CAT Rotary Track Drill SK-35 3002-51214 Reedrill Blasthole Drill Service Manual – PDF DOWNLOAD

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© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

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REEDRILL, INC. CONTENTS* SK-35 SERVICE :МANUAL

INTRODUCTION PART I

EQUIPMENT DESCRIPTION

PART II

TROUBLESHOOTING AND REPAIR

PART III -

SUBSYSTEM DETAILS AND VENDOR MANUALS

*

See separate tаЫе of contents for Part I, Part II or Part III as applicaЫe.

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Frontis pl.ece . iii

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INTRODUCTION This manual contains maintenance information for the Reed SK-35 Blast Hole Drill. Presented in three parts, the manual describes the physical aspects of the drill, explains the functional operation, and provides troubleshooting charts with repair and disassembly procedures.

Part I presents a physical and functional description of the equipment, Part II covers troubleshooting and repair, while Part III presents detailed subsystem descriptions and maintenance information.

Included in Part III are separate manuals as appropriate for equipment components made by other manufacturers.

The Service Manual is one of a family of manuals required for effective operation and maintenance of the SK-35. Other related manuals are: 1.

Operator's Manual, SK-35/40.

2.

SK-35 Parts Manual.

3.

Engine Manual, Cummins NT-855-335 (or Optional Caterpillar 3406 DI-T).

4.

Carrier Manual, Crane Carrier Truck, Model DR2064 (or Optional Hendrickson manual as applicable).

Each part of this Service Manual is divided into Sections 1 through 10, corresponding to the topical groupings in the Parts Manual.

In using this manual, you should first become familiar with the overall function of the SK-35 Blast Hole Drill and with the individual subsystems and component units as described in Part I. Then you will be able to relate operating failures with subsystem malfunctions, and you will be able to identify the symptomatic troubleshooting information with the related functions.

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Part I EQUIPMENT DESCRIPTION Part I of the SK-35 Blast Hole Drill Service Manual contains the general physical and functional description of the unit. For service and troubleshooting see Part II and for information on Vendor Supplied equipment, see Part III.

1-0

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Part I Table of Contents Section 1

Title SK-35 DESCRIPTION AND FUNCTIONAL OPERATION

A.

B.

C. 2

2-1 2-1 2-1

Carrier Vehicle Main Frame 1. Operator's Cab a. Sliding Cab Feature b. Heater 2. Leveling Jacks 3. Fuel Tank 4. Tool Box

3-1 3-1 3-1 3-1 3-:1.

3-2 3-2 3-2

ENGINE AND DRIVE TRAIN A.

B.

C. 5

Operator's Control Console 1. Indicator Panel 2. Lower Control Panel

MAIN FRAME/CARRIER

A. B.

4

1-1 1-1 1-1 1-1 1-3 1-3

OPERATOR CONTROLS AND INDICATORS

A.

3

General Function and Specifications 1. Highway Travel and Tramming 2. Operating Power 3. General Operation Subsystems and Functional Groupings SK-35 Specifications

Diesel Engine 1. Air Cleaner 2. Exhaust and Muffler System 3. Heat Exchanger Pump Drive Unit 1. Clutch Assembly 2. Hydraulic Pump Drive a. Rotary Drive Pump b. Tandem Pumps Drive Shaft

4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3

MAIN AND AUXILIARY AIR

A.

Compressed Air Subsystem Components 1. Air Compressor 1-i

5-1 5-1

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Part I Table of Contents (Cont.)

Section 55

Title MAIN AND AUXILIARY AIR (Cont.)

B.

66

B• B.

5-4 5-4 5-4 5-4

Dust Control System Functions 1. Dust Curtains 2. Dust Collector Subsystem Function a. Roto-c1one Unit b. AMI Filter Type Dust Collector 3. Water Injection Subsystem Function Dust Control System Control Functions

0-1

6-1 6-1 6-1 6-1 6-3 6-3

MAST/ROTARY DRIVE

A. B. C.

D. E. F. 8

5-1 5- 3

DUST CONTROL SYSTEM

A.

7

2. Separator Tank Compressed Air Functions 1. Main Air System 2. Auxiliary Air 3. Air SUbsystem Control Functions 4. Air System Indicators

Mast Assembly Rotary Drive Assembly Hoist and Pu11down Assembly Hydraulic Winch Drilling Platform 1. Casing Tong Assembly 2. Dust Curtain Assembly Mast Elevators

7-1 7-1 7-1 7-3 7-4 7-4 7-4 7-4

HYDRAULIC SYSTEM

A.

B.

C.

Rotary Drive Hydraulics 1. Charge Loop 2. Drive Loop 3.

Rotary Drive Operator Control Hoist and Pu11down Hydraulics 1. High-Speed Hoist 2. Pul1down Subsystem 3. Hoist and Pulldown Operator Control General Hydraulic Pressure 1. Valve Bank Arrangement 1-ii

8-1 8-1 8-1 8-1 8-3 8-3 8-3 8-3 8-3 8- 7

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Part I Table of Contents (Cont.)

Title

Section 8

HYDRAULIC SYSTEM (Cont.)

2.

3.

4.

5.

6.

9

Leveling Jack Hydraulic Subsystem a. Leveling Jacks Mast Elevation Subsystem a. Mast Elevators b. Elevator Control functions Water Pump and Dust Collector Motors a. MOtOT Functional Operation Hydraulic Winch Pipe Rack and Tool Hydraulic Functions

8-7 8-7 8-7 8-8 8-8 8-8 8-8 8-8 8-9

ELECTRICAL SYSTEM

A.

B. C. D. E.

Engine Controls and Indicators 1. Start and Run Controls a. Ignition Switch b. Starter Button 2. Engine Gauges a. Fuel Level b. Engine Oil Pressure c. Engine Water Temperature d. Ammeter 3. Tachometer 4. Engine Hourmeter Filter Warning Subsystem 1. Warning Light Circuits 2. Test Circuit Drill Hour Meter Drill Lights Battery Connections

I-iii

9-1 9-1 9-1 9-1 9-1 9-1 9-1 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-4 9-4

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List of Illustrations

No.

Title

Page

1-1

Blast Hole Drill Components

1-2

1-2

Functional Block Diagram, SK-35 Subsystems

1-4

2-1

SK-35

2-2

3-1

Cab Heater, Simplified Diagram

3-2

4-1

Engine and Drive System

4-1

5-1

Compressed Air System, Functional Diagram

5-~

5-2

Compressor Cooling and Lubrication System, Functional Diagram

5-3

6-1

Dust Control System

6-2

7-1

Mast and Rotary Drive Components

7-2

7- 2

Hoist and Pull-Down, Simplified Diagram

7-3

~-1

Rotary Drive Hydraulic Subsystem

~-2

8-2

Hoist and Pulldown Subsystem, Simplified Diagram

8-4

General Hydraulics Subsystem, 32 GPM Pump Stage (early models)

8-5

General Hydraulics Subsystem, 32 GPM Stage (SIN 1061187 and on)

8-6

9-1

Electrical Wiring Diagram

9-2

9-2

Battery Connections

9-4

8-3a 8-3b

Operating Controls and Indicators

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SECTION 1

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SectIon 1 SK-35 DESCRIPTION AND FUNCTIONAL OPERATION This section introduces the overall function of the SK-35 Blast Hole Drill and presents the specifications for the unit. Figure 1-1 illustrates the drill and points out the locations of the major equipment units.

The Reed SK-35 is a diesel-hydraulic rotary blast-hole drill mounted on a main frame which is welded to a carrier vehicle (truck) for highway mobility. With pull-down capacity of 35,000 pounds, the drill has the capability ot drilling blast holes having diameters of 6-1/4 to j-7/8 inches. For specifications see Table 1-1.

A.

GENERAL FUNCTION AND SPECIFICATIONS

This topic should be considered as an introduction to the individual sections describing the various equipment subsystems.

1. HIGHWAY TRAVEL AND TRAMMING. The operator drives the blast hole drill to the drill site under power of the carrier vehicle. At the drill site he spots the vehicle in the desired drilling location.

Then the truck power is not used again until the drill is to be trammed to another blast hole location or transported to another site.

2. OPERATING POWER. All operating power is provided by a separate diesel engine that drives a group of hydraulic pumps and an air compressor. These provide all power requirements for setting up the drill for operation; raising, lowering, and rotating the drill stern, and blowing cuttings from the hole being drilled.

3. GENERAL OPERATION. Once the vehicle is spotted at the drill site, the operator levels and secures the unit, using three built-in jacks. Then he raises the mast and, according to the optional equipment installed on the drill, turns a pipe carousel-type pipe rack to select a drill pipe. Then the operator affixes the drill pipe to the mast and rotary drive assembly, lowers the drill into drilling position and applies the desired pull-down pressure to the drill to begin the drilling operation.

As driven ceeds, ensure

drilling begins, the operator employs air from the directlyair compressor unit to clear the drill hole. As drilling proa dust collection system entraps the dust from the drill to operator and environmental protection.

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ROTARY ROTARY DRIVE DRIVE

CARRIER CARRIER VEHICLE VEHICLE

FUEL TANK DRIVE ASSEMBLY

VALVE BANK (BEHIND PANEL)

OPERATOR'S CAB

Figure 1-1. Blast Hole Drill Components 1-2

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B.

SUBSYSTEMS AND FUNCTIONAL GROUPINGS

The overall system functions are illustrated in the block dIagram, Figure 1-2; and the major components within the various subsystems are identIfied. For functional descriptions of the various subsystems, refer to the appropriate Part I section, and for detailed information on vendor-supplied components, refer to the appropriate section of Part III. Troubleshooting and repair of the SK-35 is presented in the appropriate sections of Part II. C.

SK-35 SPECIFICATIONS

As presented here, the specifications for the SK-35 Hlast Hole Drill are divided into performance specifications and component specifications.

1. PERFORMANCE SPECIFICATIONS. The performance specifications for the SK-35 are presented in Table 1-1.

Table 1-1. Performance Specifications SYSTEM/fUNCTION

ENGLISH UNITS

METRIC UNITS

RATED CAPACITY Bit/Hole Size Range Depth-Single Pass

- 7-7/8"

2 5'

l5.88cm-20.00cm 7.62m

35,000 lbs

15.876 kg

30,000 Ibs 10 fpm 65 fpm

13,600 kg 3.0~ m/min 19.81 m/mIn

28'8" 21,000 lbs 92 fpm

8.74 m 9,525.6 kg 28.0 m/min

6~"

PULLDOWN/HOISTING SYSTEM Pulldown Capacity with 6~" (16.51cm) Drill Pipe Pulldown Capacity with 5" (12.70cm) Drill Pipe Drilling Feed Rate High Speed Pulldown Pulldown Stroke (Rotary Head Travel) Hoisting Capacity Hoisting Speed ROTARY DRIVE SYSTEM Rotation Speeds - Infinately Variable 0-135 rpm 4300 Ft-lbs Rotation Torque

0-135 rpm 594 kg-m

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Table 1-1. Performance Specifications (Continued) SYSTEM/FUNCTION

ENGLISH UNITS

METRIC UNITS

COMPRESSED AIR &WATER INJECTION SYSTEM Air Capacity

750 cfm

@

100 psi

Annular Velocity -5" Pipe - 6-3/4" Hole 12.70 cm Pipe-17.14cm Hole 6750 fpm 6~" Pipe-7-7/8 " Hole 16.51 cm Pipe-20.0cm Hole 6958 fpm Air Temperature 100F above ambient Water Injection

3 gpm maximum

21,250 Ipm @ 6.90 BAR 2120.8 m/min 2120.8 m/min 37.8C above ambient 11.36 lit/min maximum

POWER SYSTEM Standard-Cummins NT-855P-355 with Transmission and Disconnect Clutch Brake Horsepower Fuel Tank Fuel Consumption

335 @ 1200 rpm 150 gal 8-10 ga1/hr

335 @ 2100 rpm 507.8 lit 30.3-37.9 1it/hr

PIPE HANDLING SYSTEM Type-Automatic Indexing Carousel No. of Drill Rods Length of Drill Rods Diameter of Drill Rods Standard Optional

5

5

25'

7.62 m

5"

12.70 cm 16.50 cm

6~"

2. COMPONENT SPECIFICATIONS. The component specifications are presented in Table 1-2.

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Table 1-2. Component Specifications SYSTEM/FUNCTION

ENGLISH UNITS

METRIC UNITS

PULLDOWN/HOIST SYSTEM COMPONENTS Hydraulic Cylinders (Two) Bore Stroke Chain Size Speed Ratio ~ffiST

4-3/4" 14'4" 2" 2: 1

12.06 cm 4.37 cm 5.0~ cm 2: 1

4-3/4" 38-1/4"

12.U6 cm 97.17 cm

6" 38-1/4"

15.24 cm 97.17 cm

3

3

4-314" 36"

12.06 cm 91.44 cm

4-3/4" 48"

12.06 cm 121.92 cm

6 in 3 /Rev

38.7 cc/Rev

6 in 3 /Rev 3 micron absolute

:S8.7 cc/Rev 3 micron absolute

14.77:1

14.77:1

ELEVATOR COMPONENTS

Hydraulic Cylinders For Early Units (Two) Bore Stroke Hydraulic Cylinders For SIN 1061187 and On (Two) Bore Stroke DRILL LEVELING SYSTEM COMPONENTS No. of Jacks Rear Jacks (Two) Bore Stroke Front Jack (One) Bore Stroke ROTARY DRIVE SYSTEM Type-Hydraulic Axial Piston Drive Rotary Head-Heavy Duty Drive Box - All Timken Bearings Rotary Hydraulic System Closed Loop Pump-Axial Piston Variable DisplaceJl1ent Motor-Axial Piston Fixed Displacement Filtration Drive-Direct from Transmission Box

1-5

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Table 1-2.

Component Specifications (Cont.)

SYSTEM/ FUNCTI ON

ENGLISH UNITS

METRIC UNITS

3 6 in /§ev 3.5 in/Rev 1.1 in /Rev

38.7 cc/Rev 22.57 cc/Rev 22.57 cc/Rev

AUXILIARY HYDRAULIC SYSTEM Pump-Gear Pump Fi rst Stage Second Stage Third Stage Filtration-Ten Micron Drive-Direct from Transmission Box Control Valves-Spool Type

1:1

DRILLING ACCESSORIES Air Compressor-Rotary Screw Package with Oil Separator and Receiver Tank Oil Cooler-Air-Fin Type

750 cfm (900 cfm available)

OPTIONAL EQUIPMENT Dust Collector-Dry Type Water Tank Water Pump-Piston Type5 gal/min Winch Breakout Wrench Bi t Sub Adapter Slap Wrench-Automatic Ai r Operated

200 gal 5 gpm (mn)

758 lit 18.9 lit

4000 lbs 14,000 ft.lb As ordered

1814.4 kg

150 gal 200 gal 123 gal 38 gal

567 758 465 144

TANK CAPACITIES Fuel Water *Open Loop Hydraulic *Closed Loop Hydraulic

*Tank Capacity Only (Does Not Include Pumps and Lines)

lit 1i t 1i t 1i t

I

f-1 ~

'-l '..J

I

I

I

b

II

PUMP DRIVE

RETURN

55

GPM

GPM

32

GPM

I

I

1

HOIST VALVE

TT }:7

I I

I

I I

I I I

I TO OTHER TOTOOL OTHER TOOL OPTIONS

I

I

,

DUST COLLECTOR

BLOWER MOTOR MOTOR

IIIT

TANK

RER ~~

I

~ ~

WATER INJECTION MOTOR apUMP

II

WINCH WINCH

I CASING TONG TONG

RETURN RETURN

en

,_

1

en

L.H. CYL L.H

_

RETURN RETURNl

R.H. CYL RH.

t

_

RETURN

~I _ _ _ _ _ _ _ _ _ _ ---.J DUST CURTAIN CURTAIN DUST

RETURN

,~IIII

ILJ5 I"'"'----

I

I ~J~~~~

PIPE RACKl RACK PIPE CYLINDER

1I

III

-, I

PIPE RACK INDEX

I rL I I t=--------:::;1 t=--------:::::1 I~ I. I I

I

is'!' .....J DUThm DU!ULA...!.!!

~

1I

1I

II

AI';.g~~;ATED

HOIST/ PULLDOWN

TO

fDRILLING PLATFORM

WI l I

Ir MAST MAST ELEVATOR

1I

I rr9 Ri~~~y I

1"I

Figure 1-2. Functional Block Diagram, SK-35 Subsystems

HYDRAULIC TANK

II

~

~ l=

r

;::::::: ~

LAIR

!I[!

cori "

VALVE BLOCK

III I -_ _ J

REMOTE CONTROLLED VALVE

'I

II

CONTROL CONSOLE

1I 1I

'I I

AUXILIARY AIR

MAIN AIR

HYDRETURN HYD RETURN ~ LINES r-_.u.._.LL_.u.._..,LINES

II

CHARGE

<J

t>

CLOSED LOOP I, SYSTEM I

EN~INE I IEN~'NE

Ir

I ~~~:~- r=H

ROTARY HYDROSTATIC

FRONT JACK

1 ~IL

AIR} COMPRESSOR

tt

)f

* I

aOIL a: OIL AIR

AI~

r

SEPARATOR TANK

/

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SECTION 2

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Section 2 OPERATOR CONTROLS AND INDICATORS This section describes the control console and lists the function of each control and indicator. Service personnel should be familiar with the relationship of the controls and indicators to specific system functIons. For operating procedures, refer to the separate Operators Manual SK-35/SK-40.

A.

OPERATOR'S CONTROL CONSOLE

The control console contains the operating controls as well as the system indicators. The controls and indicators are shown and identified in Figure 2-1 and their functions are described in the section dealing with the particular subsystem.

1. INDICATOR PANEL. The upper part of the console is the indicator panel which contaIns the system indicators, meters and lights, as well as the engine ON/OFF switch and engine START button.

2. LOWER CONTROL PANEL. Located just below the indicator panel are two adjustable relief valves. The one on the left is the water flow control tor the dust control system and the one on the right is the pressure control for the drill pulldown.

Twelve identical control levers operate valves in the hydraulic valve bank to control the various system hydraulic functions. A shorter lever on the right side of the console controls the rotary drIve while another controls the engine throttle. On the console above the rotary drive and throttle controls is a shorter lever that controls the main air to the drill bit and the air to the pipe rack index if the system includes a pipe rack. Other controls may be present as required for optional items such as the heater fan and the auto-tool wrench.

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I. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

I I. 11.

12.

13.

14.

15.

16.

17.

I 8.

18.

19.

20.

AIR FILTER PRESSURE HYDRAULIC PRESSURE AIR "T" TANK PRESSURE ROTARY HYDRAULIC PRESSURE BIT AIR PRESSURE PULLDOWN HYDRAULIC PRESSURE ENGINE RPM ENGINE AMMETER ENGINE WATER TEMPERATURE ENGINE FUEL ENGINE OIL PRESSURE DRILL HOURMETER ENGINE HOURMETER WATER FLOW CONTROL LOOP FILTER LIGHT TANK FILTER LIGHT CHARGE FILTER LIGHT FILTER LIGHT SWITCH DRILL LIGHT SWITCH ENGINE START

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.

ENGINE ON - OFF PULLDOWN CONTROL LEVEL L.H. REAR JACK FRONT JACK R.H. REAR JACK MAST HOIST PIPE RACK PIPE RACK INDEX MAIN AIR/PIPE RACK INDEX BREAKOUT WRENCH WINCH WATER PUMP AND DUST COLLECTOR POSITIONER (OPTIONAL) HIGH SPEED HOIST PULLDOWN ROTARY DRIVE ENGINE THROTTLE DRILL/PROPEL SELECTOR ROTARY AND L.H. TRACK R.H. TRACK PROPEL LOOP FILTER LIGHT CRAWLER BRAKE AUTO-TOOL WRENCH (OPTIONAL) HEATER/FAN (OPTIONAL) AUTO MAST LOCK (OPTIONAL)

Figure 2-1. SK-35 Operating Controls and Indicators 2-2

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SECTION 3

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Section 3 MAIN FRAME/CARRIER The SK-35 Blast Hole Drill is built on a carrier vehicle so that the frame elements of the carrier become part of the main frame for the drill.

A.

CARRIER VEHICLE

The standard carrier vehicle (Figure 1-1) is a Crane Carrier 6 x 4 Truck, Model DR2064; or a Hendrickson vehicle is optionally available. This separately-powered vehicle is capable of transporting the blast-hole drill between distant locations at highway speeds.

For information on the carrier vehicle, refer to Section SS of Part II .

B.

MAIN FRAME

The SK-35 Main Frame comprises a steel deck welded to the frame of the carrier vehicle. Attached to the steel frame and deck structure are the optional operator's cab, two rear leveling jacks, a front jack with mast rests, fuel tank and a tool box.

1. OPERATOR'S CAB. The operator's cab contains the control console and an operator's chair as well as the plumbing and electrIcal system required to maintain system control. Also available for the cab is a hot-water type heater with the plumbing required to bring in and control hot water flow from the engine. Refer to the parts manual for details of the cab plumbing as well as for the assembly for the console. A seat for the operator is mounted in the control cab in front of the control console on an adjustable pedestal.

Section 2 illustrates the operator control and indicator functions, the overall system hydraulic functions are described in Section 7, and the electrical functions are described in Section 9. For operating details, however, refer to the Operators Manual SK-35. a.

Sliding Cab Feature. In its normal operating position, the cab extends past the right-hand side of the drilling unit; thus, rendering road travel illegal. for this reason, the cab is mounted on slide mounts. Three bolts may be removed, and the unit pushed inboard to permit highway travel. Because it would interfere with operation of the drill, the cab must always be repositioned to the operating position before drilling operations begin.

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b.

Heater. Figure 3-1 illustrates the heater system. Two shutoff valves at the water connections to the engine permit shutoff of the hot water through the heater during warm weather.

An electrical blower is controlled from the control panel.

Refer to the parts manual for interconnection details for the particular engine and refer to Section 9 for electrical details.

2. LEVELING JACKS. Three leveling jacks, two located at the rear of the main frame and one located at the front, serve the dual purposes of leveling the drill and steadying it for drilling operations.

Refer to Figure 8-3 for the hydraulic function of the leveling jacks. On the left side of the control console (second step) is a T-shaped spirit level that permits the operator to view the level condition of the blast hole drill. Also on this deck of the control panel are three levers that operate separate valves for each jack, so that the operator may simply manipulate the three jacks to level the vehicle. As a mechanical convenience, the barrel of the front jack extends upward -to provide a rest for the mast when the mast is lowered for load transit. For details of the hydraulic system refer to Section 8.

BLOCK VALVES

CAB HEATER SWITCH ELECTRICAL WIRE ...............

r---

==

BLOWER MOTOR

HEATER CORE

Figure 3-1. Cab Heater, Simplified Diagram 3. FUEL TANK. The standard blast hole drill is equipped with a single 150 gallon fuel tank (or an optional 200 gallon tank is available). This tank is attached underneath the main frame on the righthand side of the vehicle just forward of the rear wheels. For details of the fuel hookup for a particular engine, refer to the Parts Manual.

4. TOOL BOX. For service convenience, a tool box is mounted on top of the main trame deck just forward of the control cab. See the parts manual for details.

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SECTION 4

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Section 4 ENGINE AND DRIVE TRAIN As illustrated in Figure 4-1, the engine and drive system includes the engine with its accessory units, the pump drive unit and the drive shaft. Refer to Figure 1-1 and 1-2 for the locations of the engine and drive components and for their relationship to other system components.

HEAT EXCHANGER CLUTCH ASSEMBLY DRIVE SHAFT _ _ _ - - , COVER

I _\ AIR COMPRESSOR (REFERENCE)

DRIVE SHAFT

_ ENGINE

I _ _ _ _ ...J TANDEM PUMP

MUFFLER

Figure 4-1. Engine and Drive System A.

DIESEL ENGINE

The engine provides the primary power for the blast hole drill.

The standard engine is a Cummins NT-855-335 Engine, with other engines optionally available. Each standard diesel engine is equipped with a special air cleaner and an exhaust muffler system. Also mounted on the engine is a heat exchanger unit associated with the

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rotary drive hydraulic system.

1. AIR CLEANER. The specific air cleaner employed depends upon the engine option; however, the basic principles apply to all. Each is a dual unit having a lower element that traps the larger particles and a double filter unit that filters out the tine particles. Both the safety (inner) element and the primary louter) element are dlSposable. 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 Part II of this manual for service instructions.

2. EXHAUST AND MUFFLER SYSTEM. An exhuast muffler is installed on each engine. Although the installation varies slightly between the Cummins and the Caterpillar engines, the function of the mufflers is the same (i.e. to cut down on the noise generated by the engine).

A special heavy-duty muffler is also optionally available.

3. HEAT EXCHANGER. Although mounted on the front of the engine radiator, the heat exchanger is not a part of the engine; but rather, this unit is used to cool the hydraulic fluid for the rotary hydraulic system. While the same heat exchanger is employed for either engine, the mounting requirements differ from one engine to the other.

Refer to the Parts Manual for installation details, and refer to Part I, Section 8 for the heat exchanger function.

B.

PUMP DRIVE UNIT

The pump drive unit consists of a bell housing, clutch assembly and a transmission gear case. The gear case, accommodates the hydraulic drive pumps.

1. CLUTCH ASSEMBLY. The hand-operated clutch enables the operator to decouple the engine for easier starting. The unit is normally equipped with a dual-disk clutch; however, a special heavy-duty Rockford clutch may be ordered. A Zerk fitting located on the bell housing enables greasing of the throw-out bearing by means of a tube connected from the Zerk to the bearing.

2. HYDRAULIC PUMP DRIVE. The two-pump drive consists of a gear box assembly having two hydraulic pump drives, one on the left and one on the right, plus a center drive fitted with a yoke for coupling of the compressor drive shaft.

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Although the pumps are part of the overall hydraulic system (Section 8), they are described briefly in the following paragraphs.

C.

a.

Rotar Drive Pump. The rotary drive pump is a hydrostatic pump ocated on the left hand side of the hydraulic drive unit. This pump is a single-stage unit that powers the rotary system for the drill.

b.

Tandem Pumps. This set of pumps consists of a three-stage unit and a piggy-back unit. The three-stage unit provides power to all the hydraulics except the rotary drive, and the piggy-back pump charges the rotary pump. The miscellaneous hydraulic systems associated with the three-stage pump all draw fluid from the hydraulic reservoir, with the fluid drain returning to the sump.

t

DRIVE SHAFT

Enclosed in a safety guard, the drive shaft couples the engine to the air compressor. Designed for ease in removal, the shaft may be easily disconnected from the air compressor in case of compressor failure. This feature enables use of the hydraulic system to pull the drill string out of the hole and move to a service location, even when the air compressor is not operational.

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SECTION 5

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Section 5 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 Section 5 of Part III for details of the vendor-manufactured components.

A.

COMPRESSED AIR SUBSYSTEM COMPONENTS

As illustrated in Figure 5-1, 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 5-2 illustrates the compressor lubrication and cooling tunctions. Although the following topics briefly describe the functions of the compressor and separator tank, you should refer to the vendor's manual in Section 5 of Part III for functional details of these units.

1. AIR COMPRESSOR. A single-stage, positive-displacement, oilflood-lubricated type air compressor is located on the right-hand side of the main frame behind the engine and hydraulic drive system.

The compressor operates in association with the separator tank (Topic 2) to provide compressed air at 750 CFM to the rotary drill and to other air operated components as required. The air compressor is engine driven by means of a quick-disconnect drive shaft from the hydraulic drive transmission. Refer to Part III, Section 5 for air compressor details.

In operation, the compressor unit receives oil from the separator tank sump. Besides acting as a coolant for the compressor, the oil seals the linkage 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.

2. 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 blowdown valve is located in a common line between the compressor and tank.

5-1

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AIR COMPRESSOR

AIR VALVE

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DRAIN VALVE

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MAIN AIRI PIPE RACK INDEX

Figure 5-1. Compressed Air System, Functional Diagram

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AIR/COOLANT

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TOOL WRENCH CONTROL

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Figure 5-2. Compressor Cooling and Lubrication System, Functional Diagram B.

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 Part II of this manual for service instructions.

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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 stern to imerge from the drill bit, blowing out the particles from the blast hole. The butterfly valve is controlled by means of a control lever on the operator control panel, as described in Topic 3. Water is injected into the main air manifold by means of an air loop to the water inject10n system as described in Section 6.

2. 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.

3. AIR SUBSYSTEM CONTROL FUNCTIONS. The main air control valve, controlled by a lever on the control console, can be operated in two directions. Pulling the lever operates the valve in such direction as to apply control air to the butterfly valve, thus providing air to the drill. Pushing the lever forward, operates the air valve in such direction as to apply control air to the pipe rack, unlocking the pipe rack indexing pin. When the automatic tool wrench is provided, a lever mounted to the lower edge of the control panel operates an· air control valve to control the wrench.

4. 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 tilter.

The difference between the filter pressure gauge and the "T" pressure gauge readings indicates the condit1on 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 drill has operated, as opposed to the number of hours the engine has operated (as indicated on the engine hour meter.)

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SECTION 6

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Section 6 DUST CONTROL SYSTEM The dust control system Figure 6-1 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.

Also part of the dust control system is a water injection system that injects water into the main air stream to help control dust accummulation.

A.

DUST CONTROL SYSTEM FUNCTIONS

The general functions of the dust control subsystem units are described in the following topics. For the operator control functions, however, see Topic B. 1. DUST CURTAINS. The dust curtains are attached to a frame work underneath the drilling platform. Actually, part of the drilling platform that forms the base for the mast assembly, these curtains are covered in Section 7.

2. 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 dust collector may be a Roto-clone dynamic precipitator, or dry filter-type unit containing a series of filter elements. a.

Roto-clone Unit. The Roto-clone precipitator precipitates out the dust which drops down to be expelled from the bottom of the dust collector unit. At the same time, the unit acts as an exhaust blower to exhaust the cleansed air from the unit. A hopper at the bottom of the unit contains the dust which is removed through a hopper door.

b.

Dry Filter Type Dust Collector. Although the Roto-clone removes the larger partlcles, environmental conditions may sometimes require removal of finer particles. Therefore, a filtertype dust collector is offered as an option.

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 6-1

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DUST CURTAIN

DRILLING PLATFORM

DUST AIR

Be

CONTROL VALVE

I

MOTOR

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STRAINER WATER TANK

AIR CONTROL VALVE

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FLOW CONTROL VALVE

WATER PUMP

-1----

CONTROL LEVER

-----,

Figure 6-1. Dust Control System

DUST COLLECTOR

AIR DISCHARGE

o

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I CON-rn;L-coNS~ -

MAIN AIR HEADER

TO DRILL

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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 subsystem.

3. WATER INJECTION SUBSYSTEM FUNCTION. As described in Section 5, 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. As shown In Figure 6-1, the pump provides water trom 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.

B.

DUST CONTROL SYSTEM CONTROL FUNCTIONS

The operator controls (Figure 6-1) for the dust control system consist of a hydraulic control lever and a water tlow 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 control operates the water pump hydraulic motor and the Roto-clone hydraulic motor. Pushing the lever forward engages the water pump motor and pulling the lever back engages the Roto-clone motor. The water flow control operates a needle valve that controls the amount of water being injected into the main air stream.

See Section 8 for Hydraulic System details.

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SECTION 7

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Section 7 MAST/ROTARY DRIVE The mast and rotary drive subsystem components are illustrated in Figure 7-1. This subsystem consists of the mast structure having the drill platform as its base, the rotary drive, the hoist with its pulldown cylinders, mast elevating cylinders, casing tong, and the dust curtains associated with the dust control subsystem.

A.

MAST ASSEMBLY

The mast assembly is a steel frame-work 24 feet in length containing a base assembly which becomes the drill platform when the mast is elevated to a drilling position. The mast structure contains the rotary drive subsystem, hoist and pulldown subsystem, casing tong and a hydraulically driven wrench with related cable and sheaves.

The mast assembly pivots from a point a few feet above its base so that it may be tilted to the vertical position or lowered to the horizontal position by means of the mast elevating cylinders. In the lowered position, the mast rests on a mast rest incorporated with the front jack. When the mast is fully elevated, an automatic latch mechanism locks the mast into place. Then, before the mast may be lowered, the lock must be released. (Note that earlier models had two locking pins to secure the mast in the up-right position.)

B.

ROTARY DRIVE ASSEMBLY

The rotary drive assembly consists of a gear case with a hydraulic drive motor and an air swivel connected to the top. The hydraulic motor operates the drive to rotate the drill stem during drilling operations. The swivel connects the stationary air input with the rotating drive. Refer to Section 8 for a description of the rotary drive subsystem.

C.

HOIST AND PULLDOWN ASSEMBLY

The hoist and pulldown assembly consists of left-hand and righthand hydraulic cylinders with a chain arrangement permiting elevation of the rotary drive assembly. The mechanics of this assembly can best be understood by considering the cylinder and chain arrangement for one side as shown in Figure 7-2.

Each chain is actually in two sections. One end of the upper chain is secured at the top of the mast and threaded over a roller sprocket, in a moveable cylinder guide frame then over a fixed roller 7-1

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HYDRAULIC LINES

ROTARY GEAR CASE

WINCH DETAIL IJrIl.l.,,*...;.,i~ _ _ ROTARY ROT A R Y W~-IU~--

DR IV E DRIVE

DUST CURTAINS

Figure 7-1. Mast and Rotary Drive Components

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TOP

-+ ROTARY DRIVE ASSEMBLY

LOWER ROLLER CHAIN

UPPER ROLLER CHAIN

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CYLINDER FRAME CHAIN TIGHTENING

CHAIN TIGHTENING

Figure 7-2. Hoist and Pull-Down, Simplified Diagram sprocket at the top of the mast, and to the rotary drive assembly, where the chain is attached. One end of the lower roller chain is affixed near the center of the mast, and the chain is threaded over a second roller sprocket in the moveable cylinder guide, then threaded through a fixed roller sprocket at the lower end of the mast to be attached to lower side of the rotary drive assembly. Chain adjustment for tightness may be accomplished at the two points at which the chain is attached to the mast.

The hoist and pulldown cylinder arm is attached to the cylinder guide frame so that operation of the hydraulic cylinder moves the frame upward or downward, as the operator elects. Thus, moving the cylinder guide frame upward or downward, moves the rotary drive assembly as desired. The distance that the hydraulic mechanism moves is multiplied by two so that the rotary drive assembly moves twice as far at twice the speed of the hydraulic cylinder guide block.

Thus, when the hydraulic cylinder extends to its maximum or retracts to its minimum positions the rotary drive assembly moves up to the top of the mast or down to the bottom of the mast. This system permits the operator to quickly raise the drill stem up out of the hole or lower it for drilling.

Another function of the hoist and pulldown system is to maintain pulldown force on the drill during drilling operations. This force is maintained by the same mechanism used for the hoist except that the cylinders are supplied from a different pump. The operator can control the system to maintain the drill at any force desired up to the maximum pulldown force for the blast hole drill unit. See Section 8 for a description of the hydraulics and for operator control functions.

D.

HYDRAULIC WINCH A winch powered by a hydraulic motor is located near the lower 7-3

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end of the mast. A cable from the winch is threaded through sheave blocks at the top of the mast and attached to a hook for utility hoist purposes. See Section 8 for the associated hydraulics and for operator control functions.

E.

DRILLING PLATFORM

The platform at the base of the mast serves as a drilling plattorm when the mast is in vertical position. The drilling platform contains the casing tong and the dust curtain assemblies.

1. CASING TONG ASSEMBLY. The casing tong assembly is attached underneath the drilling platform. For operation, the casing tong is fastened around the casing and turned by remote control from the control console. The casing tong is actuated by a hydraulic cylinder connected into the system plumbing. See Section 8 for the associated hydraulics and for operator control functions.

2. DUST CURTAIN ASSEMBLY. A front and rear dust curtain are attached underneath the drill platform by means of three clamps with cap screws and hex nuts. The bottoms of the curtains are attached to a base plate by means of a clamp band.

F.

MAST ELEVATORS

Two hydraulic cylinders with the associated plumbing serve to elevate the mast to a vertical position for operation. For mast elevation hydraulic function and control see Section 8.

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SECTION 8

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Section 8 HYDRAULIC SYSTEM Hydraulic power for all systems is obtained from two pumps driven by the engine through the gear box. The right-hand (outboard) pump is a tandem unit consisting of a three-stage pump piggy-back charge pump.

The three-stage pump draws fluid from one section of the hydraulic reservoir and provides power to all the hydraulic units in the system except rotary drive. This three-stage pump consists of a section that delivers hydraulic fluid at 55 gallons per minute, a section that delivers fluid at 32 gallons per minute and one that delivers fluid at 10 gallons per minute. The specific functions of these pumps within the system will be discussed in the applicable topics of this section. The pump that operates piggy-back through the three-stage pump is a charge pump for the rotary hydrostatic pump installed on the rear of the three~stage pump. The charge pump draws fluid from the second section of the hydraulic reservoir, and maintains the charge on the rotary hydrostatic pump that provides hydraulic power for the rotary drive unit. Control of all the elements except the rotary drive is through a valve block having valves operated by control cables from the control console. For control of the rotary drive unit, a cable control from the console controls the volume of the hydrostatic pump and thereby controls the rotary drive speed. The separate hydraulic subsystems are described in the remainder of this section.

A.

ROTARY DRIVE HYDRAULICS

As shown in Figure 8-1, the rotary drive hydraulics consist of a charge loop and a drive loop.

1.' CHARGE LOOP. Fluid is drawn from the reservoir and applied through a filter to the hydrostatic pump to maintain the charge on the hydrostatic pump. A portion of the output of the charge pump is bypassed through a relief valve to a cooler where the hydraulic fluid is cooled and returned to the tank.

2. DRIVE LOOP. The rotary drive loop includes the hydrostatic pump, the rotary drive motor, and a loop filter. Hydraulic fluid is driven in one direction to turn the rotary element forward and driven in the reverse direction to reverse the rotary element. The loop filter removes foreign particles from the hydraulic fluid in the loop.

3. ROTARY DRIVE OPERATOR CONTROL. The rotary element is controlled by varying the output of the hydrostatic pump. The pump 8-1

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MAIN AIR HOSE

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DRAINS

Figure 8-1. Rotary Drive Hydraulic Subsystem contains a control assembly that enables a reversal of the direction of flow in order to reverse the element. The control assembly also provide continuously variable flow control to result in a continuously variable speed for the rotary element. The rotary pump control assembly is operated by means of a control cable from a control lever on the operator console.

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B.

HOIST AND PULLDOWN HYDRAULICS

The hoist and pulldown hydraulics subsystem comprizes the 55 and 10 GPM pump stages and the two hoist and pulldown cylinders, with the contr.ol elements required for operation. This subsystem serves both high-speed hoist and pulldown functions. The hoist operates at high speed to quickly raise the rotary drive head to pull the drill string out of the hole or to lower it back down. The pulldown function maintains a constant force on the drill bit during drilling operations.

The subsystem elements are shown in Figure 8-2 and the functions are discussed in the following topics.

1. HIGH-SPEED HOIST. For the high-speed hoist system the 55 GPM pump delivers hydraulic fluid to the hoist cylinders under control of the high-speed hoist valve. This valve is not a part of the valve bank but IS separately located on the mast pivot support. The amount of hydraulic pressure on the hoist cylinders is_adjusted by a relief valve operated from the console. The hoist is hydraulically counterbalanced to maintain its position after each move.

2. PULLDOWN SUBSYSTEM. The 10 GPM pump operates in association with a pulldown control valve in the lower valve bank to maintain continuous pressure on the hydraulic cylinders, and thus to maintain a continuous pulldown force on the drill bit. The relief valve for the pulldown system is controlled by the operator to maintain the desired pulldown force.

3. HOIST AND PULLDOWN OPERATOR CONTROL. A control lever on the console provides operator control for the high speed hoist. Pushing the lever forward raises the hoist and pUlling the lever back lowers the hoist. Two separate operator controls are provided for the pulldown subsystem. The pulldown lever applies the pulldown pressure while the relief valve adjustment sets the pulldown to the desired pressure. Pushing the pulldown lever forward releases the pulldown pressure and pulling the lever back applies the pressure. The pulldown pressure applied to the hydraulic cylinders is indicated directly on the Pulldown Pressure gauge on the indicator panel.

C.

GENERAL HYDRAULIC PRESSURE

The 32 GPM pump stage operates the general hydraulic subsystems.

These include the leveling jacks, mast elevation cylinders, water pump and blower motor, winch, casing tong, plus the pipe rack cylinder and other tool options as ordered. Control for the hydraulic elements is valve block on the valve bank. The elements of the general hydraulic subsystem are shown in Figure 8-3. Note that Figure 8-3a applies to earlier machines while Figure 8-3b applies to current machines, starting with serial number 1061187 and on.

8-3

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RELIEF VALVE

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PULLDOWN CONTROL VALVE (IN VALVE BANK)

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SS GPM 55 PUMP STAGE

OPERATOR __ ......

ADJUSTMENT

10 GPM PUMP STAGE

HOIST CYL.

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rigure 8-3a. General Hydraulics Subsystem, 32 GPM Pump tigure Stage (early models)

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RH RH REAR REAR JACK JACK

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1. VALVE BANK ARRANGEMENT. The physical arrangement of the valve banks vary slightly between the earlier and latter serial numbers. Because Figure 8-3 is a simplified diagram illustrating functions only, the valves are not pictured in actual order. Also, the relief valves associated with these valve banks are not illustrated.

For an understanding of the hydraulic flow division between the upper and lower valve banks, and also for the location of the actual valve blocks, refer to Figure 8-1 of Part II. You should refer to the hydraulic schematic for the blast hole drill as required tor understanding ot the hydraulic functions. The 32 GPM pump draws fluid trom the hydraulic reservoir and delivers it under pressure to the upper valve bank manifold, where the pressure is available to each control valve in that bank. from the lower outlet of the upper bank, the fluid is routed through a flow divider to the lower valve bank where it is input to the manifold just below the first control valve, to provide hydraulic fluid at 16 GPM to the remaining valves in that bank. The first control valve is not shown in Figure 8-3 because it is associated with the pulldown system as previously described. The pressure at 16 GPM's is then available to all the elements operated from the lower valve block, and unused fluid is routed from the lower manifold back to the return header. The functions of the various valves in the upper and lower control banks are described, with the associated component functions, in the following topics.

2. LEVELING JACK HYDRAULIC SUBSYSTEM. The following topics describe the leveling jack functions and the operator control of these functions. a.

Levelin~

Jacks. Hydraulic pressure from the upper valve block IS applIed through individual control valves to the separate jack cylinders. Each control valve operates independently to raise or lower its associated jack. A counter-balance valve holds each jack in position after the control valve is returned to neutral so that the jack will not retrack by itself when the operating pressure is removed.

For the earlier machines that jack control valves are the only valves on the upper valve block; however, for machines starting with serial number 1061187, the mast elevation control valve is also located on the upper valve block. As described in topic 3b, operator control of the leveling jacks.

Three control levers on the console control the leveling jacks. Pulling a lever lowers the associated jack to raise the machine at that point and pushing the lever raises the jack to lower the machine at that point. The operator uses these controls in conjunction with the T-shaped level indicator to level the machine before operation.

3. MAST ELEVATION SUBSYSTEM. For earlier machines the mast elevation control valve is located in the lower valve block with access to hydraulic pressure at a flow rate of 16 GPM. In the early models 8-7

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this flow rate was adequate because the cylinders were only 4-1/2 inches in diameter. For a later models beginning with serial number 1061187, the mast elevation cylinders are 6 inches in diameter requiring hydraulic pressure at a flow rate of 32 GPM. Therefore, for the later models this valve is located in the upper valve block. Reter to Figure 8-3a for the earlier models and refer to Figure 8-3b for the later models. a.

Mast Elevators. The mast elevation control valve applies hydraullc fluid to the mast elevator cylinders to raise the mast for drilling operations or lower the mast for tramming or road travel. Counter-balance valves secure the cylinders in any position when the valve is returned to neutral. However, drilling is not to be performed except when the mast is fully elevated and locked by pins or a detent.

b.

Elevator Control Functions. The elevator control valve is operated by a single lever on the control console. Pushing the lever forward operates the cylinders to lower the mast to the horizontal position, and pulling the lever raises the mast to the vertical position. Essential to the mast raising and lowering operation is the placement of locking pins to lock the mast in the vertical position, or operation of the detent that holds the mast vertically. The pins must be put in place when the mast is raised and removed before the mast can be lowered. For drills equipped with the detent lock, the detent latches automatically when the mast is raised to the vertical position. However, the latch must be released before the mast may be lowered to the horizontal position.

4. WATER PUMP AND DUST COLLECTOR MOTORS. The functions and control of the water pump and dust collector motors are described in the following topics. a.

Motor Functional 0leration. The two pump motors are operated by the same contro valve on the lower valve block. Operating the valve in one direction operates the dust collector motor and operating the valve in the other direction operates the water pump motor. Common use of one valve is made possible by the fact that the water injection system and the dust collector system do not operate at the same time. Thus, pushing the valve control lever forward engages the water pump motor and pulling the lever back engages the Roto-c1one motor or MPI filter system blower motor.

5. HYDRAULIC WINCH. The hydraulic winch is operated directly from a valve on the control block by means of a lever on the control console. Pushing the lever forward turns the winch in the direction to lower the hook, and pulling the lever back operates the winch in a

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direction to raise the hook.

6. PIPE RACK AND TOOL HYDRAULIC FUNCTIONS. The casing tong, pipe rack hydraulic cylinder, pipe rack index motor and other tool options are operated by valves on the lower valve block assembly through control levers on the console.

8-9

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SECTION 9

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Section 9 ELECTRICAL SYSTEM Due to the extensive use of hydraulics in the blast hole drill, the electrical system is quite simple. In fact, most of the circuits are associated with the engine controls and indicators. Figure 9-1 illustrates the overall wiring for the blast hole drill. For electrical information on the carrier vehicle refer to the manufacturer's manual.

A.

ENGINE CONTROLS AND INDICATORS

This topic describes the controls and indicators associated with engine operation. The engine controls and indicators consist of the start and run controls, engine gauges, tachometer, and engine hour meter.

1. START AND RUN CONTROLS. The start and run controls are the ignition switch and starter button. a.

Ignition Switch. Operation of the ignition switch applies battery voltage to the engine electrical circuits and engine instruments including the tachometer and engine hour meter.

This switch must be turned ON in order to read the instruments and to start and run the engine.

b.

Starter Button. The start button operates the engine starter to crank the engine.

2. ENGINE GAUGES. The engine gauges are described in the following topics. Although the fuel system is a separately installed system, the fuel level gauge is handled with the engine gauges due to its significant relationship to the engine. The tachometer and engine hour meter however are handled in separate topics. a.

Fuel Level. The ground side of the fuel level gauge is connected through the fuel sender in the fuel tank, so that the gauge indicates the fuel level in the tank.

b.

Engine Oil Pressure. The ground side of the engine oil pressure guage is connected through the oil pressure sender attached to the pressure side of the engine oil pump. This 9-1

N

I

r.o

j

blaCk "

:) I

g"

16 g.

~' iIIi

l,,,.",.

I

FUEL LEVEL GAUGE

1

whltf

AMMETER

12 g"

DRILL LIGHTS

rod

whlt~

~

i3

FILTER L1(,HTS SWITCH

.

AIR PRESSURE SWITCH

black IG 94

rf'd 16

1-

~TER

DRILL

r"'\~~IjR

_

L Q

(1~:IJll

i

CHARGE PUMP OIL FIL TER

black. 16

rfd I&Qd

Q

TANK

tbga rtd

Q

P

WARNING LIGHT

~OIL"LTER

BtU~j(l.:k

Figure 9-1. Electrical Wiring Diagram (Typical)

blur

SENDER

10 Qa

r

I ., -=:1

I ".'61"TACHOMETERtj

,,\low 16 ¥

~'Og"

~I

og", I

bf~16u

W~lltf

16gd

I? li

I

br~Jwn

OIL PRESSURE SENDER

-.b~

FUEL SENDER

bit"

TACl-10METE".

ENGN: _NG BULKHEAD

Oil

"

010

O·

08

01

o.

OJ

BI007191

BI007191

gauge indicates the engine oil pressure whenever the engine is operating. c.

Engine Water Temperature. The engine water temperature gauge is connected through the temperature sender mounted on the engine cylinder head. This gauge indicates the engine coolant temperature any time the ignition switch is turned on.

d.

Ammeter. The ammeter indicates the charge rate or current draIn on the battery.

3. TACHOMETER. The electronic tachometer operates from a tach generator attached to the engine to indicate engine RPM at any time the engine is operating.

4. ENGINE HOURMETER. In the diagram, the engine hourmeter is shown connected directly to the ignition switch to operate whenever the ignition switch is turned on. In later units however, this meter is connected through the oil pressure sender so that the hour meter will operate only while the engine is running.

B.

FILTER WARNING SUBSYSTEM

This subsystem provides a visible indication to the operator in case one of the three filters in the hydraulic system becomes clogged.

1. WARNING LIGHT CIRCUITS. The hydraulic charge pump, loop and tank oil filters all have warning lights on the control panel to indicate when the filters are clogged. In these functions, battery voltage is applied to a warning light on the console through a pressure switch on the filter unit. Each pressure switch senses a high pressure differential across the filter when the filter becomes clogged, and duly indicates this condition on the instrument panel.

2. TEST CIRCUIT. A built-in test circuit checks the lights of the charge pump oil filter and loop oil filter circuits. For this circuit, the Filter Lights toggle switch on the indicator panel applies battery voltage to one contact of each pressure switch lights simultaneously, thus showing whether the bulbs are good. The switch contact arrangement is such that the filter switch circuit has no effect on the lamps when the Filter Lights switch is turned off. There is no built-in test circuit for the tank oil filter warning light.

C.

DRILL HOUR METER A pressure switch, operated by main air pressure any time the 9-3

BI007191

air is turned on the drill, applies operating voltage to the drill hour meter, so that the meter indicates only those hours during which the drill operates.

D.

DRILL LIGHTS

The illumination lights for night time operation are connected through to the battery through the drill light switch on the instrument panel. This is simply a toggle switch which may be operated to turn the drill lights on or off.

E.

BATTERY CONNECTIONS

The battery-to-starter connections for the drill system are shown in Figure 9-2. Electrical power for the other circuits is taken off at the starter and solenoid connectors.

STARTER POSITIVE BATTERY CABLE

12V BATTERY

o

0

0

0

NEGATIVE (GROUND) BATTERY CABLE

12V BATTERY

o

0

0

0

Figure 9-2. Battery Connections

9-4

BI007191

Part II SERVICE AND TROUBLESHOOTING Part II of the SK-35 Blast Hole Drill Service Manual includes service and troubleshooting procedures. Section I of Part II is a general service section which includes the lubrication and general service information, and the other individual sections contain the service and troubleshooting information for the various subsystems of the SK-35. These sections correspond to the functional description sections in Part I and to the component breakdowns in the Parts Manual.

2-0

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Part II Table of Contents Section 1

Title GENERAL SERVICE

A.

B• B.

2

Lubrication 1. General Lubrication Information a. Carrier Lubrication b. SK-35 Drill System Lubrication 2. Engine Lubrication 3. Winch Assembly Lubrication 4. Dust Control Blower Lubrication a. Blower Lubrication (Normal Operation) b.

Blower Lubrication (Special Conditions) c. Repacking Blower Bearings 5. Compressor Service and Lubrication Procedure a. Service Air Compressor b. Check Oil Level Every 50 Hours c. Change Oil Every 500 Hours Preventive Maintenance

1-1 1-1 1-1 1-1 1-1 1-5 1-5

1-5 1-5 1-6 1-6 1-6 1-6 1-6 1-7

OPERATOR'S CONTROLS AND INDICATORS SERVICE

A.

B.

C.

Upper Panel Indicators and Controls 1. Engine Controls and Indicators a. Engine RPM Indicator b. Engine Ammeter c. Engine Fuel Level Gauge d. Engine Oil Pressure e. Engine Water Temperature Gauge f. Engine Hourmeter g. Ignition Switch h. Engine Start Button l. Air Pressure Indicators 3. Hydraulic Pressure Indicators a. Hydraulic Pressure Gauge b. Rotary Hydraulic Pressure c. Pu1ldown Pressure 4. Hydraulic Filter Indicator Lights a. Loop Filter Light b. Charge Pump Oil Filter Light c. Tank Oil Filter Warning Light d. Filter Lights Switch 5. Drill Lights Switch Lower Console Control Functions Console Maintenance 2-i

2-1 2-1 2-1 2-1 2-1 2-1 2-3 2-3 2-3 2-3 2-3 2-4 2-4 2-4 2-5 2-5 2-5 2-6 2-6 2-6 l-6 2-6 2-6

BI007191

Part II Table of Contents (Cont.)

Section 2

Title OPERATOR'S CONTROLS AND INDICATORS SERVICE (Cont.)

1.

2.

3

Console Routine Maintenance Control Maintenance Adjustments a. Hydraulic Control Levers b. Mast Lock Control Lever c. Console Repair

MAIN FRAME COMPONENT/CARRIER SERVICE A.

Carrier Vehicle Service and Maintenance Carrier Vehicle Lubrication 2. Carrier Routine Service Main Frame Service and Maintenance 1. Paint and Finish Touchup 2. Inspection of Main Frame Components Repositioning Control Cab Main Frame Troubleshooting 1. Fuel Level Indicator Sender ~.

Detecting Leveling Jack Troubles 3. Cab Heater Fault Isolation Main Frame Repair 1. Leaking Jack Cylinders, Temporary Fix 2. Repacking Jack Cylinders 3. Lubricating Jack Casings Fuel Tank and Fuel Line Maintenance 1.

B. C. D.

E.

F. 4

2-6 2-8 2-8 2-8 2-8

3-1 3-1 3-1 3-1 3-1 3-1 3-1 3-3 3-3 3-3 3-3 3-4 3-4 3-5 3-6 3-6

ENGINE AND DRIVE TRAIN SERVICE A.

B.

Engine and Drive Train Service Procedures 1. Engine Service Procedures Oil Bath Air Cleaner Service L. • 3. Disposable-Filter Type Air Cleaner Service a. Inspection and General Service b. Element Replacements 4 . Clutch and Drive Assembly Service a. Inspection of the Drive and Drive Shaft Units b. Lubrication c. Clutch Adjustment The Engine and Drive Train Repair 1 . Muffler Replacement 2-ii

4-1 4-1 4-1 4-1 4-3 4-3 4-4 4-4 4-4 4-4 4-4 4-4

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Part II Table of Contents (Cont.)

Section 4

Title ENGINE AND DRIVE TRAIN SERVICE (Cont.)

2.

5

4-4 4-5 4-5 4-5

MAIN AND AUXILIARY AIR SYSTEM SERVICE A.

B. C. D.

6

a. Throttle Control Cable Drive Shaft Assembly Removal and Replacement and Timing a. Drive Shaft Removal b. Drive Shaft Replacement

Main and Auxiliary Air Subsystem Lubrication and Routine Service 1. Drain Receiver Condensate 2. Service Air Filter 3. Check Oil Level 4. Change Oil 5. Inspection a. Oil Lines and Cooler b. Air System Hoses Check For Inverted Thermal Bypass Valve Troubleshooting Repair of Main and Auxiliary Air System 1. External Plumbing System 2. Air Compressor and Separator Component Repair

5-1 5-1 5-1 5-1 5-1 5- 2 5-2 5-2 5-2 5-2 5-2 5-3 5-3

DUST CONTROL SYSTEM SERVICE A.

B.

Dust Collection System Service 1. Dust Collection System Lubrication a. Dust Curtains b. Hose Connections to the Dust Collector.

2. Dust Collector Unit Service a. Roto-Clone Unit Service 1) Dust Removal 2) Inspection of Uni t b. Impulse-Type Dust Collector 3. Dust Collector Motor and Hydraulic System Service a. Dust Collection Motor Hydraulic Plumbing Service b. Dust Collector Hydraulic Motor Water Injection System Maintenance 1. Water Injection System Service 2-iii

6-1 6-1 6-1 6-1 6-1 6-1 6-2 6- 2 6-2 6-2 6-2 6-2 6-2 6-2

BI007191

Part II Table of Contents (Cont.)

Section 6

Title DUST CONTROL SYSTEM SERVICE (Cont.)

2.

3.

4.

5.

7

6-3

M.P.I. Service

6-4

6-3 6-3

MAST ASSEMBLY SERVICE

A.

B.

c.

8

Water Injection System Inspection Water Injection Hydraulic System Plumbing Water Injection System Hydraulic Motor

Hoist and Pulldown Mechanical System Service 1. Hoist Roller Chain Maintenance a. Chain Adjustment b. Rotary Head Level Adjustment 2. Hoist Hydraulic Cylinder Service a. Check for Hydraulic Seal Leak b. Leaking Hoist and Pulldown Cylinders, Temporary Fix c. Pulldown Cylinder Leakage Test d. Repacking the Hoist and Pulldown Cylinder Mast Elevation Mechanical System Service 1. Elevation Hydraulic Cylinder Service a. Check for Hydraulic Leak b. Examine the Seal Around the Cylinder Rod for Evidence of Leakage c. Leaking Elevation Cylinders, Temporary Fix d. Repacking the Elevation Cylinder 2. Mast Lock Service Rotary Drive Assembly Service 1. Hydraulic Motor Service 2. Rotary Gearcase Service a. Routine Maintenance Service b. Rotary Gearcase Disassembly Procedure c. Rotary Gearcase Assembly Procedure

7-1 7-1 7-2 7-2 7-4 7-4 7-4 7-5

7-6 7-6

7-7 7-7

7-7 7-7 7-8

7-9 7-9 7-9 7-9 7-10 7-10 7-16

HYDRAULIC SYSTEM MAINTENANCE

A.

Rotary Hydrostatic System Maintenance 2-iv

8-1

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Part II Table of Contents (Cont.)

Section 8

Title HYDRAULIC SYSTEM MAINTENANCE (Cont.)

1.

B.

C.

Rotary System Pressure and Reliet Valve Functions 2. Rotary Hydrostatic System Filter Replacement a. Loop and Charge Filters b. Tank Filter Element Replacement 3. Rotary Hydraulic Pressure Check and Adjustment a. Gauge Installation for Rotary Pressure Adjustment b. Rotary Low Pressure (charge) Adjustment c. Pump Inlet Check Inspective Procedure d. Rotary High Pressure Adjustment e. Cross-Over Relief Poppets Check f. Hydrostatic Pump Neutral Setting Procedure g. Case Drain Inspection Procedure h. Remove Pressure Gauges 4. Rotary Hydrostatic System Troubleshooting 5. Rotary Hydrostatic System Repair Hoist and Pulldown Hydraulic System Maintenance 1. Hoist and Pulldown System Pressure and Relief Valve Functions a. High Speed Hoist Functions b. Hoist Counter Balance Valve c. Pulldown Hydraulic System 2. Hoist and Pulldown Hydraulic Pressure Checks and Adjustments a. High Speed Hoist Relief Valve Setting b. Pulldown Pressure Adjustment c. Hoist Counterbalance Adjustment 3. Hoist and Pulldown System Troubleshooting 4. Hoist and Pulldown Hydraulic System Repair General Hydraulic System Maintenance 1. General Hydraulic System Pressure and Relief Valve Functions 2. General Hydraulic System Pressure Check and Adjustment 2 -v

8-3 8-3 8-3 8-5 8-5

8-6 8-6 8-6

8-7 8-8

8-9

8-10 8-10 8-10 8-10 ~-14

8-14 8-14 8-14 8-14 8-14 8-16 8-16 8-16

8-17 8-17 8-17 8-21 8-21

BI007191

Part II Table of Contents (Cont.)

Section 8

Title HYDRAULIC SYSTEM MAINTENANCE (Cont.)

Upper Valve Bank Pressure Adjustment b. Lower Valve Bank Relief Valve Setting c. Leveling Jack Counterbalance d. Mast Elevator Counterbalance General Hydraulic System Troubleshooting General Hydraulic System Repair a.

:)

.

4.

9

8-21 8-21 ~-23

8-23

8-23 8-23

ELECTRICAL SYSTEM SERVICE A. B.

Electrical System Troubleshooting Electrical System Component Replacement

2-vi

9-1 9-1

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List of Illustrations

No.

Title

Page

1-1

Blast Hole Drill Components

1-2

1-2

Carrier Unit Lubrication Diagram

1-3

1-3

Overall System Lubrication and Maintenance Diagram

1-4

2-1

SK-35 Operating Controls and Indicators

2-2

2-2

Air Pressure Gauges and Take Otf Points

2-3

2-3

Hydraulic Pressure Gauges and Takeoff Points

2-5

2-4

Control Lever Maintenance and Lubrication

2-7

3-1

Control Cab Positioning

3-2

3-2

Typical Jack Cylinder Assembly and Parts List

3-4

4-1

Disposable-filter Type Air Cleaner

4-2

4-2

Drive Shaft Timing

4-6

7-1

Roller Chain Adjustments

7-1

7-2

Rotary Head Alignment

7-3

7-3

Hoist Cylinder Illustration and Parts List

7-5

7-4

Mast Elevation Cylinder and Parts List

7-8

7-5

Rotary Gearcase Disassembly Procedure

7-10

7-6

Rotary Gearcase Assembly Procedure

7-17

8-1

Gauges and Tools Required for Adjusting Hydraulic System

8-2

Simplified Rotary Hydrostatic System Diagram With Maintenance Points

8-4

8-3

Pump Inlet Check Valve

8-7

8-4

Cross-Over Relief Valves

8-9

8-5

Smile Plate (Detent Plate)

8-9

8-6

Simplified Hoist and Pu11down Hydraulic System Diagram with Maintenance Points

8-15

8-2

2-vii

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List of Illustrations (Cont.)

No.

Title

8-7

Simplified General Hydraulic System Diagram Showing Service Points

8-17

8-8

Counterbalance Valve Adjustment

8-22

9-1

Instrument Panel Wiring Diagram, Cummins NT855 Engine

9-2

Wiring Diagram, Caterpillar 3406 DI-T

9-3

9-2

2- viii

BI007191

List of Tables

No. 1-1

1-2 1-3 1-4 8-1 8-2 8-3 8-4

Title Carrier Unit, Lubrication Chart SK-35 Drill System Lubrication Chart Caterpillar Engine Lubrication Chart Cummins Engine Lubrication Chart Pressure Settings for System Elements Rotary Hydraulic System Troubleshooting Hoist and Pulldown Troubleshooting General Hydraulics Troubleshooting

2-ix

Page 1-4 1-6

1-8 1-9

8-1 8-11 8-18 8-24

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SECTION 1

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Section 1 GENERAL SERVICE This section contains the recommended lubrication procedures and introduces the preventive maintenance philosophy as developed for the individual subsystems covered in Sections 2 through 9. Refer to Figure 1-1 for SK-35 component locations.

A.

LUBRICATION

The frequency of oil changes, filter element cleaning and replacement, and equipment lubrication should be based on the operation environment and severity of service. The equipment lubrication diagrams and charts show the general locations of lubricating points and designate equipment units which require scheduled periodic lubrication. For additional lubrication information, refer to vendor manuals for the individual equipment components.

1. GENERAL LUBRICATION INFORMATION. Overall lubrication requirements are illustrated here while specific procedures for the various subsystems are presented in the topics that follow.

To prevent contamination, the fittings, caps, and filler plugs should be thoroughly cleaned before lubricating or filling with hydraulic fluids. a.

Carrier Lubrication. Figure 1-2 illustrates the lubrication pOInts for the carrier vehicle and Table 1-1 provides the lubrication information corresponding to the points.

Refer to the manufacturer's manual on the carrier unit for additional service details.

b.

SK-35 Drill System Lubrication. Figure 1-3 illustrates the lubrication points for the SK-35 drill system, and Table 1-2 provides the information data for the test points.

2. ENGINE LUBRICATION. Engine lubrication requirements depend upon the engine option for the blast hole drill. Table 1-3 provides engine lubrication data for the Caterpillar engine and Table 1-4 provides information for the Cummins engine. For other service details on the engine refer to the manufacturer's manual for the particular engine installed.

1-1

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ROTARY DRIVE

CARRIER VEHICLE

FUEL TANK DRIVE ASSEMBLY

VALVE BANK (BEHIND PANEL)

OPERATOR'S CAB

Figure 1-1. Blast Hole Drill Components 1-2

VI

I

......

2

18

Figure 1-2. Carrier Unit Lubrication Diagram

5

18

BI007191

......

~

~ I

UnIversal JOint & Slips SlIps Universal

2 3 4 5 6 7

Spring Sorina Shackle

Torque Rod Fittings

Rear Axle

Steering Powe r Steen ng

Engine Crankcase

Transmission

17

18

19

20

21

TIe Rod & Cvllnder Sockets Clutch Sub lever

ShIft· L.H. Clutch Shift· Throwout Bearing

8 9 10 11 12 13 14 15 16

Brake Actuating ActuatIng Shafts Cab Tilt T"t Pins P,ns Speedometer Adapter KIng P,n Bearings K 109 Pin Water Pump Clutch Pedal Ltnkage L.nkage Steering Steerlna Gear Bogle Boale Fittings F IHlngs ShIft - R.H. Clutch Shift

BearIngs Wheel Bearings

DESCRIPTION

1

TEM NO. ~TEM

Clark Allison

ATF Type II"A" All Oil TVDe "A" Oil ATF Type

Oil on

CD CD CD CD CD

Caterpllier Caterp" I er Cummins International Harvester Detroit Diesel Ford

Oil Oil Oil Oil

10W-30 10W-30 lOW-3D

No.2 Multi-Puroose No.2 Multi-Purpose No.2 Multi-Purpose No.2 Multi-Purpose Required

Grease 77 NLGI NlGI NlG' NlGI NlGI NlG I NlGI None

Vickers Garrison

Fuller Spicer

Multi-Purpose MultI-Purpose Multi-Purpose Multi-Purpose Multi·Purpose Multi-Purpose Multi-Purpose Multi-Purpose

TYPE OF LUBRICATION LUBRICA liON

NlGI No.2 Multi-Purpose NlGr NlGI No.2 Multi-Purpose Multi-Puroose

HD-90 Grease 77

No.2 No.2 No.2 No.2 No.2 No.2

HD-90 SAE 90 HD-140 HD-90

I

NlGI NLGI NLGI NLGl NLGI NlGII NLG NLGI NLGI

Grease HD-90 H0-90 Grease 77

Standard Saddle Mount Ball Stud (Not Shown) 8all Eaton Clark Rockwell Coleman

Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard

Grease Packed 011 0" Bath Standard

OPTIONS

Table 1-1. Carrier Unit, Lubrication Chart

Check and F 1/1 "I jf if Req'd, Req'd.

Check and fillI F" If Req'd Req'd..

Change Engine EngIne 011 0"

Check and F" I if Req'd.

Check and fill F "I if Req'd.

Grease

Grease

Grease Grease Check Cneck Grease Grea!'ie Grease Grease Grease Grease Grease

Grease Gre3se Grease

Grease

Grease

1,000

Gredse Gre<lse

5.000

Clun Clean & Fill &

10.000

LUBRICATION INTERVAL DAILY DAilY

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I

VI

o

o o

o

AWATER PUMP

WATER TANK

o

A

ROTOCLONE SHAFT WINCH

C

COMPRESSOR SEPARATOR TANK

I

APIPE A RACK SUPPORT

APIPE

IIIr=---;lj "I~

/

~

RACK CAROUSEL

RACK ROLLE

--

Figure 1-3. Overall System Lubrication and Maintenance Diagram

A PIPE

RACK SUPPORT

RACK CAROUSEL-------..

CAROUSEL-------...

APIPE PIPE.

0;

CROTARY (,EARCASE-------('EARCASE~

ROTARY UNION AIR SWIVEL

A PIPE

PINS -LOWE.R

NOTE. REFERENCE CODE LETTERS TO LUBRICTION/MAINTENANCE CHART

'-/

rn-,

ENUINE COOLANT

I--'

o

• "..

HO 1ST

PULLDOWN

A

SPROCKETS- BEARIN(,S

A

A

SPROCKETS-B£ARIN(,S

~ HOIS'Vt'ULLDOWN

SPROCKETS - BEARIN(,S

HOISVPULLDOWN

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NO. OF FITTINGS One( l) One(l) Two(2} Two(2) Four(4} Four(4) Eight(8} Eight(8) One(l) One( 1} Two(2) Two(2} Two(2) Two(2} Three(3} Three(3) Two(2} Two(2) Two(2} Two(2) One( l) One(l} E1even(ll} E1 even( 11} -

CHECK POINT Sight Gauge Sight Gauge Case Plug Case Plug Case Plug Fitting

II

NOTE:

I

0\

-

LUBRICATION INSTRUCTIONS CHECK CHANGE AS REQUIRED Every 3 Months AS REQUIRED Every 3 Months Each Shift Every 2 Months Each Shift Every 3 Months Each Month Annually Each Month Annually Each Month Annually

l

CHANGE RESERVOIR HYDRAULIC OIL WHEN OIL HAS TURNED DARK, OR WHEN OIL LOOKS MILKY .

one(l} ounce per shift. *Drain approximately one(l)

DESCRIPTION *Contro1 System Hydraulic Oil *Rotary System Hydraulic Oil *Rotary Gearcase Pump Drive Gearcase Winch Gearcase Center Pivot Axle Crawler Motor Gear Boxes

....... ......

LUBRICATION FREQUENCY Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift Once Each Shift

IIB" - HYDRAULIC OILS - "C "C' - GEARCASE GREASES - - - - - - - - - - - "B

DESCRIPTION Rotary Union Air Swivel Mast Pivot Pins Mast Hoist Cylinder Pins Hoist/Pu11down Sprockets Pipe Rack Roller Pipe Rack Carousel Pipe Rack Support Engine/Compressor Drive Shaft Engine C1 utch .

Dust Control Blower Shaft Water Pump Control Levers

"A" - LUBRICATION POINTS

Table 1-2. SK-35 Drill System Lubrication Chart.

II

RECOMMENDED OILS AND GREASES lOW Hydraulic Oil ATF Type "A" "A Oil EP-90 Gear Grease EP-90 Gear Grease EP-90 Gear Grease Multi-Purpose Grease EP-90 Gear Grease

RECOMMENDED GREASES Multi-Purpose Grease

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-.....j .......:J

II

f-Io f--i

Indicator Case Indi cator Case Indicator & Panel Light Case Indicators & Pane1 Lights Li gh ts Panel

*Compressor Air Intake Control Hydraulic System

Every 1000 Hours Every 500 Hours Every 1000 Hours

Every 1000 Hours

AS REQUIRED

CHANGE INTERVAL AS REQUIRED

"E" "Ell -- FILTERS

RECOMMENDED & FLUIDS OILS & SAE 30W Oi 1 Water/Antifreeze Distilled Water ATF Type "A" Oil Water/Antifreeze

Filter Element-Part #40983 Oil Filter Element-Part #42291 Engine Oil Filter-Part #42282

10 Micron Element-Part #30343

RECOMMENDED FILTERS Air Cleaner-Compressor &Engine Primary P/N-43490 Safety P/N-43491 Indicator-Part #43481

LUBRICATION INSTRUCTIONS CHECK CHANGE/FILL Each Shift Every 250 Hours Each Shift As Required Each Shift As Required Each Shift As Required Each Shift As Required

& FLUID LEVELS

*Fi1ters should be changed at recommended intervals and/or when indicators or lights show filters are dirty. *Filters

Compressor Oil Inlet Oi1- CUM-NT855 Engine Oil-

Rotary Hydraulic System

CHECK POINT Case Indi cator

CHECK POINT Dipstick Radiator Cap Battery Caps Gauge Tank Cover

DESCRIPTION *Engine Air Intake

*Drain water once per shift.

DESCRIPTION Cummins Engine Oil Engine Coolant Battery Water Compressor Separator Tank Water Tank

HDIIIl -- OIL IlD

Table 1-2. SK-35 Drill System Lubrication Chart (Cant.)

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Table 1-3. Caterpillar Engine Lubrication Chart

Time Interval - Hours Item

Daily

250

Engine Oil

X

XXX

Air Cleaner Indicator Piston

X

Coolant Level

X

Clutch Shift Collar, Lubricated

X

Main Shaft Bearing Oil Reservoir

X

Zinc Rods in Raw Water System

X

Engine Oil Filter

500

1000

2000

XXX

Fan Belts

X

Fan Hub &Water Pump

X

Engine Dust Collector Cap

X

Woodward Governor Control &Motor

X

Air Cleaner Element

XXX

Adjust Valves

X

Engine Idler

X

Rear Bearing of Generator

X

X CHECK

Note:

XX CLEAN

XXX CHANGE

For additional information refer to the Engine Manual

1-8

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Table 1-4. Cummins Engine Lubrication Chart

Time Interval - Hours Item Engine Oil Oil Bath Cleaner

Dai ly X

250

2000

8000

xxx

X

Pre-Cleaner Dust Pan Air Cleaner

XX X

Air Cleaner Element

XX

Air Oil Bath Cleaner

XX

Coolant Level

X

Check Leaks

X

XXX

Engine Full-Flow Oil Filter

XXX

By-Pass Filter

XXX

Aneroi d Oi 1

X

XXX

Hyd. Gov. Oil

X

XXX

Adjust Injectors/Valves

X

Fuel Filters

XXX

Fuel Tank Breather

XX

Crankcase Breather

XXX

Oil Bath Air Cleaner Tray Screen

XX

Air Compressor Breather Element

XXX

Water Filter

XXX

Fan Belts

X X

Aneroid Adjustment Aneroid Breather

XXX

External Radiator

XX

Fan Hub Idler &Water Pump

X

Fuel Pump Filter Screen &Magnet X CHECK

4000

XX CLEAN

XXX XXX CHANGE

1-9

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3. WINCH ASSEMBLY LUBRICATION. To lubricate the hydraulic winch assembly, proceed as follows: a.

Keep gear housing filled to level of side plug with SAE number 140 all purpose gear oil.

b.

Drain gear housing and fill with new oil every 6 months.

c.

Do not mix different kinds of oil.

d.

Occasionally lubricate grease fittings on winch and universal joints with ordinary cup grease. Lubricate winch hanger bearing with SAE number 140 all purpose gear oil.

4. DUST CONTROL BLOWER LUBRICATION. Lubrication requirements for the dust control blower depend upon operating conditions. a.

b.

Blower Lubrication (Normal Operation). Lubricate the dust control subsystem blower according to the following procedure: 1)

Use multi-purpose roller bearing grease NLGI Grade 1 or 2 containing rust inhibitors and anti-oxident additives.

Suggested minimum oil viscosity: 400 SSU @ 100oF.

2)

Grease for high speed operation should meet following requirements: 1) Suitable for temperatures up to 22S o F continuous; 2) dynamically stable, 3) must not churn or whip; and 4) minimum oil viscosity 400 SSU @ 100oF.

3)

Suitable products are: Texaco RB #2, American Rykon #2, Gulf Crown #2, Chevron SRI #2.

Blower Lubrication (Special Conditions). The following instructions are to be observed for special conditions.

1)

Increase frequency of lubrication during conditions of abnormal moisture dirt.

2)

Consult fan manufacturer for proper lubrication if beaoings are subject to temperatures below OOF or above 200 F.

3)

Prior to extended shutdown or storage, lubricate bearings.

4)

During extended shutdown or storage, rotate shaft monthly to aid corrosion protection.

1-10

BI007191

c.

Repacking Blower Bearings. To clean and repack the bearings, proceed as follows: 1)

Remove bear1ng cap.

2)

Clean out old grease.

3)

Repack with fresh grease, packing bearing full, and packing housing reservoirs on both sides of bearing to bottom of shaft.

5. COMPRESSOR SERVICE AND LUBRICATION PROCEDURE. The following procedure covers the lubrication and service points for the compressor system. a.

b.

Service Air Comeressor. The following are to be performed on a scheduled bas1s: 1)

Service air filter as described in section 5 for the compressed air system.

2)

Drain receiver condensate as follows: a)

Open receiver drain valve just enough to permit a trickle flow and allow water to drain out.

b)

Close valve when oil appears.

Check Oil Level Every 50 Hours. Check the oil level as follows: 1)

Shut down the machine long enough to permit oil foam to settle.

WARNING Never add oil when receiver is pressurized.

c.

2)

Remove any accumulated dirt from filter cap prior to opening.

3)

Check the level and add oil to f111.

Change Oil Every 500 Hours. Every 500 hours, change oil as follows: 1)

Drain oil from sump.

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B.

2)

Fill with 25 gallons of C2 ATF oil.

3)

Change oil filter element at each oil change. (See Section 5).

4)

Lubricate control and linkage.

5)

Clean oil return line strainer.

6)

For extremely severe duty, consult factory for specific recommendations.

PREVENTIVE MAINTENANCE

To maintain the drill in optimum condition at all times, a preventive maintenance program should be established. This program should ensure the minimum maintenance required while the drill is idle, and regular scheduled maintenance while the drill is in operation. The sustained maintenance program should be set up on a "before operation, during operation, and after operation" schedule.

Service and Maintenance requirements for the subsystems are presented as applicable in Sections 2 through 9. For additional preventive maintenance information on the purchased components, refer to the vendor manuals on the individual components in Part III of this manual.

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SECTION 2

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Section 2 OPERATOR'S CONTROLS AND INDICATORS SERVICE Although there is very little service to perform on the operator's console, the indicator readings are vital to other diagnostic operations for the subsystems. Also, manipulation of the controls is often necessary in order to obtain the required indications.

This section is not intended for use by the operator identifying control and indicator positions, etc. Rather, the information given here is slanted toward system diagnostics. For example, the specific point of takeoff for the pressure indication, etc., are given. For the locations and names of the controls and indicators refer to Figure 2-1.

A.

UPPER PANEL INDICATORS AND CONTROLS

For application in system diagnostics, the indicators and controls located on the upper panel are discussed according to functional area.

1. ENGINE CONTROLS AND INDICATORS. The engine controls and indicators are essential to operating and monitoring the diesel engine.

a.

Engine RPM Indicator. The engine RPM indicator is an electronic tachometer connected with the tachometer sender installed on the engine. This indicator displays the engine speed directly in RPM.

b.

Engine Ammeter. This indicator is a conventional ammeter wired into the engine electrical system. The ammeter indicates battery charge or discharge.

c.

Engine Fuel Level Gauge. The fuel level gauge is connected with a fuel sender in the fuel tank to indicate the fuel level in the tank. This gauge receives operating voltage only when the ignition switch is turned on.

d.

Engine Oil Pressure. The oil pressure gauge is connected with an oil pressure sender tapped into the engine lubrication system, to indicate the engine oil pressure.

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I. I. 2.

2.

3.

3.

4.

4.

5.

5.

6.

6.

7.

7.

8.

8.

9.

9.

10.

10.

II. II. 12.

12.

13.

13.

14.

14.

15.

15.

16.

16.

17.

17.

18.

18.

19.

19.

20.

20.

AIR FILTER PRESSURE AIR HYDRAULIC PRESSURE HYDRAULIC AIR "T" TANK PRESSURE AIR ROTARY HYDRAULIC PRESSURE ROTARY BIT AIR PRESSURE BIT PULLDOWN HYDRAULIC PRESSURE PULLDOWN ENGINE RPM ENGINE ENGINE AMMETER ENGINE ENGINE WATER TEMPERATURE ENGINE ENGINE FUEL ENGINE ENGINE OIL PRESSURE ENGINE DRILL HOURMETER DRILL ENGINE HOURMETER ENGINE WATER FLOW CONTROL WATER LOOP FILTER LIGHT LOOP TANK FILTER LIGHT TANK CHARGE FILTER LIGHT CHARGE FILTER LIGHT SWITCH FILTER DRILL LIGHT SWITCH DRILL ENGINE START ENGINE

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.

ENGINE ON· OFF PULLDOWN CONTROL LEVEL L.H. REAR JACK FRONT JACK R.H. REAR JACK MAST HOIST PIPE RACK PIPE RACK INDEX MAIN AIR/PIPE RACK INDEX BREAKOUT WRENCH WINCH WATER PUMP AND DUST COLLECTOR POSITIONER (OPTIONAL) HIGH SPEED HOIST PULLDOWN ROTARY DRIVE ENGINE THROTTLE DRILL/PROPEL SELECTOR ROTARY AND L.H. TRACK R.H. TRACK PROPEL LOOP FILTER LIGHT CRAWLER BRAKE AUTO·TOOL WRENCH (OPTIONAL) HEATER/FAN (OPTIONAL) AUTO MAST LOCK (OPTIONAL)

Figure 2-1. SK-35 Operating Controls and Indicators 2-2

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e.

Engine Water TemKerature Gauge. The water temperature gauge is connected wit a temperature sender in the engine cylinder head to indIcate the engine water temperature. The gauge is connected with a power source only when the ignition switch is turned on.

Engine Hourmeter. The engine hourmeter is connected through the oil pressure switch so that the meter counts hours so long as the engine is operating and maintaining oil pressure.

g.

Ignition Switch. The engine ignition switch makes battery voltage available for starting and running the engine and for operating the gauges.

h.

Enyine Start Button. The engine start button applies battery vo tage to the starter solenoid, thus operating the starter to start the engine.

2. AIR PRESSURE INDICATORS. The three air pressure gauges with the pressure takeoff points at which the measurements are taken are illustrated in Figure 2-2.

FILTER PRESSURE

BIT PRESSURE

TANK PRESSURE

MAIN AIR HEADER

(J)i:::=:::::::::J c::::==1 ~ '-{l--nMAIN AIR

Figure 2-2. Air Pressure Gauges and Take Off Points

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The pressure indicated on the Tank Pressure gauge is the pressure of the oily air in the receiver tank before separation, and the filter indication on the Filter Pressure gauge is the pressure of the air on the outlet side of the filter. Thus the difference in the readings of these two gauges represents the filter differential pressure (which should normally operate at less than 10 psi). A greater difference indicates incomplete air/oil separation or a clogged filter.

The minimum pressure valve associated with the filter is set to prohibit the pressure from decreasing below 45 psi. Should this valve fail to operate properly, the filter could collapse; should the filter collapse, the valve should be serviced and the filter replaced. Refer to the manufacturer's instructions in Section 5 of Part ill for air compressor details.

The bit pressure indicator is tapped into the main air header to indicate the pressure applied to the drill string.

For functional details of the compressed air system refer to Section 5 of Part I and for service details refer to Section 5 of Part II, and for details of individual components built by other manufacturers refer to the vendor information in Part III. 3. HYDRAULIC PRESSURE INDICATORS. The three hydraulic pressure gauges with the pressure take off points are shown in Figure 2-3. The Hydraulic Pressure gauge is connected to the 32 gpm output of the three-stage hydraulic pump, the Rotary Hydraulic Pressure gauge operates from a takeoff of the hydrostatic power pump in the closed loop system; and finally, the pulldown pressure gauge reads the output of the 10 gpm pump stage only. The rotary pressure gauge reads pressure in both directions. There is no pressure gauge to indicate the output pressure of the 55 gpm pump stage, nor is there a gauge to directly indicate the output of the charge pump. a.

Hydraulic Pressure Gauge. This gauge indicates the output pressure of the 32 gpm pump. Because the 32 gpm pump operates in an open loop system no pressure is developed unless one of the equipment units powered by the system is operated, and maximum pressure is exerted when the operating unit is stalled out. The maximum pressure is determined by the adjustment of the relief valve within the system. Refer to Section 8 for the relief valve adjustment procedure.

b.

Rotary H~draulic Pressure. The rotary hydraulic pressure gauge in icates the amount of pressure applied to the rotary hydraulic motor, and the pressure indication is independent of the direction'of rotation. Maximum pressure is developed when the driven element is stalled out. l-4

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HYDRAULIC PRESSURE

PULLDOWN PRESSURE FROM 10 GPM PUMP

FROM 32 GPM PU M P ROTARY HYD. PRES.

---------+-------1 po--_-'--_--,

'-t'

32 GPM VALVES

/

TO JACKS

}

FLOW DIVIDER

CONTROL

TO MISC. HYDRAULIC COMPONENTS

16 GPM VALVES }

10 GPM

TO PULLDOWN CYLINDERS

Figure 2-3. Hydraulic Pressure Gauges and Takeoff Points Due to the operation of the charge pump, there should always be a slight pressure indication on the rotary gauge whenever the engine is running. For relief valve adjustment refer to Section 8. c.

Pulldown Pressure. The pulldown pressure gauge indicates the hydraulic pressure output of the 10 gpm pump stage. This pressure also is maximum when the greatest load is placed on the pulldown system. Refer to Section 8 for adjustment of the pulldown relief valve.

4. HYDRAULIC FILTER INDICATOR LIGHTS. Three lights indicate the condition of the filters in the rotary hydraulic system, and a toggle switch tests two of these lights. a.

Loop Filter Li~ht. This light is connected to a switch on the loop oil fIlter. If the loop filter differential pressure becomes too high, indicating a clogged filter, the warning light illuminates.

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b.

Charg~ Pump Oil Filter Light. This warning light signals a high differential pressure on the charge pump oil filter, to indicate that the filter is clogged and needs service.

c.

Tank Oil F1lter Warn1ng Light. This warning light indicates a high differential pressure, and thus, a service requirement for the tank oil filter.

d.

Filter Lights Switch. When operated, this switch applies a test voltage to the loop oil filter and charge pump oil filter warning lights, thus illuminating these lamps to test the bulbs. The test switch does not test the warning lamp for the tank oil filter.

5. DRILL LIGHTS SWITCH. The Drill Lights switch applies battery voltage to the drill lights.

B.

LOWER CONSOLE CONTROL FUNCTIONS

The controls on the lower console consist of the hydraulic valve operating levers, the engine throttle control, air control valves, water flow control valve, pulldown control and mast lock release, together with any optional control elements required for special equipment options. The locations of the control levers are shown in Figure 2-1, and the functions of the individual controls are described with the functions of the individual subsystems. The console requires minimum routine maintenance; however, you should note the topics covered below.

C.

CONSOLE MAINTENANCE

The console maintenance consists of routine maintenance and adjustments as illustrated in Figure 2-4 and described in the following paragraphs.

1. CONSOLE ROUTINE MAINTENANCE. At the beginning of each operating shift, the operator should perform the following:

a.

Inspect console, checking all indicating devices and controls for obvious damage.

b.

While performing operating check as given in Operator's Manual verify that all controls and indicators function properly.

c.

Check the loop filter and charge filter lights by operating the filter light switch and verifying that the two warning lights illuminate. If a lamp fails to illuminate, replace the bulb.

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HYDRAULIC LEVER

VALVE BANK CABLE GREASE FITTING

CABLE PIN & COTTER KEY

NUT CLEVIS

VALVE BANK CABLE HOOKUP

TYPICAL HYDRAULIC CONTROL LEVER. CONSOLE IN CONTROL CAB

BALL & SOCKET JOINT

BRACKET /

~-f~-1~11 -\~-f~~lll\-

BRACKET

NUT BALL & SOCKET JOINT

CONTROL CABLE

CONTROL CABLE

ENGINE THROTTLE HOOKUP ROTARY HYDROSTATIC PUMP CABLE TAKE UP THREADS

CLEVIS

NUT

MAST LOCK DOG HOOKUP

Figure 2-4. Control Lever Maintenance and Lubrication

NOTE This test does not check the tank filter light. d.

During each shift that will extend past night fall, check the drill lights by operating the switch and verifying that all drill lights illuminate, then turn the switch oft until all lights are needed.

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e.

Using general purpose grease, lubricate each hydraulic control lever and the mast lock lever, being sure to lubricate the mast lock itself.

2. CONTROL MAINTENANCE ADJUSTMENTS. The following are normal maintenance adjustments. a.

Hydraulic Control Levers. Hydraulic control levers normally do not require adjustment during service, as they have enough control movement to ensure full operation of the valve in both directions, even if a control cable should become stretched slightly during use. For adjustment of the hydraulic systems associated with the hydraulic control levers, refer to Section 8.

b.

Mast Lock Control Lever. Normal useage of the mast lock control may cause the cable to be stretched slightly so that the latch will not disengage properly. You should check the operation of this latch once during each shift to be sure that it operates properly. In the event the control lever will not operate the latch, you should take up the cable on the latch end, then agaIn check the operation.

I

WARNING

l

He sure the mast lock is set before operating the drill.

c.

Console Re~air. Normal console repair consists of replacing any damage or malfunctioning components. Refer to the Parts Manual for the parts numbers, and replace any element only with the recommended replacement parts.

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SECTION 3

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Section 3 MAIN FRAME COMPONENT/CARRIER SERVICE Most assembly elements A.

of the service requirements for the main frame/carrier are for the carrier vehicle. However, the other main frame should be inspected periodically and repaired as necessary.

CARRIER VEHICLE SERVICE AND MAINTENANCE

Only the routine preventive maintenance service for the carrier vehicle is outlined here. For detailed information on service and repair, refer to the manufacturer's manual.

1. CARRIER VEHICLE LUBRICATION. For lubrication of the carrier vehicle refer to Section 1 and to the carrier vehicle manufacturer's manual as applicable.

2. CARRIER ROUTINE SERVICE. The fluid levels and tire pressures should be maintained according to the manufacturer's recommendations, and any other routine maintenance performed as recommended by the manufacturer.

B.

MAIN FRAME SERVICE AND MAINTENANCE

The following inspections and maintenance service should be performed as required.

1. PAINT AND FINISH TOUCHUP. The main frame deck structure, control cab, fuel tank, fuel box and other fixtures should be examined periodically for paint damage and repainted as necessary to inhibit rust and corrosion.

2. INSPECTION OF MAIN FRAME COMPONENTS. As a part of a general inspection procedure, the fuel tank, fuel lines, leveling jacks and associated plumbing should be inspected for damage or leaks and repaired as necessary.

C.

REPOSITIONING CONTROL CAB

The operators cab may be moved inboard to decrease the overall vehicle width for legal road travel. To reposition the cab, refer to Figure 3-1 for details and proceed according to the procedure below.

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R.H. SUPPORT

SLIDE MOUNT

SECTION BB

VIEWS SHOW CAB INBOARD

\

l

~

./6'...

J

SECTION AA

\ o 1/ I "I,

.-,....,

/.---

+

It

A

O?J

, -.,

,\ \

,l-

\, ......

"

//

~

-:...-..;"'.....

BOLT & NUT

+ SECTION C C

B

I

I

+ B

I'

...

~

C

-

Figure 3-1. Control Cab Positioning 1.

To move the cab inboard, proceed as follows:

NOTE This operation will require considerable force so you should be sure you have adequate help before attempting the operation. a)

Remove cap screw and lock nut securing control cab lower mounting lip to lower bracket located just behind jack casing.

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b)

Remove cap screws and lock nuts attaching left-hand and right-hand supports to center mounting lip of control cap.

NOTE The control cap should now be free to be pushed inboard.

2.

D.

c)

With assistance of others as required, push cab inboard to line up outside bolt hole in lower mounting lip with bolt hole in lower bracket, and to line up center hole in central mounting lip with hole in left-hand support while lining up outboard bolt hole with hole in righthand support.

d)

When three sets of holes are aligned, reinstall three bolts removed previously.

To extend cab for operation, reverse above procedure.

MAIN FRAME TROUBLESHOOTING

Troubleshooting generally consists of troubleshooting the individual subsystems; however, you should observe the following: 1. FUEL LEVEL INDICATOR SENDER. Improper fuel gauge indication noted during operation or functional check could indicate a faulty level sender in the fuel tank.

2. DETECTING LEVELING JACK TROUBLES. Faulty leveling jacks may be detected through inspection, through operating difficulties encountered, or during the hydraulic pressure tests outlined in Section 8•

3.

CAB HEATER FAULT ISOLATION. Check out the heater as follows: a.

Check blower motor by operating console switch, checking all three positions and observing blower operation.

b.

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

c.

If heater fails to heat, check shutoff valves at plumbing connections to engine to be sure they are turned on, then check the heater plumbing.

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E.

MAIN FRAME REPAIR

In general, repair of the main frame components entails removing the faulty component and replacing it with the correct part as designated in the parts manual. However, you should observe the following procedures as applicable.

1. LEAKING JACK CYLINDERS, TEMPORARY FIX. Whenever a cylinder is determined to be leaking hydraulic fluid around the packing, a new packing kit generally should be installed. However, to avoid downtime until a cylinder overhaul can be scheduled, you may be able to stop the leak temporarily by removing shims from the cylinder cap.

To remove the shims, refer to the jack cylinder illustration, Figure 3-2, and proceed as follows:

8 7 L - TORQUE

BOlTS TO 10 FT LBS.

ITEM

PART NO.

1 2 3 4 5 6 7 8 9 10

40449 42665 5989 40447 30287 19725 40460 40061 34606 16610 18849 42646 30502 14069 40470 30285 41547

11

12 13 14 15 16 17

QIL.

DESCRIPTION

PACKING GLAND 1 CAPSCREW HEX STL 3/8 IN - UNC X 2 3/4 IN 12 LOCK WASHER 3/8 IN 12 CYLINDER CAP 1 BACK UP RING 4 3/4 IN 00 X 1/8 IN W 1 o RING 4 3/4 IN 00 X1/8 IN W 1 BARREL ASSEMBLY 1 JACK ASSEMBLY SHAFT 1 ROD SPACER 1 o RING 1 1/2 IN 00 X1/8 IN W 1 5.0 FT. PISTON PACKING 1/4 IN SQ. ELASTIC STOP NUT 1 1/4 IN DIA. 1 PISTON 4 3/4 IN 00 1 SHAFT PACKING 1 CYLINDER SHIM 6 IN 00 X1/32 IN 4 ROD WIPER 1 ROD WIPER RETAINER 1

Figure 3-2. Typical Jack Cylinder Assembly and Parts Lis t

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a.

Remove cylinder from machine and remove cap screws and lock washers (items 2 and 3) from end of cylinder.

b.

Separate packing gland (item 1) with rod wiper retainer (item 17) from cylinder cap (item 4).

c.

According to extent of leak, remove shims litem 6) as necessary to enable compressing of packing (item 14) to stop leak.

d.

Replace packing gland with rod wiper retainer back on cylinder cap.

e.

Align holes in rod wiper retainer, packing glad, cylinder cap, and barrel assembly and replace cap screws and lock washers.

f.

Tighten cap screws and torque to 10 ft. lbs.

g.

Replace cylinder on machine and place machine in operation.

h.

Observe cylinder when operation resumes, and take corrective action if leak continues.

i.

When shims are replaced without repacking, note this fact on maintenance log so cylinder may be repacked as soon as practical.

2. REPACKING JACK CYLINDERS. The surest way to stop a jack cylinder leak is to tear down and repack the cylinder. To repack the hydraulic cylinder proceed as follows: a.

Remove cylinder from machine.

b.

Refer to illustrated parts list in Section 3 of Parts Manaul while performing remainder of cylinder packing procedure.

c.

Remove the cap screws and lock washers (items 2 and 3).

d.

Separate cylinder cap (item 4) from jack cylinder, and separate rod wiper retainer (item 17) packing gland (item 1) and cylinder cap (item 4).

e.

Remove and discard rod wiper (item 16), piston packing (item 14) and back up ring and a-ring (items 5 and 6, respectively) .

f.

Remove jack cylinder shaft (item 8) with piston (item 13) from cylinder assembly.

g.

Remove elastic stop nut (item 12) and separate piston 3-5

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from jack cylinder shaft. If piston, (item 13) is worn replace it with an equivalent new part. h.

Remove a-ring (item 10) and piston packing rings (item 11) •

i.

Replace all a-rings and packing with new parts as identified in Parts Manual parts list, and reassemble jack cylinder in reverse order of disassembly procedure, torqueing the cap screws to 10 ft. lbs.

j.

Reinstall cylinder on machine.

3. LUBRICATING JACK a grease Zerk, grease it cylinder is not equipped apply grease directly to F.

CASINGS. If jack casings are equipped with by applying a small quantity of grease. If with a grease Zerk, extend the jack fully and the inner casing.

FUEL TANK AND FUEL LINE MAINTENANCE

If components of the fuel tank or fuel line require replacement refer to Section 3 of the parts manual for component replacements and for assembly/disassembly detail.

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SECTION 4

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Section 4 ENGINE AND DRIVE TRAIN SERVICE This section is divided into two main topics. Topic A includes drive train preventive maintenance and service procedures, and Topic B contains repair procedures.

A.

ENGINE AND DRIVE TRAIN SERVICE PROCEDURES

These service procedures cover the diesel engine, air cleaner, pump drive unit and compressor drive shaft. For hydraulic pump service procedures refer to Section 8.

1. ENGINE SERVICE PROCEDURES. Lubrication requirements, fluid levels, and general service requirements are covered in Section 1.

Refer to the engine manufacturer's manual on the specific engine for more detailed service requirements.

2. OIL BATH AIR CLEANER SERVICE. Service the oil bath-type air cleaner as follows: CAUTION Under extremely dusty conditions, more frequent inspections and service of the air cleaner may be required. a.

Inspect air cleaner at least every day (more frequently under dusty conditions).

b.

Clean cup and change oil when oil becomes thick or when 1/2 inch of dirt collects at bottom of cup.

c.

Always refill to exact oil level as indicated on cup.

d.

Examine hoses, clamps and connections between air cleaner and engine. Tighten loose clamps and replace damaged hoses.

3. DISPOSABLE-FILTER TYPE AIR CLEANER SERVICE. Service for the disposable-filter type air cleaner, Figure 4-1, includes general inspection and replacing the elements as required.

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4

7

1 2 3 4 5 6 7 8 9 10 11 12

@ 14

PART NO. ill:.. ~ 45810 1 43491 1 45786 2 45787 1 43490 1 45788 1 45812 1 45811 22 45813 1 43480 1 45808 1 45809 1 43621 1 43624 1 43622 1

DESCRIPTION BODY ASSEMBLY-UPPER ELEMENT (SAFETY) GASKET NUT ELEMENT (PRIMARY) NUT-WING COVER O-RING CLAMP ASSEMBLY-UPPER SHROUD ASSEMBLY BODY ASSEMBLY-LOWER CLAMP ASSEMBLY-LOWER DUST CUP-HORIZONTAL DUST CUP-VERTICAL VALVE-VACUATOR

Figure 4-1. Disposable-Filter Type Air Cleaner 4-2

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a.

b.

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.

2)

Verify that air cleaner mounting bolts and clamps are tight, holding air cleaner securely.

3)

Check dust cup to make sure it is sealing completely around air cleaner body.

4)

Be sure vacuator valve is in place, not inverted or damaged, and free from obstruction. Squeeze this valve daily to exhaust accumulated dust.

5)

Check body of air cleaner for dents and damage which could cause a leak or damage the elements.

6)

Make sure all inlet accessories are free from obstruction and securely mounted.

Element Replacements. To replace the elements refer to Figure 4-1 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 (12) and remove dust cup (13).

Remove and wash lower body (11) and dust cup.

2)

Release catches and remove cover and O-ring (7) from upper body assembly (1).

3)

Remove wing nut (6) and gasket (3) securing outer (primary) element (5).

4)

Remove primary element.

5)

Remove inside nut (4) and gasket (3) and remove small (safety) element (2).

6)

To replace elements with new components obtain correct replacement elements, together with O-ring and two gaskets, and replace them in reverse order of disassembly.

7)

When replacing elements, gaskets and O-ring, it is a good idea to replace two O-rings (8) on lower element also.

8)

If desired, it is possible to clean the elements rather than replace them at each change. However, you should always replace the elements annually or after each 6 cleanings whichever occurs first. Refer to SK-3s/SK-40 Operator's Manual for cleaning procedure.

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4. CLUTCH AND DRIVE ASSEMBLY SERVICE. Service for the clutch and drive assembly includes inspection, lubrication, and clutch adjustment. a.

Drive and Drive Shaft a t unIts, procee as

inspect the

~ r:EiEl

After any maintenance or repair that includes disconnecting or removing the drive shaft, be sure the drive shaft is timed as described in B Drive Shaft Replacement and Timing.

1)

Inspect drive shaft for proper connection and timing.

(See Topic 2).

2)

Inspect pump drive unit for any obvious damage.

3)

Test operation of clutch to be sure it engages and disengages distinctly and completely.

b.

Lubrication. Lubricate clutch and compressor drive shaft as specifIed in Section 1. specif1ed

c.

Clutch Adjustment. If the clutch will not pull the load or If it heats excessively, it requires adjustment. The adjust1£ ment procedure varies slightly between the Rockford clutch and the twin disk clutch. For the adjustment procedure refer to the manufacturer's information in Part III, Section 4.

B.

THE ENGINE AND DRIVE TRAIN REPAIR

the the

For repair of the engine and hydraulic drive system, refer to respective manufacturer's manuals. However repair procedures for accessory items are outlined below.

1. MUFFLER REPLACEMENT. Should the muffler require replacement refer to the parts list in Section 4 of the Parts Manual and replace the unit with the correct replacement item. a.

Throttle Control Cable. Should the throttle control cable require replacement, replace it with proper cable and ball and socket joint as listed in engine and drive assembly parts list in Parts Manual. After replacement or as indicated by an 4-4

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operating check, adjust cable length (See Figure 2-4) between the ball joint and the control cable to give correct throttle/ lever relationship.

2.

DRIVE SHAFT ASSEMBLY REMOVAL AND REPLACEMENT AND TIMING

a.

Drive Shaft Removal

b.

1)

Disconnect drive shaft at compressor end by removing four cap screws and nuts.

2)

Remove cap screws and remove drive shaft cover from drive shaft.

3)

Remove drive shaft from pump drive unit and repair or replace as necessary.

Drive Shaft Replacement 1)

Install repaired drive shaft or new replacement back into union with pump drive unit (Refer to parts manual, Section 4 for correct replacement part.)

2)

Replace drive shaft cover over drive shaft, and secure to pump drive unit with cap screws removed in above procedure.

It is essential that the drive shaft universal joints be installed in the same place.

3)

If you separate elements of drive shaft put shaft together so that the universal joints are aligned shown in 4-2.

back as

4)

Secure drive shaft to compressor unit, using cap screws removed above.

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A

8 ~I'----

NOTE: A

&

B MUST BE ALIGNED IN SAME PLANE.

Figure 4-2. Drive Shaft Timing

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SECTION 5

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Section 5 MAIN AND AUXILIARY AIR SYSTEM SERVICE The main and auxiliary air system consists of the vendor supplied air compressor and separator with the required plumbing, control and drive functions.

A.

MAIN AND AUXILIARY AIR SUBSYSTEM LUBRICATION AND ROUTINE SERVICE

Service of the main and auxiliary air system should be performed on a periodic basis with attention given to the service points specified In Section 1 and to the considerations as defined in the following topics.

1. DRAIN RECEIVER CONDENSATE. Once during each shift, open receiver drain valve a crack before startup to drain water from tank.

Close when oil appears.

2. SERVICE AIR FILTER. Periodically service the intake air filter as specified in Section 1. The air filter is functionally identical to the disposable-filter type air cleaner, the service of which is described in Section 4. Refer to Section 4, Topic A3, as required to service air filter.

3. CHECK OIL LEVEL. At the interval specified in Section 1 shut down machine long enough to permit oil foam to settle. Then check oil level.

LEE] Never add oil when receiver is pressurized.

Remove any accummu1ated dirt from filler cap before opening it.

4. CHANGE OIL. At the interval specified in Section 1, perform the following: a.

Drain oil from the separator tank and refill with 14 gallons of SAE lOW heavy duty oil for normal operation.

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NOTE Consult weather b.

5. leakage

B.

the manufacturer for severe operation.

When changing the oil, lubricate the control and linkage and clean the oil return strainer.

iNSPECTION. Periodically inspect the plumbing for damage and as follows:

a.

Oil Lines and Cooler. Inspect oil lines and cooler for damage or leaks, especially noting if any leaks occur around joints.

Repair or replace any hoses, connect10ns or other components as required. (Refer to Parts Manual, Section 5; and to vendor manuals in Part III, Section 5.)

b.

Air System connection operating, or replace Section 5;

Hoses. Inspect air hoses, connection to standpipe, from standpipe to swivel, etc. With air compressor inspect system, feeling for any air leaks. Repair components as necessary. (Refer to Parts Manual, and to vendor manuals in Part III, Section 5).

CHECK FOR INVERTED THERMAL BYPASS VALVE

Upon initial operation of the machine or before operating the unit after major compressor repair, check the machine to be sure the thermal bypass valve is not inverted. To do this, operate the unit with the compressor running for several minutes, while periodically feeling the heat exchanger. After the system reaches operating temperature, the heat exchanger should begin to warm up. If it remains cool then the bypass valve is malfunctioning. Refer to the manufacturer's information in Part III, Section 5 for corrective maintenance.

C.

TROUBLESHOOTING

For troubleshooting of the air compressor and separator system, you should become familiar with the system function as described in Part I, Section 5; then systematically analyze the system to determine the cause of the problem. For specific problems isolated to the air compressor or tank, refer to the manufacturer's manual in Part III. D.

REPAIR OF MAIN AND AUXILIARY AIR SYSTEM

When troubleshooting or inspection indicates a faulty component repair as directed below.

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1. EXTERNAL PLUMBING SYSTEM. Repair any plumbing problem by tightening connections and so forth as required or replacing components as necessary. For component replacement refer to Section 5 of the Parts Manual and replace the components as illustrated.

2. AIR COMPRESSOR AND SEPARATOR COMPONENT REPAIR. To repair air compressor or separator refer to the vendor manual in Part III, Section 5.

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SECTION 6

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Section 6 DUST CONTROL SYSTEM SERVICE The dust control system service is divided into the service required for the dust collection system, and the service required for the water injection system.

A.

DUST COLLECTION SYSTEM SERVICE

~he service for the dust collectlon system includes an overall inspection of the system, and service for the dust collection unit.

1.

DUST COLLECTION SYSTEM INSPECTION

a.

Dust Curtains. The dust collection system operation depends upon a negative air pressure being maintained within the curtained area under the drilling platform.

b.

1)

Examine dust curtains for any missing components, tears or improper hangings.

2)

Repair any flaws as required so dust curtain integrity is maintained.

Hose Connections to the Dust Collector. Maintenance of the negative air pressure in the curtained area requires that the hose system be intact.

1)

Examine vacuum hose between dust collector unit and drilling platform to be sure there are no tears, loose connections, or other alr leaks.

2)

Repair or replace hose as necessary to maintain the integrity of the suctlon system.

2. DUST COLLECTOR UNIT SERVICE. The service requirements for the dust collector unit depend upon the type of unit installed. The service requirements for the particular units are described in the following topics. a.

Roto-Clone Unit Service. Service the Roto-Clone unit as follows:

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1)

Dust Removal The hopper must not be allowed to fill completely with dust because its upper section serves as a settling chamber.

2)

a)

Empty hopper frequently during each new drilling operation to establish an interval for dust removal.

b)

After establishing the appropriate interval, remove dust on schedule.

c)

During operation, notice if dust begins to accumulate more rapidly, and adjust schedule as required to keep hopper from becoming filled.

Inspection of Unit Periodically clean unit and inspect it for excessive wear or damage, observing the manufacturer's instructions as provided in Part III of this manual.

b.

Impu1se-Ty~e Dust Collector. Hecause of the complexity of this unlt, serVlce is more critical than for the Roto-Clone. You should set up and adhere to a consistent service schedule for this unit. Refer to the manufacturer's instructions in Part III, Section 6, for service and repair of unit.

3. DUST COLLECTOR MOTOR AND HYDRAULIC SYSTEM SERVICE. Service the dust collector motor and hydraulic system as follows:

B.

a.

Dust Collection Motor Hydraulic Plumbing Service. Refer to the hydraulic schematic and inspect plumbing associated with dust collector motor. Repair and/or replace any plumbing components as required, using replacement parts as illustrated in the Parts Manual, Section 6.

b.

Dust Collector Hydraulic Motor. For service and repair of the hydraulic motor refer to the manufacturer's recommendations ln Part III, Section 6.

WATER INJECTION SYSTEM MAINTENANCE

The water system maintenance consists of service, inspection and repair as outlined in the following topics.

1. WATER INJECTION SYSTEM SERVICE. Normal service for the water injection system consists of lubricating the water pump shaft, filling 6-2

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the water tank as required and cleaning the strainer in the system.

Refer to the Table in Section 1 for frequency of lubrication. A schedule should be set up for cleaning the strainer so that the strainer does not become clogged. The water tank level should be monitored continuously and the tank maintained at an adequate water level, with antIfreeze added for cold weather operation.

L. WATER INJECTION SYSTEM INSPECTION. The elements of the system should be inspected periodically, and the operation of all unIts checked to be sure the system is functioning properly.

3. WATER INJECTION HYDRAULIC SYSTEM PLUMBING. Inspect the hydraulic plumbing to be sure there are no leaks, and if any leaks are found repair or replace the faulty components in accordance with the Parts Manual, Section 6.

4. WATER INJECTION SYSTEM HYDRAULIC MOTOR. For service and repair of the water injection system hydraulic motor refer to the manufacturer's information in Part III, Section 6.

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SERVICE AND MAINTENANCE MANUAL FOR M.P.!.

DUST COLLECTOR SYSTEMS

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SERVICE AND MAINTENANCE MANUAL FOR REEDRILL M.P.I. DUST COLLECTORS - ALL REEDRILL MODEL MACHINES.

INDEX: 1.

Introduction & general recommendations

2.

Preventative maintenance

3.

General maintenance and trouble shooting

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INTRODUCTION & GENERAL RECOHMENDATIONS The Dust Collector System on your drilling rig is designed to remove the dust from the drilling air prior to discharge to the atmosphere and the cleanliness of the air being discharged from the unit meets known environmental standards.

The fan, filter, filter cleaning, ducting, and dust box capacities have been sized to be compatable with the rig drilling rates in most known materials.

A certain

relation has been established to the volume of drilling air, hole size, depth and drill penetration rates.

In order for the dust collector to function properly over the life span of the drilling rig, periodic checks must be made of the fan, ducting and dust box.

filters,

filter cleaning system,

Specifically, after every 160 hours

of operation, fan speed, back flushing regulator pressure setting and back flushing cycle rate should be checked to agree with standards as set in the Preventative section.

~1aintenance

In addition, at every 160 hours or sooner, inspection

and maintenance under General

~1aintenance,

Section I causes

(1) through (4) should be performed.

The elements in the multiple filter system are designed for a life of 600 hours and up before replacement is required on Dust Collector systems and 300 hours and up on total collection systems.

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PREVENTATIVE MAINTENANCE There are two obvious indications as to when the collection system is not functioning properly.

The most common indicator,

and one with the greatest number of possible causes is dust escaping from around the hole (dust box area).

The second indica-

tion of malfunction is dust discharge from the fan.

Three elemental checks can be made to expedite analysis of failed systems or systems that are beginning to fail.

These

checks are as follows and should be considered part of the drill rig preventative maintenance program; 2.1

Fan Speed

(Check every 160 hours)

(Measure with a Frahm Vibratory Reed Tach or other appropriate device).

With the hydraulic system

fluid at maximum operating temperature, the fan speed should be within 300 RPM of nominal speed recommended by rig manufactures.

If variable fan

speed control is provided, the fan speed should be within 300 RPM of maximum available as stated by rig manufacturer.

Caution - fan speed should

not exceed 4,000 RPH.

Refer to Reedrill specifica-

tions, Page 6.

2.2

Backflushing Pressure Regulator (Check every 160 hours) Remove existing gauge from regulator and check with master gauge.

Adjusting range from 35 to 50 P.S.I.

Caution - Do not operate above 50 P.S.I.

Note:

Pressures higher than 50 P.S.I. will reduce filter and timer life.

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2.3

Backflushing Cycle Rate - (Check every 160 hours) The quick opening air valves used for back flushing the filters make an audible

blastin~

sound

and should be heard from 3.5 to 6 second intervals.

The A)

followin~

cause and cure chart apply to 2.1, 2.2, & 2.3.

FAN SPEED TOO SLOW (Refer Reedrill Specifications, Page 6.)

CAUSE

CURE

1.

Hydraulic motor worn out

Replace motor-make sure return line plumbed to shaft end of motor & shaft rotation is proper.

2.

Fluid level low in hydraulic system

Add Fluid

3.

Hydraulic pump worn out

Replace Pump

4.

Fan turning in wrong direction

Orient cam ring as applicable to motor being used and attach pressure line opposite shaft end of motor.

B)

BACKFLUSING CYCLE RATE TOO FAST on SLOW

CAUSE

CURE

1.

Timer contaminated from oil and water.

Fix constant bleed on water bowl at regulator.

2.

Pressure not in 35 to 50 P.S.I. range.

Check regulator gauge for accuracy and adjust regulator.

3.

Timer stalled at low temperature

Punch shifting buttons on Pneucon spool valves.

4.

Timer worn out.

Replace Pneucon timer. Replace seals in Hydraulic Inc. timer.

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B)

BACKFLUSING CYCLE RATE TOO FAST OR

SL~~

- CONTID

CAUSE

CURE

5.

Cut or breaks in small sensing line tube to quick opening valves.

Replace tubing.

6.

Quick opening valve stuck closed or open.

Identify and replace quick opening valve. Timer will not start under this condition.

GENERAL MAINTENANCE & TROUBLE SHOOTING The fan speed, backflushing pressure and backflushing rate are the known measureable values to proper collector operation.

The following causes with checks and cure also apply to proper system operation and anyone or a combination of can be cause for system failure.

I.

PROBLEH:

DUST ESCAPING FROM AROUND THE HOLE OR DUST BOX.

CAUSE

CHECK

CURE

1.

Dust skirt on box around top of hole torn or missing.

Visual inspection

Repair or replace as required

2.

Split rubber deflector in top of dust box around drill stem worn or missing.

Visual inspection

Replace rubber deflector.

3.

Dust suction post in top of dust box blocked.

Visual inspection Remove suction duct if necessary.

Chip out caked cuttings - repair or replace deflection shield.

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I.

PROBLEM:

DUST ESCAPING FROM AROUND THE HOLE OE DUST BOX. CONT'D

CAUSE

CHECK

CUR.E

4.

Suction duct plugged or leaking.

Visual inspectionCheck for holes worn by abrasive cutting-check all joints for leaks.

Clean out duct and repair or replace as required.

5.

Skirt won't touch ground to create seal.

Visual inspectionRig jacked level on slope & skirt is off ground on down hill side-angle drilling & drill stem not semitrical to dust box.

Special dust box needed-i.e., longer skirts or longer and wider box.

6.

Transition hopper clogged.

Remove transition hopper.

Chip out caked cuttings-shorten dropout duct.

7.

Dump flap worn or damaged.

Remove transition hopper.

Repair or replace flap.

8.

Dust hopper and/or cutting hopper clogged.

Visual inspectionopen hopper door & reach under barrier flap betwee dust hopper and cutting hopper on "LL" and "LR'f series.

Chip out caked cuttings.

9.

Filters severely plugged.

Visual inspectionRemove filters & check for dust packed on reverse (inside) of filter can.

Blow clean inside & outside, check for holes or install new filters, run backflushing unit with fan idle as possible means of cleaning.

If filters have indication of oil coating, check regulator water trap and fan motor shaft seal.

10. Top of dust collector full of dust.

Visual inspectionremove inspection plate.

Blow clean with compressed air-check filters for holes or ruptures & tighten wing nuts on filter retainer rods.

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II. PROBLEU:

DUST DISCHARGE FROM FAN-

CAUSE

CU:qE

CHECK

1.

Filter rupture

Remove filtersBlow clean with air-using good light source, inspe~t for holes.

Replace all filters.

Remove inspection plate from top section and blowout all residual dust.

2.

Filter seal leak.

Visual inspectionCheck for rubber backed washer under each wing nut.

Tighten wing nuts on filter retention rods.

Remove inspection plate in top section and blowout residual dust.

REEDRILL MODEL

MPI MODEL

RECOMMENDED RPM's

SK-25

LR 1500

2510

SK-35

LR 1800

3080

SK-40

LR 1800

3080

SK-50

LL 30001

4000 maximum 3800 nominal

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SECTION 7

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Section 7 MAST ASSEMBLY SERVICE This section contains service and repair information for the mast with its associated components and the rotary drive system. The service covered in this section will be limited to the mechanical aspects of the related systems and to the individual components. For the related hydraulic systems and systems maintenance refer to Section 8.

A.

HOIST AND PULLDOWN MECHANICAL SYSTEM SERVICE

The service and repair for the hoist and pulldown system consists of the maintenance associated with the roller chain elements and with the hoist and pulldown cylinders.

1. HOIST ROLLER CHAIN MAINTENANCE. As shown in Figure 7-1, each of the four roller chain sections are adjustable, and this adjustment is critical to operation of the hoist and pulldown system.

NOTE: TYPICAL ARRANGEMENT FOR ONE SIDE. ADJUSTMENTS FOR OTHER SIDE IDENTICAL

TOP-'

ROTARY DRIVE ASSEMBLY

LOWER ROLLER CHAIN

UPPER ROLLER CHAIN

, :

0 I

rt:::r:=T===========~~~~====~~5~r~~ or

'-..tC-

"rom :'

-filJj~:

'. ~

HOIST Be PULLDOWN CYLINDER

CHAIN TIGHTENING

CYLINDER FRAME

CHAIN TIGHTENING

Figure 7-1. Roller Chain Adjustments 7-1

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a.

Chain Adjustment. To adjust the rotary hoist roller chains proceed as follows: 1)

Be sure mast is lowered and resting on the mast rest.

2)

With engine and hydraulic system operating, move the rotary head to the top end of the mast.

3)

Refer to Figure 7-1 and adjust the two lower chains as follows.

4)

a.

Loosen stop nut and back off inner nut on two upper chain tightening bolts.

b.

Loosen outer stop nut on lower chain tightening bolt.

c.

Adjust inner nut to allow room for stop nut and still allow about 1" of threads to show on outer end of bolt. Be sure to allow same number threads projecting from each bolt.

d.

Tighten stop nut.

Refer to Figure 7-1 and adjust the two upper chains as follows. a.

b.

With mast lowered to the head rest sight chain as follows: 1)

Assume a position to enable sighting chain from a horizontal angle perpendicular to the roller chain.

2)

Observe swag of chains at mid length of mast.

3)

Adjust upper tightening bolt on each chain until top of chain is even with lower edge of mast angle iron.

4)

Tighten both stop nuts on chain tightening bolts.

Rotary Head Level Adjustment. First spot and level the drill unit, raise the mast, then level the rotary head as follows.

1)

Refer to Figure 7-2 and lower head almost to drilling platform.

2)

Carefully lower head to be sure rotary head output shaft (Figure 7-2A) is aligned with hole in drilling platform (Figure 7-2B).

3)

If head is not aligned, loosen cap screws and nuts (Figure 7-2C) and adjust head within the left and right hand guides so that rotary head output shaft is aligned.

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ROTARY HEAD

DRILL PIPE

ROTARY HEAD

DRILLING PLATFORM

" S S S

ISSSS"

'\

ALIGNED

t\ SS

\

sss'"

A LIGNED

Figure 7-2. Rotary Head Alignment 4)

Tighten cap screws and nuts (Figure 7-2C) being careful to keep head in alignment.

S)

Raise rotary head to the top of mast and install a section of drill pipe.

6)

Lower head carefully to check alignment of drill in hole in drilling platform (Figure 7-2B).

7)

If drill pipe does not align up so that it is centered in hole, readjust rotary head in guides and recheck the alignment.

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NOTE Failure of this procedure to yield proper alignment could indicate a stretched chain, which must be replaced.

2. HOIST HYDRAULIC CYLINDER SERVICE. Service of the hydraulic cylinder includes inspection and repair as necessary. a.

b.

Check for Hydraulic Seal Leak 1)

Cycle hoist two or three times then take it to top of mast, adjust hold-down pressure to maximum, and let set for a minute or two.

2)

Examine the seal around cylinder rod for evidence of leakage. If leakage is present, perform procedure as outlined in Topic c or d below.

Leakin Fix. Whenever a raulic fluid around the packing, a new packing kit generally should be installed. However, to avoid downtime until a cylinder overhaul can be scheduled, you may be able to stop the leak temporarily by removing shims from the cylinder cap. To remove the shims, refer to the hoist and pul1down cylinder illustration, Figure 7-3, and proceed as follows: 1)

Remove cylinder from machine and remove cap screws and lock washers (items 14 and 15) from end of cylinder.

2)

Separate packing gland (item 3) with rod wiper retainer (item 16) from cylinder cap (item 2).

3)

According to extent of leak, remove shims (item 13) as necessary to enable compressing of packing (item 12) to stop leak.

4)

Replace packing gland with rod wiper retainer back on cylinder cap.

5)

Align holes in rod wiper retainer, packing gland, cylinder cap, and barrel assembly, replace cap screws and lock washers, and torque to 10 ft. lbs.

6)

Tighten cap screws and torque to 10 ft. lbs.

7)

Replace cylinder on machine and place machine in operation.

8)

Observe cylinder when operation resumes, and take corrective action if leak continues.

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ITEM

PART NO. 18278 40738 40737 30287 19725 40129 40131 40130 19727 46548 11165 46675 18139 40739 42730 5975 40827 46673 40162 46674 11164

1 2 3 4 5 6 7

8 9

10 11

12 13 14 15 16 17 18 19 20

QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 6 1 4 1 4 1

DESCRIPTION WIPER SCRAPER HOIST & PULLDOWN CAP PACKING GLAND BACKUP RING 4 3/4 IN OD X 1/8 IN o RING 4 3/4 IN OD X 1/8 IN HOIST & PULLDOWN CYLINDER SHAFT R.H. BARREL L.H. BARREL o RING 2 3/4 IN OD X 1/8 IN HOIST & PULLDOWN CYLINDER PISTON LOCK WASHE'I{ PISTON WEAR RING PACKING SET PACKING GLAND CYLINDER SHIM CAPSCREW HEX STL 1/2 IN DIA-UNC X 2 IN LOCK WASHER 1/2 IN DIA ROD WIPER RETAINER PISTON RING SPACER PISTON RING NUT

Figure 7-3. Hoist Cylinder Illustration and Parts List 9)

When shims are removed without repacking, note this fact

on maintenance log so cylinder may be repacked as soon as practical. c.

Pu11down Cylinder Leakage Test. To test the pu11down cylinder for leakage past the piston, proceed as follows: 1)

Bring rotary gear case to bottom of mast.

2)

Disconnect the line connected to shaft side of pu11down cylinder.

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3)

Pressurize piston side of pulldown cylinder by stroking control lever. No oil should flow from shaft side of cylinder, and there should be little or no leakage.

4)

If appreciable leakage is observed, the piston seals must be replaced as outlined in Topic d.

d.

the Hoist and Pulldown C linder. When a leak is surest way to stop the leak is to cylinder. To repack the hydraulic 7-3 and proceed as follows: 1)

Remove cylinder from machine.

2)

Refer to illustrated parts list in Section 7 of Parts Manual while performing remainder of cylinder packing procedure.

3)

Remove cap screws and lock washers (item 14 and 15).

4)

Separate cylinder cap (item 2) from cylinder, and separate rod wiper retainer (item 16), packing gland litem 3) and cylinder cap (item 2).

5)

Remove and discard rod wiper (item 1), piston packing (item 4) and back-up ring and a-ring (items 11 and 12, respectively).

6)

Remove cylinder shaft (item 6) with piston (item 9) from cylinder assembly.

7)

Remove nut (item 11) and lock washer (item 10) and separate piston from cylinder shaft. If piston (item 9) is worn, replace it with an equivalent new part.

8)

Remove a-ring (item 8) and piston packing rings (item 17, 18, 19).

9)

Reassemble cylinder in reverse order of disassembly procedure, torqueing cap screws to 20 Ft. Lbs.

10)

Reinstall cylinder on machine.

11)

Observe during operation to verify that cylinder does not leak.

NOTE The cylinder shown above contains the new piston and piston packing.

It is recommended that new pistons be installed at time of cylinder rebuild.

B.

MAST ELEVATION MECHANICAL SYSTEM SERVICE

Mast elevation system vator hydraulic cylinders

service and the

includes maintenance of the elemast locking catch.

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1. ELEVATION HYDRAULIC CYLINDER SERVICE. Service of the elevator hydraulic cylinder includes checks for hydraulic leaks and repair as necessary. a.

Check For Hydraulic Leak. Cycle hoist two or three times, then raise It to the top of mast and adjust pulldown pressure to maximum, and let set for a minute or two.

b.

Examine the Seal Around the Cylinder Rod for Evidence of Leakage. If leakage is present perform procedures as outlined in topic c or d below.

c.

Elevation Cylinders, Tern orar' Fix. Whenever a cyliner is etermIne to e lea Ing y raullc luid around the packing, a new packing kit generally should be installed.

However, to avoid downtime until a cylinder overhaul can be scheduled, you may be able to stop the leak temporarily by removing shims from the cylinder cap. To remove the shims, refer to the elevation cylinder illustration, Figure 7-4, and proceed as follows: 1)

Remove cylinder from machine and remove cap screws and lock washers (items 15 and 16) from end of cylinder.

2)

Separate packing gland (item 3) with rod wiper retainer (item 10) from cylinder cap (item 7).

3)

According to extent of leak, remove shims (item 8) as necessary to enable compressing of packing (item 4) to stop leak.

4)

Replace packing gland with rod wiper retainer back on cylinder cap.

5)

Align holes in rod wiper retainer, packing gland, cylinder cap, and barrel assembly, replace cap screws and lock washers, and torque to 10 ft. lbs.

6)

Tighten cap screws securely.

7)

Replace cylinder on machine and place machine in operation.

8)

Observe cylinder when operation resumes, and take corrective action if leak continues.

9)

When shims are replaced without repacking, note this fact on maintenance log so cylinder may be repacked as soon as practical.

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3 7 4

6 13

14

17

9 15 16

1

11 12

ITEM

PART NO. ----

!IT.L.

1 2 3 4 5 6 7 8 9 10

40498 40083 40449 14069 40163 30502 40447 40470 30285 41547 30287 19725 16610 18849 7728 5989 34091

1 1 1 1 1 1 1 4 1 1 1 1 1 5 12 12 1

11

12 13 14 15 16 17

2

DESCR1PTI ON BARREL ASSEMBLY ELEVATING CYLINDER SHAFT CYLINDER PACKING GLAND SHAFT PACKING ELEVATION CYLINDER ASSEMBLY SPACER PISTON 4 3/4 IN 00 CYLINDER CAP SHIM ROD WIPER ROD WIPER RETAINER BACKUP RING 4 3/4 00 X 4 1/4 10 X 1/8 IN W o RING 4 3/4 IN 00 X 4 1/4 IN 10 X 1/8 IN W o RING 1 1/2 IN 00 X 1 1/4 IN 10 X 1/8 IN W PISTON PACKING 1/4 IN SQ CAPSCREW HEX STL 3/8 IN - UNC X 2 3/4 IN LOCKWASHER 3/8 DIA. ELASTIC STOP NUT 1 1/4 IN - UNC

Figure 7-4. Mast Elevation Cylinder and Parts List d.

Retackin g the Elevation Cylinder. When a leak is found in a cy inder, the surest way to stop the leak is to tear down and repack the cylinder. To repack the hydraulic cylinder proceed as follows: 1)

Remove cylinder from machine.

2)

Refer to illustrated parts list in Section 7 of Parts Manual while performing remainder of cylinder packing procedure.

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3)

Remove the cap screws and lock washers (items 15 and 16).

4)

Separate cylinder cap (item 7) from cylinder, and rod wiper retainer (item 10), packing gland (item cylinder cap (item 7).

5)

Remove and discard rod wiper (item 9), piston packing litem 4) and back-up ring and O-ring (items 11 and 12, respectively) .

6)

Remove cylinder shaft (item 2) with piston (item 6) from cylinder assembly.

7)

Remove elastic stop nut (item 19) and separate piston from cylinder shaft. If piston (item 6) is worn, replace it with an equivalent new part.

8)

Remove O-ring (item 13) and piston packing rings (item

separate 3) and

14) .

9)

Replace all O-rings and packing with new parts as identified in Parts Manual parts list, and reassemble cylinder in reverse order of disassembly procedure, torqueing the cap screws to 10 ft. lbs.

10)

Reinstall cylinder on machine.

llJ

Observe during operation to verify that cylinder does not leak.

2. MAST LOCK SERVICE. To service the mast lock, proceed as follows:

C.

a)

Periodically lubricate dog and cable assembly.

b)

Examine lock for wear or damage and replace if necessary.

c)

Adjust as necessary, using the procedure outlined in Section 2.

ROTARY DRIVE ASSEMBLY SERVICE

Service for the rotary drive assembly consists of service for the hydraulic motor and service for the rotary drive gearcase.

1. HYDRAULIC MOTOR SERVICE. For servlclng the hydraulic refer to the manufacturer's instructions in Part III of this 2. ROTARY GEARCASE SERVICE. sists of routine maintenance and

motor manual.

Service for the rotary gearcase conassembly/disassembly procedures.

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a.

Routine Maintenance ~ervice. Routine maintenance for the rotary drive gearcase consIsts of performing the following once each shift.

1)

Examine air swivel for leaks and check for freedom of operation.

2)

Examine overall gearcase assembly for any wear or obvious damage and take corrective action.

3)

Tighten all mounting bolts securely.

4)

Check level of grease and if necessary add grease as specified in Section 1.

b.

To disassemble the outlined in Figure

1) Remove reducer (1) with breather.

Disassembly, Plate 1.

2) Remove 6 hex caps crews (2) and remove output cover (3).

Disassembly, Plate 2.

Figure 7-5. Rotary Gearcase Disassembly Procedure.

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3) Remove 4 hex capscrews (4) and remove bearing cover ( 5) •

Disassembly, Plate 3.

4) On motor mounting flange (6) cut loeb-vires (7).

5) Remove 6 hex capscrews

(~)

and remove the motor mount bracket, then remove the input shieve and bearing (6) .

Disassembly, Plate 4.

6) Cut lockwire (9) and remove 6 hex capscrews (10) securing lockrings (11) and (12) together.

NOTE This ring has no holes to accommodate spanner.

7) Using a chain wrench if necessary, thread outer lockring (11) off outlet shaft.

Disassembly, Plate 5.

Figure 7-5. Rotary Gearcase Disassembly Procedure (Sheet 2).

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NOTE Pointer shows hole for accommodation of chain wrench.

8) Using spanner wrench or chain wrench, loosen inner lockring (12) and thread it off outer shaft.

Disassembly, Plate 6.

9) Knock out two dowel pins (13), remove 20 hex cap-

screws, lockwashers and nuts (14) and remove cover from housing

NOTE Upper output bearing cone lifts out with cover.

Disassembly, Plate 7.

10) Note that step 9 exposes output gear (15), intermediate gear (16), as well

as the upper bearing cone (17) for the intermediate shaft and the lower bearing (18) for the input shaft.

Disassembly, Plate 8.

Figure 7-5. Rotary Gearcase Disassembly Procedure (Sheet 3).

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11) Remove intermediate pinion shaft (19) and gear with both bearing cones. Disassemble pinion assembly as required.

Disassembly, Plate 9.

12) Remove Snap Ring (20) from output shaft.

Disassembly, Plate 10.

13) Remove output gear (21).

Disassembly, Plate 11.

Figure 7-5. Rotary Gearcase Disassembly Procedure lSheet 4).

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14) Remove output spacer (22).

Disassembly, Plate 12.

15) Note that step 14 leaves only output shaft (23) with its bearing, intermediate bearing cup (24), and input bearing (25).

Disassembly, Plate 13.

16) Now turn housing over to

expose seal retainer (26), and drill stem adapter (27). Block housing up to clear adapter.

17) Remove 6 hex capscrews (28) and lift off seal retainer (26).

Disassembly, Plate 14.

Figure 7-5. Rotary Gearcase Disassembly Procedure (Sheet 5) .

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18) Lift out two oil seals, (29) and (30).

Disassembly, Plate 15.

19) Remove hex capscrews (31) and remove inner seal retainer (32).

Disassembly, Plate 16.

20) Lift output shaft (23) with drill stem adapter (27), lower output bearing (33), and spacer (not shown), then disassemble the output assembly.

Disassembly, Plate 17.

Figure 7-5. Rotary Gearcase Disassembly Procedure (Sheet 6).

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21) Remove lower input bearing (18) from housing and remove

lower intermedIate bearing cone (34), using a hammer and pin as necessary.

Disassembly, Plate 18

L2) Remove input pinion (35)

and bearing (if not already removed) and remove intermediate upper bearing cone (36) from cover.

Disassembly, Plate 19 figure 7-5. Rotary Gearbox Disassembly Procedure (Sheet 7).

c.

Rotary Gearcase Assembly Procedure. To assemble the rotary gearcase, perform the-procedure outlined in Figure 7-6 starting on page 7-17. Refer also to the plates of Figure 7-5 as necessary and as directed.

Before starting assembly, inspect housing and main cover for loose sand and scale. Make sure all flange faces and bores are free of nicks and burrs.

7-16

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1) To begin assembly of output shaft components, place shaft (23), on end with largest diameter down.

2) Put RTV sealant on inner surface of spacer (37), then place spacer on shaft (23). Press spacer against shaft shoulder to ensure tight oil sealing.

3) Press bearing cone (38) onto shaft (23) and seal fir firmly against spacer.

4) install drill stern adapter (39) on large end of shaft.

5) Set assembly (Figure 7-5), Plate 18) aside until needed.

•

Assembly, Plate 1.

6) Place housing on bench, flange side down; then press intermediate bearing cup lSee Item 34, Figure 7-5, Plate 18) into bore and seat firmly against housing shoulder.

~

Take care to keep foreign matter out of bearing assembly.

7) Again stand shaft on end, larger diameter down; then lift housing, -flange side up, and ease it down over shaft until bearing cup is seated against case.

NOTE At this point, the housing should rotate freely about the hollow shaft.

8) Block up shallow end of housing to ensure stability (Figure 7-5, Plate 1.)).

9) Press bearing cup (24) into the intermediate bore and make sure cup is seated (Figure 7-5, Plate 13).

10) Press ball bearing (25) into the input bore and seat bearing (figure 7-5, Plate 13). Make sure bearing rotates freely.

Figure 7-6. Rotary Gearcase Assembly Procedure, Sheet 1.

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11) Press gear (15) onto spline shaft (23) and tap into place with a mallet.

12) Lock gear into place with snap ring (20). Be sure that snapring is well seated in groove.

13) Assemble intermediate pinion (Figure 7-5, Plates 8 and 9) as follows: a. Seat Bearing cone l19) on gear tooth end of pinion.

Plate 2.

b. Press gear (16) on spline with hub side of gear facing up. c. Press on bearing cone (17) until seated, with gear against pinion shoulder. Gear should have no float.

14) Place intermediate pinion subassembly (set aside in Step 6) into intermediate bore with pinion end down (Figure 5-7, Plate 9, Item

Assembly, Plate 3.

19) .

15) Place input pinion (Item 36, Plate 19, Figure 7-5) into housing.

16) Keeping bored end up, drive pinion into ball bearing (Item 18, Figure 7-5, Plate 18).

17) Place housing gasket on

hOUS~

flange and align holes.

.~.

Take care to alIgn pInIon with bearing bore so that pinion seats properly and rotates freely.

18) Place main cover over assembled housing and align dowel holes.

This operation may require some manipulating to get the pinIon seated properly. figure 7-6. Rotary Gearcase Assembly Procedure, Sheet 2.

7-18

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19) Drive in the two dowels (13), one at each end of cover.

20) Bolt housing and cover together using hex caps crews (14), nuts and lockwashers (Figure 7-5, Plate 7).

21) Torque nuts to 70-100 ft. lbs.

22) Press output bearing cup (located under Item 40) into cover bore and seat cup against shoulder.

Assembly, Plate 4.

23) Press output bearing cone (40) onto shaft and drive down until snug against cup.

24) Thread lockring (12) onto shaft and screw down to bearing shoulder.

25) Place spanner wrench on lockring (12) and strike wrench two or three times with mallet to lock ring down.

Assembly, Plate 5.

26) Rotate housing back and forth about shaft to see that rotation is free.

27) If assembly does not rotate freely about shaft, proceed as follows: a. Lift assembly and support housing so that shaft is suspended. b. Place plate over top end of shaft and strike several times with 30 to 40 pound bar. Repeat step 27 as necessary.

Assembly, Plate 6.

Figure 7-6. Rotary Gearcase Assembly Procedure, Sheet 3.

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28) When bearings are adjusted, screw in lockring (11).

Leave about a 1/8" gap between lockring (11) and lockring (12J. 29) Place hex cap screws through lockring (11) and thread them into lockring (12). Torque to 27-32 ft. lbs, then lockwire (9).

30) Figure 7-6, Plate 8 illustrates intermediate bearing cover (5) with intermediate bearing cover gasket and shims (41).

Assembly, Plate 7.

31) Press intermediate bearing cup (Figure 7-5, Plate 6, Item A) into intermediate bearing bore and tap down against bearing cone.

32) Place cover (5) over bore and start hex caps crews l4) and lockwashers. ~3)

Begin to tighten down capscrews while rotating assembly back and forth about shaft, using output shaft as pivot.

Assembly, Plate 8.

34) Tighten bolts alternately until bearings begin to bind and unit does not move easily.

35) Using a feeler gauge, check gap between housing boss and cover. Check in three places about boss, then average the three readings.

36) Pick a combination of shims that add up to total of step j5 plus an additional .004 to .006 in. on boss.

37) Replace and tighten down cover, then check for freedom of movement by again rotating housing.

38) If bearings still bind, remove cover, strike housing several times about intermediate bore to free bearings, then repeat procedure.

Figure 7-6. Rotary Gearcase Assembly Procedure, Sheet 4.

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39) Once adjustment is complete, torque bolts to 2j-32 ft. lbs.

40) Next, install oil seal into output cover (3), making sure seal is seated firmly in bore.

41) Place output cover gasket on main cover output boss.

42) Place output cover (3)

over bore and bolt down with hex capscrews (2) and lockwashers; then torque to 27-32 ft. lbs.

3 ",'

~~

',.

43) Replace pipe plug (42) into opening on side of cover.

".~

Assembly, Plate 9.

44) Place ball bearing over end of input pinion and start bearing into bore.

NOTE Plate 8 shows input pinion with pump flange installed.

45) Make sure bearing is squarely aligned in bore and then drive into seat against pinion shoulder.

~

Insufficient end float will preload the ball bearings.

46) Check and adjust end float as follows: a. Measure distance from outer race of ball bearing to face of bearing boss. b. Measure length of pilot on pump mounting flange and subtract 0.020 in. as an allowance for thickness of gasket.

NOTE There should be a difference of 0.020-0.030 in. of gap remaining to assure proper end float.

Figure 7-b. Rotary Gearcase Assembly Procedure, Sheet 5.

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d. 1f necessary add an additional gasket to create proper gap.

47) With selected gasket(s) in place, secure pump flange on boss with hex capscrews with lockwashers.

48) Torque capscrews to 17-32 tt. 1bs, then lockwire screws.

Whole assembly should now rotate freely around output shaft.

49) Refer to Plate 9 and install breather as follows: a. Thread pipe reducer (1) into hole near intermediate bore. b. Assemble breather (45), reducer (44), and street ell, (43). c. Install breather assembly into pipe reducer (1) already installed.

50) Turn gearcase over and secure shallow end of housing on blocks.

51) Put pipe plug into drain hole on intermediate boss, and tighten down snuggly.

52) Place gasket (46) over output bore and install inner oil seal retainer using hex capscrews (31) and lockwashers torqued to 2732 ft. lbs, (32).

Assembly, Plate 10.

53) Before installing first half of face type oil seal (30), be sure outer sealing lip is clean and free from contamination and insert oil seal with inner metal lip up into inner oil seal retainer.

54) Lightly grease outer surface.

Assembly, Plate 11.

Figure 7-6. Rotary Gearcase Assembly Procedure, Sheet 6.

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55) In a similar manner, insert second half of seal (29) into outer seal retainer (26) in the same way.

56) Spread a thin uniform coat of RTV sealant (47) around shaft just behind spacer (37- Plate 7) and on end of spacer.

57) Press retainer l26J onto end of shaft behind spacer (37-Plate 7) making sure outside diameter of (26) does not interfere with inner retainer (32) so that retainer will turn freely.

Assembly, Plate 13.

58) Bolt retainer (26) to spacer (37) with hex capscrews (28) and lockwashers torqued to 14-18 ft. lbs. (See Disassembly, Plate 8). .

NOTE This face type oil seal is hardened, ground, and lapped for application where extremely dirty conditions exist.

Assembly, Plate 14

Figure 7-6. Rotary Gearcase Assembly Procedure, Sheet 7.

7-23

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SECTION 8

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Section 8 HYDRAULIC SYSTEM MAINTENANCE In order to perform the maintenance as described in this section, you should be familiar with the hydraulic system functions and with the functions of the operator controls and indicators as described in Part I, as well as with the mechanical service requirements described in the previous sections of this volume. Also, you should understand the symbols used in hydraulic schematics and be familiar with the schematics associated with the SK-35 systems.

NOTICE Disassembly of certain items such as the hydraulic pumps and motors and the air end of the compressed air system will void the warranty. Refer to the warranty information associated with your particular SK-35 unit for specific details.

[EE] Contamination of the hydraulic system can seriously affect the life expectancy of the hydraulic components. You should cap all open lines and inlets after component removal, and you should be especially careful to ensure that any hydraulic components removed for warranty consideration are kept clean during return to the manufacturer.

In general, maintenance of each system consists of pressure adjustments, troubleshooting, and repair. However, the rotary hydraulic system also contains three filters which must be replaced as required. Table 8-1 gives standard pressures for various points in the hydraulic systems, and Figure 8-1 designates gauges and special tools required for maintenance.

Table 8-1. Pressure Settings for System Elements PRESSURE ELEMENT 1.

2.

JACKS MAST ELEVATING

PSI 2300 2300 8-1

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Table 8-1. Pressure Settings for System Elements PRESSURE ELEMENT 3.

4.

5.

6.

PSI

PULLDOWN CONTROL a. STACK VALVE RELIEF b . PILOT OPERATED PULLDOWN RELIEF VALVE RAPID HOIST ROTARY/PROPEL a . COMPENSATOR b. HIGH PRESSURE RELIEF (MOTOR) CHARGE PRESSURE

GAUGES AND GAUGE HOLE REQUIREMENT:

1750 1700 l50U

3500

4500

300

TOOLS REQUIRED:

ADAPTER (37825) 1/4 NPT (FEMALE) TO JIC (MALE)

§nn EXISTING 1/4 HOSE

(I)

9/1ll OPEN END

(I)

7/8 OPEN END

(I)

12" ADJUSTABLE

(I)

3/16 HEX KEY

(I)

1/4 HEX KEY

DISCONNECT FROM SHUTTLE VALVE AND SCREW ONTO 0-5000 PSI LIQUID FILLED GAUGE

1/4 NPT

r-

1/4" HOSE 2' (APPROX)

I

~f------~ 1/4 JIC (FEMALE)

utdlm

1/4 JIC TO "0" RING (39694)

tdJlIJ

ADAPTER (37825) 1/4 NPT (FEMALE) TO 1/4 JIC (MALE)

Figure 8-1. Gauges and Tools Required for Adjusting Hydraulic System 8-2

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A.

ROTARY HYDROSTATIC SYSTEM MAINTENANCE

Maintenance of the rotary hydrostatic system includes filter replacement, pressure checks and adjustment, troubleshooting and repair.

1. ROTARY SYSTEM PRESSURE AND 8-2 is a simplified representation tem. Also included on this diagram in the maintenance procedures. for hydraulic schematic.

RELIEF VALVE FUNCTIONS. Figure of the rotary drive hydraulic sysare maintenance points referenced details of the system, refer to the

Charge oil for the rotary pump is provided by the charge pump through a 3 micron filter to the cross check valves in the rotary pump inlet. The cross-check valves conduct the charge oil to the lowpressure side of the circuit.

Powered through the hydraulic drive by the diesel engine, the rotary pump circulates the hydraulic fluid through the loop to operate the rotary drive system. The volume and direction of fluid flow is determined by the setting of the control assembly as operated by a lever on the operator's console.

The hydraulic pressure in the loop at any given time depends upon the load on the rotary drive. However, this pressure is limited by the 4000 psi average pressure setting of the compensator on the pump control assembly and 4500 psi (maximum) pressure relief valves across the rotary drive motor.

Because the system may be operated in both forward and reverse directions, two relief valves are required.

The Rotary Hydraulic Pressure gauge on the console panel indicates the pressure in either direction at any given time. Because the system exerts maximum pressure only when maximum force is required, it is necessary to stall out the rotary drive to obtain maximum hydraulic pressure.

Although the gauge is intended to indicate the system high pressure, it also responds to charge pressure. Thus, so long as the drive is operating the gauge should not return quite to zero -- even when the rotary system is not under load.

2. ROTARY HYDROSTATIC SYSTEM FILTER REPLACEMENT. Three types of filter elements are used in the rotary hydrostatic system. Two are the single element loop and charge filters mounted in assemblies external to the hydraulic tank, and one is a dual-element filter located in the hydrostatic section of the tank. a.

Loop and Char~e Filters. The loop and charge filters each contaln filter e ements number 40983. To replace one of these elements, proceed as follows: 8-3

00

...

HIGH PRESSURE GAUGE PORT 1/8 NPT GAUGE ATTACHES TO OTHER END OF HOSE

i r

CASE DRAIN

COOLER

I

ROTARY DRIVE MOTOR

I

TANK FILTER

...._.J

J

FOR DRAIN CHECK, DEl ¥ T A C H LINES

II

I HYDRAULIC TANK

I I

i

-------------,

~--------------------I----I , I I

•

RELIEF VALVE ADJUSTMENT

• :LR~/OUTLET "~

HIGH PRESSURE RELIEF VALVES AND PILOTS

Figure 8-2. Simplified Rotary Hydrostatic System Diagram With Maintenance Points.

CHARGE PUMP

CHARGE FILTER

HYDRAULIC PUMP

LOOP FILTER

•

LOW PRESSURE RELIEF VALVE

LOW PRESSURE RELIEF VALVE DRAIN PORT

REMOVE CAP TO ADJUST WITH 3/16 ALLEN WRENCH

LOW PRESSURE RELIEF VALVE

SMILE PLATE

LOW PRESSURE (CHARGE) GAUGE PORT 1/4 SAE O-RING

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1)

Using a filter wrench, remove filter bowl.

2)

Remove and discard filter element.

3)

Thoroughly clean filter bowl.

~ GEl

Do not touch new filter element directly with hands.

b.

4)

Open polyurethane bag, being careful not to touch filter element.

5)

Turn back bag enough to allow insertion of filter, and place filter into position before removing bag.

6)

Using an a-ring as necessary, replace filter bowl over the filter element and secure bowl taking care not to overtighten.

Tank Filter Element Replacement. To replace the tank filter elements, proceed as follows: 1)

Disconnect electrical switch assembly from top of filter unit.

2)

Using handle provided, remove filter unit from tank.

3)

Remove cover assembly and piston at top of unit.

4)

Remove two filter elements, being careful to ensure that flat washer at bottom of tie rod remains in unit.

5)

Without touching new elements with hands, install two new elements on tie rod, handling elements by plastic cover bags.

6)

Replacing the cover a-ring as necessary, replace piston and cover assembly on unit.

7)

Replace unit in hydrostatic tank.

8)

Reconnect filter switch to receptacle provided.

3. ROTARY HYDRAULIC PRESSURE CHECK AND ADJUSTMENT. As described in Topic A, the hydraulic pressure for the rotary system is read directly on the Rotary Hyd. Press. gauge on the console panel.

Although the control panel gauge may be used for high pressure checks, it is recommended that a gauge (Figure 8-1) be installed at 8-5

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the pump for high pressure adjustments. It is also necessary to install a low pressure for measuring the low (charge) pressure. a.

Gauge Installation for Rotart Pressure Adjustment. The gauge and tool requirements for adjusting the rotary hydraulic pressure are illustrated in Figure 8-1. To install the gauges for rotary pressure adjustment, proceed as follows.

1)

Locate high pressure gauge port on shuttle valve. (Figure 8 - 2) •

b.

2)

Disconnect opposite end of the hose which is connected to port located in Step 1.

3)

Using the 1/4" NPT to JIC adapter, connect the 0 to 5,000 psi gauge to high pressure port.

4)

Locate low pressure (charge) gauge port on control assembly (Figure 8-2).

5)

Using the 1/4" JIC to O-ring adapter, the 1/4" by 2' hose section, and 1/4" NPT to 1/4" JIC adapter as illustrated in Figure 8-2, connect the 0 to 1,000 psi gauge to low pressure port.

Rotary Low Pressure (charge) Adjustment. To set the charge pressure proceed as follows: NOTE If unable to obtain proper low pressure adjustment or if faulty operation is observed refer to Topic c.

c.

1)

With engine operating at 1200 rpm observe the low-pressure gauge.

l)

Operate rotary drive control lever so that rotary drive is turning.

3)

While observing low pressure on gauge, adjust low pressure relief valve (Figure 8-2) for 30~ psi.

Pump Inlet Check Ins~ective Procedure. If faulty or erratic operation is observe and improper pump inlet check valve operation is suspected, refer to Figure 8-3 and perform the following: 1)

Remove rear pump cover. ~-6

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2)

Examine inlet check seats. Seats should be flush with back of pump. Should be tight.

3)

Push on check balls to assure that they are seating properly. Seating against back of seat.

4)

Do not attempt to remove or repair a loose check ball seat. The pump must be replaced.

SPRING

BALL

Figure 8-3. Pump Inlet Check Valve

d.

Rotary High Pressure Adiustment. Adjust the rotary pressure in accordance with the ollowing procedure: NOTE If unable to obtain required results from this test, check cross-over relief poppets as in Topic e.

1)

Engage table wrench with drill stem so that rotary drive can be blocked to build up full pressure. Screw in compensator adjustment screw approximately 2 turns.

2)

Set engine speed at 1200 rpms.

[BE] To avoid damage to the system, do not stall rotary drive for long periods of time.

3)

Stall rotary drive in forward direction with engine set at 1200 RPM. 8-7

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4)

Adjust forward rotation high pressure relief valve (Figure 8-2) on rotary motor until high pressure gauge reads 4500 psi.

5)

Stall rotary in reverse direction with engine speed set at 1200 rpm.

NOTE If high pressure cannot be raised to 4500 psi, screw in compensator adjustment sufficiently to permit high pressure relief to be set.

e.

6)

Adjust reverse rotation high pressure relief valve (Figure 8-2) on rotary motor until gauge reads 4500 psi.

7)

Back out compensating adjustment screw 4 turns.

8)

Stall rotary in forward direction with engine set at 1200 rpm.

9)

Advance compensating adjustment screw until high pressure gauge reads 4,000 psi.

10)

Repeat stall a few times to ensure repeatability of this setting.

11)

Lock all adjustment screws and repeat pressure check one more time.

Cross-Over Relief Poppets Check. If relief valves are suspected of being faulty, refer to Figure 8-4 and perform the following: 1)

Remove both hex plugs in the back of the motor relief valve block.

2)

Extract both poppets from their bores.

3)

Inspect each poppet for cracks or plugged orifices or stickiness in the bores.

4)

Replace if necessary.

5)

Do not under any circumstances attempt to hone the bores or reduce the poppet's diameter in any manner.

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HIGH PRESSURE RELIEF ADJUSTING SCREW

"0" RING

SPRING

SEAT

PLUG

"0" RING

POPPET

RELIEF VALVE BLOCK

Figure 8-4. Cross-Over Relief Valves f.

Hydrostatic Pump Neutral Setting Procedure. If unable to find neutral setting for rotary control, refer to Figure 8-5 and proceed as follows:

ADJUSTING SCREW SMILE PLATE (DETENT PLATE)

----~:i~Jmr11ml

-----...r:1

DETENT DETENT' BALL -

LOCK NUT

Figure 8-5. Smile Plate (Detent Plate)

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g.

h.

1)

Loosen the two cap screws retaining the smile plate.

2)

Disconnect the cable actuator from the pump control lever.

3)

With the control lever ball detented in the smile plate detent hole, manually move the control lever and smile plate until high pressure gauge reads no higher than the normal charge pressure reading.

4)

Tighten the smile plate cap screws.

sJ

Move the control lever forward and reverse and return to neutral.

6)

Observe high-pressure gauge. It must not read higher than normal charge pressure. If it does, repeat the above neutral setting procedure.

Case Drain Inspection Procedure. To check the case drain in either the rotary pump or rotary motor, proceed as follows: 1)

Disconnect pump case drain line from reservoir.

2)

Remove closed loop reservoir tank cover.

3)

Direct stream of oil from pump case drain line into tank.

4)

Stroke pump with rotary blocked to build full pump pressure.

5)

With container of known size and stop watch (or with flow meter) measure case drain flow. This flow should not exceed 5 GPM. If it does, replace pump and check for system contamination. If pump must be replaced, case drain flow in this circuit for companion pump or motor should be checked.

Remove Pressure Gaufes. After pressure setting is complete, remove gauges insta led in Topic a, reconnect high pressure line, and recap the low pressure port.

4. ROTARY HYDROSTATIC SYSTEM TROUBLESHOOTING. Table 8-2 is a troubleshooting guide for the rotary hydraulic system. The guide may be used as a cause/remedy chart for troubles encountered during operation or during the pre-operation check in the Operator's Manual. Useage of this chart should help locate common problems in the rotary hydrostatic system.

5. ROTARY HYDROSTATIC SYSTEM REPAIR. The normal field repair for a faulty rotary system component is replacement of the component.

However, many of the components may be repaired under shop conditions.

8-10

....... ........ ....... ........

II

00 00

2. Check rotary pressure

1. Check rotary head rotation

PROBLEM/TEST

Perform Test No.2 Perform Test No.2

Faulty rotary motor Faulty rotary drive

Faulty rotary drive (Mechanical lock) Pilot section of pilot relief valve faulty

Check rotary drive and repair or replace as necessary

Faulty rotary motor (Mechanical lock)

c. Full pressure in both directions

d. Full pressure in one direction -inadequate pressure in other d~ rection.

Check rotary motor and replace if necessary

Faulty rotary pump

b. Slight lcharge) pressure in both directions

Readjust or replace

Check rotary pump and replace if necessary.

Faulty charge system

a. No pressure in either direction

Check charge system

Perform Test No.2

Inadequate hydraulic pressure -- both directions

b. Does not rotate in either direction

Perform Test No.2

CORRECTIVE ACTION

Inadequate pressure -- one direction

PROBABLE CONDITION

a. Rotates one direction only

TEST OBSERVATION

Table 8-2. Rotary Hydraulic System Troubleshooting

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N

~

.....

I

00

4. Note HP pressure relief valve setting, then screw in slightly while observing pressure

3. Note compensator setting, then screw in slightly while observing pressure

PROBLEM/TEST

i

Relief valve out of adjustment

Compensator adjustment is not problem

b. Pressure does not increase a. Pressure increases

Compensator out of adjustment

Adjust relief valve

Set compensator to original setting and perform Test No.4.

Adjust compensator

Check pump and motor case drain and if excessive (over 5 GPM) replace pump or motor

Perform Test No. 5

Relief setting out of adjustment Excessive pump or motor case drain

No.33 Perform Test No.

Perform Test No. No.55

Pump or motor case drain excessive Compensator out of adjustment

CORRECTIVE ACTION

PROBABLE CONDITION

a. Pressure increases

f. Still can't get full pressure in either direction after checking compensator and relief setting

e. Cantt Can't get full pressure in either direction

TEST OBSERVATION

Table 8-2. Rotary Hydraulic System Troubleshooting (Cont.)

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t.N

J--I

.....

I

00

7.

7 . Can't find neutral on control

6. Check motor case drain

S. Check Pump case drain

PROBLEM/TEST

b. Smile plate can be adjusted to find neutral

pump control

pump out of ISmile adjustment

I Bad

System plumbing fault

b. Rotary motor case drain not excessive a. Smile plate cannot be adjusted to find neutral

Bad rotary motor

a. Rotary motor case drain excessive (over 5 GPM)

system

Adjust and secure smile plate

Replace pump

plumbing.

I Troubleshoot

Replace rotary motor

Pump is probably okay I Perform Test No.6 No. 6

b. Rotary pump case drain not excessive

Replace rotary pump

Set relief valve to original setting and perform Test No.5

CORRECTIVE ACTION

Bad pump

Relief valve adjustment is not problem

PROBABLE CONDITION

a. Rotary pump case drain excessive (over 5 GPM)

b. Pressure does not increase

TEST OBSERVATION

Table 8-l.

8-Z. Rotary Hydraulic System Troubleshooting (Cont.)

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In general, the repair procedures for purchased components are covered in the vendor manuals included in Part III. However, some of the more common procedures relating to the rotary system are included in the following paragraphs; while assembly/disassembly procedures for the rotary drive unit are given in Section 7 of this volume.

B.

HOIST AND PULLDOWN HYDRAULIC SYSTEM MAINTENANCE

The hoist and pulldown hydraulic system maintenance consists of pressure checks, adjustments, troubleshooting and repair procedures.

1. HOIST AND PULLDOWN SYSTEM PRESSURE AND RELIEF VALVE FUNCTIONS. Figure 8-6 is a simplified representation of the hoist and pulldown system, including maintenance points referenced in the maintenance procedures. a.

High Speed Hoist Functions. Hydraulic pressure to drive the high speed hOlst is developed by the 55 gpm section of the three-stage pump and is controlled by a cable operated DA5 valve. The pressure is adjusted by means of a relief valve (Figure 8-6). Since there is no console panel pressure gauge to read the hoist pressure, setting of this pressure requires installation of an auxiliary gauge (see Figure 8-1). To obtain maximum pressure it is necessary to run the hoist all the way to the top to stall it out.

b.

Hoist Counter Balance Valve. A counter balance valve across the output and input of the hoist is adjusted to offset the weight of the drill string.

c.

Pulldown Hydraulic System. The pulldown hydraulic system pressure is supplied by the 10 gpm section of the three-stage pump. Pulldown pressure is indicated by a gauge on the console panel.

Operator controls for the pulldown consist of a pilot operated relief valve and a lever controlled hydraulic valve. Maximum pressure for the system is set by a relief valve connected across the control valve. The operator adjusts the pilot operated control valve for the desired pulldown pressure and then applies that pressure to the hoist and pulldown cylinders by means of the pulldown control valve.

2. HOIST AND PULLDOWN HYDRAULIC PRESSURE CHECKS AND ADJUSTMENTS. The hoist and pulldown pressure checks and adjustments consist of settings for the two high pressure relief valves and the counter balance valve.

8-14

f-oO ......

V1

II

ex·

55 GPM PUMP STAGE

TO RETURN HEADER

RELIEF VALVE

TO RETURN HEADER

I

RELIEF VALVE

-

"'-.

D~5 VALVE AT Df35

FAST HOIST VALVE

085 VALVE (LOCATED AT HOIST PIVOT SUPPORT)

INSTALL GAUGE AT INPUT TO 085 VALVE

PULLDOWN CONTROL VALVE

(

\

I

/

~

--I~~··-

COUNTERBALANCE an III<:::TMFNT AnJlJSTMENT ;LOCATED ;LOCATEO ON RETURN HEADER

HOIST CYL.

Figure 8-6. Simplified Hoist and Pulldown Hydraulic System Diagram with Maintenance Points

CCONSOLEI

OPERATOR ADJUSTMENT (CONTROL CONSOLE)

10 GPM PUMP STAGE

(LOCATED IN L.OWER VALVE BANK)

HOIST CYL.

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Hi,h Speed Hoist Relief Valve Setting. The procedure is as £0 lows:

a.

b.

1)

Install a pressure gauge as indicated in Figure 8-6.

2)

Operate high speed hoist control to drive rotary head to top of mast.

3)

While applying pressure by means of high speed hoist control valve, observe gauge installed in step 1.

4)

Adjust high speed hoist relief valve for an indication of pressure as indicated in Table 8-1.

Pulldown Pressure Adjustment. To adjust the pulldown pressure, proceed as follows: 1)

Bottom out pulldown cylinder by running rotary gearcase to top of mast.

2)

Turn console pulldown control knob fully in.

S)

Screw in relief valve adjustment of pilot control pulldown valve completely.

4)

Adjust relief valve in bottom-most section of a valve stack mounted on deck (See Figure 8-6). Set valve to appropriate specification indicated in Table 8-1.

S)

Re-adjust relief valve and pilot control pulldown valve to specification in Table 8-1.

NOTE The console pulldown pressure control valve may now be adjusted to suit drilling conditions.

c.

Hoist Counterbalance Adjustment. The counterbalanced by means of a single located on the return header (Figure is required, refer to Figure 8-7 and

hoist cylinders are counterbalance valve 8-6). When adjustment proceed as follows:

1)

Loosen stop nut (2) and turn adjustable guide (1) (counting number or portions of turns) into solid point.

2)

Then back out adjustable guide 3 or 4 turns.

3)

Loosen stop nut (4), and turn adjustable seal (3) clockwise to increase pressure or counterclockwise to decrease pressure.

8-16

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Figure 8-7. Counterbalance Valve Adjustment 4)

When desired pressure is obtained, lock down stop nut (4) by holding cap adjustment (5) and seal adjustment (3) from turning and tighten stop nut (4).

5)

Turn adjustable guide (1) into solid point and back out to original position. Hold adjustable seal (3) and adjustable guide (1) while tightening stop nut (2).

3. HOIST AND PULLDOWN SYSTEM TROUBLESHOOTING. Table 8-3 is a troubleshooting guide for the hoist and pulldown system. The guide may be used as a cause/remedy chart for troubles encountered during operation or during the pre-operation check in the operator's manual.

Useage of this chart should help locate common problems in the hoist and pulldown hydraulic system.

4. HOIST AND PULLDOWN HYDRAULIC SYSTEM REPAIR. The normal field repair for a faulty component in the hoist and pulldown system is replacement of the components. However many of the components may be repaired under shop conditions.

In general, the repair procedures for purchased components are covered in the vendor manuals included in Part III; however certain repair procedures and information are given in Section 7 of this volume.

C.

GENERAL HYDRAULIC SYSTEM MAINTENANCE

Maintenance on the general hydraulic system includes pressure checks, relief valve adjustments, troubleshooting and repair procedures.

8-17

00

~ ~

II

00

Adjust pressure to

Improper manifold relief valve adjustment

Improper valve bank relief valve adjustment Further checks are required

b. Pressure can be raised by screwing in relief adjustment on manifold relief c. Pressure can be raised by screwing in relief valve in valve bank d. Pressure cannot be raised by screwing in relief valve in valve bank

Proceed to Test No.4

sp~c

Adjust pressure to spec

Operator adjustments had not been properly made

Adjust the pulldown control pressure as desired

Inspect and replace shaft seal as necessary

Inspect and replace pump as necessary

Adjust counterbalance valve

CORRECTIVE ACTION

a. Pressure can be raised by screwing in pulldown control

Dynapower shaft seal has failed

b. Oil is red

3. Pull down pressure is inadequate (although head goes up and down)

Shaft seal in gear pump has failed

a. Oil is clear

2. Oil runs out of pump drive breather

Counter balance valve out of adjustment

PROBABLE CONDITION

a. Head comes down eratically

TEST OBSERVATION

1. Raise & lower rotary head &verify that head comes down smoothly

PROBLEM/TEST

Table 8-3. Hoist and Pulldown Troubleshooting

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I-'

II

....

00 00

6. Hoist and pulldown pressure check

s. Perform pulldown S. cylinder leakage test

4. Check for stuck cam valve plunger

PROBLEM/TEST

speed hoist I Problem is pump not go up and and hoist pullis slow

Proceed to Test No.9

Problem is high speed I Proceed to Test No.8 hoist pump

c. High speed hoist will not go up and down, but hoist pulldown is okay d. High will down down

Inspection or service I Proceed to Test No.7 required

b. High speed hoist operator okay but hoist pulldown is slow

None required

Replace or repair pump

System function is normal

Pump faulty

b. Cylinder does not leak

I Repair cylinder

Proceed to Test No. S

Free sticky cam valve plunger

CORRECTIVE ACTION

a. High speed hoist operator okay, and slow hoist operator okay

Cylinder seal faulty

Further checks are needed

b • Cam valve plunger b. is out

a. Cylinder leaks

Cam valve plunger is stuck

PROBABLE CONDITION

a. Cam valve plunger is not out

TEST OBSERVATION

(Cant.)

Table 8-3. Hoist and Pulldown Troubleshooting (Cont.)

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o

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I

00 00

replacement of pilot valve correct pulldown problem

10. Does repair or

of pump and operation of auxiliary units

9. Check rotation

valve in high speed hoist valve

8.

8 • Check relief

7. Screw in console pulldown control knob

PROBLEM/TEST

I

System is okay

Check relief valve in valve bank

a. Yes

b. No

Adjust relief valve as required

Adjust pressure as required

Repair or replace pump and readjust pressure

Pump is faulty

b. Pump is rotating but auxiliary units do not operate

Clean or repair valve and readjust pressure

Repair or replace pump and readjust pressure

Hydraulic drive clutchl Check hydraulic drive or gear box is faulty

Relief valve in high speed hoist valve requires cleaning or repair

55GPM SSGPM Pump has malfunctioned

Inspect, clean and replace if necessary, then proceed to Test No. 10

Adjust as required

CORRECTIVE ACTION

a. Pump is not rotating

b. Relief valve does not operate properly

Valve is okay

Pilot relief valve has malfunctioned

b. Knob will not adjust pUlldown pulldown pressure correctly

I a.

Knob was misadjusted

PROBABLE CONDITION

a. Knob adjust pulldown pressure okay

TEST OBSERVATION

Table 8-3. Hoist and Pulldown Troubleshooting (Cont.)

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1. GENERAL HYDRAULIC SYSTEM PRESSURE AND RELIEF VALVE FUNCTIONS. Figure 8-8 is a simplified diagram of the general hydraulic system, showing maintenance points. The 32 gpm stage of the three-stage hydraulic pump provides hydraulic pressure for the general hydraulic system. The system elements operated by the 32 gpm pump are controlled through two banks of valves that are operated by levers and control cables from the operator's cab. A separate relief valve is provided for each of the two valve banks. However, only one pressure gauge on the console indicator panel indicates the pressure for both valve banks. On earlier machines, the upper valve bank only operated the hydraulic jacks; however, on later machines the upper valve bank also operates the mast elevator hydraulic cylinders. The hydraulic schematic indicates the actual configuration for the particular machine.

The pressure for the elements operated by the upper valve bank is set by a relief valve as indicated in Figure 8-8; and the pressure available for these functions is not affected by the setting of the relief valve in the lower relief valve bank.

The hydraulic fluid passes through a flow divider before being applied to the lower bank, so that the lower valve bank receives only half the volume of fluid delivered to the upper valve bank. If one of the elements in the upper valve bank is turned on, no hydraulic pressure is available to the lower valve bank. However, when none of the upper valves are turned on, pressure is available to the lower bank, and the pressure is read on the hydraulic pressure gauge. This pressure may be adjusted to a point below the relief valve setting for the upper bank; however, it would be pointless to set this relief valve above the setting for the upper valve bank.

2. GENERAL HYDRAULIC SYSTEM PRESSURE CHECK AND ADJUSTMENT. Separate pressure check adjustment procedures are required for the upper and lower valve bank. a.

b.

Upper Valve Bank Pressure Ad{ustment. To check and adjust the pressure of the upper va ve bank proceed as follows: 1)

Stall out system by operating one jack all the way to top.

2)

Observe pressure indication on hydraulic pressure gauge.

Pressure should be as indicated on console hydraulic pressure gauge.

3)

Set relief valve for upper bank (See Figure 8-8) for pressure settings as specified for jacks and mast elevations in Table 8-1.

Lower Valve Bank Relief Valve Setting. With all the valves in the upper bank closed, operate the mast elevator control to bottom out the cylinders.

8-ll

N N

I

00

RETURN

RETURN

RE::TURN

RELIEF VALVE

OUTLET

MID INLET

INLET

LOWER VALVE BANK

OUTLET

INLET

UPPER VALVE BANK

RETURN

PULL,DOWN

PIPE RACK

CASING TONG

PIPE RACK INDEX

PIPE POSITIONER (OPTIONAL)

COUNTERBALANCE FOR JACKS IS FIXED

FRONT JACK

~ ~

COUNTERBALANCE FOR ELEVATORS IS FIXED

MAST ELEVATOR

Figure 8-8. Simplified General Hydraulic System Diagram

FROM 10 GPM PUMP

FLOW DIVIDER

HYDRAULIC PRESSURE

32 GPM PUMP

R.H. REAR JACK

CB

CB

L.H. REAR JACK

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NOTE If the mast elevator control valve for your drill is located on the upper valve bank, substitute the pipe rack hydraulic cylinder or any hydraulic cylinder operated by the upper bank. If your drill has no hydraulically operated cylinder operated from the upper bank, you may block off the hydraulic outlets for a control valve and operate that valve to stall out the system.

1)

With system stalled out, observe pressure indication on console hydraulic gauge for specified indication as shown for mast elevators in Table 8-1.

2)

As necessary, adjust relief valve associated with lower bank (Figure 8-8) to produce specified hydraulic pressure (Table 8-1).

c.

Leveling Jack Counterbalance. The counterbalance valves on the two rear jacks are fixed and normally require no adjustment. When changing valves, refer to manufacturer's information.

d.

Mast Elevator Counterbalance. The mast elevator cylinders each have a counterbalance cylinder. However, these valves are fixed and normally require no adjustment. When changing valves, refer to manufacturer's information.

3. GENERAL HYDRAULIC SYSTEM TROUBLESHOOTING. Table 8-4 is a troubleshooting guide for the general hydraulic system. The guide may be used as a cause/remedy chart for troubles encountered during operation or during pre-operation checks in the operators manual.

Useage of this chart should help locate common problems in the general hydraulic system.

4. GENERAL HYDRAULIC SYSTEM REPAIR. The normal field repair for a faulty hydraulic system component is replacement of the component.

However some of the components may be repaired under shop conditions.

In general, the repair procedures for purchased components are covered in the associated vendor manuals included in Part III. However, certain assembly/disassembly procedures are presented in the following topics.

8-23

~ ~

N N

I1

oc

3. Water pump will not operate

2. Mast elevator will not operate

1. Jack will not operate

PROBLEM/TEST

Check jack and repair as required (See Section 3)

Faulty jack

Check elevator cylinders and repair as required lSee Section 7)

Faulty valving or plumbing Faulty elevator cylinders

b. Hydraulic pressure normal

Check out valves and plumbing Check water pump motor by vendor specifica tions specifications

Problem in general hydraulic system Faulty valving or plumbing Faulty water pump motor

a. Hydraulic pressure low (Table 8-1) b. Hydraulic pressure normal

Perform Test No.6

Check out valves and plumbing

Problem in general hydraulic system

a. Hydraulic pressure low Cfable 8-1)

Tes t No. b Perform Test

Check out valves and plumbing

Faulty valving or plumbing

b. Hydraulic pressure normal

Perform Test No.6

CORRECTIVE ACTION

Problem in general hydraulic system

PROBABLE CONDITION

a. Hydraulic pressure low (Table 8-1)

TEST OBSERVATION

Table 8-4. General Hydraulics System Troubleshooting

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N N

I

00

5.

S. Winch does not operate

4. Dust Collector does not operate

PROBLEM/TEST

Check out valves and plumbing Check out cable and winch and unjam or repair per manufacturer's recommendations

Faulty valving or plumbing Winch mechanism frozen or jammed

b. Hydraulic pressure normal

Perform Test No.6

Check out dust collector mechanism and repair per manufacturer's instructions

Mechanism is jammed or frozen

Problem in general hydraulic system

Check dust collector motor and replace or repair

Faulty dust collector motor

a. Hydraulic pressure low

Check out valves and plumbing

Faulty valving or plumbing

b. Hydraulic pressure normal

Perform Tes t No.6

Check and free water pump. Replace if required

CORRECTIVE ACTION

Problem i~ general hydraulic system

Water pump has frozen

PROBABLE CONDITION

a. Hydraulic pressure low lTable LTable 8-1)

TEST OBSERVATION

Table 8-4. General Hydraulics System Troubleshooting lCont.)

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N

I

•

00

o. Hydraulic pres6. sure low

PROBLEM/TEST a. Is problem evidenced only when using elements operated from lower valve bank?

TEST OBSERVATION

Check upper bank relief valve, Topic 2a Check 3l GPM pump and repair or replace Check valving and plumbing

b. Faulty 32 GPM pump

c. Faulty valving or plumbing

Check lower bank relief valve setting as outlined in Topic 2b of this section

CORRECTIVE ACTION

a. Upper bank relief valve may be faulty

If answer is no:

If answer is yes, relief valve associated with lower valve bank is probably at fault

PROBABLE CONDITION

Table 8-4. General Hydraulics System Troubleshooting (Cont.)

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SECTION 9

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Section 9 ELECTRICAL SYSTEM SERVICE Electrical system service consists of troubleshooting the electrical system and replacing any faulty elements or wiring.

A.

ELECTRICAL SYSTEM TROUBLESHOOTING

Figure 9-1 is an electrical wiring diagram for the system during a Cummins engine and Figure 9-2 is a wiring diagram for the system using a Caterpillar engine. Should your drill unit be equipped with a Detroit Diesel engine, refer to the manufacturer's wiring diagram.

In the event of electrical problems, refer to the appropriate wiring diagram and isolate the electrical problem to a faulty element or wiring branch; then replace the element or wiring as required.

B.

ELECTRICAL SYSTEM COMPONENT REPLACEMENT

To replace electrical components or wiring refer to Section 9 of the Parts Manual for the component parts numbers or wire size.

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