause of the shutdown. This will clear all faults except when the aux inputs are programmed for either shutdown immediate or warning immediate, or if the engine ECU is broadcasting a shutdown fault.

In the event of a fault that causes the engine to shutdown, the cause of the event will be indicated on one of the 11 status lights on the right hand side of the controller. When the cause of shutdown is corrected, the controller can resume normal operation.

Optional Equipment

10-83

GenSets–Murphy Controller Operation LED Status Lights Eleven LEDs separated into two banks (see Fig. 1) are provided on the faceplate. The LEDs Bank 1 includes 6 LEDs and Bank 2 includes 5. In Setup mode, these banks form a binary code to indicate either the controller setup configuration or error status, which is indicated by the last 8 (red) LEDs. Refer to Tables 1, 2, 3 and 4 for configuration and status listings. One LED is located next to the AUTO button to indicate that the controller is waiting for the remote start input to become active. The LED Status lights are (from top to bottom):

LED Status Light Descriptions: LEDs

Description

Engine Running

If the green LED is ON, then the unit is receiving a speed signal, indicating that the engine is above the crank cut speed.

ECU Status

If the green LED is on solid, it indicates that in a J1939 application the ECU and the unit are communicating properly. If the LED is blinking slowly the ECU is broadcasting a “wait to start” message. If the LED is blinking fast, the ECU is NOT communicating properly.

Remote Start/ If the green LED is on, then the remote start input is active and if the system is in AUTO Crank Rest mode, it will try to start. If the LED is blinking, the crank cycle has ended and is now in crank rest cycle. Low Oil Pressure

If the red LED is on, the controller has caused the engine to shutdown and lockout. If the LED is blinking, the engine ECU has transmitted a SPN for an oil pressure related condition. If the LED comes on before the crank sequence, it indicates the Low Oil Pressure Input is not grounded (close/fault) while the engine is off.

High Engine If the red LED is on, the controller has caused the engine to shutdown and lockout. If the Temperature LED is blinking, the engine ECU has transmitted a SPN for an engine temperature related condition. Overspeed

If the red LED is on, the controller has caused the engine to shutdown and lock out due to engine speed exceeding the setpoint.

Underspeed

If the red LED is on, the controller has caused the engine to shutdown and lock out due to engine speed falling below the minimum needed for proper operation.

Table continued on next page.

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Optional Equipment

GenSets–Murphy Controller Operation Overcrank/ Start Fail

If the red LED is on, the controller has exceeded the set number of start attempts without receiving a valid speed signal indicating that engine speed is above crank disconnect. This causes the engine to shutdown and lockout.

Charge Fail

If the red LED is on, it indicates that the battery-charging alternator is not charging the cranking batteries, or that the battery charger fail output is on.

Auxiliary 1

If the red LED is on, it indicates that this custom-configured input is active. On an ECU (ECM) equipped engine, if this LED is blinking slowly, it indicates that one or more engine parameters are near exceeding engine manufacturer’s setpoints. If the LED is blinking fast, it indicates that one or more engine parameters have exceeded the setpoints, and the ECU has issued a fault. In this case the engine has most likely shut down or is running in a derated condition.

Auxiliary 2

If the red LED is on it indicates that this custom-configured input is active.

For more information, see Table 2 – LED States for Normal Operating Mode. NOTE: If the Overspeed and Underspeed LED’s are both blinking, the controller has lost its speed signal.

Optional Equipment

10-85

GenSets–Murphy Controller Operation Setting up the Cascade To enter the SETUP MODE, first remove DC power to the Cascade controller for approximately 10 seconds. On the back of the controller are four DIP switches, set switch #1 to ON (see schematic at right) then restore DC power. The AUTO mode LED will blink to indicate that the Cascade is in the SETUP MODE. When in the SETUP MODE, pressing the “MAN” (Manual) button steps up thru the entire list of parameters. The pattern of the top six LEDs, LEDs Bank 1 (see “Fig. 1”), is used to indicate which parameter is selected. The pattern will change once each time the “MAN” button is pressed. Pressing the “OFF” button steps up thru all the available values for each parameter. The pattern of the bottom five LEDs, LEDs Bank 2 (see “Fig. 1”), is used to indicate which value is selected. The pattern will change once each time the OFF button is pushed. Pressing the “AUTO” button stores the displayed value. If any value is changed, it will blink until stored, except a value of zero. If any value is changed but not stored, and then the parameter is changed, the value will still be what was shown originally. If you accidentally go past a desired parameter or value, you can step back by pressing the down arrow button. The parameter/value list and corresponding LED indication are shown on Table 1 – Parameter Values and Corresponding LED Indication. When you are finished with setup, set switch #1 to in the Normal Operating Position (OPEN), remove DC power for 10 seconds, then restore DC power.

Modes of Operation Setup Mode Refer to the section “Setting up the Cascade” and “Table 1 – Parameter Values and Corresponding LED Indication”. Normal Operating Mode (Engine Control Mode) The DIP switch #1 must be in the open position in order to enter this mode upon power up. “Table 2 – LED States for Normal Operating Mode” shows the meaning of each LED state for this mode.

10-86

Optional Equipment

GenSets–Murphy Controller Operation Error Mode Upon power up, when the DIP switch #1 is in the normal operating position (open position) and an error is detected in the user configuration, the Error Mode will be accessed. The LEDs will blink fast indicating the error. To correct the errors before the unit can operate in Engine Control Mode, the user will need to go back to Setup Mode. “Table 3 – Error Codes LED States” and “Table 4 – Configuration Error Codes” show the meaning of each LED state and configuration for the Error Mode. Sleep Mode In Auto Mode the Cascade will enter Sleep Mode after 2 minutes of inactivity. The unit will exit Sleep Mode on key press or remote call to run. It will not enter Sleep Mode if there is an active fault. NOTE: If PVA Gages are connected, Sleep Mode is not available.

Optional Equipment

10-87

GenSets–Murphy Controller Operation Installing the Cascade Auto-Start Controller The Cascade controller offers automatic start/stop control with easy configuration for a broad number of engine driven applications.

Tools Needed To install the Cascade, the following tools are needed: x

#2 Philips (cross head) head screwdriver

5/16” Nut driver to fit #6-32 machine nuts

Wire for hook-up (rising cage clamp suitable for 14-24 gage wire)

Mounting the Cascade WARNING – Explosion Hazards This Equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D or Non-hazardous locations only. Explosion Hazard – Substitution of components may impair suitability for Class I, Division 2. Explosion Hazard – Do not disconnect equipment while the circuit is live or make sure the area is known to be free of ignitable concentrations.

NOTE: This unit shall be mounted in a Type 1 electrical enclosure (minimum requirement) for other than indoor applications.

10-88

Optional Equipment

GenSets–Murphy Controller Operation Cut a 5.63 x 4.06 in. (143 x 103mm) mounting hole, and drill four 0.169 in. (4.3mm) diameter holes for the mounting screws. See Schematic below:

Recommended Wiring Practices WARNING: For applications involving automatic start equipment, we strongly recommend the installation of an appropriate Emergency Stop safety device. The CASCADE is designed for pilot-duty use. Outputs should be connected to relays to pilot the loads. Wire the CASCADE controller with 18-gage stranded wire. 1. To help prevent electrical noise and voltage drop to the controller during cranking and preheat, wire the controller DC power connections directly to the cranking battery. This will also help improve “Low battery” starting capability. 2. When using a battery charger, it should be connected directly to the battery to help prevent electrical noise which could cause an engine ECU or associated equipment to operate erratically. 3. Never route low voltage DC wiring in the same conduit as high voltage AC wiring. Noise from electrical loads such as motors and variable frequency drives can be coupled into the engine ECU, governor, or associated equipment and may cause erratic operation.

Optional Equipment

10-89

GenSets–Murphy Controller Operation 4. Always use twisted shielded pair wires for the magnetic pickup wiring. Ground one end of the shield only. 5. In spark ignited engine applications, always use resistive spark plugs and spark plug wires, as these greatly reduce the amount of radiated noise. 6. Always place a snubbing diode (sometimes also called a flyback, antikickback or reverse bias diode) directly across any inductive load. This helps eliminate a common source of electrical noise, as well as increases the operating lifetime of any solid-state output. 7. Always use twisted shielded pair communications wiring for RS-485 and SAE J1939 compliant wiring for J1939 communications. Make sure that terminating resistors (if required) have the correct rating and are installed properly.

Typical Wiring Diagrams Cascade – Basic Engine AC Speed Sensing

10-90

Optional Equipment

GenSets–Murphy Controller Operation Cascade – Basic Mechanical Engine MPU Speed Sensing

Optional Equipment

10-91

GenSets–Murphy Controller Operation Cascade – Basic ECU Engine ECU Speed Sensing

10-92

Optional Equipment

GenSets–Murphy Controller Operation Inc/Dec Throttle (Manual), Line Fill Delay, Low Oil/Coolant Level, Preheat, Common Alarm

40 &

Optional Equipment

00 02 0 94

10-93

GenSets–Murphy Controller Operation Mechanical Engine MPU Speed Source, Low Liquid Level Shutdowns Warmup-Cooldown Output

10-94

Optional Equipment

GenSets–Murphy Controller Operation Mechanical Engine Winter/Summer Switch, Preheat Output, and Run & Idle Switch Output

40 &

Optional Equipment

00 02 0 94 10-95

GenSets–Murphy Controller Operation Specifications Power input: 9-35VDC continuous - operates during total blackout for 2 sec. min. Power consumption: Sleep Mode (Manual): 2mA typical; (Automatic), 10mA typical. Running Mode (Manual): 45mA typical; (Automatic): 50mA typical. Operating/Storage temperature: -40 to 85°C; (-40 to 185°F). Humidity: 0-100%, non-condensing. Housing: UV stabilized black polycarbonate and epoxy encapsulation. Weather tight and includes sealing gasket to keep moisture and debris out of enclosure. Properly mounted controller will maintain NEMA4 / IP65 rating of enclosure. Vibration: Rated to 6G. Impact: Rated to 10G. Inputs: Dedicated digital inputs for low oil pressure, high engine temperature, remote start, DC charge fail/Alternator fail. Two aux inputs are configurable for multiple functions. Outputs: 7 – 4 auxiliary, configurable (1A DC protected). 3 dedicated outputs for Crank, Fuel/ECU, Alternator excitation. Outputs are low side FET switches. Crank attempts: 3, 5, 10, Continuous. Crank Rest: 5-60 seconds, adjustable. Shutdown lockout time delay: 5, 10, 15, 20, 25, 30 seconds. Crank Disconnect speed setting: Field settable 0-9999 RPM (16-60Hz AC freq input). Overspeed/underspeed trip point setting: ±5 to 50% of nominal. Speed sensing inputs: Magnetic pickup (5-120VAC RMS / 0-10 kHz) & AC frequency (30600VAC RMS / 16-80 Hz). CANbus interface: Directly reads engine speed, oil pressure, coolant temperature, system voltage, & engine status data* from SAE-J1939 enabled engines. MODbus interface: In J1939 applications drives PVA series analog gages. Gages limited to tach (0-3000 rpm), coolant temperature, oil pressure (0-100 & 0-150), DC volts (12v & 24v), AC freq, and audible alarm. *Engine status data limited to low oil pressure, high engine temperature, “Wait to start” status, Warning & Fault lamp information, and communication error.

10-96

Optional Equipment

GenSets–Murphy Controller Operation

Optional Equipment

10-97

GenSets–Murphy Controller Operation

10-98

Optional Equipment

GenSets–Murphy Controller Operation

Optional Equipment

10-99

GenSets–Murphy Controller Operation

10-100

Optional Equipment

GenSets–Murphy Controller Operation

Optional Equipment

10-101

Notes

10-102

Optional Equipment

HotStart Engine Heater Operation P/N: 216229-000 rev-4

Installation Instructions CSM FORCED CIRCULATION HEATER READ CAREFULLY FOR PROPER INSTALLATION AND OPERATION Customer Support: (509) 536-8660 E-Mail:sales@hotstart.com

ADDITIONAL SUPPORT CAN BE FOUND AT www.hotstart.com

Model CSM Forced Circulation Engine Coolant Heater The CSM forced circulation heater combines a pump, heating elements and temperature control system. It is created to heat engine coolant that consists of 50/50 glycol and water mixture. The heater is designed to provide heating for engine displacements of 15L to 100L size. The continuous circulation of the coolant provides uniform heating throughout the engine. The heater is used to heat diesel and gas engines for stationary land power, marine, large mining and construction equipment. After energizing the system, engine coolant is circulated via the centrifugal pump, through the heating tank and back to the engine. The pump stays on and continues this circulation process even when the heating elements are off to ensure uniform engine temperatures. A 24VDC signal is required to de-energize the system when the engine is running. The heaters are supplied with ratings that include both single phase and three phase in various voltages from 120V to 690V. Wattages from 3kW to 12kW. Please read carefully: The safety of any system incorporating this heater is the responsibility of the assembler. The safe and proper use of this heater is dependent upon the installer following sound engineering practices. If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Hotstart’s installation recommendations and all applicable electrical safety standards must be followed (reference directive 2006/95/EC in EU countries). All work must be performed by qualified personnel only. The heater must be connected to a suitable protective earthing conductor. The power supply must be protected by a suitable overcurrent limiting device. A means of disconnection from power supply is required. Hotstart recommends that a power switch or circuit-breaker be located near the heater for safety and ease of use. Reference markings on the heater for specific ratings. Use care when handling this heater. Lift by grasping the inlet end of the tank with one hand and the outlet at the pump with the other.

NOTICE

System Mounting Requirements The CSM heating system must be mounted in the horizontal position. The pump shaft must be in the horizontal position at all times for proper lubrication and cooling of shaft end bearing. Refer to drawing on page 2. Be sure to mount the system as low as possible in reference to the engine coolant level. DO NOT mount the heating system directly to the engine (the system must be isolated from engine vibration). DO NOT mount directly to the skid if the engine is not isolated from the skid.

Optional Equipment

10-103

HotStart Engine Heater Operation System Installation Coolant Supply Line Connect a MINIMUM 1-inch N.P.T. coolant supply hose or pipe from the main coolant drain of the engine to the inlet of the heating system. Drawing coolant from a location low in the coolant system will ensure head pressure to the pump. The supply line must remain level or angle downward to eliminate air pockets. When approaching a plumbing obstacle, go around the obstacle instead of over it. Coolant Discharge Line Connect a MINIMUM 1-inch N.P.T. coolant return hose or pipe from the outlet of the CSM to the highest possible location on the engine coolant system at the furthest possible location from the suction line. This connection enables heated coolant to be circulated through the entire engine. Personal Injury: This product generates heat during operation. Operation of heating system with closed isolation valves could result in high pressure and serious injury. It is the responsibility of the installer and operator to ensure that no unsafe condition can result from the generation of pressure. In EU countries, PED (97/23/EC) compliant pressure relief may be required (125psi maximum)

CAUTION

NOTE: Your system may be configured with optional, non-restrictive shut-off valves in the coolant lines allowing maintenance on the heating system without draining the engine coolant. Isolation Valves, PRP203011000 may be ordered from Hotstart. NOTE: If the heating system is plumbed with rigid pipe, use flexible lines near the heating system long enough to provide freedom from vibration in all directions.

Coolant Requirements The heating system is designed for use with a 50/50 mixture of low-silicate antifreeze and distilled water. Pre-mixed products are recommended. If not using a pre-mixed solution, ensure that the liquids are well mixed prior to filling the engine’s cooling system. Do not exceed a concentration of more than 60% antifreeze as element failure can result. NOTE: After the heating system is mounted and the engine is refilled with coolant, loosen outlet flange at pump to bleed the air out of the system. DO NOT ENERGIZE THE HEATING SYSTEM AT THIS TIME. Run the engine until it reaches normal operating temperature to eliminate trapped air that may still be present in the engine. Personal Injury: Hot surfaces are a potential injury hazard. It is the responsibility of the assembler to ensure that hot surfaces are not easily accessible to untrained personnel during operation.

CAUTION

10-104

Optional Equipment

HotStart Engine Heater Operation System Wiring

NOTICE

Operation of the system during engine operation may cause damage to the heater The heating element package is pre-wired to the system wattage and voltage; altering the supplied wiring configuration can result in heater failure. All connections in the junction box should be checked during installation. Vibration during shipment can cause screws to loosen.

CAUTION

WIRING TO HEATING SYSTEM MUST BE PERFORMED BY A QUALIFIED ELECTRICAIN AND CONFROM TO ALL NATIONAL, STATE AND LOCAL ELECTRICAL CODES.

CAUTION

DISCONNECT ALL POWER SOURCES PRIOR TO PERFORMING ANY MAINTENANCE ON THE HEATING SYSTEM.

Main Power Wiring Connect the specified voltage and phase to the terminal blocks located in the main control box of the heating system. A user- supplied circuit breaker (rated at the appropriate amperage) is required for use in the main power feed line. For 3 phase applications, the terminal blocks are labeled L1, L2 and L3. For single phase applications, use terminal blocks labeled L1 and L2. 24 VDC Shutdown Connect a user-supplied source of 24 VDC electricity to the terminal blocks labeled A1 and A2 in the control box. When present, this 24 VDC shutdown signal will disable the heating system to prevent operation while the engine is running. The standard heating systems are wired such that the relay is normally closed (a 24 VDC signal when the engine is running disables the heating system). Terminal and Conduit Connections The electrical enclosure of the CSM heater must remain closed to protect terminals from moisture and vapor. Make certain that proper conduit connectors are used for the installed conditions. Terminations in all enclosures require the wire be rated at a minimum of 60º C. Selected wire must be sized in accordance with heater amperage.

Optional Equipment

10-105

HotStart Engine Heater Operation System Start-Up Check List After system installation has been completed, follow these steps for proper system start-up. Step 1

Check and tighten all electrical and plumbing connections.

Step 2

Ensure isolation valves are open before starting system.

CAUTION

Personal Injury: OPERATION OF HEATING SYSTEM WITH CLOSED ISOLATION VALVES COULD RESULT IN SERIOUS INJURY.

Step 3

Ensure that all air was bleed from system and engine was ran during installation (reference installation section of this manual for details).

Step 4

Energize system and monitor for correct operation. - The pump motor operates very quietly and only a slight vibration can be felt when placing hand on the motor. - The outlet hose should be approximately 5°F (3°C) warmer than the inlet. - The engine temperature should gradually start rising. - The Heater should be de-energized when the engine starts.

Step 5

Check heating system and plumbing for coolant leaks.

Maintenance CAUTION

Personal Injury: Disconnect and lockout electrical supply to heater before servicing the heater or any part of the installation.

Periodic Maintenance Yearly: 1. Drain, clean, and flush cooling system 2. Check for cracked and/or weakened hoses and replace if necessary 3. Tighten and check electrical wiring and connections for wear and excessive heat 4. Remove element and clean element and tank Every 3 years or 25,000 hours of operation 1. Replace thermostat 2. Replace contactor The thermostat and contactor used in this system are critical components to prevent excessive temperatures that could lead to an unsafe condition. Regular inspection and replacement of these components is required to ensure continued safe operation. This is the responsibility of the maintenance personnel.

WARNING

Replacement Fuse Type All replacement fuses should be: “slow-blow” Type Midget Size (10mm x 38mm) Single Phase 120V, 208V, 220V & 240V - 250V (Hotstart p/n: PRP231026-002) Single and 3 Phase 400V & 480V - Primary: 500V (Hotstart p/n: PRP231059-002) - Secondary: 250V (Hotstart p/n: PRP231026-002) Single and 3 Phase 575V - Primary: 600V (Hotstart p/n: PRP231068-002) - Secondary: 250V (Hotstart p/n: PRP231026-002) 10-106

Optional Equipment

Shock Sub–Cushion Connector Model 18-120-6363 Shock Sub

Optional Equipment

10-169

Shock Sub–Cushion Connector Model 18-120-6363 Shock Sub (cont.)

10-170

Optional Equipment

Shock Sub–Cushion Connector Model 18-120-6363 Shock Sub (cont.)

Optional Equipment

10-171

Shock Sub–Cushion Connector Model 18-120-6363 Shock Sub (cont.)

10-172

Optional Equipment

Shock Sub–Cushion Connector Model 18-120-6363 Shock Sub (cont.)

Optional Equipment

10-173

Shock Sub–Cushion Connector Model 18-120-6363 Shock Sub (cont.)

10-174

Optional Equipment

© 201 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. Printed in U.S.A.