CAT Rotary Track Drills QXR 1120 Surface Drill MAINTENANCE MANUAL - PDF DOWNLOAD

BI620146

QXR MAINTENANCE MANUAL

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SERVICE MANUAL (08/03/25)

I

Address:

Cubex Ltd. 1218 Redonda St., Box 13, Grp 524, RR5 Winnipeg, Manitoba Canada, R2C 2Z2

Phone:

(204) 694-5505

Website:

www.cubex.net

Main Fax:

(204) 633-0665

Parts Dept. Fax:

(204) 633-0678

Copyright © 2009 Printed in Canada

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SERVICE MANUAL (08/03/25)

II

Getting Familiar…

There are 8 sections.

Sections have modules for serviceable components.

Safety & Important Notices

Service Info

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SERVICE MANUAL (08/03/25)

III

Planning your PM program…

Read Section 1 and 2.

Read the first page of each module.

Look at each page for 3 to 5 seconds.

Review the sample PM Program Forms.

Plan your PM Program.

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TABLE OF CONTENTS (08/03/25)

I

Finding the Information…

Table of Contents (10268) Page

1.0

Introduction

1.1

Operating/Maintenance Safety

1-01-001

1.2

Safety Training Registration

1-02-001

1.3

Warranty & Claim Form

1-03-001

2.0

General Maintenance

2.1

Drill Assembly

2-01-001

2.2

Break-in Maintenance

2-02-001

2.3

PM Program

2-03-001

2.4

PM Schedules

2-04-001

3.0

Undercarriage

3.1

Track Adjustment

3-01-001

3.2

Final Drive

3-02-001

4.0

Feed Arrangement

4.1

Mast Feed System

4-01-001

4.2

Top Drive

4-02-001

4.3

Top Drive Motor

4-03-001

4.4

Breakout Wrench

4-04-001

4.5

Carousel Assembly

4-05-001

4.6

Expander Pin System

4-06-001

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TABLE OF CONTENTS (08/03/25)

II

5.0

Hydraulic System

5.1

Hydraulic Circuits

5-01-001

5.2

Hydraulic Symbols

5-02-001

5.3

Hydraulic Pump

5-03-001

5.4

Hydraulic Cylinders

5-04-001

5.5

Control Valves – On/Off Type

5-05-001

5.6

Motorized Pulldown & Holdback Control

5-06-001

5.7

Counterbalance Valves

5-07-001

5.8

Hydraulic Filtration

5-08-001

5.9

Proportional Valves

5-09-001

6.0

Drill Air Circuit

6.1

Air Schematic

6-01-001

6.2

Sullair Compressor

6-02-001

6.3

Water Pump

6-03-001

6.4

Grease Injection

6-04-001

7.0

Electrical

7.1

Electrical Circuits

7-01-001

7.2

Electrical Components

7-02-001

7.3

On/Off Valve Activation

7-03-001

7.4

Types of Valves

7-04-001

7.5

Testing of Valve Solenoid

7-05-001

7.6

Testing On/Off Valves

7-06-001

7.7

Proportional Valves

7-07-001

7.8

Fault Monitoring System

7-08-001

7.9

Accra-Feed System

7-09-001

7.10

Operator Interface PanelView 1000

7-10-001

7.11

QXR Canbus Electrical System

7-11-001

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TABLE OF CONTENTS (08/03/25)

III

8.0

Troubleshooting Guide

8.1

Troubleshooting the Tram Drive

8-01-001

8.2

Troubleshooting the Hydraulic System

8-02-001

8.3

Troubleshooting the Water Injection Pump

8-03-001

8.4

Troubleshooting the Air Driven Oil Injection Pump

8-04-001

8.5

Troubleshooting the Air Driven Grease Injection

8-05-001

8.6

Troubleshooting the Air Delivery System

8-06-001

8.7

Troubleshooting the Hammer

8-07-001

8.8

Troubleshooting the Drill Bit

8-08-001

8.9

Troubleshooting the Depth Laser

8-09-001

Appendix Sauer Danfoss Hydraulic Pumps

A

Caterpillar Undercarriage Owner’s Manual

B

Hydraulic Schematic

C

Air Schematic

D

Electrical General Arrangement

E

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1.0 INTRODUCTION (08/03/25)

1.0 INTRODUCTION This symbol warns of possible danger. Proceed with caution.

Module Date (Year/Month/Day) Page Number

Updating of Manual Updated modules will be issued for revisions and corrections as required.

Please keep your manuals updated.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-001

1.1 Operating/Maintenance Safety When operating this machine, the safety of the operating crew and other workers in the area must be the principal concern. All persons operating this machine must understand the necessary safety precautions to help minimize the risk of accidents and injury. The operator must ensure that all fire fighting equipment is in working order, inspect the condition of all walkways, handrails, ladders, and guards.

Personal Protection Equipment All safety equipment such as hardhat, steel cap boots, safety goggles, hearing protection, gloves, etc., should be worn while operating this machine.

Snug fitting clothing should be worn by the operator in and around the drill so as not to be caught up in any moving machinery.

Overhead and Buried Utilities Special precautions must be taken by everyone when using a drill rig in the vicinity of electrical power lines and other utilities. Underground electricity is as dangerous as overhead electricity. Be aware and always suspect the existence of underground utilities such as electrical power, gas, petroleum, telephone, sewer, and water.

Electricity can shock, burn and cause death.

•

Overhead and buried utilities should be located, noted, and emphasized on all holeboring location plans and hole-boring assignment sheets.

•

When overhead electrical power lines exist at or near a drilling site or project, consider all wires to be live and dangerous.

•

Watch for sagging power lines before entering a site. Do not lift power lines to gain entrance.

•

Before raising the drill rig mast on a site in the vicinity of power lines, walk completely around the drill rig. Determine what the minimum distance from any point on the drill rig to the nearest power line will be when the mast is raised and/or being raised. Do not raise the mast or operate the drill rig within a minimum of three (3) meters of any electrical power line or other obstruction.

•

Only move the drill rig with the mast down.

If there are any questions concerning the safety of drilling on sites in the vicinity of overhead power lines, call your supervisor.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-002

Ask for Assistance If a sign warning of underground utilities is located on a site boundary, do not assume that underground utilities are located on or near the boundary or property line under the sign; call the foreman and check it out. The underground utilities may be a considerable distance away from the warning sign.

Always contact the foreman before drilling. Determine jointly, with utility personnel, the precise location of underground utility lines. Mark and flag the location.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-003

1.1.1 Drill Operation and Maintenance Safety Read all safety instructions provided here and those provided in the Operator’s Manual before operating and servicing the drill. General safety and accident prevention regulations laid down by local authorities must also be followed.

1.1.2 General Safety Instructions 1. Observe all safety procedures when operating and servicing the equipment.

2. Be completely familiar with the operating and maintenance procedures before inspecting, operating, or servicing the drill or booster. You must read and understand all procedures described in each manual.

3. Do not inspect or repair any components without properly shutting down the drill, water pump, and air supply.

4. Keep all non-essential personnel away from the operator’s controls and the maintenance area while service work is in progress.

5. Any modifications to controls or operating procedures must be noted clearly on equipment and all operators must be advised of changes.

6. Inspect hoses, hose connection safety devices, fittings, and supply lines at frequent intervals for indication of wear or damage. Repair or replace damaged components immediately.

7. Check all bolts, nuts, and adjustments frequently for proper tension. Check all fluids at recommended intervals.

8. Do not stand under the mast at any time.

9. Disconnect the electrical power supply to the drill and booster before washing.

10. Wear protective gear when operating, diagnosing, or servicing the equipment.

11. Do not weld or grind near electrical wiring or supply lines.

12. Keep hands, clothing, rags, and tools away from moving parts.

13. Keep shields and guards in place. Do not operate equipment with the electrical panel door open.

14. Keep safety and instruction decals clean. Replace them if they are not clearly legible.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-004

1.1.3 Safety Instructions for Driving and Operating 1. Do not move the drill if it is in potentially unstable conditions or if visibility is obscured in any way.

2. Check for overhead restrictions and ground clearances before moving drill. Do not drive over electrical cable or pressurized hoses or allow any vehicles to do so at any time.

3. Check that all controls on the drill are in off positions before connecting the electrical power, mine air, and water supply line.

4. Check for any damage that might have occurred to the drill. Repair any damaged components immediately, before starting the drill.

5. Check the water hose for damage or leakage before starting the pump.

6. Restrain the water hose to minimize vibration of the hoses.

7. Check that personnel are clear of the drill before starting system. High pressure leaks from hydraulic, pneumatic, and water systems could result in injuries.

1.1.4 Safety Instructions for Servicing 1. Follow all service procedures at recommended intervals.

2. Before inspecting, disconnecting, or removing any hydraulic or mechanical components, secure the mast by placing it on solid ground or floor. Move the top drive assembly to the lowest position on the mast. Secure the mast with a hoist or restraining equipment. Follow proper shutdown procedures.

3. Make sure that the servicemen are in a dry and safe position when working with electrical circuits.

4. High-pressure leaks from hydraulic and pneumatic systems could result in injuries. Use protective gear when inspecting leaks.

5. Secure all moving components with proper restraining devices before removing or loosening any hydraulic components. This is to prevent components from shifting when hydraulic components lose pressure.

6. Relieve pressure from track tensioning system before servicing. Unscrew relief plug slowly to allow the high pressure grease to escape. Use extreme caution when working on tracks.

Keep fingers away from track shoes.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-005

7. Tag the drill and pump to prevent accidental start-up. Signs must be clearly visible to alert of service in progress.

8. Tag or mark hoses, wires, or components to assist in reinstallation.

9. Cap or plug all hydraulic or pneumatic connections immediately after removal.

10. Cap fluid ports to keep foreign material from entering components during servicing.

11. Clean grease fittings with a clean cloth before greasing.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-006

1.1.5 Warning, Caution, and Danger Decals Warning, Caution, and Danger decals are affixed to the applicable components or appropriate locations. Relevant safety instructions are written on the decals. Read these instructions carefully. Some of the main decals are illustrated below, along with safety instructions.

Observe the following safety instructions on the decals shown below BEFORE operating the drill: Mast Function Keep personnel away from the mast when positioning.

Decal is at control panel and valve controls.

Keep personnel away when performing mast set-up functions.

Pinch point.

Stay clear while operating.

Decal is at slide-over.

Rotating Drive Hazard Stay clear while operating.

Decal is at rotating components.

Decal is at compressor drive.

Do not operate without guard.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-007

Observe the following safety instructions on the decals shown below BEFORE servicing the drill:

Danger! Compressed Air! Relieve pressure from receiver before servicing.

Decal is at booster air receiver/drain valve.

Danger! Keep flames and sparks away from battery.

Danger! High pressure leaks may cause injury.

Danger! Outriggers and mast stingers can cause serious crushing injury – stand clear.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-008

1.1.6 Fluid and Filter Notices:

Fill with Hydraulic Fluid Only Decal is at hydraulic tank.

Fill with Rock Grease Only

Decal is at rock grease tank.

1.1.7 Safety Reminders:

Check that the drill is safe to work on.

Position mast on T-rest before moving drill.

Disengage torque hubs for towing.

Engage torque hubs to apply brakes.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-009

Perform this Safety Check before welding:

Disconnect electrical panel before doing any welding.

Perform these Safety Checks when completing maintenance:

Check that all hose fittings are tight.

Check that all pressurized air hoses are secured with hose connection safety devices.

Check that all controls are in the off position before connecting the power supply.

Check that all valves are in the off position before connecting the air system and power supply to the drill unit.

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1.1 OPERATING/MAINTENANCE SAFETY (08/03/25)

1-01-010

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Cubex's Safety Training Registration (95/09/14)

Joe

Cubex issues a Certificate to each person attending the Safety Program. Please photocopy this form, have each Student fill it out and return to Cubex.

Doe

Please print.

Name

Job Title

Company Address City

State

Zip

Be aware of the safety procedures when operating and servicing Drilling Equipment.

1. Safety symbols - Know the safety symbols.

- Know the operating and maintenance procedures.

5. Fluid leakage - Wear protective gear when investigating hydraulic leaks. High pressure jet streams may cut skin and result in injuries.

2. Compressed air system - Relieve the air pressure before servicing.

- Check that all air hoses are secured with safety chains.

- Keep away from hot compressor components.

6. Drilling - Use sufficient water to reduce inhaling of dust.

- Be cautious when using the breakout wrench to avoid injury.

3. Protective equipment - Wear safety glasses, ear protection, dust masks and proper clothing.

- Check that all guards are in place.

7. Equipment maintenance - Replace worn or damaged parts immediately.

Well-maintained equipment is required for maximum personal safety.

- Inspect the Ansul Fire Suppression System periodically if equipped with this option.

4. Operating precautions - Keeps hands away from moving components.

- Check that the path is clear before tramming.

- Check that personnel is away from drill while tramming or positioning.

- Check that the mine air supply hose and high voltage cable have free movement for tramming.

- Engage the torque hubs to apply brakes and disengage them for towing.

- Place the mast on T-rest before moving drill.

Safety . . .

It takes only a few seconds.

I fully understand these safety procedures and I will practice them to my best knowledge and ability.

Signature

Date

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WARRANTY CLAIM FORM - F102

CUBEX Ltd.

Phone: (204) 694-5505

Claim No.

Fax: (204) 633-0665

W-

1218 Redonda St., Box 13, Grp 524, RR5, Winnipeg, Manitoba, Canada, R2C 2Z2

2. Model

1. Distributor Distributor’s Claim No.

Serial No.

Owner

Hour Meter Reading

Page

of

3. Failure

Date

Cubex use only

Repair Date

Failure Description

Receiving Date Credit Memo No.

Failure Cause

Approved

Rejected

Comments Repair Procedures Followed

4. List Qty.

of Parts used Part No.

Cost Approval Description

Net Cost

Qty.

Part No.

Approved Cost

Total Parts

5. Labour

Claimed

Description of Repair

6.

Hours

Rate

Total

Hours

Rate

Total Labour Costs

Parts Returned

$

Total Parts

Comments

Sub-Total Exchange Rate

I certify that the parts and labour claimed for repair were used as indicated and that failure did not appear to have resulted due to negligence, misuse, accident and that the equipment was not altered without written permission from Cubex.

Total Credit Date App'd. by

Signature

Date

$

Th is e

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2.0 GENERAL MAINTENANCE (08/03/25)

2.0 GENERAL MAINTENANCE

READ INSTRUCTIONS BEFORE SERVICING OR OPERATING!

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2.1 DRILL ASSEMBLY (08/03/25)

2-01-001

2.1 Drill Assembly Refer to the Parts Manual for Part Numbers, Descriptions, and Parts Locations.

CAUTION! Be familiar with the operating procedures before operating the drill.

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2.1 DRILL ASSEMBLY (08/03/25)

2-01-002

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2.2 BREAK-IN MAINTENANCE (08/03/25)

2-02-001

2.2 Break-in Maintenance Preventative Maintenance Interval: At the first 50 hours The break-in maintenance is necessary to readjust some of the components after the initial wear. It also includes the regular Preventative Maintenance (PM) checks as well as changing the fluids.

CAUTION! Familiarize yourself with the PM procedures before performing the break-in maintenance.

General Inspection 1. Clean and wash the drill.

2. Perform the general maintenance procedures as outlined in Fig 2.3.1 (Section 2.3).

3. Change pressure filter and return filter.

4. Check for hydraulic leaks.

5. Check the complete drill for unusual indications.

6. Change crankcase oil in water pump. Use hydraulic fluid.

7. Check bearing pre-load on top drive (see Section 4).

8. Open the control panel and inspect wires, terminals, and conduits.

WARNING! By Qualified Electricians Only!

9. Refer to engine and compressor service manuals.

10. Inspect carousel for proper operation.

11. Perform a 250 Hour Inspection.

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2.2 BREAK-IN MAINTENANCE (08/03/25)

2-02-002

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2.3 PM PROGRAM (08/03/25)

2-03-03

2.3 Preventative Maintenance Program The PM program includes scheduled inspections and overhauling of drill components. Read this section carefully. PM Schedules are enclosed ready for photocopying.

This section contains the following: Lubrication Points and Intervals Lubrication Types/System Capabilities Lubrication Cross-over Table:

Refer to this table for approved fluid types

QXR Automatic Lubrication System Drill Filtration Points and Intervals Bolt Torque Table:

Refer to this table when no specific rating is given

Pipe Thread Grease Pump PM Schedules:

Service forms for 250, 1000, and 2000 hours

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2.3 PM PROGRAM (08/03/25)

2-03-04

15

7 2

13

9

10

14

8

3

5

9

11

12

6

4

Fig 2.3.1 Lubrication Points

1

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2.3 PM PROGRAM (08/03/25)

2-03-05

2.3.1 Lubrication Because of the severe operating conditions normally encountered in drilling operations, lubrication is very important. See the information on the following pages for lubrication instructions.

2.3.1.1 Rock Drill Grease Rock drill grease is used in the grease injection system for lubricating the hammer.

Please refer to Section 6.4 Grease Injection for information on the rock drill grease lubrication system.

2.3.1.2 Lubrication Points and Intervals Refer to Fig 2.3.1 and the following table for lubrication points and intervals.

Table 1 Lubrication Points and Intervals Key

Component

Type

Interval/Hrs

Service By

1

Water Pump Oil

Shell Tellus T-37

8

Operator

2

Rock Oil Tank

Rock Oil

8

Operator

Rock Grease Tank

Rock Grease

8

Operator

3

Top Drive Oil

SAE 80W-90

8

Operator

4

Torque Hub

SAE 80W-90

250

Maintenance

5

Air Swivel

Extreme Pressure Grease

250

Maintenance

6

Track Tension

Extreme Pressure Grease

250

Operator

7

Mast Boom Fittings

Extreme Pressure Grease

8

Operator

8

Cab Boom Fittings

Extreme Pressure Grease

8

Operator

9

Cylinder Pin

Extreme Pressure Grease

50

Operator

10

Intake Valve – Comp.

Extreme Pressure Grease

8

Operator

11

Osc. Pivot – Outside

Extreme Pressure Grease

8

Operator

12

Osc. Cylinder

Extreme Pressure Grease

8

Operator

13

Engine

Esso XD3 Extra 15W-40

8

Operator

14

Compressor

Esso XD3 Extra 10W

8

Operator

15

Osc. Pivot – Inside

Extreme Pressure Grease

8

Operator

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2.3 PM PROGRAM (08/03/25)

2-03-06

2.3.1.3 Lubrication Types The recommended lubricants and system capacities are listed below. Substitute lubricants must meet these specifications. Mixing different types of gear lubrication should be avoided.

Table 2 Lubrication Types/ System Capacities Equipment

Lubrication

Capacities

Engine Oil

SAE 5W-30 – low temperature

15.1 gal (57 ℓ)

SAE 15W-40 – high temperatures Top Drive

Gear Oil 80W-90 – low temperature

6.3 qts (6 ℓ)

SAE 140 – high temperatures Grease Tank

Esso AROX NM 000

8.4 gal (32 ℓ)

Hydraulic Tank

Esso NUTO H46

70 gal (265 ℓ)

Torque Hubs

Gear Oil SAE 80W-90

Half full 44 fl. oz. (1.3 ℓ)

Water Pump

Esso NUTO H46

40 fl. oz. (1.2 ℓ)

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2.3 PM PROGRAM (08/03/25)

2-03-07

2.3.1.4 Lubrication Cross-over Refer to this Cross-over Table for alternate suppliers. If these brands are unavailable, your local supplier will be able to recommend alternatives using these specifications.

Table 3 Lubrication Cross-over Fluid Type

Shell Oil

Esso (Mobil)

Petro-Canada

Mohawk

XD3 Extra 15W40 Engine Oil Spirax HD SAE 80W-90

Mobil HD 80W-90

Gear Lube 80W-90

Gearlube GL5 80/90 HP

Darina XLEP2

Mobilux

Precision EP2 EP102

N/A

Tellus T-37

Mobil NUTO H46

Harmony HVI-36

Mohawk V132

Madrela S46 or SAE 10W

Mobil RARUS 1024 or SAE 10W

N/A

N/A

Gear Oil

Grease

Hydraulic Oil

Compressor Oil

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2.3 PM PROGRAM (08/03/25)

2-03-08

2.3.1.5 QXR Automatic Lubrication System The Automatic Lubrication system installed in the Cubex QXR uses an air operated pump.

Operation is controlled by the QXR’s PLC. The system uses 59 SL32 and 10 SL1 injectors for grease delivery to lubrication points on the unit. These injectors are mounted together in banks of 2 to 6 depending upon location and the number of grease points in the area where the bank is mounted. Each injector is individually set to deliver the correct amount of grease to the point it is servicing, which depends on pin size and usage.

Refer to Fig 2.3.2 for injector bank location.

Lubricate all points every 8 hours.

Inspect pins and/or bushings at all points marked every PM (250 hours).

Mast

Mast Boom

Cab Boom

Grease Pump

Frame

Fig 2.3.2 Injector Bank Locations

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2.3 PM PROGRAM (08/03/25)

2-03-09

Asco Valve

Grease Pump Asco Valve allows air to the pump…

Grease flows from the pump to the mast boom and the frame…

Frame

Mast Boom

and to the mast and the cab boom…

Mast

Cab Boom until the preset pressure has been reached, then the pressure switch automatically shuts down the system.

Pressure Switch – located on the mast

Fig 2.3.3 Auto-Lube operation

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2.3 PM PROGRAM (08/03/25)

2-03-010

Panelview Settings The settings for the Auto-Lube system are through the Panelview display.

1. Touch the Config button on any screen to access the Password screen. Refer to Fig 2.3.4 and Fig 2.3.5.

Config button

Fig 2.3.4 Config button on drilling screen

Press the Password button

Fig 2.3.5 Password screen

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2.3 PM PROGRAM (08/03/25)

2-03-011

2. Press the Password button (see Fig 2.3.5); this will bring up two options, Config Password and Admin Password. See Fig 2.3.6.

Press the Config Password button

Fig 2.3.6 Config Password and Admin Password 3. Press the Config Password button and a keypad will appear on your screen. Enter 129124 and press the Accept button. 129124 is the standard password. Refer to Fig 2.3.7.

Password display

Accept button

Fig 2.3.7 Keypad

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2.3 PM PROGRAM (08/03/25)

2-03-012

4. Several new options will appear on the left side of the screen. For the Auto-Lube settings, press the Lube/Grease/Water button. See Fig 2.3.8.

Press the Lube/Grease/ Water button

Fig 2.3.8 New options 5. Once inside the Lube/Grease/Water screen, you can select from three Auto-Lube options; Chassis Grease On Time, Chassis Grease Off Time, and Chassis Grease Settings. Press the Chassis Grease Settings button to open the Auto Cycle and the One Cycle options. See Fig 2.3.9.

Pressing the Auto-Cycle button will cause the system to run automatically with the settings provided in the Chassis Grease On Time and the Chassis Grease Off Time screens.

Pressing the One Cycle button will cause the system to run through one cycle only. This is generally done for troubleshooting and maintenance purposes.

Other options are available in this screen; however only the Chassis Grease On Time, Chassis Grease Off Time, and Chassis Grease Settings buttons relate to the Auto-Lube system.

Auto-Lube options

Press the Chassis Grease Settings button to open the Auto-Cycle and One Cycle options.

Fig 2.3.9 Lube/Grease/Water screen

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2.3 PM PROGRAM (08/03/25)

2-03-013

6. Press the Chassis Grease On Time button to set the maximum on time for the Auto-Lube cycle. The keypad will open; use it to input your settings. See Fig 2.3.10.

Press the Chassis Grease Off Time to set the off time for the Auto-Lube cycle. Again, use the keypad to input your settings. See Fig 2.3.11.

The Chassis Grease On Time screen and the Chassis Grease Off Time screen are virtually identical. Ensure you are in the correct screen for the time you are setting; the active button will be outlined in green (refer to Fig 2.3.10 and 2.3.11).

Active button

Fig 2.3.10 Chassis Grease On Time screen

Active button

Fig 2.3.11 Chassis Grease Off Time screen

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2.3 PM PROGRAM (08/03/25)

2-03-014

Alarms The Auto-Lube system uses a pressure switch to control the length of the grease cycle. Once the pressure switch detects the system at the preset pressure, the system is automatically shut down until the next cycle. If the preset pressure has not been reached by the maximum on time (set in the Chassis Grease On Time screen – see Fig 2.3.10), the system will shut down and your screen will show an error (the error button will be outlined in red). See Fig 2.3.12.

Example – the applicable error will be outlined in red

Reset button Error button outlined in red

Fig 2.3.12 Error indicated

Press the error button to open the error message screen. The applicable error will be outlined in red.

Investigate and correct the error. Once completed, press the Reset button to resume normal operations.

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2.3 PM PROGRAM (08/03/25)

2-03-015

Setting the Air Pressure for the Grease Pump The air pressure that operates the grease pump should be regulated to 70 psi (4.8 bar). A regulator is located on the right side of the grease pump. Turning the handle clockwise on the regulator will increase the pressure setting. The gauge on top will display the pressure setting for the regulator.

Pressure Gauge

Regulator

Grease Pump

Fig 2.3.13 Grease Pump Regulator and Pressure Gauge

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-016

Setting the Pressure Switch The pressure switch for the Auto-Lube system is located at the bottom of the mast (see Fig 2.3.14).

Pressure Switch

Fig 2.3.14 Pressure Switch location The pressure switch should be set to 2400 psi (165.5 bar). Refer to Fig 2.3.15 and Fig 2.3.16 Switch is provided with scale showing both psi and bar

Remove protective cap

To adjust the pressure setting of the switch, turn the self-locking adjustment screw clockwise (to decrease) and counter-clockwise (to increase).

Fig 2.3.15 Step 1

Fig 2.3.16 Step 2

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-017

Adjusting the SL1 Injectors The locknut must be loosened to make the adjustment. Turning the adjustment screw in (clockwise) will decrease the displacement of the injector (see Fig 2.3.17).

The SL1 injectors are located on the frame (see Fig 2.3.18). These injectors are set at one turn out from the minimal setting, which displaces approximately 0.012 in3 of grease per cycle.

Adjustment Screw

Locking Nut

Fig 2.3.17 SL1 Injectors

Fig 2.3.18 Injectors on Frame

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-018

Adjusting the SL32 Injectors The locknut must be loosened to make the adjustment. Turning the adjustment cap in (clockwise) will decrease the displacement of the injector. Refer to Fig 2.3.19. Output with the adjustment cap hand tightened is 0.001 in3. Maximum output is achieved with five turns clockwise at 0.0014 in3 per turn.

The SL32 injectors are located on the mast, the mast boom, and the cab boom (see Fig 2.3.20, Fig 2.3.21, and Fig 2.3.22). These injectors are set at the maximum setting, which displaces approximately 0.008 in3 of grease per cycle.

Adjustment Cap

Locking Nut

Fig 2.3.19 SL32 Injectors

Fig 2.3.20 Injectors on Mast Boom

Fig 2.3.21 Injectors on Mast

Fig 2.3.22 Injectors on Cab Boom

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-019

2.3.2 Bolt Torque Use these ratings when no specific torque rating is specified.

Prevailing torque rating is the torque necessary to rotate a fastener after the mating components are in full contact. These torque ratings are for dry threads.

Table 4 - BOLT TORQUE TABLE Coarse and Fine Threads, Grade 8 Bolt Diameter

Torque (ft.-lbs.)

Torque (N-m)

1/4 - 20 1/4 - 28 5/16 – 18 5/16 – 24 3/8 – 16 3/8 – 24 7/16 – 14 7/16 – 20 1/2 – 13 1/2 – 20 9/16 – 12 9/16 - 18 5/8 – 11 5/8 – 18 3/4 – 10 3/4 – 16 7/8 – 9 7/8 – 14 1–8 1 – 14

12 14 24 27 44 49 70 78 105 120 155 170 210 240 375 420 605 675 910 990

16 19 33 37 60 66 95 106 142 163 210 230 285 325 508 570 820 915 1230 1340

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-020

4 2

3

12 6

10

11

8

13

5

1

7

14

Fig 2.3.8 Drill Filtration

9

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-021

2.3.3 Drill Filtration Points and Intervals Refer to Fig 2.3.8 and the following table for filtration points and intervals.

Table 5 Drill Filtration Key

Filter Type

Intervals

Service

250 Hours 250 Hours 250 Hours 2000 Hours

Maintenance Maintenance Maintenance Maintenance

250 Hours 250 Hours 250 Hours 8 Hours 250 Hours

Maintenance Maintenance Maintenance Operator Maintenance

250 Hours 250 Hours

Maintenance Maintenance

250 Hours

Operator

1000 Hours

Operator

2000 Hours

Operator

2000 Hours

Maintenance

Cummins Engine 1 2 3 4

Air Filter – Primary/Secondary (2) Engine Oil Filters (2) Fuel / Water Separators (2) Coolant Element

Compressor 5 6 7 8

Air Filter Main Fluid Filter Moisture Separator Filter Drain the moisture separator Oil Separator

Hydraulics 9 10

Hydraulic Pressure Filters (2) Hydraulic Return Filter

Cab Pressurizer 11

Air Filter – Primary

Grease Injection 12

Moisture Separator Element

Air Conditioner 13

Clean or replace filter screens

Water Strainer (2) 14

Clean or replace strainer

NOTE: Water Strainer filters are different sizes (100 microns and 200 microns).

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-022

2.3.4 Pipe Thread Grease Pump Preventative Maintenance Tasks At the first 50 hours:

Clean and inspect pump.

1000 Hour Intervals:

Cleaning and visual inspection. Replace worn parts.

Grease Pump Specifications

Pressure Ratio:

50:1

Air Pressure:

Min 80 psi

Maximum Output Pressure:

4000 psi

Delivery Output:

0.55 cu.in. (8 ccm)/cycle

Fig 2.3.14 Pipe Thread Grease Pump

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-023

2.3.4.1 Safety Adequate personal protection is recommended to prevent splashing of material on the skin or in the eyes. ALWAYS disconnect air coupler from the pump when the pump is not being used.

WARNING! To reduce the risk of injury from splashing or static sparking when flushing the pump with solvents, always hold a metal part of the dispensing valve firmly to the side of a grounded metal pail and operate pump at lowest possible fluid pressure.

Perform the following Pressure Relief Procedure before checking, servicing, installing, cleaning or repairing any part of this system: 1. Disconnect the air supply to the pump.

2. Point the dispensing valve away from yourself and others.

3. Open the dispensing valve into an appropriate container until pressure is relieved.

WARNING! Failure to heed the following warnings, including misuse, overpressurizing, modifying parts using incompatible chemicals and fluids, or using worn or damaged parts, may result in equipment damage and/or serious personal injury, fire, explosion, or property damage.

Do not exceed the stated maximum working pressure of the pump, or of the lowest rated component in your system.

Do not alter or modify any part of this equipment.

Do not operate this equipment with combustible gas.

Do not attempt to repair or disassemble the equipment while the system is pressurized.

Make sure all grease connections are securely tightened before using this equipment.

Always read and follow the grease manufacturer’s recommendations regarding grease compatibility, and the use of protective clothing and equipment.

Check all equipment regularly and repair or replace worn or damaged parts immediately.

Never point the dispensing valve at any part of the body or at another person.

BI620146

2.3 PM PROGRAM (08/03/25)

2-03-024

Never try to stop or deflect material from dispensing valve or leading connection or component with your hand or body.

Always check equipment for proper operation before each use, making sure safety devices are in place and operating properly.

Always follow the pressure relief procedure after shutting off the pump, when checking or servicing any part of the system, and when installing, cleaning or changing any part of the system.

2.3.4.2 Maintenance An air line filter/regulator/lubricator is recommended for use with pump to remove harmful dirt and moisture from your compressor air supply, and to provide automatic air motor lubrication.

If an air line lubricator is not used, the following procedure should be performed daily: 1. Disconnect air coupler from air fitting.

2. Fill air coupler with No 10 SAE motor oil and reconnect to air fitting.

3. Operate pump to distribute lubricant.

To prevent water or air corrosion, never leave the pump filled with water or air. Flush the pump first with a compatible solvent and then again with mineral spirits or oil based solvent.

Repair is limited to replacement of listed service parts. Special procedures and tools are required.

BI620146

2.4 RECOMMENDED TOOLS (08/03/25)

2-04-001

2.4 Recommended Tools: •

Standard Allen wrench set & metric Allen wrenches

•

Pliers - needle nose, vise grip, channel lock, sidecutters

•

Standard screwdrivers - 1 large, 1 small, 1 straight & 1 Phillips

•

Hammer

•

Tape Measure

•

Punch, chisel, pry bar

•

14” Pipe wrench & 24” pipe wrench

•

8” Crescent wrench

•

12” Crescent wrench

•

3/8 Drive ratchet set, sockets - 1/2, 9/16, 5/8, 3/4

•

3/8 x 6 Extension

•

1/2 Drive ratchet set, sockets - 9/16, 3/4, 15/16, 1-1/8

•

1/2 x 6 Extension

•

Multi-meter

•

Combination wrench set - 7/16, 1/2, (2) 9/16, 5/8, 11/16, 3/4, 7/8, 15/16, 1-1/8, 1-1/4, 1-3/8, 1-1/2

•

O-ring Pack

•

Gasket scraper

•

Knife

•

Torque wrench

•

Preload tool

•

CT16208-WH21 Saver Sub Breakout Wrench Holding Tool #21 Thread

•

CT16208-WH24 Saver Sub Breakout Wrench Holding Tool #24 Thread

•

CT16208-WH28 Saver Sub Breakout Wrench Holding Tool #28 Thread

•

CT16208-WH30 Saver Sub Breakout Wrench Holding Tool RB30 Thread

BI620146

2.4 RECOMMENDED TOOLS (08/03/25)

2-04-002

BI620146

250 Hour

Work Order # ______________________

Unit __________________________

Serial # _______________________

Hour Meter ________________________

Date __________________________

By ___________________________

PM Schedule QXR Drill Main Assemblies / Actions: General:

Service Codes: Clean, wash

Track Assembly Track tension

Adjust:

Service Codes: Grease lubrication Water pump coupling

Extreme Pressure Grease

Cylinder pins

Extreme Pressure Grease

Feed extension pins

Extreme Pressure Grease

Air swivel – top drive

Extreme Pressure Grease

Drive Train Hydraulic brakes

Inspect:

Seals

Fluid Inspection

Test:

Brakes

Torque hubs

Gear Lube SAE 80W-90

Tramming motor

Inspect:

Seals

Hydraulic tank

ESSO NUTO H46 or equal

Torque hub

Inspect:

Seals

Compressor

MOBIL 10W or equal

Engine

See Cummins Manual

Gear Triple

Gear Lube SAE 140 high temp 80W90 low temp

Mast Mast boom

Inspect:

Bushings, pins

Mast connection

Inspect:

Bushings, pins

Fluid Changes

Cab boom

Inspect:

Bushings, pins

Top drive

Gear Lube SAE 140 high temp 80W90 low temp

Jib boom

Inspect:

Pulleys, pivot joint

Water pump

ESSO NUTO H46 or equal

Chain Feed

Inspect:

Pulleys, bushings, chain

Engine

See CAT/Cummins manual

Carousel

Inspect:

Wear liner, bearings, bushings

Adjust:

Arm, clamp pressure

Miscellaneous

Wear guide

Inspect:

Under top drive mounting plate

Control gauges

Sliders

Inspect:

Sliders and guide bars for wear

Adjust:

Lower Mast

@ Top drive mounting plate

Electrical

@ Carrier block

Electrical panels:

Inspect: for proper operation

Inspect wires, terminals, conduits, joysticks

Inspect:

Clevises, pins

Inspect:

Cylinders, centralizer jaws

Filter Changes

Top drive

Adjust:

Bearing pre-load

QTY

Description

Top drive motors

Inspect:

Seals

2

Engine Oil Filter

Centralizer

Inspect:

Remove debris

2

Primary Fuel Filter

Boom expander pins

Inspect:

6 points; refer to Maint. Manual

A/R

Primary Engine Air Filter

Hydraulic Circuit Hydraulic pump

Inspect:

Seals, hoses, fittings

Cylinders

Inspect:

Seals, rods

Inspect:

Air hoses, fittings, hose safety devices

Part Number

A/R

Secondary Engine Air Filter

1

Compressor Oil Filter

Air Circuit Air hoses

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Cummins Engine

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector (if equipped)

N – See Note

Refer to the Parts Manual

BI620146

BI620146

500 Hour

Work Order # _____________________

Unit _________________________

Serial # ______________________

Hour Meter _______________________

Date _________________________

By ___________________________

PM Schedule QXR Drill Main Assemblies / Actions: General:

Service Codes: Clean, wash

Track Assembly Track tension

Adjust:

Service Codes: Grease lubrication Water pump coupling

Extreme Pressure Grease

Cylinder pins

Extreme Pressure Grease

Feed extension pins

Extreme Pressure Grease

Air swivel – top drive

Extreme Pressure Grease

Drive Train Hydraulic brakes

Inspect:

Seals

Fluid Inspection

Test:

Brakes

Torque hubs

Gear Lube SAE 80W-90

Tramming motor

Inspect:

Seals

Hydraulic tank

ESSO NUTO H46 or equal

Torque hub

Inspect:

Seals

Compressor

MOBIL 10W or equal

Engine

See Cummins Manual

Gear Triple

Gear Lube SAE 140 high temp 80W90 low temp

Mast Mast boom

Inspect:

Bushings, pins

Mast connection

Inspect:

Bushings, pins

Fluid Changes

Cab boom

Inspect:

Bushings, pins

Top drive

Jib boom

Inspect:

Pulleys, pivot joint

Water pump

ESSO NUTO H46 or equal

Chain Feed

Inspect:

Pulleys, bushings, chain

Engine

See CAT/Cummins manual

Carousel

Inspect:

Wear liner, bearings, bushings

Adjust:

Arm, clamp pressure

Miscellaneous

Wear guide

Inspect:

Under top drive mounting plate

Control gauges

Sliders

Inspect:

Sliders and guide bars for wear

Adjust:

Lower Mast

@ Top drive mounting plate

Electrical

@ Carrier block

Electrical panels:

Gear Lube SAE 80W90

Inspect: for proper operation

Inspect wires, terminals, conduits, joysticks

Inspect:

Clevises, pins

Inspect:

Cylinders, centralizer jaws

Top drive

Adjust:

Bearing pre-load

QTY

Description

Top drive motors

Inspect:

Seals

2

Hydraulic Pressure Filter

Centralizer

Inspect:

Remove debris

2

Hydraulic Return Filter

Boom expander pins

Inspect:

6 points; refer to Maint. Manual

Hydraulic Circuit

Filter Changes

2

Engine Oil Filter

2

Primary Fuel Filter

Part Number

1

Engine Water Filter

Hydraulic pump

Inspect:

Seals, hoses, fittings

A/R

Primary Engine Air Filter

Cylinders

Inspect:

Seals, rods

A/R

Secondary Engine Air Filter

1

Compressor Oil Filter

Air Circuit Air hoses

Inspect:

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Air hoses, fittings, hose safety devices Cummins Engine

1

Moisture Separator Element Control Circuit

1

Moisture Separator Element – Accessory Circuit

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector (if equipped)

N – See Note

Refer to the Parts Manual

BI620146

BI620146

1000 Hour

Work Order # ____________________

Unit ________________________

Serial # _______________________

Hour Meter ______________________

Date ________________________

By ____________________________

PM Schedule QXR Drill Main Assemblies / Actions: General:

Service Codes: Clean, wash

Track Assembly Track tension

Service Codes: Air Circuit Air hoses

Inspect: Air hoses, fittings, hose safety devices

Rock oil pump

Inspect: Seals

Adjust: Grease lubrication

Drive Train Seals

Water pump coupling

Extreme Pressure Grease

Cylinder pins

Extreme Pressure Grease

Hydraulic brakes

Inspect: Test:

Brakes

Feed extension pins

Extreme Pressure Grease

Tramming motor

Inspect:

Seals

Air swivel – top drive

Extreme Pressure Grease

Torque hub

Inspect:

Seals Fluid Changes

Mast

Top drive

Gear Lube SAE 80W90 ESSO NUTO H46 or equal

Mast boom

Inspect:

Bushings, pins

Water pump

Mast connection

Inspect:

Bushings, pins

Compressor

MOBIL 10W or equal

Cab boom

Inspect:

Bushings, pins

Engine

See CAT/Cummins Manual

Jib boom

Inspect:

Pulleys, pivot joint

Gear Triple

Gear Lube SAE 140 high temp 80W90 low temp

Chain Feed

Inspect:

Pulleys, bushings, chain

Carousel

Inspect:

Wear liner, bearings, bushings

Miscellaneous

Adjust:

Arm, clamp pressure

Control gauges

Inspect:

Under top drive mounting plate

Inspect:

Sliders and guide bars for wear

Electrical

Adjust:

@ Top drive mounting plate

Electrical panels:

Wear guide Sliders

Inspect: for proper operation

Inspect wires, terminals, conduits, joysticks

@ Mast connection plate @ Carrier block

Filter Changes

Chain tensioners

Inspect:

Springs and bushings

QTY

Description

Lower Mast

Inspect:

Clevises, pins

2

Hydraulic Pressure Filter

Inspect:

Cylinders, centralizer jaws slip plate flats, drill table

2

Hydraulic Return Filter

Top drive

Top drive motors

Inspect:

Bearing pre-load

2

Engine Oil Filter

Adjust:

Bearing pre-load

2

Primary Fuel Filter

Part Number

Torque:

Mtg. Plate bolts

1

Engine Water Filter

Inspect:

Seals

A/R

Primary Engine Air Filter Secondary Engine Air Filter

Torque:

Motor Bolts

A/R

Centralizer

Inspect:

Remove debris

1

Compressor Oil Filter

Boom expander pins

Inspect:

6 points; refer to Maint. Manual

1

Moisture Separator Element Control Circuit

1

Moisture Separator Element – Accessory Circuit

Hydraulic Circuit Hydraulic pump

Inspect:

Seals, hoses, fittings

Cylinders

Inspect:

Seals, rods

Control valves

Inspect:

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Seals Cummins Engine

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector (if equipped)

N – See Note

Refer to the Parts Manual

BI620146

BI620146

2000 Hour

Work Order # ____________________

Unit __________________________

Serial # ________________________

Hour Meter ______________________

Date __________________________

By _____________________________

PM Schedule QXR Drill Main Assemblies / Actions: General:

Service Codes: Clean, wash

Service Codes: Cylinders Control valves

Track Assembly Track links

Track roller

Air Circuit

Idler wheel

Idler wear

Air hoses

Drive sprocket

Sprocket wear Adjust

Drive Train Hydraulic brakes

Seals, rods

Inspect

Seals

Check

For proper installation

Inspect

Air hoses, fittings, hose safety devices

Link wear

Track rollers

Track tension

Inspect

Water Pump

Perform

Pressure test clean strainer

Rock Oil Pump

Inspect

Seals

Grease lubrication Inspect

Seals

Water pump coupling

Extreme Pressure Grease

Test

Brakes

Cylinder pins

Extreme Pressure Grease

Tramming motor

Inspect

Seals

Feed extension pins

Extreme Pressure Grease

Torque hub

Inspect

Seals

Air swivel – top drive

Extreme Pressure Grease

Mast boom

Inspect

Bushings, pins

Hydraulic tank

ESSO NUTO H46 or equal

Mast connection

Inspect

Bushings, pins

Top drive

Gear Lube SAE 80W90

Cab boom

Inspect

Bushings, pins

Water pump

ESSO NUTO H46 or equal

Jib boom

Inspect

Pulleys, pivot joint

Compressor

Mobil 10W or equal

Chain Feed

Inspect

Pulleys, bushings, chain

Engine

See Cummins Manual

Carousel

Inspect

Wear liner, bearings, bushings, drive

Gear Triple

Gear Lube SAE 140 high temp 80W90 low temp

Adjust

Arm, clamp pressure

Wear guide

Replace

Under top drive mounting plate

Miscellaneous

Sliders

Inspect

Sliders and guide bars for wear

Control gauges

Adjust

@ Top drive mounting plate

Mast

Fluid Changes

@ Mast connection plate

Electrical

@ Carrier block

Electrical panels:

Inspect: for proper operation

Electrical panels:

Chain tensioners

Inspect

Springs and bushings

Lower Mast

Inspect

Cylinders, centralizer jaws slip plate flats, drill table

Replace

Clevises, pins

Top drive

Inspect

Bearing pre-load

QTY

Description

Part Number

Adjust

Bearing pre-load

2

Hydraulic Pressure Filter

Torque

Mounting Plate bolts

2

Hydraulic Return Filter

2

Engine Oil Filter

Refer to the Parts Manual

Torque

Motor Bolts

2

Primary Fuel Filter

Inspect

Seals

1

Engine Water Filter

Top drive motors

Filter Changes

Centralizer

Inspect

Remove debris

A/R

Primary Engine Air Filter

Boom expander pins

Inspect:

6 points; refer to Maint. Manual

A/R

Secondary Engine Air Filter

1

Compressor Oil Filter

1

Moisture Separator Element Control Circuit

Hydraulic Circuit Hydraulic pump

Inspect

Seals, hoses, fittings

1

Moisture Separator Element – Accessory Circuit

Inspect

Operating pressure

1

Receiver Tank Separator Element

Standby pressure Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Cummins Engine

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector (if equipped)

N – See Note

BI620146

BI620146

3.0 UNDERCARRIAGE (08/03/25)

3.0 UNDERCARRIAGE

USE PROPER LIFTING EQUIPMENT!

BI620146

BI620146

3.1 TRACK ADJUSTMENT (08/03/25)

3-01-001

3.1 Track Adjustment Track tension is maintained by pressurizing the track-tensioning cylinder with grease. Adjust the track tension every 250 hours as follows: 1. Move drill to level ground and position track links as shown in Fig 3.1.1.

2. Place straight edge on middle section of track assembly and measure sag.

3. Add extreme pressure grease to fill valve until sag is 3/8" (10 mm) to 1/2" (12 mm).

WARNING! Use relief plug to discharge pressure in track tensioning cylinder before removing or servicing any track components.

Relief Plug Fill Valve

Fig 3.1.1 Track Adjustment

BI620146

3.1 TRACK ADJUSTMENT (08/03/25)

3-01-002

BI620146

3.2 FINAL DRIVE (08/03/25)

3-02-001

3.2 Final Drive For information on the Caterpillar Final Drive, refer to the Caterpillar Industrial Products, Inc. Support Literature Owner’s Manual (located in Appendix B).

Fig 3.2.1 Final Drive

BI620146

3.2 FINAL DRIVE (08/03/25)

3-02-002

BI620146

4.0 FEED ARRANGEMENT (08/03/25)

4.0 FEED ARRANGEMENT

DANGER! Keep personnel away from drill while operating!!

BI620146

BI620146

4.1 MAST FEED SYSTEM (08/03/25)

4-01-001

4.1 Mast Feed System PM Tasks A visual inspection of the cylinder rods is necessary to locate pitting or damage to the surfaces.

Damaged rod surfaces collect foreign matter that enters the hydraulic system.

Adjustment of the sliders on the top drive mounting plate, mounting plate and carrier block are required to eliminate excessive play.

50 Hour Intervals:

•

Inspect slider adjustment, zero clearance is required

250 Hour Intervals:

•

Adjust sliders at top drive mounting plate and carrier block

•

Inspect cylinder rods for wear indications

•

Inspect wear guides

•

Adjust sliders on mast connection plate and carrier block

•

Torque top drive mounting bolts

•

Inspect chain tensioners and bushings

•

Inspect guide bars

•

Inspect wear guides

•

Check feed cylinder for by-pass

•

Replace wear guide

•

Inspect chain tensioners, bushings and idlers

1000 Hour Intervals:

2000 Hour Intervals:

WARNING! Secure or support mast before removing any components or loosening hydraulic fittings.

BI620146

4.1 MAST FEED SYSTEM (08/03/25)

4-01-002

Top Drive Mounting Plate Inspect gap and clearance

¾ NC Hex Capscrew Torque to 375 ft-lbs (508 N-m) ½ NC Hex Capscrew Torque to 105 ft-lbs (142 N-m)

Inspect gap and clearance

Inspect wear guide under mounting plate

¾ NC Setscrew

Tighten bolts every 250 hours Mast Connection Plate

Guide Bar

Inspect gap and clearance

Slip Plate

Fig 4.1.1 Mast Feed System

BI620146

4.1 MAST FEED SYSTEM (08/03/25)

4-01-003

4.1.1 QXR Feed Chain Adjustment

1” to 2” of sag from centerline of mast

Fig 4.1.2 Feed Chain Tension To achieve proper tension of the feed chains both must be adjusted so there is 1” to 2” of sag in each chain at mid point on the mast as shown above. This is accomplished by adjusting the tension of each chain with its corresponding tension block. Ideally, the tension adjustment should be made evenly across both tension adjusters. This is to prevent over-tensioning of the adjusters and collapsing the springs, which are needed to cushion the feed chain.

NOTE: Under normal operating conditions the chain will stretch over time. Once the chain has stretched beyond the limit of the adjusters, individual links can be removed from either chain to bring them back to a normal adjustable length.

BI620146

4.1 MAST FEED SYSTEM (08/03/25)

4-01-004

4.1.1.1 Top Chain Adjustment Refer to Fig. 4.1.3 1. Move top drive to bottom of mast.

WARNING! Make sure equipment is shut off before making adjustments.

2. Back off locking nut.

3. Turn adjusting nut clockwise to tighten chain.

4. Do not collapse tension springs completely as they are needed to cushion the chain.

5. If more chain tension is required, it can be made up with the other tension adjuster. The adjustment should be made evenly between both tension adjusters.

6. Tighten locknut against adjusting nut once proper chain tension is achieved.

Remove access plate

Locknut

Adjusting screw

Fig 4.1.3 Top Chain Adjustment

BI620146

4.1 MAST FEED SYSTEM (08/03/25)

4-01-005

4.1.1.2 Bottom Chain Adjustment Refer to Fig. 4.1.4 1. Move Top drive to bottom of mast.

WARNING! Make sure equipment is shut off before making adjustments.

2. Back off locking nut.

3. Turn adjusting nut clockwise to tighten chain.

4. Do not collapse tension springs completely as they are needed to cushion the chain.

5. If more chain tension is required, it can be made up with the other tension adjuster. The adjustment should be made evenly between both tension adjusters.

6. Tighten locknut against adjusting nut once proper chain tension is achieved.

Adjusting screw

Locknut

Fig 4.1.4 Bottom Chain Adjustment

BI620146

4.1 MAST FEED SYSTEM (08/03/25)

4-01-006

4.1.2 Slider Adjustment Periodic adjustments of the sliders is required to keep the top drive mounting plate, mast connection plate and carrier block parallel to the guide bars. The purpose of these adjustments is to maintain zero clearance between the sliders and the guide bars by adjusting the setscrews.

Refer to Fig. 4.1.5 Procedures for top drive mast connection plate 1. Rotate mast to vertical position. Move top drive mounting plate and mast connection plate to bottom of mast. Ensure that these are in lowest position.

2. Inspect gap settings as shown below, at all four corners of plate assembly.

3. Turn all setscrews an equal amount until no clearance exists between sliders and guide bars. Ensure that mounting plate is parallel to guide bars.

4. Turn all setscrews 1/4 turn to create a snug sliding fit. Tighten lock nuts.

5. Torque top drive mounting bolts to 375 ft.-lbs. (508 N m) 6. Move top drive mounting plate and mast connection plate up and down. Inspect sliders for zero clearance.

Wear Guides At the specified intervals, inspect and replace the wear guides, which are located under the top drive mounting plate. ¾” set screws

Wear Guide

Equal gaps at left, right, top, and bottom

Equal gaps at left, right, top, and bottom

Guides

Slider

Fig 4.1.5 Wear Guides

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4.1.3 Carrier Block Refer to Fig. 4.1.6 1. Bring the mast to horizontal position and align the carrier block with the opening on the mast.

2. Inspect gaps between sliders (item 6) and adjuster wedges (item 4).

3. Turn the setscrews (item 18) on equal amount until no clearance exists between sliders and guide bars.

4. Move the carrier block back and forth by cylinder for few times. Inspect the gaps again and tighten the screws if necessary. Tighten the lock nuts.

Section of slider housing

Fig 4.1.6 Carrier Block

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4.1.4 Feed Chain Block Periodic inspection of the feed chain, idlers, and pins are required as shown in Fig 4.1.7.

INSPECT EVERY 250 HOURS UNLES NOTED. Refer to Fig. 4.1.7

Check idler, pin, and guides

Check spring, bushing, and chain tension Carrier Block

Tighten as required

Check spring, bushing, and chain tension Tighten as required Feed Cylinder

Check idler, pin, and guides Every 8 hours, clear cuttings and debris from idler

Fig 4.1.7 Feed Chain Block

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4.1.5 Jib Boom Inspect Jib Boom every 250 hours.

Refer to Fig 4.1.8 1. Inspect cylinder pins and cylinder Arm

2. Apply grease to nipple; check for excessive leaking

3. Inspect sheaves and spacer washers

4. Apply grease to nipple; check for excessive leaking

5. Check for excessive play in swivel joint by wiggling arm

6. Inspect winch cable; replace as required

Fig 4.1.8 Jib Boom

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4.1.6 Triple Jaw Breakout (TJBO) PM Tasks The Triple Jaw Breakout (TJBO) requires minimal servicing but the cylinders and clevis pins need to be inspected.

250 Hour Intervals:

1000 Hours Intervals:

•

Inspect cylinders

•

Remove debris from centralizer tube

•

Inspect centralizer jaws and inserts

•

Inspect cylinder clevises and pins

•

Inspect centralizer jaws and inserts

•

Inspect drill table

Breakout Jaws

Vise Jaws

Centralizer Jaws

Fig 4.1.9.a Triple Jaw Breakout (TJBO)

Fig 4.1.9.b Triple Jaw Breakout (TJBO)

Jaw, Breakout

Capscrew

Tong Die

Jaw, Breakout

Fig 4.1.10 Jaw Assembly

Capscrew

Tong Die

Fig 4.1.11 Jaw Assembly from above

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4.1.6.1 Overhaul procedure Servicing the TJBO is limited to checking and repairing the hydraulic cylinders and replacing the cylinder pins.

Refer to Fig. 4.1.9 1. Dismantle the assembly as illustrated in Fig. 4.1.12.

2. Inspect centralizer jaws and replace as required.

3. Inspect the inserts and replace as required.

4. Overhaul the hydraulic cylinders as required.

5. Reassemble the lower masts in reverse order.

Fig 4.1.12 Triple Jaw Breakout

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4.2 Top Drive PM Tasks The top drive requires minimal maintenance; however, certain precautions must be taken to ensure long life of the unit. The top drive is exposed to severe vibration and shock loading.

The frequency of rebuilding the top drive assembly depends on the drilling conditions as well as maintenance of the unit.

It is essential to check the preload of the bearings after the first 50 hours of service as well as every 250 service hours, adjusting as required. This will prevent movement of the driveshaft when the bearings have excessive play. The movement will damage the oil seals and possibly damage the driveshaft wear sleeve and seal housings, causing loss of oil and eventual failure of the top drive.

NOTE: A special tool is required to check the bearing pre-load. Order the tool from Cubex (CT16208-WH24) or manufacture it from an old drill pipe (See Fig 4.2.1).

Daily:

250 Hour Intervals:

1000 Hour Intervals:

2000 Hour Intervals:

•

Check oil level

•

Check for oil leaks

•

Bearing Pre-load Adjustment

•

Change gear oil

•

Torque bolts on rotation motors

•

Torque bolts at mounting plate

•

Inspect top drive and rebuild as required

WARNING! Disconnect electrical power, mine air, water supply and relieve pressure in air receiver before servicing.

Support mast before removing or loosening hydraulic components or fittings.

Technical Specifications:

Lubricant:

Gear Lube SAE 140 - High temp.

SAE 80W-90 - Low temp.

Capacity:

6.3 qts. (6 l)

Weight:

780 lbs. (350 kg)

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4.2.1 Using the Right Equipment When working on a 6240 top drive, it is recommended that the correct stand is used to hold the unit while working on it. This stand must be capable of rotating the top drive 360° and securely holding it in the required position as shown in Fig 4.2.1.

Also required will be a bearing warmer (see Fig 4.2.1).

Top Drive

Bearing Warmer

Stand

Fig 4.2.1 Stand

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4.2.2 Checking Bearing Pre-load NOTE: This procedure is for Preventative Maintenance.

A special tool is required to check the bearing pre-load. Order the tool from Cubex (CT16208WH24) or manufacture it from an old drill pipe (See Fig 4.2.2).

It is critical to maintain the correct pre-load on the drive shaft bearings. The test is to determine the force required to rotate the driveshaft. The pre-load is adjusted by adding or removing shims, installed under the bearing cap.

1. Move top drive to a comfortable working position and drain oil. Rotate mast until top drive motors are facing down.

WARNING! Secure full load of mast and top drive.

Disconnect electrical power, mine air, water supply and relieve pressure in air receiver before proceeding.

2. Remove top drive motors and cap hydraulic lines.

3. Install Pre-load Checking Tool into drive shaft sub. Place torque wrench on nut, and measure torque required to rotate drive shaft. Torque must be between 65 75 ft.-lbs. (88 - 102 N m).

NOTE: If pre-load is within limits, remove Pre-load Checking Tool and reassemble top drive. Otherwise proceed with Adjusting Bearing Pre-load.

Alternative Field Method for Checking Pre-load 1. Move the top drive to a comfortable working position and drain the oil.

2. Install the Preload Checking Tool into the driveshaft saver sub. Using a torque wrench rotate the driveshaft and read the torque required to turn it. Torque must be between 100- 110ft/lbs (136-150Nm) rolling torque (torque must be read while turning the driveshaft).

NOTE: If the preload is within limits, remove the Pre Load Checking Tool.

Otherwise, proceed with Adjusting Bearing Preload.

Fig 4.2.2 Pre-load Checking Tool (CT16208-WH24)

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4.2.3 Adjusting Bearing Pre-load Normal wear tends to reduce the pre-load. Shims, placed under the bearing cap, must be removed to compensate for wear. The shims are available in 2 sizes - 0.005” (0.127 mm) clear and 0.010” (0.254 mm) – white, with both being found under the cap.

NOTE: This procedure is continued from "Checking Bearing Pre-load"; therefore the air pressure is already relieved.

1. Remove bearing cap. Remove one shim, bolt bearing cap back in place and torque bolts (30) to 375 ft.-lbs. (508 N m). Turn driveshaft two full revolutions.

NOTE: When removing the bearing cap, care must be taken to insure that there are no burrs on the wear sleeve that might damage the seal as the cap is being removed.

2. Recheck bearing pre-load by measuring rotation torque. Repeat step 1 and recheck bearing pre-load until correct torque is achieved.

3. Remove Pre-load Checking Tool. Reassemble top drive and reconnect power.

Rotate mast until air swivel is up, and check oil level in top drive.

4.2.4 Removing Top Drive The top drive can be removed with the mast in the horizontal or vertical position.

1. Break saver sub before removing top drive from mast. To break and install saver sub, follow the instructions given in Section 4.2.8.

WARNING! Disconnect electrical power, mine air, water supply and relieve pressure in air receiver before servicing.

2. Drain the oil into a suitable container.

3. Support weight of top drive using crane or suitable restraining device.

4. Disconnect air hoses and hydraulic hoses, capping all lines.

5. Remove 8 of the ¾” retaining bolts and lift off the top drive.

6. Clean and wash exterior of top drive.

7. Install the top drive on a suitable holding device.

8. Proceed with disassembly instructions.

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4.2.5 Disassembly Procedure NOTE: Use bearing warmer or press to remove and install bearings and sleeves.

Refer to Fig 4.2.4 1. Remove the hydraulic motors.

2. Remove the splined piston (if your model is so equipped).

3. Remove the upper seal housing bolts and then remove the housing by turning in the previously installed set screws.

4. Remove the oil seal from the housing and discard.

5. Remove the gear housing top plate.

6. Remove the driveshaft bearing cup and pinion bearings from the plate.

7. Remove the driveshaft assembly from the gear housing using a suitable lifting device.

8. Remove the bearing cones, sleeves, and bullgear from the driveshaft using a suitable press. Avoid damaging the driveshaft surfaces.

9. Remove both pinion gears and lower pinion bearings from the gear housing. It may be necessary to remove 4 of the 1/8” pipe plugs from the bottom of the gear housing and use a pin punch to push the bearings out.

10. Remove the bottom bearing cap bolts and the bottom bearing cap. It may be necessary to use the two set screws previously installed in the cap.

11. Remove the bearing cup from the gear housing.

12. Clean and inspect all parts, replacing any worn components.

Fig 4.2.3 Disassembly

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4.2.6 Assembly Procedure The top drive assembly has been split into 4 parts: Lower Gear Housing assembly, Upper Gear Housing assembly, Driveshaft assembly, and Final assembly.

NOTE: The Lower Gear Housing and Upper Gear Housing assemblies can be completed while warming the bearings during the Driveshaft assembly.

4.2.6.1 Lower Gear Housing Assembly 1. Install pinion bearings onto pinion gear (2 sets).

Pinion Gear

Pinion Bearing

Fig 4.2.4.a

Fig 4.2.4.b

2. Install bearings and gear into the lower gear housing. The lower gear housing should have previously been installed on the appropriate stand (see Section 4.2.1).

Use a rubber mallet and/or brass punch to ensure the bearings are seated all the way to the bottom (edge should be below housing edge).

Lower Gear Housing

Fig 4.2.5.a

Bearing edge below housing edge

Fig 4.2.5.b

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4.2.6.2 Upper Gear Housing Assembly 1. Install pinion bearings in upper gear housing.

Use a rubber mallet and/or brass punch to ensure the bearings are seated all the way to the bottom (edge should be below housing edge). See Fig 4.2.6 Pinion Bearing Bearing edge below housing edge

Pinion Bearing

Upper Gear Housing

Fig 4.2.6 2. Install the outer ring from bearing assembly CX001423 (see Fig 4.2.7.a and Fig 4.2.7.b) into upper gear housing.

Use a rubber mallet/brass punch to ensure the outer ring is seated all the way to the bottom (edge should be bottomed out). See Fig 4.2.8.a and Fig 4.2.8.b

Outer Ring

Fig 4.2.7.a

Fig 4.2.7.b Outer Ring

Fig 4.2.8.a

Fig 4.2.8.b

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4.2.6.3 Driveshaft Assembly CAUTION! Use gloves whenever you are removing items from the bearing warmer. Parts can be extremely hot.

1. Using a bearing warmer, heat CX001442 spacer. When warm, install on driveshaft CX004939 (not on threaded end).

Driveshaft Spacer

Threaded end of driveshaft

Fig 4.2.9.a

Fig 4.2.9.b

2. Heat large CX001423 bearing assembly on bearing warmer (can take up to 30 minutes; be sure to rotate the bearings on the warmer to heat evenly). Use a temp stick (rated for 250°F) to check on bearing temperature; check 3 spots to ensure it’s heated evenly.

NOTE: It is during this step and during step 10 (warming bearings) that the Lower Gear Housing and the Upper Gear Housing assemblies can be completed.

Temp Stick

Bearings

Fig 4.2.10.a

Fig 4.2.10.b

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3. When the bearings are heated, drop onto the driveshaft on top of the spacer (remember to use gloves). Ensure the bearing ring is touching the spacer.

Bearing Assembly

Spacer Driveshaft

Threaded end of driveshaft

Fig 4.2.11 4. Heat and install upper CX001433 spacer sleeve on top of bearing assembly. Ensure it is seated all the way down.

Spacer Sleeve

Fig 4.2.12.a

Fig 4.2.12.b

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5. Heat and install upper wear sleeve CX001425 on top of spacer sleeve. Ensure tapered edge is facing up.

Tapered edge

Tapered edge

Fig 4.2.13.a

Upper Wear Sleeve

Fig 4.2.13.b

6. Invert (turn over) driveshaft so threaded end is up. Determine thread direction. If threads are circling to the right, unit is left hand rotation and vice versa.

Thread direction

Rotation direction (marked on driveshaft by assembler)

Fig 4.2.14

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7. Install bullgear on the driveshaft. Place the bullgear on the driveshaft properly (up for L/H rotation, etc) using the rotation direction determined in step 6. “Up” is toward the threaded end. See Fig 4.2.16 NOTE: Bullgear has “up for L/H rotation” and “up for R/H rotation” inscribed on either side. See Fig 4.2.15.a and Fig 4.2.15.b

Fig 4.2.15.a

Fig 4.2.15.b

Fig 4.2.16

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8. Install collector cups on bullgear (both sides – top and bottom). The open end of the collector cup MUST BE facing the direction of rotation. The collector cups gather oil and direct it to the bearings.

Collector Cup

Open end facing rotation direction

Collector Cup (underneath) Open end facing rotation direction

Rotation direction

Fig 4.2.17 9. Warm and install bottom spacer CM16216 on top of bullgear. Both sides are tapered, so it can be installed either way.

Bottom Spacer

Fig 4.2.18.a

Fig 4.2.18.b

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10. Heat bearing cone CP16205 on the bearing warmer. Install on top of the bottom spacer. Ensure it is seated all the way to the bottom.

Bearing Cone

Fig 4.2.19.a

Fig 4.2.19.b

11. Heat and install the lower spacer sleeve on top of bearing cone.

Lower Spacer Sleeve

Fig 4.2.20

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12. Heat and install lower wear sleeve (tapered edge outward) on top of the lower spacer sleeve. Ensure it’s seated at the bottom.

Tapered edge

Lower Wear Sleeve

Fig 4.2.21

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4.2.6.4 Final Assembly 1. Invert driveshaft (turn over: threaded end at bottom). Using a crane or other hoisting equipment, install driveshaft assembly into lower gear housing.

Fig 4.2.22.a

Fig 4.2.22.b

2. Using Loctite 518, apply to surface of lower gear housing. Install gasket on lower gear housing. Apply Loctite 518 to surface of gasket.

Loctite 518 (red)

Fig 4.2.23.a

Gasket (green)

Fig 4.2.23.b

Loctite 518 (red)

Fig 4.2.23.c

3. Apply Lubriplate No. 105 Motor Assembly Grease (white) to the interior of the upper gear housing (outer ring of bearing assembly) and to the bearing assembly.

Lubriplate

Fig 4.2.24.a

Fig 4.2.24.b

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4. Install upper gear housing on to the lower gear housing. It may be necessary to use a rubber mallet to seat housing firmly on gasket. Ensure the pinion gears are fitting into the pinion bearings in the upper gear housing.

Pinion Bearings

Fig 4.2.25.a

Fig 4.2.25.b

5. Install 16 (sixteen) bolts (3/4-10 UNC Hex Hd. Bolt, 2.5 lg.) and washers (3/4” Lockwasher) into the upper gear housing. Use Loctite 243 (blue threadlock) on bolt threads. Using a torque wrench, torque bolts to 250 ft lbs.

NOTE: Do not install the oil seals at this time. The repeated removal during pre-load setting can damage seals.

Loctite 243 (blue) Bolts (16)

Torque bolts to 250 ft lbs

Fig 4.2.26.a

Fig 4.2.26.b

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6. Invert top drive on stand (threaded end up). Apply Lubriplate grease to bearing cone CP16205 and bearing cup CP16204. Use rubber mallet to seat the bearing cup approximately ½” above the housing level.

NOTE: It is very important NOT to push the bearing cup as far as it will go. Pushing it too far can prevent the bearings from rolling freely. Instead, allow the pressure of the bearing cap installation (steps 8 and 9) to seat the bearing cup properly.

Lubriplate on interior of bearing cup

Lubriplate on bearing cone

Fig 4.2.27.a

Fig 4.2.27.b

Bearing Cup Seated approx. ½” above the housing level.

Fig 4.2.27.c 7. Add several shims (exact number to be determined during pre-load setting) to the housing. Discard the thickest shims from shim set CX001438.

Shims

Fig 4.2.28

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8. Install bearing cap CX001410 onto housing. Ensure the fill plug is facing forward from the mounting side. It may be off-center depending on the position of the bolt holes.

Mounting side (side attached to stand)

Bearing Cap

Fill Plug

Fig 4.2.29

9. Install 6 (six) bolts (3/4-10 UNC Hex Hd. Bolt, 2.5 lg.) and washers (3/4” Lockwasher) into the bearing cap. Torque bolts to 250 ft lbs.

NOTE: DO NOT use Loctite 243 on the bolt threads at this time. Bearing cap and bolts may need repeated removing during pre-load setting.

Bolts and Washers Torque to 250 ft lbs

Fig 4.2.30

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10. Setting the bearing pre-load: a. Insert the pre-load tool into the threaded end of driveshaft. Tighten. b. Use a torque wrench to check rolling torque (needs to be approx. 80 ft lbs). c. If rolling torque is outside limits: Remove bearing cap, add (to lower torque) or remove (to raise torque) shims, re-install bearing cap and bolts, and recheck rolling torque until it is within limits. *IMPORTANT: Always re-torque bolts to 250 ft lbs before checking pre-load. d. Once you have reached the correct rolling torque, remove bolts and apply Loctite 243 to the bolt threads. Re-install bolts and torque to 250 ft lbs. e. Remove pre-load tool.

Pre-load tool See also Fig 4.2.2

Fig 4.2.31.a

Fig 4.2.31.b

11. Lubricate seal CX001436 and wear sleeve contact surfaces. Install seal with spring/open side down. NOTE: Spring can bend; if bent, it will not seal correctly.

BE CAREFUL. Use rubber mallet and/or level to seat the seal evenly.

Spring

Fig 4.2.32.a

Lubricate wear sleeve surfaces

Fig 4.2.32.b

Use level to seat seal evenly

Fig 4.2.32.c

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12. Install cover plate CX001444 with Loctite 518 and gasket, using 3 (three) bolts (3/8-16 UNC Hex Hd. Bolt, 3/4 lg.) and washers (3/8” Lockwasher). Also plug the hole in the side with a bolt.

Bolt example

Cover Plate Bolt in side

Fig 4.2.33.a

Loctite and Gasket

Fig 4.2.33.b

13. Install 4 (four) pipe plugs (1/8-27 NPT) into holes in casting. Use Loctite 587.

Pipe Plugs Pipe Plugs

Fig 4.2.34

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14. Invert (turn over) top drive on stand. Apply Lubriplate grease to seal CX001435 and wear sleeve contact surfaces. Install seal with spring/open side down. NOTE: Spring can bend; if bent, it will not seal correctly. BE CAREFUL. Use rubber mallet and/or level to seat the seal evenly.

Lubriplate on wear sleeve surface

Fig 4.2.35

O-ring installed

Seal installed

Fig 4.2.36 15. Install o-ring CP16001 onto driveshaft using Lubriplate grease. Refer to Fig 4.2.36

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16. Install Labyrinth Cap, Upper (CX004944); use mallet to seat as far as it goes.

Labyrinth Cap, Upper

Fig 4.2.37.a

Fig 4.2.37.b

17. Install second o-ring CP16001 into upper labyrinth cap, using Lubriplate grease.

O-ring installed

Fig 4.2.38

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18. Fit air swivel CX004940 onto the upper labyrinth cap, aligning the bolt holes. Use 8 (eight) bolts (1/2-13 UNC Hex Hd. Bolt, 2 1/2 lg. gr.8+) and washers (1/2” Lockwasher). Apply Loctite 243 to the bolt threads and fasten the air swivel to the upper labyrinth cap. Torque bolts to 70 ft-lbs.

NOTE: Air swivel must have threaded part facing forward (same as the fill plug in step 8). Tighten bolts.

Air Swivel Threaded hole

Bolts and washers

Fig 4.2.39 19. Install pinion locking tools (CT16208-WS) into pinion gear. This prevents components from turning while tightening the saver sub.

Install Pinion Locking Tool here (both sides) Pinion Locking Tool

Fig 4.2.40.a

Fig 4.2.40.b

CAUTION! After installation of the pinion locking tools, do not engage the drill’s rotation either forward or reverse, as damage to the top drive may occur.

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20. Hand-tighten the saver sub onto the top drive.

Saver sub

Fig 4.2.41

21. Move top drive to breakout bench and secure with bolts. Using the breakout wrench (CT16208-W), torque the top drive to 1550 psi.

Secure top drive to bench with bolts

Saver sub breakout h

Breakout bench

Fig 4.2.42 22. Once torqued, remove the top drive from the breakout bench and move to table.

Remove the pinion locking tools.

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23. Using bolts (1/2-13 UNC 12 point Bolt, 3/4 lg.) and washers (1/2” High collar Lockwasher), with Loctite 243 on the bolt threads, attach motors to top drive.

NOTE: placement is important, as one motor has side ports and another has bottom ports. Tighten as much as possible.

Side Ports (yellow)

Bottom Ports (yellow)

Fig 4.2.43.a

Fig 4.2.43.b

24. Install lower Labyrinth Cap CX001409. Insert and tighten cap screw with allen key.

Lower Labyrinth Cap

Fig 4.2.44.a

Cap screw

Fig 4.2.44.b

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25. Install fill plugs to oil drain/fill holes (both sides).

Install fill plug

Install fill plug

Fig 4.2.45.a

Fig 4.2.45.b

26. Using silicone adhesive/sealant, seal holes in top drive. Allow to dry.

27. Top up oil to proper level.

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4.2.7 Top Drive Installation 1. Place the spacer over the t-bar and onto the top drive mounting plate with the 8 holes aligned 2. Hoist the top drive onto the spacer with the large shaft facing the bottom of mast and the 8 holes aligned 3. Install eight 3/4” bolts with 3/4” lock washers through the top drive and spacer and into the top drive mounting plate

NOTE: Mast and spacer on your model of drill may be different than those shown here.

However, installation is the same.

Fig 4.2.46 Ref No.

Part No.

Qty

Description

1

Refer to Parts Manual

1

6230/6240 Top Drive Assembly

2

CQ66403-2

1

Spacer – Top Drive

3

BHC0750

8

3/4-10 UNC Hex HD. Bolt, 2.75” LG.

4

WLR0750

8

3/4” Lock Washer

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4.2.8 Saver Sub Field Procedures 4.2.8.1 Removal 1. Lower the top drive to the bottom of travel and support the mast safely to remove the hydraulic motors.

2. Clean the top of the top drive to prevent debris from entering the top drive, which will cause premature wear.

3. Remove both hydraulic motors from the top drive assembly; cap all hydraulic lines to prevent contamination of the hydraulic system.

4. Install the pinion locking tools (CT16208-WS) and secure each with four bolts.

Refer to Fig 4.2.33 and Fig 4.2.34 CAUTION! After installation of the pinion locking tools, do not engage the drill’s rotation either forward or reverse, as damage to the top drive may occur.

Pinion Locking Tool Prevents the driveshaft from turning during saver sub removal

Fig 4.2.47.a

Pinion Locking Tool

Fig 4.2.47.b

5. Raise the top drive so the saver sub is at the same height as the breakout cylinder.

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6. Install the saver-sub breakout wrench (CT16208-W) on the saver-sub, then install the appropriate wrench holding tool and connect to the breakout cylinder with the cylinder in the extended position. Refer to Fig 4.2.35

Saver sub breakout wrench

Breakout cylinder connected in the extended position to allow movement for breaking saver sub

Fig 4.2.48 7. Retract (if cylinder is mounted on the left side of mast) or extend (if cylinder is mounted on right side of mast) the breakout cylinder until the joint is broken.

WARNING! To prevent possible injury, do not stand in the path of the wrench while breaking the joint.

Breakout cylinder retracted; saver sub joint loosened

Fig 4.2.49 8. After the joint is broken, remove the saver sub retainer and wrench, and remove the saver sub by hand.

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4.2.8.2 Installation 1. Thread the saver sub onto the driveshaft by hand. Ensure the threads have been coated with anti-seize.

2. Remove the pinion locking tools.

3. Reinstall top drive motors and all hydraulic lines. Torque motor bolts to 105 ft-lbs.

4. Reduce forward rotation torque to minimum by turning the needle valve labeled “Forward Rotation Torque” counter-clockwise.

5. Install the breakout wrench onto the saver sub then install the appropriate wrench holding tool.

6. Rotate the top drive forward until the wrench contacts the right edge of the mast, keeping all personnel clear of area.

With wrench against the mast, apply 2500 psi forward rotation to tighten the saver sub to the shaft

Wrench Holding Tool

Fig 4.2.50 7. Push the high rotation torque button; check gauge to ensure a pressure of 2500 psi.

8. Release the button to return to 1600 psi after making up the saver sub; check the pressure gauge to ensure the pressure has reduced.

9. Relieve the forward pressure with the joystick to remove the breakout wrench.

10. Remove the breakout wench holding tool and breakout wrench.

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4.2.9 Air Swivel Field Procedures PM Tasks 50 Hour Intervals:

•

Check for external leaks, lubricate grease nipple

2000 Hour Intervals:

•

Remove and disassemble air swivel, inspect seals and O-rings

4.2.9.1 Removing Air Swivel Refer to the beginning of the section if the top drive needs to be removed.

1. Lower the top drive to a comfortable working position to remove the air swivel.

2. Clean the top of the top drive to prevent debris from entering the top drive, which will cause premature wear.

3. Remove the anti rotation bracket (bolted on) from the top drive mounting plate.

4. Remove the main air supply line from the air swivel.

5. Remove air swivel from top drive by undoing and removing bolts, then lift off the air swivel.

NOTE: If the Air Swivel is to remain off the top drive for any length of time the drive shaft should be covered to prevent any debris from entering the top drive.

Main air supply line

Anti-rotation Bracket

Fig 4.2.51.a

Fig 4.2.51.b

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4.2 TOP DRIVE (08/03/25)

4-02-032

4.2.9.2 Installation of Air Swivel 1. Clean and examine the threads of both the saver-sub and drive shaft for any damage i.e. burrs, nicks, damage to the threads and replace the o-ring on the Air Swivel.

2. Lubricate the o-ring. Refer to Fig 4.2.38 for location of o-ring.

3. Install the air swivel wrench on the top drive and install bolts and washers, using Loctite 243 on the bolt threads.

Air Swivel

Bolts and washers

Fig 4.2.52 7. Install the main air supply line from the air swivel.

8. Install the anti rotation bracket from the top drive mounting plate.

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4.2 TOP DRIVE (08/03/25)

4-02-033

4.2.9.3 Dismantling Air Swivel Refer to Fig 4.2.53.a, and Fig 4.2.53.b 1. Remove upper cover plate and bolts. The bearings directly under the upper cover plate will come off with it.

2. Loosen the bolts on the lower cover plate.

3. Remove the outer tube from the air swivel.

Upper Cover Plate and Bolts

Items removed

Outer Tube

Fig 4.2.53.a

4.2.9.4 Assembly Procedure Re-assemble in reverse order.

Fig 4.2.53.b

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4.2 TOP DRIVE (08/03/25)

4-02-034

4.2.9.5 Inspection of Parts 50 Hour Intervals 1. Inspect the air swivel for air leaks from the vent holes. An air leak indicates that the seals inside the air swivel require replacement.

Vent Holes

Fig 4.2.54

2000 Hour Intervals 1. Remove and disassemble air swivel; inspect all seals, bearings, and O-rings.

Lower bearing O-rings (show n in blue)

Upper bearing

Fig 4.2.55

Fig 4.2.55

NOTE: All seals and bearings should be replaced at time of rebuild.

Fig 4.2.55

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4.3 TOP DRIVE MOTOR (08/03/25)

4-03-001

4.3 Top Drive Motor PM Tasks Replacing seals and O-rings is routine maintenance but a complete overhaul is time-consuming.

Motor replacement is recommended.

250 Hour Intervals:

•

Inspect seals

NOTICE! Rebuilding the hydraulic pumps is recommended for qualified maintenance technicians only.

Motor Specifications: Top Drive Motor CP17014-6 Displacement:

12.1 in3/rev (198 cm3/rev.)

Continuous Pressure:

2800 psi (193.5 bar)

Continuous Flow:

20 gpm (76 l/min.)

Speed:

0 - 349 rpm

Weight:

36 lbs. (16.3 kg.)

BI620146

4.3 TOP DRIVE MOTOR (08/03/25)

Fig 4.3.1 Top Drive Motor

Fig 4.3.2 Rotor Clearance

4-03-002

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4.3 TOP DRIVE MOTOR (08/03/25)

4-03-003

Dismantling Top Drive Motor Remove the top drive motors from the top drive assembly, plug the hose fittings, and proceed as outlined below.

Refer to Fig 4.3.1 1. Clean the outside of the motor and drain the fluid. Clean all parts, except seals, in petroleum-based solvent, then dry them with compressed air. Keep parts separate to avoid nicks and burrs.

2. Place motor in a vise with coupling shaft facing down and jaws gripping housing flange.

3. Draw an alignment mark down the outside of the motor from cover (2) to housing (18) to assist orientation when assembling the unit.

4. Remove bolts (1), end cover (2) and seal ring (4). Discard seal ring. Inspect end cover (2) for operating conditions. A polished pattern is normal wear created by commutator assembly.

Discoloring indicates excessive fluid temperature, thermal shock or extreme speeds. If discoloring exists, inspect items 2, 5, and 8 for scoring or distortion.

5. Remove commutator ring (6) and inspect it for cracks or burrs.

6. Remove commutator (5). Remove seal from commutator, using an air hose blowing air into the ring groove until the seal (3) is lifted out. The seal (3) must be discarded after removal.

NOTE: Item 5 and commutator ring (6) are sold as matched sets.

7. Remove manifold (7) and inspect it for cracks or surface scoring. Replace it if required. A polished pattern on the ground surfaces from commutator or rotor rotation is normal. Remove and discard seal rings (4) from both sides.

NOTE: The manifold is constructed of bonded plates and cannot be dismantled any further. Compare configuration of both sides of the manifold to ensure that the same surface is reassembled against the rotor set.

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4.3 TOP DRIVE MOTOR (08/03/25)

4-03-004

8. Remove rotor set (8) and wear plate (9) together, keeping rotor set in its assembled form. Then, mark the position to allow installation in the same location. Keeping the original position increases the service life of the torque motor. Remove and discard seal ring between item 9 and item 8.

NOTE: Some motors may have a rotor set with two stator halves with a seal ring (4) between them and two sets of vanes. Discard the seal ring if the stator halves become disassembled.

9. Check rotor vane clearance as follows: Place the rotor set (8) and wear plate (9) on a flat surface then rotate the rotor as illustrated in Fig 4.3.2. Measure the clearance between the vane and rotor lobe. Replace the rotor set if the clearance is more than 0.005" (0.13 mm). If this motor is equipped with two sets of stators, repeat above procedure on other side.

10. Inspect drive link (10) for damaged splined. No noticeable lash should be apparent between mating spline parts.

11. Remove seal ring (4) from item 18. Remove thrust bearing (11) from coupling shaft (12) and inspect it for wear.

12. Remove coupling shaft (12) and check it for wear. Replace it if the two diameters show wear in excess of 0.020" (0.51 mm).

13. Remove inner thrust bearing (13) to inspect condition. Remove item 16, and item 17. Remove seal (20) using a seal puller.

14. Remove bearing (19) using a suitable bearing puller.

Assembly Procedure 1. Reassemble in reverse order including the additional steps below.

2. Pack bearing (19) with grease as it is not lubricated with hydraulic fluid.

3. Apply grease to all seal rings (4). Install two studs that are 0.50" (13 mm) longer than bolts (1) into item 18 to guide external parts during installation.

4. Install bolts (1) and torque to 24 ft.-lbs. (32 N m).

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4.4 BREAKOUT WRENCH (08/03/25)

4-04-001

4.4 Breakout Wrench PM Tasks Clean and replace components as required. The knurled inserts require replacement more frequently.

250 Hour Intervals:

•

Visual Inspection

•

Cleaning Assemblies

Fig 4.4.1 Breakout Wrench

Service Procedure Servicing the wrench is limited to replacing chain components, pins, and springs. Consult the Parts Manual for replacement parts.

1. Dismantle the assemblies as illustrated in Fig 4.4.1.

2. Replace worn inserts and parts as required. Clean chains and replace them when necessary.

3. Assemble in reverse order.

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4.4 BREAKOUT WRENCH (08/03/25)

4-04-002

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4.5 CAROUSEL ASSEMBLY (08/03/25)

4-05-001

4.5 Carousel Assembly PM Tasks The carousel requires frequent lubrication and inspection.

8 Hour Intervals:

Lubrication of grease nipples, operators must check that drill pipes align with top drive

250 Hour Intervals:

Visual inspection of bearings, pins, and pipe guides

2000 Hour Intervals:

Repeat 250 Hour inspection, inspect carousel drive, check hydraulic cylinders and motor

WARNING! Secure or support mast before inspecting or servicing drill. Drill pipe may move if pipe clamping pressure is set incorrectly.

Check Pipe Alignment Every 50 Hours 1. Check that the pipe clamps have sufficient force to hold drill pipes.

2. Check drill pipes align with top drive.

Fig 4.5.1 Pipe Alignment

BI620146

4.5 CAROUSEL ASSEMBLY (08/03/25)

Carousel Inspection at 250 Hours 1. Inspect top wear liner.

2. Inspect washers for wear.

3. Inspect bearings.

4. Inspect cylinder pins and clamp pins.

5. Inspect bushings inside clamp and washers.

6. Inspect cylinder bearing.

7. Repeat steps 4 and 6.

8. Repeat steps 2 and three.

9. Inspect bottom wear liner.

Fig 4.5.2 Carousel Inspection

4-05-002

BI620146

4.5 CAROUSEL ASSEMBLY (08/03/25)

2000 Hour inspection 1. Inspect and shim bearing as required.

2. Inspect driven indexer and washer.

3. Inspect drive indexer.

4. Inspect hydraulic motor for leaks.

Fig 4.5.3 2000 Hour Inspection

4-05-003

BI620146

4.5 CAROUSEL ASSEMBLY (08/03/25)

4-05-004

4.5.1 Carousel Adjustment The carousel requires adjustment when the drill pipes do not align with the top drive or when the clamping force of the pipe clamp is insufficient.

You must also perform these adjustments when replacing carousel components. Tighten screws to torque values shown in Table 4 Bolt Torque Table.

4.5.1.1 Pipe Clamp Adjustment Adjusts clamping jaws. Perform lower and upper adjustment simultaneously.

1. Load drill pipe into clamps and tighten pipe into top drive.

2. Turn locknut counterclockwise to unlock cylinder rod adjustment. Release the clamping pressure on the drill pipe by turning the cylinder rod into the cylinder eye (clockwise). Turn the cylinder rod until there is no more clamping pressure.

This will give a starting point for tightening the clamps.

3. Adjust cylinder rod until clamp grips drill pipe firmly, by turning the cylinder rod out of the clevis (counter-clockwise). Open pipe clamp and turn the cylinder rod two more revolutions out of the clevis (counter-clockwise) to make final adjustment to clamping pressure. Tighten lock nuts. Remove drill rod from drill table.

Load drill pipe into clamps and tighten pipe into top drive

Pipe Clamp Cylinder

Locknut Clamp Cylinder Rod

Fig 4.5.4 Pipe Clamp Adjustment

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4.5 CAROUSEL ASSEMBLY (08/03/25)

4-05-005

4.5.1.2 Clamp Arm Adjustment Adjusts drill pipe with top drive location. Perform lower and upper adjustment simultaneously.

The adjustment of the pipe clamp shaft will change the position of the pipe clamps in and around the carousel around the pipe shaft clamp axis.

Pipe Clamp Shaft Adjustment

Adjusting Bolts

Locknuts Locknut

Cylinder Rod

The adjustment of the cylinder will change the position of the carousel arm assembly around the indicated axis.

Carousel Arm Assembly Cylinder Adjustment

Fig 4.5.5 Lower Carousel Adjustment

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4.5 CAROUSEL ASSEMBLY (08/03/25)

4-05-006

Pipe Clamp Shaft Adjustment

Locknuts

The adjustment of the pipe clamp shaft will change the position of the pipe clamps in and around the carousel around the pipe shaft clamp axis.

Adjusting Bolts

Locknut

Cylinder Rod

Carousel Arm Assembly Cylinder Adjustment

The adjustment of the cylinder will change the position of the carousel arm assembly around the indicated axis.

Fig 4.5.6 Upper Carousel Adjustment

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-001

4.6 Expander Pin System – Mast Boom The expander pin system is used in the mast boom of your drill. The Expander System consists of an axle that is tapered at both ends, expansion sleeves, pressure washers, and fastening elements. The parallel expansion of the sleeves eliminates play in the pivot lugs. This was introduced to the QXR series of drills to reduce the amounts of maintenance and repairs required on the main pivot and swing cylinder of the boom assembly.

IMPORTANT! Re-torque is an intricate part of the installation and crucial to the success of the repair. Make sure to follow the Torque Schedule in Table 7.

Check the torque at regular service intervals. Apply appropriate torque according to Table 6. Tighten until the torque wrench “clicks out” on setting.

Proper greasing of your machine pivots is crucial for the functioning and durability of the Expander System. It is strongly recommended that grease with 3-5% molybdenum disulfide be used, as it allows much less wear and gives increased load carrying capability.

Fig 4.6.1 Expander System

BI620146

4.6 EXPANDER PIN SYSTEM (08/03/25)

Expander pin metric bolt size reference

Fig 4.6.2 Expander pin metric bolt size reference

Fig 4.6.3 Pin CX002332

4-06-002

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-003

4.6.1 Torque and Maintenance Intervals 4.6.1.1 Torque Recommendations

Table 6 Bolts and Specialty Fasteners UNIT

M12

M14

M16

M20

M24

M30

M36

M42

N-m

70

115

175

350

500

600

700

900

Lb-ft

52

85

129

258

369

443

516

664

M12

M14

M16

M20

M24

M30

M36

M42

N-m

65

115

175

250

350

500

600

700

Lb-ft

48

85

129

184

258

369

443

516

Nuts, Standard Height UNIT

Nuts, Low Height UNIT

M12

M16

M20

M24

M30

N-m

60

125

200

275

350

Lb-ft

44

92

148

203

258

Spanner Nuts UNIT

M17

M25

M35

M45

M55

M65

M75

M85

N-m

50

120

250

500

600

700

800

900

Lb-ft

37

89

184

369

443

516

590

664

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-004

4.6.1.2 Torque Schedule Re-torque according to Table 7.

Table 7 Hours of Operation * When you re-torque and the wrench “clicks out” on setting without adding additional torque, you have successfully seated the expansion sleeves.

After 1 hour After 3 hours After 10 hours or 1 day* After 40 hours or 4 days*

If the expansion sleeves have not seated within one week of operation, call your Cubex representative.

4.6.1.3 Mounting/Dismounting Tools Most Expander System assemblies do not need any special tools for installation and dismounting.

If special tools are needed, they will be supplied with the assembly. If excessive force is needed or if space is limited, we recommend the use of Expander Mounting/Dismounting Tools (sold separately).

4.6.1.4 Installation 1. Prior to installation, ensure there are no existing structural damages (i.e. cracks, severely bent lug ears, etc) that would affect the alignment of the pivot lugs. If damage exists, it may result in the Expander System not functioning properly. Repair structural damage before proceeding with installation.

2. Double check the minimum and maximum wear points of the lug holes to ensure that you have the correct size expansion sleeve for each side of the pin. Each expansion sleeve expands to a maximum of 2.0 mm (0.08 in). If the maximum wear diameter of the lug hole is more than 2.0 mm (0.08 in) larger than the diameter of the sleeve, contact your Cubex representative to order the correct oversize expansion sleeve.

NOTE: If you attempt to install the expander system with improperly sized expansion sleeves, the installation will not be successful.

3. Visually inspect the bore surface of the mounting lugs. Remove any ridges or other irregularities.

If the lug hole has more than 1.5 mm (0.06 in) difference between the minimum and maximum wear, the hole must be bored or ground out to a difference of les than 1.5 mm (0.06 in).

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-005

4. Lubricate the expander pin and the expansion sleeves with bearing grease for easy insertion. First, insert only the expander pin into the bore, then install the sleeves, tension washers, and fastening elements. Be sure not to damage the thread or the tapered ends of the expander pin. Refer to Fig 4.6.4.

Fig 4.6.4 5. Hand-tighten the assembly centered (or positioned as required) in its final position in the pivot.

6. Before tightening the system, find the appropriate torque value for the corresponding fastening element in Table 6. Torque the fastening elements alternately in order to maintain an equal clearance between the tension washers and the mounting lugs on both sides of the expander system. Tighten until the torque wrench “clicks out” on setting. Refer to Fig 4.6.5.

Fig 4.6.5 Tightening the System

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-006

CAUTION! The tension washer located between the fastening element and the end of the expander pin should NEVER come in contact with the pivot lug. If this occurs on only one side of the pin, begin again at step 4.

If either tension washer comes in contact with the lug (A) or the end of the expander pin (B), the expansion sleeve is incorrectly specified. See Fig 4.6.6.

The system must be fitted with a larger oversize expansion sleeve.

Fig 4.6.6 Tension Washer Fitting 7. Lubricate the pivot using grease with 3-5% molybdenum disulfide before operating the machine. Proper lubrication maintenance will greatly extend the life of the expander system.

8. Once the initial torque regiment and pivot lubrication have been completed, start the machine and move the unit back and forth. Tighten again until torque wrench “clicks out” on settings. This procedure ensures that the expansion sleeves have properly seated.

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-007

4.6.1.5 Dismounting 1. Unscrew the fastening elements on both sides of the assembly and remove the washers. See Fig 4.6.7.

Fig 4.6.7 2. Tap the expander pin body alternately on both sides until the expansion sleeves come loose. Use a piece of plumbing pipe between the expander pin and the mallet/hammer in order to not damage the threads. Make sure that the pipe does not come in contact with the expansion sleeve. See Fig 4.6.8.

Fig 4.6.8 3. Remove the expansion sleeves with channel lock pliers or a similar tool. See Fig 4.6.9.

Fig 4.6.9 4. Remove the expander pin.

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4.6 EXPANDER PIN SYSTEM (08/03/25)

4-06-008

BI620146

5.0 HYDRAULIC SYSTEM (08/03/25)

5.0 HYDRAULIC SYSTEM

CAUTION! Wipe up spills immediately!

WARNING! Before servicing any hydraulic components or loosening hose fittings, secure the mast as follows: 1. Place the mast on solid ground or floor.

2. Move the top drive assembly to the lowest position on mast.

3. Support the mast with hoist or restraining equipment.

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5.1 HYDRAULIC SYMBOLS (08/03/25)

5-01-001

5.1 Hydraulic Symbols Symbols

Description

Filter or strainer Variable Displacement Pump with One Direction Flow Fixed Displacement Pump Check Valve Ball Valve Pressure Relief Valve Shuttle Valve Internal Orifice Control Valve, 3-position, solenoid with spring return, manual lever control Flow Direction Reservoir Return Pilot Line Hydraulic Line Fig 5.1.1 Hydraulic Symbols

BI620146

5.1 HYDRAULIC SYMBOLS (08/03/25)

5.1.1 Hydraulic Schematic

Fig 5.1.2 Hydraulic Schematic See the Appendix for a full size schematic.

5-01-002

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5.1 HYDRAULIC SYMBOLS (08/03/25)

5-01-003

#

PART No.

DESCRIPTION

QTY

#

PART No.

DESCRIPTION

QTY

1 2 3 4 5

CP17157 CX071313 CP000894 CP001075 CP17192A CP17192-1 CP17192-2 CP17192-3 CP17192-4 CP17192-5 CP17192-6 CP17417 CP47505-101 CQ20100-27A CX000672 CP17026-5 CP19024 CP000813 CP000812 CP000817 CP000421 CX001670 CX001666 CP17152 CP17120-2 CP17600 CP000301 CX002540 CP18322-2 CP17148 CP17112-1 CM77603 CX041118 CX047435 CX072533 CX041120 CQ41109 CP47248-2

Pressure Reducing Valve Cyl. 3.75x140.25 STK, 2.25 Rod, Feed Return Filter Element Return Filter Fan Drive Control Assy (Compts below) Electronic Control Module Cable Harness Plug PTC Temp Sensor Proportional Pressure Relief Manifold Block – T-8A Cavity Harness Plug – Temp Sensor Hydraulic Oil Fill Pump 2-Section Feed/Tram Valve Radiator Assembly 24VDC Direct Acting Valve ¾ Check Valve Pressure Switch Hyd. Motor 80cc Hyd. Motor 125cc Hyd. Pump 100cc (LIM 74cc) Hyd. Pump, 100cc, RH Hydraulic Pressure Filter, Argo Pressure Filter Element, Argo Valve Pressure Reducing Pressure Gauge 0-5000 psi Flow Restrictor, 0.039” Pressure Sensor 0-5000 psi 10-Section Set-Up Valve Motor (CAT Water Pump) Valve Assembly, 3 Way Actuator Air On/Off Cyl. 5”x47.5 STK, 2.25 Rod, Feed Ext Cyl. 7”x37.8 STK, 3” Rod, Mast Dump Cyl. 7”x11.8” STK, 3” Rod, Mast Swing Cyl. 7”x20” STK, 3” Rod, Boom Swing Cyl. 7”x20” STK, 3” Rod, Boom Lift Cyl. 4”x13” STK, 2” Rod, Lift/Swing Valve Counterbalance

1 1 A/R 1 X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 A/R 1 2 1 3 1 1 1 1 1 1 1 1 1 2 1

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

CX041116 CP47249 CP000457 CP65004 CX077006 CX000529 CX000530 CX002450 CP000777 CM47050 CX001596 CP000054 CM78811 CM78810 CX000101 CM78809 CP17014-26 CP47505-102 1140484 CP17014-6 CP000053 CP17017 CX002549 CX002791 CX002792 CP17600-1 CP47573-1 CP000037 CP18111 CX002284 CP000824 CX002896 CP001393 CP001416 CP001425 CP001032 CP001033 CP001041

Cylinder Oscillation Valve Oscillation Lockout 9 Section Drilling Valve, TJBO Hydraulic Motor Winch Cylinder, Breakout Quick Coupling Male ¼” Quick Coupling Female ¼” Cyl 2.50 Dia x 5.31 ST Elbow Block, Code 61 4-bolt Cylinder Centralizer Cylinder Divertor Pipe Arm Sequence Manifold Cyl. 2.25x4.5 STK, 1.25 Rod, Car. Arm Cyl. 2.5x6.13 STK, 1.25 Rod, Clamp Arm Accumulator Cyl. 2.75x2.91 STK, 1.25 Rod, Clamp Hyd Motor 3 CIR, Carousel Rotation 2-Section Rotation/Tram Valve Hydraulic Motor, Tramming Hydraulic Motor, Rotation Accra Feed Manifold Breather TJBP Cyl 5x3 ST Valve, Load Check Flow Divider Flow Restrictor, 0.060” Valve, Single Load Check TJBO Manifold Valve Assy Window Sight Hydraulic Tank – 80 Gallon Oil Level/Temp Sensor Hydraulic Motor, Rotation Check Valve, 7 psi Sandwich Block, Code 62 Size 20 Sandwich Block, Code 62 Size 16 Counterbalance Valve Direct Control Sol Valve Mounting Block Kit

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

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

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5.1 HYDRAULIC SYMBOLS (08/03/25)

5-01-004

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5.2 HYDRAULIC CIRCUITS (08/03/25)

5-02-001

5.2 Hydraulic Circuits An open-loop, hydraulic system is used with a variable displacement, pressure compensating supply pump. The load sensing function strokes the pump up when flow is required, and destrokes when the system is idle.

PM Tasks The hydraulic system requires limited maintenance. The filter elements and hydraulic fluid must be replaced at the recommended intervals.

Keep all cylinders, motors and valves clean. The cylinder rods are the main source where contamination may enter into the hydraulic system. Replace damaged components immediately. Investigate all leaks, using extreme caution. Worn or damaged hoses must be replaced without delay.

All maintenance should be performed in a clean, well-lit work area. Extreme cleanliness is required when servicing hydraulic components.

250 Hour Intervals:

•

See Section 5.8 Hydraulic Filtration. Inspect system for leaks.

1000 Hour Intervals:

•

Change hydraulic fluid.

WARNING! High pressure oil leaks may cause injury. Use extreme caution and proper protective gear when investigating hydraulic leaks.

After installing hydraulic components and hoses, check that hydraulic actuators are operating in direction as indicated on controls.

BI620146

5.2 HYDRAULIC CIRCUITS (08/03/25)

Hydraulic Circuits Operating Temperature:

100° to 150° F (38° to 65° C)

Fluid Type:

Shell Tellus T 37

System Capacity:

70 gal. (265 L)

Pump Specifications Pump supplies Feed, Left Tram, Drilling Valves Part No.:

CP000421

Rotation:

Right Hand

Capacity:

6.0 cin (100 cc) 34 gpm (129 l/min) @ 1800 rpm

Filling Volume:

0.4 gal (1.6 l)

Weight:

73 lbs (33 kg)

Pump supplies Rotation, Right Tram, Set-up Valves Part No.:

CP000421

Rotation:

Right Hand

Capacity:

6.0 cin (100 cc) 34 gpm (129 l/min) @ 1800 rpm

Filling Volume:

0.4 gal (1.6 l)

Weight:

73 lbs (33 kg)

Pump supplies Rad Fan Part No.:

CP000817

Rotation:

Right Hand

Capacity:

6.0 cin (100 cc) 34 gpm (129 l/min) @ 1800 rpm Stroke limited to 74 cc

5-02-002

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5.2 HYDRAULIC CIRCUITS (08/03/25)

5-02-003

Pressure and Flow Settings

P-1 Pump Circuit (Feed, etc)

P-2 Pump Circuit (Rotation, etc)

System (Operating) Pressure:

4000 psi (276.4 bar)

4000 psi (276.4 bar)

Stand-by Pressure:

400 psi (27.6 bar)

400 psi (27.6 bar)

Relief Valve:

4400 psi (304.0 bar)

4400 psi (304.0 bar)

Pressure Reducing Valve:

2800 psi (193.2 bar)

Not equipped

Pressure and Flow Settings

P-3 Pump Circuit (Fan)

System (Operating) Pressure:

2700 psi (207 bar)= 1450 RPM (Max Cooling) 2000 psi (138 bar) = 1250 RPM 1500 psi (103 bar) = 1100 RPM 1000 psi ( 69 bar) = 900 RPM (Winter Setting)

Stand-by Pressure:

400 psi (27.6 bar)

Adjustment Sequence The hydraulic adjustments are preset and require setting only after servicing the pump or the control valve or when a change in performance is noticed. When overhauling the pump and valves at the same time, follow this adjustment sequence.

1. System (Operating) Pressure:

Located on the pump’s control valve.

2. Standby Pressure:

Located on the pump’s control valve, this is the minimum pressure when the pump is running idle.

3. Pressure Reducing Valve:

Mounted before inlet sections of drilling valves.

4. Relief Valve:

Located on the inlet cover in each valve bank.

5. Valve Pressure:

Located in each valve section, allowing independent settings for both valve ports.

6. Valve Flow:

Located in each valve section, allows independent settings for both valve ports. See section 5.5 Control Valves for individual pressure and flow settings.

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5.2 HYDRAULIC CIRCUITS (08/03/25)

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5.3 HYDRAULIC PUMP (08/03/25)

5-02-001

5.3 Hydraulic Pump This model of pump is designed for open-loop, closed center, or load-sensing hydraulic systems.

Flow is proportional to the drive speed and the displacement. By adjusting the position of the swashplate it is possible to smoothly vary the flow.

The “Load Sense” type of control registers the load at a point away from the pump. In the case of your Cubex drill, a pilot line from the hydraulic control valves sends the pressure signal back to the pump. The pump control then tries to keep the output pressure above the load requirements by the standby or differential pressure (Pressure Compensation). The differential pressure is generally in the area of 400 PSI. Principals of Operation The displacement mechanism of this series of pumps operates via two stroking pistons (large and small) which adjust the position of the swashplate. The smaller of the two stroking pistons (1) works in conjunction with its spring (2) to always try to move the swashplate to maximum angle and therefore the pump to maximum displacement. High-pressure oil is continually routed from the outlet (pressure) port to the small stroking piston via the control oil drilling (3). Working in opposition to this on the opposite of the swashplate is the larger stroking piston (4). If pressurized fluid is routed to the larger stroking piston (4) it will exert a force to de-stroke the pump to a lower displacement value. Since piston (4) has a larger area than piston (1) the pump will de-stroke with pressure on both cylinders. It is therefore possible to control the pump displacement by changing the pressure applied to the larger of the two stroking pistons. All the pump controls work on the same principal of controlling the pressure on this large stroking piston (4) in order to vary the pumps displacement.

Fig 5.3.1 Hydraulic Pump

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CAUTION! Rebuilding hydraulic pump is recommended for qualified maintenance technicians only.

When reinstalling pump, ensure that pump housing is filled with hydraulic fluid before starting.

5.3.1 Installation 5.3.1.1 Pre Start-up 1. When you are installing a new pump because of a failure or gradual decrease in performance it is important that you change the pressure and return elements in the system. The entire hydraulic system requires flushing and installation of new hydraulic oil (as specified in the maintenance manual).

2. Be sure the hydraulic oil level in the tank is sufficient.

3. Remove the case drain fitting and fill the case with clean hydraulic oil. Reconnect the line when full.

4. Loosen the suction line at the pump to allow air to bleed from the line. When oil starts to run out reconnect the line.

5. Place a 4000-psi gauge at the pump outlet for testing.

5.3.1.2 Start-up 1. With a wrench remove the protective nuts (see Fig 5.3.2) from the set screws for the differential pressure and compensator control adjusters. Loosen the jam nuts and unscrew both adjustments until you no longer feel any resistance from the control springs. Be sure not to screw them all the way out. This will allow the pump to start a minimum pressure.

2. If the pump is diesel driven, very slightly loosen off the outlet pressure hose or a downstream hose connection. Bump the starter for 2 to 3 second periods to allow air to escape from the line and pump cavity. When oil starts to leak at the connection, you loosen retighten the fittings.

3. If the pump is driven with an electric motor, jog the starter for the motor and follow the same procedure as described for a diesel motor. After you tighten the fitting you used to bleed out the air, run the electric motor. If the pump is noisy, “crack” the fitting again to bleed of the air. Air is probably still in the suction line or pump.

4. Once the pump runs quite, adjust the differential (Standby) pressure setscrew (See Fig 3.1) clockwise until the pressure on the outlet of the pump is at the required standby pressure. See the hydraulic section of the maintenance manual for the proper setting for your equipment. Once you have set the pressure lock the jam nut and replace the protective nut on the differential pressure adjustment.

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5. Next set the compensator control adjustment to recommended setting found in the hydraulic section of the maintenance manual. To achieve this you will have to bottom out a control at the valve bank where the load sense pilot line was connected. This is done to provide a signal back to the pump to determine a setting for the compensator. Once the compensator is set tighten the jam nut and replace the protective nut.

Differential (standby) Pressure Adjustment

Jam Nut

Protective Nuts

Jam Nut Load Sensing Connection

Case Drain

System (operating) Pressure Adjustment

Inlet and Outlet

Fig 5.3.2 Hydraulic Pump

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5.3.2 Adjustments 5.3.2.1 System (Operating) Pressure Adjustment The system pressure is set at the pump’s control valve, mounted at the rear of the pump (see Fig 5.3.1). If the drill is not equipped with a system pressure gauge, connect a gauge on the inlet side of the pressure filter. Install a T-fitting and cap the line if the gauge is to be removed later.

1. Remove the protective cap and loosen the locknut on the system pressure adjustment. Check that personnel are away from the drill and start pump.

2. Set pressure to 4000 psi (278 bar) for a QXR drill by turning the setscrew with a 4mm allen key. Turn it counter-clockwise to reduce pressure. One turn creates a pressure change of approximately 725psi (50bar).

3. Reinstall the protective cap and torque to 15ft-lbs (21 N m).

5.3.2.2 Stand-by Pressure Adjustment The stand-by pressure is the minimum pressure maintained during zero pump load. It is set at the control valve mounted at the rear of the pump.

1. Install pressure gauge on inlet side of pressure filter.

2. Remove the protective cap and loosen the locknut on the stand-by pressure adjustment. Check that personnel are away from the drill and start pump.

3. Set pressure to 400 psi (27.6 bar) by turning the setscrew.

4. Reinstall the protective cap and torque to 6 ft-lbs (8.1 N m).

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5.3.3 Testing the Pump The condition of a pump can be determined by checking the flow.

Install a flow meter in series with a restrictor valve on the discharge line of the pump (Make sure the restrictor valve is large enough to handle the flow from the pump). Run this line back to the tank (see Fig 5.1). Make sure the load sense line is included in the circuit.

While the pump is running, slowly restrict the flow with the valve you installed. As the flow is restricted it should actually increase due to the load sense of the pump. The flow increase should continue until the pressure reaches 80 to 90 percent of the compensator pressure. At this point the flow will drop off as the pressure reaches 100 percent of the compensator pressure at which point the flow will be zero. See Table 5.3.A to determine the expected flow from your pump @ 1750 rpm.

Restrictor Valve

Flow Meter

Return back to tank

Load Sense Line

Fig 5.3.3 Test Circuit Pump Size

Acceptable Pump Flow

71 cc

27.5 to 31 gpm

100 cc

39 to 44 gpm Table 5.3.A

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The approximate condition of a pump can also be determined by the flow produced from the case drain. No more than 10 to 12 percent of the pump output should be coming from the case drain. This means at a speed of 1750 RPM, the case drains contained in Table 5.3.B should apply.

Pump Size

Acceptable Pump Flow

71 cc

27.5 to 31 gpm

100 cc

39 to 44 gpm Table 5.3.B

NOTE: For a case drain leakage test it is recommended that you DO NOT use a flow meter. This is because piston pumps are very sensitive to case drain pressure. Using a flow meter in most cases causes a certain back pressure that could damage the pump. Instead, use the manual method of directing the case drain into a pail of known volume while measuring the time and calculating the flow.

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5.3.4 Troubleshooting the Pump Problem

Cause

Explanation

Corrective Action

Hydraulic system is not performing as it should. For example the drill has lost performance.

Standby pressure is set to “low”.

A low standby pressure setting will cause the pump to destroke too soon, preventing the required flow from reaching the hydraulic system.

Check the differential pressure setting.

Pump is bypassing.

The pump has been contaminated, cavitated, aerated, or otherwise worn.

Check the pump’s condition. If the pump does not pass standards, replace.

Loss of load sense signal.

The load sense line has become disconnected or obstructed and the signal is not getting back for the pump to compensate.

Check the load sense line for leakage at fitting, breakage, or an obstruction.

The case drain of the pump generates excessive heat.

Pump is worn.

If the pump is contaminated, its efficiency will deteriorate and manifest itself as a case drain leak.

Check the acceptable pump performance as outlined in Section 5. Change pump out as necessary.

Pump is noisy.

Pump is cavitating / aerating.

If a piston pump is being starved of oil or has air trapped in the oil (aeration), it will sound noisy when running.

Shut the system down.

Make certain the inlet to the pump is not restricted.

Make certain there are no kinks, twists, or obstructions in the suction line.

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5.3.5 Factors Affecting the Pump’s Life The weak link of swashplate piston pumps is the slipper pad arrangement and there are a number of conditions that may detrimentally affect the life of the pump by damage in this area. Essentially there are four possible conditions which may contribute to a failure in this area. These conditions are contaminated fluid, too high a vacuum at the pumps inlet, excessive case pressure and too low of an operating pressure.

5.3.5.1 Contaminated Fluid Besides the obvious accelerated wear caused by contaminated fluid, in extreme cases contaminants can also plug the lubrication passages in the piston/slipper pad area. The principle of the slipper pad design is that the hydraulic force, which pushes the piston towards the swashplate is counteracted by a pressure force acting in the opposite direction.

High-pressure oil in the piston chamber is routed via a drilling through the piston knuckle and slipper pad to a recess between the slipper and swashplate. This area is designed to have an effective area, which precisely balances the pressure forces caused by the piston.

1. If this passage becomes plugged with contamination…

2. Lubrication and hydrostatic balancing are lost here…

3. Which causes slipper pad failure.

Fig 5.3.4 Contamination The relatively small drillings keep the leakage low and the volumetric efficiency in the pump high. If the system has a high level of contamination it is possible that these drillings can become plugged. This would lead to an accelerated failure of the slipper pad since both lubrication and balancing forces would be lost.

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5.3.5.2 Poor Suction Conditions The piston/slipper assemblies are connected together via a crimp connection. This type of connection is excellent under compression but cannot stand high tensile forces. During the suction process, the piston is drawn back out of the bore because of the retaining plate pulling on the slipper pad. If the vacuum at the pump’s inlet is too high it will oppose this motion and the tensile force will increase to a point where two modes of failure occur.

The retaining plate flexes and allows the slipper to lose contact with the swashplate.

On the pressure side of the pump’s rotation, the slipper is once again brought to contact as the high-pressure oil forces the piston back. At this point, the slipper is damaged due to rounding of the slipper corners from uneven re-seating contact.

Repetition of this process will damage the slipper to a point where it can no longer retain its lubricating pool of oil and the pump will fail.

The high vacuum forces the slipper pad to simply be pulled off the piston knuckle if the tensile strength of the connection is overcome.

CAUTION! Unfortunately, it is difficult to detect this failure by listening to the operation of the pump and the pump will keep running until it is destroyed.

1. Too much vacuum here…

2. Or too high a case pressure here…

3. Will cause slipper pad lift-off and slipper/piston serration.

Fig 5.3.5 Poor Suction Conditions

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5.3.5.3 Excessive Case Pressure Excessive case pressure has the same effect on the piston/slipper assembly, as does the too high of vacuum condition. As can be seen in Fig 5.3.6, the two areas actually work together to force the piston to the left, causing a high tensile force in the piston/slipper connection.

Because of this, a marginal suction condition and a marginal case pressure condition may work together to cause a failure of this type.

Fig 5.3.6 Excessive Case Pressure In order to avoid damage by either of the above two conditions, the suction line and drain line should be optimized. This means that the pump should always have a flooded suction (mounted below the oil reservoir oil level) and there should be limited resistance in the suction line itself. Therefore, the amount of bends should be minimized and only full area shut-off valves should be used if required. The case drain should be full sized and as short as possible back to the reservoir. It is not advisable to tee the case drain line in with any other return lines and each pump case should be routed individually back to the reservoir.

5.3.5.4 Too Low an Operating Pressure The running area between the slipper pad and the swashplate relies on high pressure oil for lubrication. If the pressure at the outlet of the pump is too low (i.e. The pump outlet is unloaded to tank), excessive wear will occur in this area causing premature pump failure.

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5.3.5.5 Cavitation/Aeration Cavitation results when air, which is typically entrained or dissolved in the hydraulic fluid, is allowed to expand because of a low-pressure situation. This occurs in pump inlets, which by nature have a low-pressure condition. The expanded gas bubbles at the inlet collapse with considerable force as the pumping chamber is exposed to system pressure. This collapsing action results in rapid energy losses in the form of heat and noise. This energy level is also high enough to cause serious damage to the lens plate and/or the cylinder barrel of the pump.

Aeration is somewhat different than cavitation, however the resulting noise and damage to the pump is nearly identical. Aeration occurs when there are air bubbles present in the reservoir fluid at atmospheric pressure (typically caused by excessive foaming or vortexing at the pump inlet). These air bubbles are then drawn into the inlet line of the pump and ultimately cause of the same damage as described in cavitation.

Damage caused by cavitation and / or aeration

Fig 5.3.7 Cavitation / Aeration

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5.4 HYDRAULIC CYLINDERS (08/03/25)

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5.4 Hydraulic Cylinders All cylinders are double acting.

PM Tasks The cylinder rods are the main source where contamination enters the hydraulic system. Any surface damage on the cylinder rods hold foreign matter that is absorbed into the hydraulic fluid. Keep the cylinders clean and in good condition. If premature cylinder failure is suspected, perform the cylinder inspection noted below.

250 Hour Intervals:

•

Wash and inspect cylinder rods, rod wipers

1000 Hour Intervals:

•

Wash and inspect cylinder rods, rod wipers

•

Inspect cylinder operation

NOTICE Washing cylinder rods extends seal life.

The following tools are recommended for servicing the telescopic feed cylinders:

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5.4.1 Double Acting Cylinders 1. Dismantle each double acting cylinder separately. Clean and degrease all parts and tools contacting seals.

2. Deburr sharp edges that may contact seals.

3. Use hydraulic fluid on parts and seals before installation.

5.4.2 Cylinder Inspection Perform a cylinder inspection if premature cylinder failure is suspected.

1. Improper installation of seals is apparent when cuts or nicks in seals are noticed. This is the most frequently occurring problem.

2. Break-down or softening of seals may indicate incompatible seal types.

3. Physical damage of seals may indicate fluid contamination. Most external contamination enters the system during rod retraction. Look for scratched rod and cylinder surfaces.

4. Hardening of seals may indicate hot running conditions.

5.4.3 Cylinder Overhaul Seal types must be compatible with the fluid and temperature range. Refer to the Parts Manual for service kits.

1. Clean, inspect and replace all parts. Lubricate seals and all parts that contact seals.

2. Referring to Parts Manual, reassemble cylinder in reverse order.

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5.5 CONTROL VALVES – ON/OFF TYPE (08/03/25)

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5.5 Control Valves – On/Off Types The control valves are load-sensing types. Valves, which control cylinders, are equipped with closed center spools. Valves, which operate motors, are fitted with open center spools.

Proportional models are used where variable flow is required and On-Off types are installed in the remaining applications (See next page). Depending on the drill’s options, the valves are manually or electrically operated. Refer to the Troubleshooting Section and Electrical Section when determining operating problems.

PM Tasks Periodic maintenance is limited to external inspections. Overhauling the control valves includes replacing O-rings, seals and setting the pressure and flow. See Valve Specifications below for these settings. If additional parts need servicing, it may be more economical to replace the individual valve sections.

1000 Hour Intervals:

Visual inspection

2000 Hour Intervals:

Visual inspection. Operate controls to check for proper operation

WARNING! After installing hydraulic components and hoses, check that hydraulic actuators are operating in direction as indicated on controls.

CAUTION! Two types of valves are used: On/Off and Proportional.

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Controls

Valve Type

Flow Rating

Pressure Setting

Flow Setting

Upper Breakout Clamp

On/Off

26.4 gpm (100 l)

Note 1

Wide open

Lower Breakout Clamp

On/Off

26.4 gpm (100 l)

Note 1

Wide open

Cab Tilt

On/Off

1.3 gpm (5 l)

Note 1

Note 2

Cab Swing

On/Off

1.3 gpm (5 l)

Note 1

Note 2

Oscillation

On/Off

1.3 gpm (5 l)

Note 1

Wide open

Winch

On/Off

10.2 gpm (40.0 l)

1500 psi (103 bar)

Note 2

Breakout

On/Off

2.6 gpm (9.8 l)

Note 1

Wide open

Slip Plate

On/Off

6.6 gpm (25 l)

Note 1

Wide open

Centralizer

On/Off

6.6 gpm (25 l)

1500 psi (103 bar)

Wide open

Air

On/Off

1.3 gpm (5 l)

1000 psi (68.9 bar)

Wide open

Diverter

On/Off

2.6 gpm (10.0 l)

Note 1

Wide open

Carousel Arm

On/Off

6.6 gpm (25 l)

2800 psi (193 bar)

Note 2

Carousel Clamp

On/Off

6.6 gpm (25 l)

2800 psi (193 bar)

Wide open

Carousel Motor

On/Off

2.6 gpm (10.0 l)

Note 1

Note 2

Grinder

On/Off

10.2 gpm (40.0 l)

Note 1

Note 2

Notes: Note 1: Not applicable.

Note 2: Adjust to a speed that feels comfortable to the operator.

Relief Valve Setting: See schematics.

Note: On/Off valves are equipped with black connectors.

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5.5.1 Control Valves The valve banks consist of five major components, which are the valve section, lever assembly, end plate, inlet section, and solenoid (See Fig 5.5.1). Malfunctioning of the control valves could be a mechanical, hydraulic or electrical problem. Therefore, each criterion needs to be checked. Refer to the Troubleshooting Section when determining operating problems.

Fig 5.5.1 Valve Adjustment

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5.5.2 Relief Valve Adjustment Each valve bank has its own internal relief valve that needs to be adjusted when the control valves are serviced. The relief valve is located in the inlet section (See Fig 5.5.2).

NOTE: Operating pressure in hydraulic pump must be set correctly before performing this adjustment.

1. Remove protective cap on inlet section for relief valve 2. Move cylinder to full stroke.

Block movement of any small cylinder to build up pressure.

CAUTION! Check that blocking does not move when force is applied.

3. Open control valve to blocked cylinder and observe hydraulic pressure gauge.

Adjust relief valve setting to 3200 psi (221.1 bar). Reinstall cap and remove blocking. Reset pump pressure to spec. (max pressure).

5.5.2 Relief Valve Adjustment

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5.5.3 Valve Pressure Adjustment The valves do not require any periodic adjustment after the initial setting. After servicing the valves, set the pressure adjustment for both ports as shown in Fig 5.5.1 using the pressure setting listed in the Valve Specifications.

NOTE: On rotation valve, reverse pressure is much higher than forward pressure to allow for breaking of tool joints.

1. Block movement of any small cylinder to build up pressure.

CAUTION! Check that blocking does not move when force is applied.

2. Remove caps at valve section. Refer to pressure settings listed in Valve Specification at the beginning of section 5.5.

3. Adjust both ports independently while observing pressure gauge at control panel.

A 6 mm allen key is required. Each rotation of 360o creates a pressure change of 1400 psi (96.7 bar).

4. Reinstall caps and remove testing equipment.

5.5.4 Valve Flow Adjustment The flow adjustment screws are located on the handle section, as illustrated in Fig 5.5.2. The upper setting screw controls port ‘B’ and the lower setting screw controls port ‘A’.

1. Loosen lock nuts. Note flow setting listed in Valve Specifications at the beginning of Section 5.5.

2. Adjust both ports independently, using allen key.

NOTE: Water pump is run proportionally.

3. Tighten lock nuts at flow adjustment and remove testing equipment.

5.5.5 Valve Overhaul Overhauling any of the five valve components requires replacing of seals and O-rings. Work on each section separately to avoid mixing of parts with other valve sections. Wash the body and parts in solvent, and dry with compressed air. Inspect moving parts for wear and replace as required. Lubricate moving parts and O-rings with hydraulic fluid. When ordering replacement parts, specify the serial number and model of the drill.

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5.5.6 Valve Sections All O-rings must be replaced between each valve section (See Fig 5.5.3).

1. Remove nuts (1) and studs (3) to disassemble valve sections.

2. Replace O-rings 4, 5, 6, and 7. Reassemble in reverse order and torque nuts (1) to 200 in.-lbs. (23 N m).

5.5.7 Solenoid The solenoid is not serviceable and must be replaced when malfunctioning. A special adjustment procedure may be required for the rotation and feed valves. Refer to Solenoid Adjustment in this section if the joystick movements produce uneven speeds in both directions.

1. Remove solenoid as shown in Fig 5.5.4.

2. Replace filter (7) and O-rings (8 & 9).

3. If electrical connector is damaged, replace it with connector of same color for ease of identification (See Valve Specifications).

4. Reassemble in reverse order and torque capscrew (2) to 70 in.-lbs. (8 N m).

5.5.8 Lever Section The handle section does not require frequent servicing (See Fig 5.5.5).

1. Replace damaged parts as well as O-rings (9 &10) located between handle section and valve.

2. Reassemble and torque items 2, 4, 5, and 7 to 70 in.-lbs. (8 N m).

3. Set Flow Adjustments, as outlined previously in this section.

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5.5.9 Valve Assembly Fig 5.5.6 is a general assembly diagram and may show some additional parts. Therefore, it is critical to specify the model and serial number when ordering replacement parts. Work on one valve section at a time, to avoid mixing of parts.

1. Dismantle valve section as shown.

2. Install required parts, making sure that new parts are identical to existing ones.

3. Torque fasteners as follows: Item 17 and 19

360 in.-lbs. (40 N m)

Item 3

220 in.-lbs. (25 N m)

Item 15

70 in.-lbs. (8 N m)

4. Set Pressure Adjustment, as outlined previously in this section.

5.5.10 Inlet Section The inlet section contains the relief valve. Fig 5.5.7 is a general assembly diagram and may show some additional parts. Therefore, it is critical to specify the model and serial number when ordering replacement parts.

1. Dismantle inlet section as shown. Inspect, clean and replace parts as required.

2. Torque fasteners as follows: Item 3

360 in.-lbs. (40 N m)

Item 13 and 15

220 in.-lbs. (25 N m)

Item 6 and 23

70 in.-lbs. (8 N m)

3. Assemble and install complete valve bank into drill.

4. Start hydraulic pump and adjust relief valve in inlet section, as outlined previously in this section.

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5.6 MANIFOLD BLOCKS (08/03/25)

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Accra-Feed Manifold

Air Pressure Transducer

Rotation Pressure Switch (not installed in this picture) Low Compressor Oil Switch

Tram High/Low Pressure Reducing Valve Carousel Pressure Reducing Valve

Tram High/Low Selector Valve

Fig 5.6.1.a Accra-Feed Manifold and surrounding components

Accra-Feed Manifold located behind the panel

Fig 5.6.1.b Accra-Feed Manifold location

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5.6 Manifold Blocks The Accra-Feed manifold (see Fig 5.6.1) contains cartridge valves that control the Accra-Feed functions. Refer to Fig 5.6.2.

The Pipe Arm Sequence manifold (see Fig 5.6.4) contains cartridge valves that control the pipe arm sequence functions. Refer to Fig 5.6.3.

The TJBO manifold (see Fig 5.6.6) contains cartridge valves that control the triple jaw breakout functions. Refer to Fig 5.6.5.

5.6.1 Servicing Cartridge Valves Cartridge valves are basic service items; they are easily removed from their mounting in the cavity for cleaning or replacement. It is not necessary to remove an entire cartridge valve assembly, i.e. cartridge/body assembly, from the circuit piping or solenoid valve stack.

Simply unscrew the cartridge valve from its mounting configuration for troubleshooting or replacement.

Ensure that all loads are adequately supported and the system is depressurized before performing any service work.

While considered service items, cartridge valves are not designed to be disassembled in the field. If, for any reason, a cartridge valve does not perform as required, follow the trouble shooting steps that follow. If the cartridge still does not function, it should be replaced.

5.6.2 Troubleshooting Cartridge Valves The most common cause of failure of a cartridge valve is contamination in the hydraulic fluid, which can then lodge in the working parts of the cartridge and interfere with their operation. If necessary, the following cartridge valves can be easily cleaned without altering their settings: RP**, RV**, RS**, PB**, PP**, FX**, LP**, and LR**.

1. First secure any moving elements associated with the equipment and ensure that all loads are adequately supported.

2. Carefully de-pressurize the hydraulic system.

3. Remove the cartridge from its cavity.

4. Inspect the cartridge for visible contaminants and, if found, carefully remove any obvious particles.

5. Through the nose of the cartridge, manually operate the inner working parts several times.

Use a piece of plastic tubing to avoid damaging soft seats, sharp edges, finished surfaces or the screen protecting the pilot orifice. All parts should move freely. If possible, this inspection should be done with the cartridge submerged in clean mineral spirits.

6. After flushing, blow-dry the cartridge with clean, filtered air.

7. Replace any seals that are worn or damaged, using the appropriate seal kit.

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Fig 5.6.2 Accra-Feed Manifold schematic

Fig 5.6.3 Pipe Arm Sequence Manifold schematic

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8. Dip the cartridge in clean hydraulic fluid, and then reinstall the cartridge and tighten to the specified torque and retest.

9. If this procedure does not eliminate the operational problem, replace the malfunctioning cartridge with a new, factory-tested cartridge valve.

Pipe Arm Sequence Manifold located on the mast

Fig 5.6.4 Pipe Arm Sequence Manifold

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TJBO Manifold located on the mast

Fig 5.6.5 TJBO Manifold location

Fig 5.6.6 TJBO Manifold schematic

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Fig 5.6.7 Pipe Arm Sequence Manifold parts

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5.6 MANIFOLD BLOCKS (08/03/25)

Fig 5.6.8 Accra-Feed Manifold parts

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Fig 5.6.9 TJBO Manifold parts

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5.6.3 Installation Torque Values When installing cartridge valves, torque to values shown in Table 8.

Table 8 Cartridge Valve Torque Values Series

Torque (lb-ft)

Hex

Thread

Cavities

Z

100-120 (lb-in)

3/16”

3/8” – 24 UNF

T-382A

P

25 – 30

7/8”

M16

T-8A, T-9A

0

25 – 30

3/4”

M16

T-162A, T-163A T-10A, T-11A,

1

30 – 35

7/8”

M20

T-13A, T-21A, T-31A, T-61A T-2A, T-3A,

2

45 – 50

1 1/8”

1”-14UNS

T-5A, T-22A, T-32A, T-62A T-16A, T-17A,

3

150 – 160

1 1/4”

M36

T-23A, T-33A, T-63A T-18A, T-19A,

4

350 – 375

1 5/8”

M48

T-24A, T-34A, T-64A

BI620146

5.7 COUNTERBALANCE VALVES (08/03/25)

5-07-001

5.7 Counterbalance Valves

Counterbalance valves with pilot assist combine two valves; a check valve and a relief valve.

The check valve allow free flow from the directional valve (port 2) to the load (port 1) while a direct acting, pilot-assisted relief valve controls flow from port 1 to port 2. Pilot assist at port 3 lowers the effective setting of the relief valve at a rate determined by the pilot ratio.

Fig 5.7.1 Counterbalance Valve

BI620146

5.7 COUNTERBALANCE VALVES (08/03/25)

5-07-002

The counterbalance valve will be on of the most difficult valves you will have to ‘set’ on a piece of equipment. It is difficult to determine the setting of the valve while in the circuit in the usual manner. Because of this, the counterbalance valve has to be ‘bench set’ off the machine with a special block for this purpose.

You will need the following items to set the counterbalance valve: •

A pressure gauge that is suitable for the pressure involved.

•

A Sun Hydraulics P/N BCJ/S body with a T-2A cavity (Test Block).

•

A hydraulic hand pump.

•

Miscellaneous hoses and fittings.

See Fig 5.7.2 for set-up.

5.7.1 Making Adjustments Before removing the counterbalance valve, ensure machines and loads (i.e. Top Drive) are mechanically held in position or at rest. Also make sure that the valve is not under pressure at the time of removal.

1. Remove the counterbalance valve and install into testing block.

2. Loosen lock-nut on counterbalance valve.

3. Insert an allen key into the adjusting screw and turn out (counter-clockwise) to increase the pressure setting or in (clockwise) to reduce the pressure setting.

4. While looking at gauge, pump up test system pressure with hand pump and set valve to relieve at recommended setting. See Fig 5.7.1 for location of setting on valve.

5. Repeat several times to ensure the consistency of the setting.

Fig 5.7.2 Test Gauge

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5.7 COUNTERBALANCE VALVES (08/03/25)

5-07-003

5.7.2 Troubleshooting The most common cause of failure of a counterbalance valve cartridge is seal failure or contamination in the hydraulic fluid, which can then lodge in the working parts of the cartridge and interfere with their operation. The major symptom of a failed counterbalance valve is ‘creeping’ in the cylinder.

1. Before removing the counterbalance valve, ensure machines and loads (i.e.

Top Drive) are mechanically held in position or at rest. Also make sure that the valve is not under pressure at the time of removal.

2. Remove the cartridge from its Cavity.

3. Inspect the cartridge for visible contaminates, if found, carefully remove any obvious particles.

4. Flush the cartridge in clean mineral spirits and blow dry with clean dry air.

5. Replace any seals that are worn or damaged.

6. Dip the cartridge in clean hydraulic fluid and re-install the cartridge tightening to the specified torque.

7. If this procedure does not eliminate the operational problem, replace the malfunctioning cartridge with a new, factory tested cartridge.

BI620146

5.7 COUNTERBALANCE VALVES (08/03/25)

5-07-004

BI620146

5.8 HYDRAULIC FILTRATION (08/03/25)

5-08-001

5.8 Hydraulic Filtration Change the hydraulic fluid at the recommended intervals to get maximum service life.

PM Tasks 250 Hour Intervals:

2000 Hour Intervals:

Filter Types:

•

Change filters

•

Check filter indicators for proper operation

•

Change filters

•

Change hydraulic fluid

•

Clean pressure filter indicators

Pressure filter:

cartridge (3 micron)

Return filter:

cartridge (10 micron)

WARNING! Disconnect power supply and mine air before servicing drill.

High pressure jet leaks may cause injury.

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5.8 HYDRAULIC FILTRATION (08/03/25)

5-08-002

5.8.1 Change Hydraulic Fluid Every 2000 Hours 1. Drain hydraulic fluid and remove return filter cartridges.

2. Remove tank cover and clean tank. Flush as required.

3. Reinstall tank cover and new filter cartridges.

4. Fill with hydraulic fluid (Shell Tellus T37 or equal).

5.8.2 Return Filters 1. Use 1/2" wrench to remove end cap bolts. Remove filter element and wipe inside of filter housing. Check that bypass valve and cap seal are not damaged.

2. Lubricate seal on new filter element. Install filter and tighten end cap.

3. Start system, check for leaks and proper operation of filter bypass indicator.

Fig 5.8.2 Return Filter

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5.8 HYDRAULIC FILTRATION (08/03/25)

5-08-003

5.8.3 Pressure Filter Element Replacing the pressure filter element and servicing the filter indicator are performed at different intervals.

1. Remove drain plug from filter bowl to drain fluid.

2. Remove bowl and element, then clean inside of filter head and bowl.

3. Install new element with new O-ring which has been lubricated. Reinstall remaining filter parts.

4. Check fluid level then start system to check for leaks. If filter indicator is not performing properly, replace bypass valve inside filter head and service indicator.

When replacing bypass valve, remove filter bowl and filter indicator. Remove outlet hose connection and unscrew bypass valve by inserting suitable tool into holes provided.

Fig 5.8.4 Pressure Filter Assembly

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5.8 HYDRAULIC FILTRATION (08/03/25)

5-08-004

BI620146

5.9 PROPORTIONAL VALVES (08/03/25)

5-09-001

5.9 Proportional Valves Proportional load-sensing type valves are used where variable flow is required. Refer to the Troubleshooting Section and Electrical Section when determining operating problems.

PM Tasks Periodic maintenance is limited to external inspections. Overhauling the control valves includes replacing O-rings, seals and setting the pressure and flow. See Proportional Valve Settings below for these specifications. If additional parts need servicing, it may be more economical to replace the individual valve sections.

1000 Hour Intervals:

Visual inspection.

2000 Hour Intervals:

Visual inspection.

Operate controls to check for proper operation.

WARNING! After installing hydraulic components and hoses, check that hydraulic actuators are operating in direction as indicated on controls.

CAUTION! Operating pressure in hydraulic pump must be set correctly before performing this adjustment.

Improper Makeup & Breakout Speed may damage equipment or drill pipes.

All proportional valves are equipped with white/grey connectors.

These instructions apply to proportional valves only.

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5.9 PROPORTIONAL VALVES (08/03/25)

5-09-002

5.9.1 Proportional Valve Settings Controls

Valve Type

Flow Rating

Pressure Setting

Flow Setting

Tram, left

Proportional

47.0 gpm (177.9 l)

N/A

Wide open

Tram, right

Proportional

47.0 gpm (177.9 l)

N/A

Wide open

Rotation

Proportional

47.0 gpm (177.9 l)

See Note 1

Wide open

Feed

Proportional

47.0 gpm (177.9 l)

N/A

Wide open

Water Pump

Proportional

10.2 gpm (40.0 l)

N/A

See Note 2

Feed Extension

Proportional

10.6 gpm (40 l)

Note 3

Wide open

Mast Swing Control

Proportional

10.6 gpm (40 l)

Note 3

Note 4

Mast Dump

Proportional

10.6 gpm (40 l)

Note 3

Note 4

Boom Swing

Proportional

6.6 gpm (25 l)

Note 3

Note 4

Boom Lift

Proportional

10.6 gpm (40 l)

Note 3

Note 4

Notes:

1. Forward pressure: 1600 psi (110 bar), Reverse pressure: 3200 psi (220.6 bar). Reverse pressure is much higher than forward pressure to allow for breaking of toll joints.

2. Set flow to run water pump motor at 225 rpm using a tachometer.

3. Not applicable 4. Adjust to a speed that feels comfortable to the operator.

BI620146

5.9 PROPORTIONAL VALVES (08/03/25)

5.9.2 Flow Settings Proportional valves are used in Tram, Rotation and Feed controls.

Refer to Proportional Valve Settings when adjusting flow in each valve section.

Fig 5.9.1 Flow Adjustment

5-09-003

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5.9 PROPORTIONAL VALVES (08/03/25)

5-09-004

5.9.3 Pressure Setting Proportional valves are used in Tram, Rotation, and Feed controls.

Refer to Proportional Valve Settings when adjusting pressure in pump side module.

Fig 5.9.2 Adjusting Screw

1. Remove cap.

2. Loosen setting screw.

3. Loosen counter nut by turning it a few times.

Fig 5.9.3

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5.9 PROPORTIONAL VALVES (08/03/25)

5-09-005

4. Set pressure according to Proportional Valve Settings.

5. Turn counter nut to end stop against setting screw.

Fig 5.9.4

6. Turn setting screw in reverse direction with specified torque.

7. Mount protective plug and tighten as specified torque.

Fig 5.9.5

BI620146

5.9 PROPORTIONAL VALVES (08/03/25)

5-09-006

BI620146

6.0 DRILL AIR CIRCUIT (08/03/25)

6.0 DRILL AIR CIRCUIT

CAUTION! Wipe up spills immediately!

BI620146

BI620146

6.1 AIR SCHEMATIC (08/03/25)

6-01-001

6.1 Air Schematic See the Appendix for a full size schematic.

Fig 6.1.1 Air Schematic

BI620146

6.1 AIR SCHEMATIC (08/03/25)

6-01-002

Schematic Key # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

PART No. CP18015-10 CX000211 CP18038 CP18039 CP17017 CX000212 CP17054 CP17054-2 CP18037-002 CP18037-001 CP18016-5 CP18313-2A CX000545 CP18313-2 CP55012 CX005124 CM48024-350-38 CM48024-350-214 CM48024-350-180 CP18021 CP55010 CP18016-5 CP17020-1 CP18222-8 CX008057 CP18422-18 CP18422-18-1 048046 CP17074 CQ18422-300 CP19403 CP18025-1 CP18125 CP17013-12 CP17112-1 CM17012-1 CP000300 CP000134 CP47146 C48024-350-100 CP18115-5 CP18147-1 CM17012-2 CP18020 CP18015-4 CM18318-1 CP17052-550 250031-852 CP17013-9 CX002593 CM77033-2KIT 02250111-923 02250111-924 CP17053

DESCRIPTION Solenoid Valve Grease Injection Assy Injector Check Valve Breather Grease Tank Grease Pump Solenoid Valve Air Lubricator Air Filter Pressure Regulator Thread Greasing System Regulator, 200-600 PSI Grease Pump Assy Pressure Switch Top Drive 6240- #24 Air Hose, Top Drive-Bulkhead Air Hose, Bulkhead-Bulkhead Air Hose, Bulkhead-Bulkhead Safety Tie Pump Pressure Regulator Gauge, Water 0-1000PSI Unloader Valve, Water BEAN Water Pump Assy Water Filter (Course) Filter Element Sight Glass Cap Fill Vent 2.5" Water Tank Sensor, Water Level Check Valve, 1/2" Inline Check Valve Ball Valve Valve Actuator Actuator Bracket Pressure Sensor, 0-1000PSI Restrictor Indicator Switch Check Valve Air Hose, Bulkhead-Drill Ball Valve 1 1/2" Solenoid Valve Stub Shaft Needle Valve 1/4" 3/8" Ball Valve Water Trap Assy Safety Relief Valve Minimum Pressure/Check Valve 3/4" Ball Valve Receiver Tank Assy Filter Element W Gasket Moisture Separator Filter Element Separator Restrict. Indicator

QTY 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 8 1 1 1 1 1 1 A/R 3 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 A/R 1 A/R 1

# 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91

PART No. 048061 CP55015-2 CP18147-2 CP18006-2 CP000280 CP17059 CP17058 047525 CP17146 02250116-974 CP18422-21 CP18422-21-1 CP17057 047524 02250111-620 02250111-619 CP17062 CP17062-1 02250044-281 CX000544 CX000671 250041-069 02250051-747 409011 250025-294 046559 022033 02250055-528 CP41018-39 02250150-527 CP000108 CP000821 CP000822 250024-942 02250126-832 02250111-630 02250111-629 CP18006-1 CP17086 CP18025-5 02250107-045 CP55010-AR1 CP18146 CP55015-3 CP55015-4 CM55013 CP55005 CP000981

DESCRIPTION Gauge, Sys Press 0-600 PSI 2 Bank Injector Coil 24VDC Gauge Radiator Assembly Muffler System Blowdown Valve Repair Kit Inline Check Valve Ball Valve Water Filter (Fine) Filter Element Running Blow Down Valve Repair Kit Thermal Bypass Valve Element Main Fluid Filter Filter Element Oil Return Strainer Regulator, 100-400 PSI 1/4" NPT Ball Valve Valve Oil Stop Repair Kit For 250041-069 Cylinder, Air Inlet Control Orifice 0.187" Sight Glass Orifice Pressure Switch, Low Oil Flex Hose-S/S 3"x29-5/8" Screw Compressor 1150/500 Air Filter Assy Primary Air Filter Secondary Air Filter Gauge, Comp Discharge Temp Discharge Check Valve High Temp. Switch 300F High Temp Switch 280F Gauge 0-400 PSI Pressure Regulator Inline Check Valve Pressure Relief Valve Grease Injection Assy 2-Way Solenoid Valve 3-Bank Injector 4-Bank Injector 2-Bank SL1 Injector 4-Bank SL1 Injector Low Level Indicator

QTY 1 2 1 1 1 1 1 A/R 3 1 1 A/R 1 A/R 1 A/R 1 A/R 1 1 1 1 A/R 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 13 2 2 1

BI620146

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-001

6.2 Sullair Compressor Your new Cubex QXR Drill is equipped with an onboard two stage, high-pressure Sullair rotary screw compressor, offering superior performance and reliability along with a minimal amount of maintenance requirements.

Compared to other compressors, the Sullair is unique in mechanical reliability with virtually no wear or loss of performance. With Sullair compressors, no inspection is required of the working parts within the compressor unit.

The package includes a compressor unit, cooling and lubricating system, air inlet system, compressor discharge system, capacity control system and instruments.

Fig 6.2.1 Compressor

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-002

Housing unit showing air cavities and rotor bearing

Rotors: driving and driven

End Housing

Housing with Rotors installed Fig 6.2.2

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-003

6.2.1 Compressor Unit Functional Description Refer to Fig 6.2.2 and Fig 6.2.3 The compressor unit supplied with this drill is a two-stage positive displacement, high pressure, flood lubricated type rotary screw air compressor.

Each stage of the compressor utilizes two rotors to compress the incoming air. In the first stage, air is drawn in through the inlet system and introduced to the rotors. A driven male rotor drives a female rotor and as they turn the air is compressed and forced around to the discharge side where it is then discharged to a manifold connecting it to the high-pressure stage. The process is then repeated to obtain an even higher pressure. The quantity of air can easily be controlled by regulating the amount of incoming air or by varying the speed at which the unit rotates. The speed of the unit can be varied by engine speed or changing gear sets.

NOTE: Each Sullair rotary screw compressor uses oil as a lubricant sealant and coolant medium (mineral or synthetic). Due to the many types of oil used in the marketplace, this section will refer to oil as “fluid”.

Fluid is injected into the compressor and mixes directly with the air as the rotors turn, compressing the air. The fluid has three main functions, •

As coolant, it controls the rise of air temperature normally associated with the heat of compression.

•

It seals the leakage paths between the rotors as well as between the rotors and stator.

•

It acts as a lubricating film between the rotors allowing the male rotor to directly drive the female rotor, which is an idler.

After the air has been compressed, it is discharged in the form of an air/fluid mixture. This mixture is routed through the discharge system where the fluid is separated from the air. At this time the air flows to the service line and the fluid is directed through the cooling and lubricating system in preparation for re-injection.

Low Stage High Stage

Fig 6.2.3 Compressor

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-004

Air Filter (within)

Oil Fill Plug

Receiver Tank

Sight Glasses Correct level is halfway up the middle sight glass

Fig 6.2.4 Receiver Tank and Components

Fig 6.2.5 Separator Element and Components

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-005

6.2.2 Compressor Discharge System Functional Description The Sullair compressor unit discharges a compressed air/fluid mixture into the sump. The discharge valve is located on the compressor unit at the end opposite the drive shaft. The discharge check valve prevents discharged air from returning from the compression chamber or sump on shut down.

From the discharge valve the air/fluid mixture is directed to the sump. The sump has four basic functions: •

Acts as a primary fluid separator.

•

Serves as the compressor fluid sump.

•

Houses the final fluid separator.

•

Serves as an air tank receiver.

The compressed air/fluid mixture enters the sump and is directed against the end of the tank.

By change of direction and reduction of velocity, larger droplets of fluid fall to the bottom of the sump. The fractional percentage of fluid remaining in the compressed air collects on the surface of the final separator element as the compressed air flows through the separator. As more and more fluid collects in the element surface, the fluid descends to the bottom of the separator. A return line (or scavenger tube) leads from the bottom of the separator element to the gear case of the compressor unit. Fluid collecting on the bottom of the separator unit is returned to the compressor gear case. An orifice (protected by a strainer) is included in this return line to assure proper flow.

The sump is ASME code rated at 600 PSIG (4137kPa) working pressure. A minimum pressure valve is located downstream from the separator to assure the required minimum receiver pressure during all conditions. This pressure is necessary for proper fluid circulation and air/fluid separation.

The system is protected from excessively high sump pressures by a 550 PSIG (37.69 bar) pressure relief valve, which is located on the wet side of the separator and is vented to atmosphere. Also, a two stage High Compressor Discharge Temperature Shut Down (a warning light comes on at 285° F, the compressor will shut down at 300°. F) and High Interstage Temperature Shut Down (set at 280 deg. F) will shut the compressor unit down if the temperature exceeds the normal operating range.

Fluid is added to the sump via a capped fluid filler opening placed low on the tank to prevent overfilling to the sump. A sight glass enables the operator to visually monitor the fluid sump level. The proper level is halfway of the sight glass when the unit is shutdown. DO NOT OVERFILL. A hydraulically operated 2-inch ball valve is used to open and close the discharge air when required.

WARNING! - DO NOT open the fluid filler cap when the compressor is pressurized. Shut down the compressor and bleed the sump to 0 PSIG before removing the cap

BI620146

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-006

C - From Cooler

B - To Cooler

A - From Tank

D - To Compressor

Port Stamped on Valve

Ports Stamped on Valve

Fig 6.2.5 Thermal Valve Entrance/Exit Ports

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-007

6.2.3 Compressor Cooling and Lubrication System Functional Description The compressor cooling and lubricating system is designed to provide adequate lubrication as well as maintain the proper operating temperature of the booster. In addition to a cooler and fan, the system consists of a main fluid filter, thermal valve, fluid stop valve, and pressure bypass valve.

Fluid is used in the system as a coolant and a lubricant. The fluid is housed in a receiver/sump.

Upon start-up, the temperature of the fluid is cool and routing to the fluid cooler is not necessary. The fluid, taking the path of least resistance, flows through the thermal valve to the compressor unit.

The thermal valve has two entrance ports and two exit ports. Refer to Fig 6.2.5. These ports are stamped on the thermal valve body indicating: A - From tank B - To cooler C - From cooler D - To compressor As previously stated, upon start-up the fluid temperature is cool and routing to the cooler is not required. The fluid first enters the thermal valve and then flows on to the compressor unit, bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and Port A of the thermal valve begins to close. The closing of Port A forces a portion of the fluid through the fluid cooler.

The cooler is a radiator type cooler that works in conjunction with the fan. The fan forces air through the cooler removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve, entering at Port B. Before the temperature of the fluid becomes high enough that Port A is completely closed, cooled fluid at Port B is mixed with warmer fluid entering Port A. When the temperature of the fluid reaches 210° F (99° C) Port A is completely closed causing all fluid to flow to the cooler.

The pressure bypass valve insures a supply of fluid to the compressor during periods of excessive pressure drops across the cooler, which may occur in extremely cold weather.

After the fluid passes through the thermal valve, it is then directed through the main fluid filter. There the fluid is filtered in preparation for injection into the compression chamber and bearings of the compressor unit.

The filter has a replaceable element and a built-in bypass valve, which allows the fluid to flow even when the element becomes plugged and requires changing, or when the viscosity of the fluid is too high for adequate flow. After the fluid is properly filtered, it lubricates, seals, and cools the compression chamber as well as lubricates the bearings and gears. The fluid stop valve is held open by a pressure signal from the compressor unit.

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6.2 SULLAIR COMPRESSOR (08/03/25)

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At shutdown, the pressure signal is lost and the fluid stop valve closes, isolating the compressor unit from the cooling system.

A Low Oil Pressure Shut-Off (set at 90 PSIG) will shut the compressor unit down in the event of low or no oil pressure.

Fig 6.2.6 Fluid Stop Valve

Fig 6.2.7 Main Compressor Fluid Filter

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-009

6.2.4 Air Inlet System Functional Description The compressor inlet system consists of an air filter, restriction indicator, and interconnecting piping to the compressor.

The air filter is a two-stage dry element type filter. This filter, which incorporates a dust removal system that utilizes the exhaust to aid in keeping the filter clean, is capable of cleaning extremely dirty air. In these conditions, it is recommended to clean the air filters on a regular basis and to check the air filter restriction indicators daily.

The air filter restriction indicator (see QXR operators manual for location) will show a red signal when the restriction of the air passing through the filter becomes too high.

At this time, change the air filter element and manually reset the restriction indicator. The indicator should be checked daily, after start-up under normal conditions.

Engine Air Filters

Compressor Air Filter

6.2.8 Air Inlet System

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-010

6.2.5 Lubrication Guide The reliability of the unit is dependant upon the selection and maintenance of the lubricant.

The ambient temperature, relative humidity, discharge pressure, and contamination levels must be considered in the lubrication selection. All lubrication oil(s) mentioned will be referred to as “fluid”.

Ambient Temperature

Lubricant

Change Interval – Hours

-40°C to -10°C

Esso Mobile Rarus SCH1024

1000 hrs.

-40°C to +14°F

Esso XD3 10W

-10°C to +40°C

Esso Mobile Rarus SCH1024

+14°F to +104°F

Esso XD3 10W

Over +40°C

Esso Mobile Rarus SCH1026

Over +104°F

Esso XD3 10W

1000hrs

1000hrs

6.2.6 Application Guide Water must be drained from the receiver periodically. In high ambient temperature and high humidity conditions, condensed moisture may emulsify with the oil forming a “milky” color.

ATF is especially prone to this condition. The fluid should be changed if this condition develops.

DO NOT mix different types of fluids. Combinations of different fluids may lead to operational problems such as foaming, filter plugging, orifice or line plugging.

When ambient conditions exceed those noted or if conditions warrant the use of other extended life lubricants, contact Cubex for recommendations.

Cubex encourages the user to participate in a fluid analysis program. This could result in a fluid change interval differing from that stated in the manual.

BI620146

6.2 SULLAIR COMPRESSOR (08/03/25)

6.2.7 Control System 6.2.7.1 Purpose of Controls

Fig 6.2.9 Purpose of Controls

6-02-011

BI620146

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-012

Control or Indicator

Key #

Purpose

Compressor

75

Two-Stage Screw Compressor

Receiver Tank Assembly

49

Acts as a fluid separator, sump, and air filter

Safety Relief Valve

46

Opens receiver/sump pressure to the atmosphere should pressure inside the receiver/sump tank exceed 550 psi (37.5 bar). Located on the wet side of the tank

Minimum Pressure Valve

47

Maintains required minimum pressure in the receiver/sump tank. This valve restricts the air discharge from the receiver/sump when the pressure falls below the minimum operating pressure.

However, full flow is allowed at normal operating pressures.

Separator Restriction Indicator

51

Indicates required servicing of fluid filter. The indicator will read in the red zone when a pressure drop through the filter is excessive.

Scavenger Line Strainer

65

A wire mesh strainer for filtering coarse contaminates in the return line from the separator.

Scavenger Line Sight Glass

71

Used to indicate flow of fluid going back to the compressor unit from the fluid pickup in the receiver/sump tank. When the compressor is running at full load, fluid flow should be visible in this sight glass. There may be little or no flow when the compressor is running unloaded. A sluggish flow at full flow indicates a need to clean the fluid return line strainer and/or orifice.

Scavenger Line Orifice

72

Maintains the correct oil flow from the scavenger line.

Thermal Bypass Valve

63

Controls direction of fluid through the oil cooler depending on the temperature of the fluid.

Main Fluid Filter

64

Filters fluid prior to injection into compressor.

Fluid Stop Valve

68

Cuts off fluid flow to the compressor unit upon shutdown. On start-up, it allows fluid to flow to the compressor.

Cooler

56

Removes heat of compression from the fluid.

Manual Drain Valve

48

Manual valve for draining receiver tank.

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6.2 SULLAIR COMPRESSOR (08/03/25)

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Control Line Moisture Separator

50

Removes vaporized moisture, fluid, contaminates in a filter medium where they are merged as droplets which collect in a drain area. The drain area is cleared by hand through the petcock at the bottom.

It is recommended that this be done daily or more frequently under severe conditions.

Control Line Pressure Gauge

52

0-600 psi pressure gauge

500 psi Pressure Regulator

13

Operates the running blowdown valve while opening a pressure line between system pressure and the inlet control cylinder when in High mode. This allows the inlet control cylinder to regulate air delivery according to air demand. It is set at 500 psi.

350 psi Pressure Regulator

13

Operates the running blowdown valve while opening a pressure line between system pressure and the inlet control cylinder when in High mode. This allows the inlet control cylinder to regulate air delivery according to air demand. It is set at 350 psi.

350 psi Mode Selector Valve

86

Used to select High or Low air mode.

Check Valve

59

Prevents the flow of air in the wrong direction.

180 psi Mode Selector Valve

41

Used to select High or Low air mode.

Low Pressure Regulator Valve

66

Operates the running blowdown valve while opening a pressure line between system pressure and the inlet control cylinder when in Low mode. This allows the inlet control cylinder to regulate air delivery according to air demand. It is set at 180 psi.

Inlet Cylinder Pressure regulator

82

Opens a pressure line between the receiver/sump tank and inlet control cylinder on the rod side of the cylinder. This allows the inlet control cylinder to regulate air delivery according to air demand. It is set at 80 psi.

Air Inlet Control Cylinder

69

Regulates the amount of air allowed to enter the air inlet valve. This regulation is determined by the amount of air being used at the service line.

Silencer

57

Silences the discharge air from the running and shutdown blowdown valves.

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6.2 SULLAIR COMPRESSOR (08/03/25)

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Running Blowdown Valve

62

Vents excess receiver/sump pressure to the atmosphere when receiver/sump exceeds the desired unload pressure during operation.

Shutdown Blowdown Valve

58

Vents receiver/sump pressure to the atmosphere at compressor shutdown

Discharge Check Valve

78

Cuts off reverse flow of air/fluid mixture through the compressor discharge system at compressor shutdown.

High Temp Shut-off Switch

79

Shuts down the compressor when the discharge temperature exceeds normal operating range.

Temperature Gauge

77

Discharge temperature gauge located in the set-up and tramming control panel.

Low Oil Pressure Switch

73

Shuts down compressor if the fluid pressure going to the compressor unit bearings is insufficient.

Inter-stage High Temp Shutdown

80

Shuts down compressor when the inter-stage temperature exceeds normal operating range.

Manual Unload Valve

67

Valve to manually unload compressor.

Air Filter

76

A multi-staged dry-type filter assembly for filtering the intake air.

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6.2.7.2 Butterfly Inlet Valve Functional Description The purpose of the control system is to regulate the amount of air intake in accordance with the amount of air being used. The 2-stage compressor is designed to operate in one of the three modes of operation: the low-pressure mode up to (180 psig {12.4 bar}) and two high pressure modes (350 psig {24.1 bar}) and (500 psig {34.5 bar}). The control system consists of a 2-stage control (incorporating an inlet control cylinder and a closed inlet cylinder), running blowdown valve, and the necessary linkage to connect the inlet control cylinder to the inlet valve.

The position of the pressure selector determines the pressure that the control system will respond to. The functional description of the control system is described in four distinct phases of operation which (except for the start phase) apply to both high and low pressure modes.

Butterfly Inlet Valve Inlet Control Cylinder

Closed Inlet Cylinder

6.2.10 Butterfly Inlet Valve

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6.2.7.3 Closed Inlet Start Program The inlet system incorporates a closed inlet cylinder (larger cylinder or ‘first stage’), which allows the compressor to start with the inlet butterfly valve closed completely. It is combined with the inlet control cylinder (smaller cylinder or ‘second stage’) and operates in series with it.

System pressure is applied to the rod end of the closed inlet cylinder and fluid injection pressure to the piston end. Upon compressor start, rising system pressure holds the inlet butterfly valve closed until fluid injection reaches a pre-determined value. At this point the cylinder strokes, opening the inlet butterfly valve slightly and loading the compressor. The closed inlet cylinder will remain stroked during normal operation until shutdown, unless fluid injection pressure drops below the pre-determined value.

Once the closed inlet cylinder has stroked (loaded the compressor), pressure will rise quickly to 180 psig (12.4 bar). During this period, the low-pressure regulator is closed and the inlet control cylinder is in inoperative. When the pressure exceeds 180 psig (12.4 bar) the inlet control cylinder will function as described in the following sections.

System pressure from high/low regulators

Orifice and muffler

Oil from Receiver

From inlet cylinder pressure regulator (80 psi)

6.2.11 Closed Inlet

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6.2.7.4 Normal Operation 180 to 500 PSIG (12.4 to 24.13bar) High Pressure 0 to 180 PSIG (0 to 12.4bar) Low Pressure When the sump pressure rises above the required minimum pressure, the minimum pressure valve opens and delivers compressed air to the service line. The control pressure regulator of either mode (Low or High) remains closed, keeping the inlet control cylinder inactive.

During this phase, the compressor is operating at the full capacity for the selected mode.

6.2.7.5 Modulation 180 to 500 PSIG (12.4 to 24.13bar) High Pressure 180 to 200 PSIG (12.4 to 13.8bar) Low Pressure Should less than the rated capacity of air be used, the sump pressure will quickly rise to the upper limit of the modulating range. At this point, the control pressure regulator will gradually begin to open, applying pressure to the inlet control cylinder. This pressure causes the cylinder rod to move, partially closing the compressor inlet butterfly valve.

The closing of the inlet butterfly valve reduces the amount of air entering the compressor until it matches the amount of air being used. The modulating pressure reaching the running blowdown valve is not sufficient to cause the valve to open.

The control system will continue to operate in this manner (between the limits of the modulating range in response to varying demands for compressed air). The control cylinder has an orifice, which vents a small amount of air to atmosphere when the regulator opens.

This increases the sensitivity of the control system as well as bleeds accumulated moisture from the cylinder.

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6.2.7.6 Unload In Excess of 500 PSIG (24.13bar) High Pressure In Excess of 180 PSIG (12.4bar) Low Pressure When air requirements are reduced, the sump pressure will rise above the modulating valve range. The control pressure regulator is open and applying sufficient pressure to the control cylinder to totally close the inlet valve. At the same time, the running blowdown valve opens venting sump pressure. This will prevent additional pressure build-up due to the inlet valve leakage. The running blowdown system will continue to cycle as long as no air is being used.

As requirements for air increase, sump pressure will drop into or below the modulating range and the control system will function in accordance with that particular phase. When operating unattended for a period with no air, it is advantageous to switch to switch the pressure selector to low-pressure mode. This will reduce the sump pressure and provide a more economical operation.

When the compressor is shut down, the system shutdown/blowdown valve will open and relieve the receiver pressure.

6.2.7.7 Compressor Start Up Mode and Running Mode Low Air Pressure Refer to Fig 6.2.12 The inlet system incorporates a Butterfly Inlet Valve to control the amount of air being consumed by the compressor. The position of this valve is controlled by the Inlet Cylinder and is regulated by a pilot signal from various valves in the system.

On start up, a series of events happen simultaneously to insure the correct start of the compressor unit (with the manual unload valve in the load position).

1. Receiver tank pressure builds and the minimum pressure valve located on the discharge of the receiver maintains a minimum pressure. This insures adequate flow of oil.

2. A signal is sent to the inlet cylinder and is regulated by the inlet cylinder regulator set at 80 psi.

3. A signal from the compressor is sent to both the shutdown blowdown, closing it and the oil stop valve, opening it allowing oil to flow.

4. The High/Low solenoid is in the open position allowing a signal to the low-pressure regulator. At 180 psi (12.4 bar) the regulator opens sending a signal to the running blowdown and the inlet cylinder. A modulating effect occurs at this time until the system balances, where the amount of air being exhausted is the same as the inlet is allowing into the compressor unit. This is maintained low pressure (approx. 180 psi (12.4 bar)).

5. The 2” hydraulically controlled discharge valve for the service line is closed.

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Manual Unloader closed

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Low pressure regulator set at 180 psi

Inlet pressure regulator set at 80 psi Running blowdown valve opens (normally closed)

System blowdown valve closes (normally open)

Oil stop valve opens (normally closed)

Fig 6.2.12 Compressor Start-up Mode

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6.2.7.8 Manual Unload Mode The system can be manually unloaded to run in the low air pressure mode. When the manual unload ball valve is turned, a signal is sent to the running blowdown valve and to the inlet control cylinder, closing them.

350 psi and 500 psi selectors are closed

Manual Unloader open

Low pressure regulator opens

Inlet pressure regulator set at 80 psi Running blowdown valve opens (normally closed)

Oil stop valve opens (normally closed)

System blowdown valve closes (normally open)

Fig 6.2.13 Manual Unload Mode

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6.2.7.9 Running Mode 350 psi Air Pressure When 350 psi air pressure is selected, the 180 psi solenoid is now de-energized, closing the valve. This cuts off the signal to the low-pressure regulator. When air pressure reaches 350 psi, the High-pressure regulator now functions and opens, sending a signal opening the running blowdown and the inlet control cylinder, closing it to maintain 350 psi.

350 psi selector open

Manual Unloader closed

180 psi selector closed

Inlet pressure regulator set at 80 psi

Running blowdown valve opens (normally closed)

Oil stop valve opens (normally closed)

System blowdown valve closes (normally open)

Fig 6.2.14 Running Mode 350 psi

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6.2.7.10 Running Mode 500 psi Air Pressure When 500 psi air pressure is selected both the 180 and 350 selectors are closed. The 500 psi regulator will now function as the air pressure rises. As the air pressure rises to 500 psi the regulator opens, sending a signal to the running blowdown valve and the inlet control cylinder.

350 psi selector closed

Manual Unloader closed

500 psi selector opens

180 psi selector closed

Inlet pressure regulator set at 80 psi Running blowdown valve opens (normally closed)

Oil stop valve opens (normally closed)

System blowdown valve closes (normally open)

Fig 6.2.15 Running Mode 500 psi

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6.2.7.11 Instrumentation and Protection There is a comprehensive instrumentation and protection group on this unit to protect both the operator and unit. This package includes visual aids, shutdown protection devices and visual alarms.

The instrumentation group is provided to allow for visual verification of the operating pressures and temperatures of various systems incorporated into the compressor unit. These would include the following; 1. Air filter restriction indicator (located remote from the air filter on receiver tank).

2. Compressor discharge temperature gauge (located in the setup and tramming control panel).

3. Receiver tank pressure gauge (located in the setup and tramming control panel).

4. Separator restriction indicator (located on the receiver tank).

5. Scavenger line sight glass (located on the receiver tank).

6. Inlet cylinder regulator pressure gauge (located on the inlet pressure regulator).

There are shutdowns and warning indicators incorporated in order to protect the unit and personnel from damage and or injury. The shutdowns will shut the engine down in the event that they are activated. Warning indicators warn the operator whenever the system is not operating within its parameters. Included in this package are the following; 1. Low Oil pressure Shutdown (located on the oil distribution block shuts the engine down immediately if the pressure is below 90psi. There is a 60sec time delay on start up).

2. High Interstage Temperature Switch (N.O. switch located in the manifold connecting the low stage and high stage screws. Shuts down the engine immediately in the event that the discharge temperature of the first stage exceeds 280degF (138 deg C)).

3. High Discharge Temperature Switch (N.O. switch located in the discharge check valve of the screw activates a warning on the PanelView when the discharge temperature reaches 285degF (140.5 deg C) and shuts the engine down immediately when the temperature reaches 300degF (149 deg C).

Whenever a shutdown or warning has been activated, it will be necessary to acknowledge it by touching the PanelView on the Acknowledge symbol. The problem must then be diagnosed and repaired before continued use of the compressor. In the event of a shutdown it is necessary to allow the receiver tank to bleed down before restarting the unit.

Also included on the receiver tank is a safety valve that will exhaust receiver tank pressure to atmosphere in the event that the receiver tank pressure builds past a preset level of 550psi (37.9 bar).

NOTE: Start up should never be attempted until the receiver tank has fully bled down. If start up is attempted with high receiver pressure, damage may result.

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Compressor Discharge Pressure gauge

Compressor Discharge Temperature gauge

Fig 6.2.16 Tram/Set-up Panel

Touchscreen

Throttle Control

Fig 6.2.17 Touchscreen

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6.2.7.12 Start Up and Shutdown Procedures The following procedures should be followed whenever starting the unit up. Refer to the operator’s manual.

1. Use the daily check list to perform a pre-start check.

2. Level the drill so that the fluid level can be checked and added if necessary. Always check the fluid level after the unit has been shutdown for a minimum of 10 minutes.

3. Fill the compressor receiver/sump with fluid as recommended in the lubrication guide if required.

4. Check all connections and the general condition of the unit, including all hoses, whip checks and any visible leaks.

5. Ensure the discharge service valve is closed.

6. After start up check all the gauges while drilling. If any of them are getting close to running out of their designed parameters, as described in section 1, shut the unit down and have the problem repaired.

The following procedures should be followed whenever shutting the unit down.

1. Using the touchscreen, switch compressor to low position and allow to stabilize. See Fig 6.2.17.

2. Check that the mast is on a secured position to prevent inadvertent movement.

3. Using the touchscreen, switch system control off.

4. Using the throttle control, slow engine speed to idle and allow engine to run for at least 1 minute.

5. Shut engine down.

6. If machine is to be left idle for an extended period of time, switch the battery disconnect off (see operators manual for location).

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WARNING: This compressor unit must only be serviced by qualified personnel.

No attempt should be made to alter this unit in any manner without written permission from Cubex. Any alterations may result in serious injury or damage to the unit.

Whenever working on this unit, check that the system has fully bled off before opening any connections. Compressed air has tremendous contained energy, which is released when opened to atmosphere. The potential to cause severe injury or damage is great if proper procedures are not followed.

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6.2.7.13 Adjustment Procedures This unit requires the adjustment of four valves during set-ups. They are inlet control cylinder regulator, set at 80 psi; low air pressure regulator, set at 180 psi; high pressure regulator, set at 350 psi; and a high air pressure regulator, set at 500 psi. Start the unit with the drill air selector in the low position and allow it to stabilize. Check the inlet regulator setting and adjust to 80 psi. While still in the low position check the opening point of the low air pressure regulator. The regulator should open closing the inlet valve at 180 psi. Switch the system to 350 psi air pressure and allow the system build until the 350 psi air regulator opens. Adjust to open at 350 psi. Switch the system to 500 psi air pressure and allow the system build until the 500 psi air regulator opens. Adjust to open at 500 psi.

500 psi regulator

350 psi regulator

180 psi regulator

Fig 6.2.20 Valve Adjustment

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6.2.8 Compressor Maintenance 6.2.8.1 Main Fluid Filter Service The main fluid filter is located schematically in the coolant line between the receiver/sump and the compressor unit. The full flow filter element is replaceable. For installation of filter element follow the procedure explained below.

1. The compressor must be shut off and the compressor unit must be relieved of any pressure.

2. Rotate the filter bowl counter clockwise and remove.

3. Remove the element and discard it. These elements are not cleanable.

4. Clean the housing and filter head.

5. Apply a small amount of oil or grease to the new head seal and install it into the filter head making sure it is seated.

6. Place the new element into the head making sure it is properly seated.

7. Replace the bowl turning it clockwise and hand tightening.

Fig 6.2.21 Main Fluid Filter

Fig 6.2.22

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6.2.8.2 Thermal/Bypass Valve When repairing the thermal/bypass valve, use a repair kit and follow the repair procedure explained below: 1. With the valve removed from the fluid system, remove the four cap screws, holding the lower body to the valve body.

2. Remove the o-ring sitting in the lower body and discard.

3. Remove the element and the quad ring inside the housing and discard.

4. Note: there will be slight resistance from the quad/seal ring centered in the lower housing.

5. Turn the valve over and remove the hex plug. Remove this plug slowly as it is under spring pressure.

6. Remove the spring, sleeve and bypass piston.

7. Clean the valve parts thoroughly before reassembly.

8. Install the bypass piston, new spring and sleeve into the valve.

9. Install and tighten the new o-ring plug.

10. Coat the new quad ring with quality silicone grease. Install the new quad ring.

11. Install the new element into the housing.

12. Coat the new o-ring with quality silicone grease and install in the lower body.

13. Install the adaptor housing and tighten the four cap screws.

14. Install the four new o-rings on the hose flanges.

15. Install the valve and check for leaks.

Fig 6.2.23 Thermal/Bypass Valve

Fig 6.2.24

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6.2.8.3 Separator Element Replacement When the need for a separator element replacement is indicated by the maintenance indicator (located on the air receiver/separator tank), use the following procedure.

1. Remove the air/receiver tank lid by removing the twelve hex head cap screws.

NOTE: To assist with the removal of the tank lid, a 1”x 8 nut has been welded to the lid so an eye bolt can be inserted.

2. Remove the ¾” x 10 jam nut and sealing hex nut from the separator hold down rod.

3. Remove the round separator cover plate from the top of the separator element.

4. Remove the old separator element and discard.

5. Clean all sealing surfaces taking care not to allow scrapings to fall into the tank.

6. Before installing the new separator element, make sure to lubricate both sides of the sealing o-ring on the element. Now install the new separator element, the cover plate, the new ¾” x 10 sealing hex nut and the ¾” x 10 jam nut. Torque the sealing nut to 85 – 90 ft-lbs. (115 – 122 Nm). DO NOT over tighten as damage to the separator can result.

7. Next, install the tank flange gasket that is provided. Before installing, lubricate both sides of the gasket. Reinstall the tank lid. Install the cap screws finger tight, and then gradually tighten in a crisscross pattern in 4 – 5 steps. Always tighten the cap screws alternately at opposite sides of the cover. Torque cap screws to 200 ft-lbs. (271 Nm).

8. Clean or replace the fluid return line strainer.

9. Clean the fluid line orifice installed in the side of the compressor unit air end.

10. After 24hrs of operation, re-torque the sump cover bolts to 200 ft-lbs (271 Nm).

Fig 6.2.25 Separator Element

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Fig 6.2.26

Fig 6.2.27

Fig 6.2.28

Fig 6.2.29

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6.2.8.4 Running Blowdown Valve Maintenance When it is necessary to make repairs on the running blowdown valve follow the instructions provided below.

1. Remove the hex nut from the bottom of the valve. The poppet guide, which is secured by the hex nut, is under slight spring tension.

2. Remove the poppet guide, poppet assembly and spring from the valve body.

3. Remove and discard the old o-ring and replace it with the new o-ring provided in the kit. Be sure to lubricate the o-ring with a silicone-based lubricant.

4. Place the new spring and poppet assembly in the valve body as shown. Then place the poppet guide (with the o-ring in position) over the poppet assembly.

5. Push the hex nut down over the poppet guide and compress the spring while turning the hex nut until tight. Tighten securely with a wrench.

6. Remove the pilot cap from the top of the valve body and pull the piston out of the cap.

7. Remove the U-cup from the piston and replace it with a new one. The U-cup should be lubricated with a silicone-based lubricant.

8. Remove the gland nut from the valve body and pull the poppet pin out to allow access to the small o-ring in the top of the body.

9. Remove the small o-ring and replace it with a new one. Lubricate with a silicone-based grease.

10. Replace the poppet pin and gland nut.

11. Place the piston with the new U-cup in position back in the pilot cap with the recessed centre showing at the valve body end of the cap.

12. Replace the pilot cap and tighten securely with a wrench. At this time the running blowdown valve is ready for operation.

Fig 6.2.30 Running Blowdown Valve

Fig 6.2.31

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6.2.8.5 Shutdown Blowdown Valve Maintenance When it is necessary to make repairs on the running blowdown valve follow the instructions provided below.

1. Remove the pilot cap and push the piston out of the pilot cap.

2. Remove the U cup from the piston and replace it with the new one provided in the repair kit. Lubricate the u cup with a silicone-based grease.

3. Thoroughly clean the cap. Place the piston (with the u cup in position) in the cap so the recessed centre is showing at the valve body end of the cap.

4. Pull the retainer, poppet and spring and separate the poppet from the retainer.

5. Remove the o-rings from the inside and outside diameters of the retainer.

6. Unscrew the stem portion of the poppet to allow removal of the disc. DO NOT mar the machined finish of the poppet when unscrewing the stem.

7. Remove the disc and replace it with the new one provided.

8. Replace the stem portion and tighten securely.

9. Clean the poppet and retainer thoroughly.

10. Replace the o-rings in the retainer and lubricate thoroughly with a silicone-based lubricant.

11. Place the poppet in the retainer as it was prior to separating it.

12. Clean the valve body and place the new spring in the valve body.

13. Place the poppet and retainer back in the valve body and replace the pilot cap.

14. Tighten the pilot cap securely with a wrench and the shutdown blowdown valve is ready for operation.

Fig 6.2.32 Shutdown Blowdown Valve

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6.2.8.6 Minimum Pressure/Check Valve Maintenance The minimum pressure/check valve should be periodically disassembled, inspected for excessive wear, and cleaned or reassembled.

1. Remove the six cap screws in the cover.

2. Remove the cover, taking care not to damage the gasket.

3. Remove the piston assembly.

4. Clean and inspect parts. Any excessively worn parts should be replaced.

5. Grease the piston and pack the grooves with quality silicone grease.

6. Replace the piston assembly.

7. Replace the cover and gasket.

8. Apply locking compound to the cap screws. Replace and torque to 80 ft.lbs. (108Nm).

Fig 6.2.33 Min Pressure/Check Valve

Fig 6.2.34

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6.2.8.7 Discharge Check Valve Maintenance When servicing of the valve is required follow this procedure: 1. Remove the six cap screws from the valve body cover and remove the cover/shaft assembly.

2. Remove the gasket and spring from the valve body.

3. Remove disc/bearing assembly from the valve body.

4. Clean cover and valve body gasket surfaces.

5. Install new disc/bearing assembly into the valve housing.

6. Place the spring into the disc/bearing assembly.

7. Place the gasket on the valve body.

8. Install the cover/shaft assembly centering the shaft into the spring.

9. Install the six cover cap screws and torque to 80 ft.-lbs. (108 N-m ).

Fig 6.2.35 Discharge Check Valve

Fig 6.2.36

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6.2.8.8 Safety Valve The Safety Valve is a non-serviceable item and must be replaced if it fails. If replacement is necessary, follow these instructions.

1. Remove the failed unit and replace with new.

2. Apply a small amount of pipe dope to the male threads only of new safety valve.

3. Tighten by hand, then tighten not more than one extra turn using a wrench on the inlet hex nut.

During services it is recommended that the safety valve be cracked open to ensure that it is still functional. If the witness wire has been broken the safety valve must be replaced.

Check the pressure ratings on the safety valve as 400 PSI, 450 PSI, and 550 psi valves are available.

Fig 6.2.37 Safety Valve

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6.2.8.9 Pressure Regulator (Low / High Air Pressure Regulator) Pressure regulator valve maintenance normally requires the replacement of the internal diaphragm. Follow the procedures below for proper installation.

Refer to Fig 6.2.38 and Fig 6.2.39 next page 1. Loosen the locknut and turn the adjusting screw counterclockwise until the inner spring tension is relieved. The adjusting screw should turn freely when the spring tension is relieved.

2. Remove the spring chamber from the body to allow access to internal parts.

3. Next, remove the spring button, spring and the damper located inside the spring. The damper will stay inside the spring as it is removed. Leave the damper inside the spring as there is no need to remove it.

4. After removing the spring, remove the diaphragm stop.

5. At this time, remove the pressure plate nut and disassemble the pressure plate, diaphragm, diaphragm gasket, seat disk and seat gasket.

6. Remove and discard the seat ring.

7. Reassemble the regulator using the new parts provided in the repair kit.

8. Reassemble the diaphragm, Pressure plate, diaphragm gasket, seat disc, seat disc gasket, and tighten the nut. All of these parts with the exception of the pressure plate are provided in the repair kit.

9. Replace the seat ring with the new seat ring provided.

10. Replace the existing seat ring stop.

11. Next, place these parts in their proper place on the body and replace the spring as it was prior to removal.

12. Place the spring button over the spring as shown.

13. With all parts in order, replace the spring chamber and tighten.

14. Tighten the adjusting screw until tension is realized.

15. At this time, refer to control system adjustment procedure to readjust the pressure regulator.

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Pressure Regulators

Fig 6.2.38 Pressure Regulators

Fig 6.2.39 Interior of Pressure Regulator

6-02-038

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6.2.8.10 Fluid Stop Valve When servicing the fluid stop valve use the appropriate repair kit and follow the steps below.

The valve may be serviced without removing from its associated piping.

1. Remove the retaining ring.

2. Remove the cap and discard o-ring.

3. Remove the cap screw and flat washer from the outlet connection of the valve.

4. Remove the plate, o-ring, Teflon o-ring and washer from the valve.

5. Separate the washer and plate and discard the o-ring and spring.

6. Remove the piston, o-ring, rod and spring from the valve body. Discard the o-ring and spring.

7. Clean all parts thoroughly.

8. Install a new o-ring on the piston and coat the piston and o-ring with a silicone based grease.

9. Install the spring on the rod and install the piston, rod and spring into the valve body.

10. Assemble the cap screw, flat washer and plate. Install the o-ring onto the caps crew as shown below.

11. Install Teflon o-ring into the plate.

Fig 6.2.40 Fluid Stop Valve

Fig 6.2.41

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6.2.9 Screw Compressor 6.2.9.1 Screw Compressor Arrangement

Fig 6.2.42 Screw Compressor Arrangement

6-02-040

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6.2.9.2 Compressor Operator Daily Checklist Compressor Operator Daily Checklist Cubex Serial Number:

Date:

Operator Name:

Hour meter reading start of shift:

Foreman:

Hour meter reading end of shift:

Set Up location:

NOTE: If any of the following checks are “No”, DO NOT RUN UNIT. Pre-start Inspection

YES

NO

YES

NO

Is oil visible in receiver/sump tank glass?

Is the compressor free from oil leaks?

Are the oil cooler and fan clean?

Are hose whip checks in place?

Are hoses in good condition?

Has the signal filter been drained?

Are the fire extinguishers in place and accessible?

Has the general condition of the compressor been checked?

Operating Inspection Do all the following checks and readings under full load and air flow.

Has the unit been checked for oil leaks?

Has the unit been checked for air leaks?

Air discharge pressure Comments:

psi

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6.2.9.3 Maintenance Schedules 250 Hour Maintenance Schedule 1. Complete Compressor Operator Daily Checklist.

2. Check inlet air filter restriction indicator. Replace filters if necessary.

3. Replace oil filter element.

4. Check separator differential pressure. If differential pressure is 10 psi or higher, replace separator element.

5. Check and clean control line moisture separator element.

6. Check oil level. Top up if necessary and record amount added. See Lubrication Crossover table for details on lubricant.

1000 Hour Maintenance Schedule 1. Complete Compressor Operator Daily Checklist.

2. Check all solenoid valves for operation.

3. Check safety shutdown system, sensors, and switches.

4. Check electrical panel.

5. Inspect air inlet valve cylinder and linkages. Repair or replace any worn parts.

6. Check inlet air filter restriction indicator. Replace filters if necessary.

7. Replace oil filter element.

8. Replace separator element.

9. Inspect and clean pressure regulator valves.

10. Replace control line moisture separator element.

11. Drain and clean receiver/sump tank.

12. Replace oil. Oil capacity of the receiver/sump tank is 35 US gallons (132 litres). See Lubrication Crossover table for details on lubricant.

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6.2.9.4 Compressor Lubrication Crossover Refer to this Cross-Over list for alternate suppliers. If these brands are unavailable, your local supplier will be able to recommend alternatives using these specifications.

Lubrication Chart for Screw Compressor Fluid Type

Esso/Mobil

Shell

Chevron/Texaco

Sullair

Darina XLEP2

LONA XEP2H

MOBILUX

Extreme Pressure Grease

Synthetic

Synthetic

Synthetic

Synthetic

SHC1024 Change every 300 hrs

Corena AS68 Change every 1000 hrs

Tegra 68 Change every 1000 hrs

AWF Change every 1000 hrs

Grease

Mineral Based Compressor Oil

XD-3 Extra 10W Change every 300 hrs

Synthetic compressor fluids do not have to be changed as often as mineral based oils, which may balance out fluid costs.

CAUTION! Do not mix different types of fluids.

Do not use automatic transmission fluids.

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6.2.9.5 Compressor Troubleshooting

Symptom

Probable Cause(s)

Remedies

Compressor shuts down with air demand present

Compressor discharge temperature switch is open

Cooling air flow is insufficient. Clean cooler and check for proper ventilation.

Low fluid sump level. Add fluid Dirty compressor fluid. Change fluid.

Clogged compressor fluid filter. Change element.

Temperature regulating valve is not functioning properly. Change thermostatic element.

Defective discharge temperature switch.

Check for a short or open circuit.

Should this check out normal, the temperature switch itself may be defective.

Compressor will not build up full discharge pressure

Air demand is too high Dirty air filter Pressure regulator out of adjustment Defective pressure regulator Defective minimum pressure valve Selector switch is in Low position Signal lines are crossed between shutdown blowdown valve and running blowdown valve.

Check service lines for leaks or open valves.

Check the filter indicator and change or clean element if required.

Adjust regulator according to control adjustment instructions in the Maintenance section.

Check diaphragm and replace if necessary.

Check that piston is moving freely.

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6.2 SULLAIR COMPRESSOR (08/03/25)

Improper unloading with an excessive pressure build-up causing the pressure relief valve to open

Pressure regulating valve is set too high.

Leak in the control system causing a loss of pressure signal.

Inlet valve jammed.

Restriction in the control system.

Jammed control linkage.

Defective pressure relief valve.

Insufficient air delivery

6-02-046

Re-adjust.

Check the control lines.

Defective pressure regulating valve. Repair valve.

Free or replace valve.

Check all control lines and components.

Ice and other contaminants may cause restrictions.

Free jammed portion of linkage and adjust if necessary.

Replace pressure relief valve.

Plugged air filter.

Clean or replace.

Plugged air/fluid separator.

Replace separator element and also change compressor fluid and fluid filter at this time.

Defective pressure regulator.

Power source speed too low.

Inlet valve not opening completely.

Adjust or repair.

Re-adjust engine speed.

Re-adjust control linkage.

Excessive compressor fluid consumption

Clogged return line.

Clear orifice and strainer.

Separator element damaged or not functioning properly.

Change separator element.

Check all pipes, connections, and components.

Leak in lubrication system.

Compressor overheating

Dirty fluid cooler core.

Clean core thoroughly.

Faulty thermostat in thermal valve.

Change thermostat element.

Plugged fluid cooler tubes (internal).

Low sump fluid level.

Plugged compressor fluid filter.

Plugged fluid return line.

Clean tubes thoroughly.

Fill.

Change element.

Clean orifice and strainer.

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6.3 WATER PUMP (08/03/25)

6-03-001

6.3 Water Pump Driven by a hydraulic motor, the water pump is a positive displacement unit. It is equipped with a strainer in the suction line and a relief valve mounted in the discharge line.

CAUTION! Keep parts separate or mark components to allow installation in original locations.

Drain pump before exposing to freezing conditions.

Technical Specifications:

Pump Accessories:

Volume:

4 gpm (15 l/m) @ 225 rpm

Discharge pressure:

550 psi (37.9 bar)

Speed:

Variable

Crankcase Capacity:

1 qt. (0.95 L)

Lubricant Type:

Shell Omalla 100

Weight:

32 lbs. (14.5 kg.)

Relief Valve:

550 psi (37.9 bar)

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6.3 WATER PUMP (08/03/25)

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6.3.1 Pump Speed Adjustment The pump has a direct drive propelled by a hydraulic motor. The water pump speed is controlled by the proportional valve. Follow the procedure outlined in Section 5.5.4 Valve Flow Adjustment.

Fig 6.3.1 Water Pump

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6.3 WATER PUMP (08/03/25)

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6.3.2 Preventative Maintenance Routine maintenance is an essential part of successful pump operation. Properly maintained pumps are designed to offer years of trouble-free service.

Regular inspections also allow operators to become familiar with normal pump operation so they can recognize the signs of potential problems and schedule maintenance.

After the first 50 hours:

Daily:

2000 Hour Intervals:

Crankcase Oil

Drain and refill with new oil after the first 50 hours of operation. Insure that the magnetic drain plug is cleaned of debris.

Inlet Strainer

Inspect. Clean if required. The amount of material in the strainer will determine the interval of cleaning.

Complete Pump

General inspection of the pump and system to check for proper operation of equipment.

Piston Seals

Inspect. Observe the top of the pump case under the plastic umbrella for signs of excessive leakage. Replace if necessary.

Pump System

Flush. Required on shutdown when pumping fluids that may harden or corrode the pump if left inside.

Crankcase Oil

Inspect. Insure that the oil is at proper level and has not been contaminated by pumpage or condensation.

Crankcase Oil

Change. Drain and fill with new oil. Clean magnetic drain plug.

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6.3 WATER PUMP (08/03/25)

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6.3.3 Troubleshooting the Water Pump This section is designed to aid in the solution of pump and pump system problems. Once the problem has been identified, work through the possible causes and solutions until the problem has been corrected.

Problem

Possible Cause

No flow from pump discharge

Shaft not turning

•

Insure that driver is properly engaged

Inlet flow restricted or unavailable

•

Check supply pressure or tank level

•

Open inlet supply valve

•

Check to see if inlet strainer is blocked or clogged with debris

Pump not primed

•

See that pump is properly primed with fluid

Incorrect pump speed

•

Check that pump driver is operating at correct speed

•

Check v-belt or gear reducer for proper reduction ration

•

Check v-belts are not slipping

•

Insure that all inlet fittings are tight

•

Make sure that piston seals are not worn out and allowing air to pass across on suction stroke

•

Insure that no vortex is in tank around inlet

•

Inlet strainer is blocked or clogged

•

Insure that all fluid end gaskets and o-rings are sealing properly

Relief valve bypassing portion of pump flow

•

Check relief valve setting. Adjust or repair if necessary

Insufficient NPSH available for proper pump operation

•

Increase inlet pressure by adding booster pump, raising tank level or other methods

Valves are worn

•

Replace valves

Pump is cavitating

•

Review pump NPSH requirements vs. pump system NPSH available. Increase system NPSH available if required

•

Check to insure fluid temperature is within normal range

Piping size too small and/or too long

•

Review pump NPSH and pipe sizing recommendations.

If necessary, increase pipe size, decrease length, install booster pump, or pulsation dampener

Gas entrained in fluid

•

Check for worn packing, air leaks in fittings, or vortex in suction supply tank

Piping not supported properly

•

Improve piping supports and/or use flexible hose connections between pump and rigid piping to minimize transmitted vibrations

Pump not delivering expected flow rate

Air or gas getting into pump

Pump runs rough or knocks with an inconsistent or intermittent rhythm

Solution

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6.3 WATER PUMP (08/03/25)

Pump runs rough or knocks with an inconsistent or intermittent rhythm

Consistent knock

Excessive power end operating temperature (over 180◦)

Excessive piston cup failures

6-03-005

Valve stuck open

•

Remove obstruction between valve and seat

Valves are worn

•

Replace valves

Broken valve spring

•

Inspect springs and repair if required

Loose plunger or piston assembly

•

Inspect and tighten all assembly connections

One or more cylinders not pumping (airlocked)

•

Prime all cylinders. Allow pump discharge to flow through zero restriction by-pass valve to clear air from pumping chamber

Excessive pump speed causing valves to float

•

Reduce pump speed

Worn power end bearings

•

Replace. Note that it is normal to hear a low, consistent mechanical knock when using a power pump. This is associated with valves opening and closing and power end components loading and unloading.

Worn valves

•

Replace

Loose plunger or piston assembly

•

Inspect and tighten all assembly connections

Oil level low or oil contaminated by water

•

Check level. Flush power end and refill with new oil if contaminated

Low oil level

•

Check level, refill as required

Excess pump speed

•

Check speed rating and adjust as required

Excessive discharge pressure

•

Check pressure rating and adjust as required

Worn or damaged power end bearings

•

Replace as necessary

Incorrect oil viscosity

•

Fill with correct viscosity oil per nameplate recommendations

Belt drive overtight

•

Reduce belt tension

Pump speed too low

•

Increase speed

Pump allowed to run dry for extended periods of time

•

Insure that pump always is run with fluid in inlet tank or is shut down immediately when tank is empty

Fluid contains high concentration of solid, abrasive particles

•

Reduce level of solid, abrasive particles in fluid before they enter pump

Pump is cavitating

•

Review pump NPSH requirements vs. pump system NPSH available. Increase system NPSH available if required

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6.3 WATER PUMP (08/03/25)

Crankcase oil has milky color

6-03-006

Cylinder liner is damaged

•

Check cylinder liner for ID wear or damage. Replace if required.

Cup holder o-ring is leaking

•

Insure that the cup holder o-ring seal is properly installed and is in good shape.

Improper cup selection

•

Consult FMC for alternate cup designs to better suit the needs of your application.

Fluid contamination in power end

•

Flush power end and replace with new oil

Other Solutions Problem No flow from pump

Insufficient pressure from pump ONLY

Insufficient flow from pump ONLY

Insufficient flow OR Pressure AND rough operation

Solution •

Tank is empty

•

Inlet valve is closed

•

Inlet strainer is clogged with debris

•

Crankshaft is not turning

•

Pump speed is too slow

•

Relief valve improperly adjusted and by-passing fluid

•

Oversize or worn nozzle on equipment

•

Worn pump valves

•

Excessive leakage from pump seals

•

Pump speed is too slow

•

Relief valve improperly adjusted and by-passing fluid

•

Worn pump valves

•

Excessive leakage from pump seals

•

Valve problem:

•

Pump valve stuck in open or closed position

•

Valve assembly is damaged or unseated

•

Valve seat is washed out

•

All pump cylinders not primed

•

Inlet strainer is clogged with debris

•

Excessive gas in liquid due to:

•

Air leaks in suction line or fittings

•

High spots in suction line that allow formation of gas pockets

•

Vortex in tank near inlet pipe opening

•

Pump is cavitating due to:

•

Insufficient NPSHa (tank head or charge pressure)

•

Fluid viscosity is too high

•

Inlet line is too long and/or too small diameter

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6.3 WATER PUMP (08/03/25)

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•

Loose piston assembly

•

Valve assembly is damaged or has unseated

•

Pump is cavitating due to:

•

Insufficient NPSHa (tank head or charge pressure)

•

Fluid viscosity is too high

•

Inlet line is too long and/or too small diameter

•

Worn or damaged power frame components

•

Pump is sucking air across worn piston cups during suction stroke (usually only observed on pumps that due not have a booster pump)

Suction pressure fluctuates rapidly

•

Pump is cavitating

Fluid leaking from pump

•

Piston cups are wearing and about to fail

•

Fluid cylinder bolts are not properly tightened

•

Fluid cylinder o-rings (or gaskets) are damaged

•

Piston assembly o-rings are damaged

•

High abrasive particle content in fluid

•

Wrong style or type of piston for service

•

Piston liner is damaged

•

Pump is cavitating (cylinders may run hot)

•

Piston assembly o-ring is damaged

•

Poor quality water used (sources like lakes, streams, or fire hydrant that has not been purged)

•

Pump is allowed to run dry for extended periods of time

Pump runs rough, knocks, or vibrates ONLY

Short piston seal life

Short valve life

Cracked fluid cylinder

Crankshaft jerks or starts and stops or rotation

•

Liner wash system not properly maintained

•

High abrasive particle content in fluid

•

Valve assemblies only partially rebuilt during previous service

•

Valve assemblies damaged due to improper installation techniques

•

Poor quality water used

•

Pump is cavitating

•

Discharge pressure too high

•

Pump exposed to freezing conditions without properly draining

•

Hydraulic shock resulting from cavitation or entrained air

•

Discharge valve is stuck shut

•

Material or manufacturing defect

•

V-belts are loose and slipping (if equipped)

•

Hydraulic system relief valve is chattering (if equipped):

•

Attempting to operate pump at excessively high discharge pressure

•

Discharge line is blocked or partially obstructed

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6.3 WATER PUMP (08/03/25)

Power end overheats (in excess of 180◦F)

Broken crankshaft or connecting rod

Broken Fluid End Bolts

Power end oil is contaminated

6-03-008

•

Discharge pressure too high

•

Low oil level

•

Improper oil viscosity

•

Contaminated power end oil

•

Pump speed is too fast

•

Pump is running backwards

•

Couplings are misaligned

•

V-belt drive tension is too tight

•

Pump located too close to heat source

•

Worn or damaged power frame bearings

•

Pump exposed to freezing conditions without proper draining

•

Discharge pressure too high

•

Suction pressure too high

•

Hydraulic shock due to cavitation

•

Material or manufacturing defect

•

Bolt or nut not properly torqued

•

Discharge pressure too high

•

Excessive piping loads on fluid end

•

Pump has been operated with failed piston cup for extended periods of time

•

Use of high-pressure wash wand to clean near breather or oil seal areas

•

Deflector shields are missing or damaged

•

Crosshead extension oil seals are damaged or improperly installed

•

Excessive capacity in liner wash system

•

Improperly adjusted liner wash nozzle

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6.3 WATER PUMP (08/03/25)

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6.3.4 Service Procedures The pages in this section have been excerpted from the manufacturer’s Operation and Maintenance manual.

It contains the following information: Replacing Piston Cup Seals Replacing Suction and Discharge Valves Replacing the Power End Bearings Servicing the Wrist Pin Bearings Fastener Torque Requirements

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6.3 WATER PUMP (08/03/25)

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6.3.5 Water Pump Coupling Annual Maintenance The water pump coupling requires that the following maintenance steps be performed at least annually. For extreme or unusual operating conditions, check the coupling more frequently.

1. Check the gap and angular alignment as follows: Use a spacer bar 0.125” in thickness; insert bar as shown in Fig 6.3.2 to the same depth at 90° intervals and measure the clearance between the bar and the hub face. The difference in minimum and maximum measurements must not exceed 0.003”.

Fig 6.3.2 2. Check tightening torques of all fasteners.

3. Inspect seal ring and gasket to determine if replacement is required. If leaking grease, replace.

4. When connected equipment is serviced, disassemble the coupling and inspect for wear. Replace worn parts. Clean grease from coupling and repack with new grease. Install coupling using a new gasket.

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6.3 WATER PUMP (08/03/25)

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6.3.5.1 Periodic Lubrication Refer to Fig 6.3.3 1. Re-lube the coupling at least annually.

2. When re-lubing, remove both lube plugs and insert lube fitting. Fill with the recommended lubricant until an excess appears at the opposite hole.

CAUTION! Make certain that all plugs have been inserted after lubrication.

Fig 6.3.3

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6.4 GREASE INJECTION (08/03/25)

6-04-001

6.4 Grease Injection The grease pump injects grease into the drilling air stream. It is a pneumatically-operated unit that develops a fluid pressure of twenty five times higher than its air supply pressure (see Fig. 6.4.1, Fig 6.4.2, and Fig 6.4.3).

PM Tasks Keep grease tank, pump, injector, and valves clean. The grease tank is the main source where contamination may enter into the grease system. Drain and lubricate air supply.

Replace damaged components immediately. Investigate all leaks. All maintenance should be performed in a clean, well-lit work area. Extreme cleanliness is required when servicing injecting system components.

Fill up grease tank (13) periodically in order to avoid air trapped in the lines. Add grease every time the grease level drops below middle window sight.

Every shift:

Check grease level in the tank (13), drain air filter (3), and check oil in air lubricator (4).

250 Hour Intervals:

Inspect system for leaks

The grease injection system settings are: - air pressure in the grease pump (13) – by regulator (2).

- cycle time (from 20 sec to 24 hr) – controlled by the PLC. - amount of grease injected in a cycle – by adjusting the injector (6) to suit the drill hole size (see specifications below).

Rock Grease Pump Specifications

Grease Injector Specifications

Pressure Ratio:

25:1 – fixed setting

Max Output:

2.15 cu.in. (35.2 cc)/cycle

Air consumption @ 100 psi:

0.5 CFM per stroke

Operating Pressure:

Output:

Min

1000 psig

Max

3500 psig

Min

0.05 cu.in. (0.82 cc)

Max

0.50 cu.in. (8.2 cc)

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6.4 GREASE INJECTION (08/03/25)

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2

7

5 3

4 6

1

8

Fig 6.4.1

10

11

14

15

12

13

9

Fig 6.4.2

13

16

Fig 6.4.3

1. Gauge

6. Injector

11. Fill Cap

2. Regulator

7. Volume Adjustment

12. Sight Window

3. Air Filter

8. Vent Plug

13. Grease Pump

4. Air Lubricator

9. Grease Tank

14. Air Hose

5. Solenoid Valve

10. Breather

15. Bleed Valve 16. Check Valve

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6.4 GREASE INJECTION (08/03/25)

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WARNING! Disconnect electrical power, mine air, water supply, and relieve pressure in air receiver before servicing.

6.4.1 To Fill Reservoir Remove fill cap (11), fill with grease until level reaches top window sight (12).

Note: When filling the reservoir, caution should be used not to contaminate reservoir.

6.4.2 To Prime System Supply Lines: After grease tank (9) has been filled with recommended lubricant, turn vent plug (8) counterclockwise one complete turn and operate pump until lubricant flows freely from opening in vent plug to expel air pockets trapped. Tighten vent plug.

Feeder Lines: Fill each feed line with lubricant before connecting lines to outlets.

Injectors: Check injector (6) for proper operation. Injector stem moves when injector discharges grease. This may require cycling system several times. After checking, adjust injector for the volume required.

6.4.3 Operation The pre-determined lubrication cycle frequency is set by the PLC. When a lubrication cycle is initiated the air solenoid valve is energized and air is admitted to the pump. Lubricant is delivered to the injectors and the injectors discharge lubricant to the drill air line. When air solenoid valve (5) is de-energized, air is admitted to the opposite side of the pump air cylinder. As pump plunger returns to its retracted position, the lubricant pressure in the system is relieved, permitting the injectors to recharge.

System is now ready for the next lubrication cycle.

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6.4.4 Adjusting Flow Rate The maximum setting (flow of oil/grease) is achieved with the adjustment screw backed all the way out (counterclockwise).

6.4.4.1 Setting for a 4” Hammer To set the flow of grease/oil for a 4” hammer, which is approximately 0.3 quarts of grease per hour, you must set the adjustment screw to 30 percent of maximum adjustment.

1. Loosen locknut (see Fig 6.4.4).

2. Turn adjustment screw in clockwise with a wrench until it stops (approximately 12-1/2 turns if the adjustment screw is backed all the way out).

NOTE: Be careful not to over torque the adjustment screw. It should take minimal force to turn the screw clockwise. This will be the minimum injection setting.

3. Turn the adjustment screw counter counter-clockwise 4 turns.

4. Lock in setting on adjustment screw with locknut.

6.4.4.2 Setting for a 6” Hammer To set the flow of grease/oil for a 6” hammer, which is approximately 0.7 quarts of grease per hour, you must set the adjustment screw to 70 percent of maximum adjustment.

1. Loosen locknut (see Fig 6.4.4).

2. Turn adjustment screw in clockwise with a wrench until it stops (approximately 12-1/2 turns if the adjustment screw is backed all the way out).

NOTE: Be careful not to over torque the adjustment screw. It should take minimal force to turn the screw clockwise. This will be the minimum injection setting.

3. Turn the adjustment screw counter-clockwise 9 turns.

4. Lock in setting on adjustment screw with locknut.

These settings are approximate values and may have to be adjusted slightly depending on conditions and the manufacturer of the hammer.

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6.4 GREASE INJECTION (08/03/25)

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Adjustment Screw

Lock Nut

Injector Body

Bleed

Grease Outlet

Grease Inlet

Fig 6.4.4 Adjusting Flow Rate

Press the Lube/Grease/ Water button

Fig 6.4.5 Accessing Hammer Lubrication

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6.4.5 PanelView Settings for QXR NOTE: The adjustments in the section are to be done by qualified maintenance personnel.

For injecting oil, the setting of the injector can be maintained, but the timers for on and off must be adjusted by maintenance personnel. This screen can be accessed just as accessing the Auto-Lube settings (see Section 2.3.1.5, Panelview Settings, steps 1-3). After completing those steps, continue as follows: 1. Several new options will appear on the left side of the screen. For the Hammer Lubrication settings, press the Lube/Grease/Water button. See Fig 6.4.5.

Once inside the Lube/Grease/Water screen, you can select from two Hammer Lubrication options; Hammer Lubrication On Time and Hammer Lubrication Off Time.

2. Press the Hammer Lubrication On Time button to set the maximum on time for the Hammer Lubrication cycle. The keypad will open; use it to input your settings. See Fig 6.4.6.

Press the Hammer Lubrication Off Time to set the off time for the Hammer Lubrication cycle. Again, use the keypad to input your settings. See Fig 6.4.7.

The Hammer Lubrication On Time screen and the Hammer Lubrication Off Time screen are virtually identical. Ensure you are in the correct screen for the time you are setting; the active button will be outlined in green (refer to Fig 6.4.6 and Fig 6.4.7).

The timer settings for either grease or oil are as follows: Oil:

8 seconds on

7 seconds off

Grease:

10 seconds on

20 seconds off

Fig 6.4.6 Hammer Lubrication On Time

Fig 6.4.7 Hammer Lubrication Off Time

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7.0 ELECTRICAL (08/03/25)

7.0 ELECTRICAL

WARNING! Servicing the Control Panel is for Qualified Electrical Technicians ONLY!

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7.1 ELECTRICAL CIRCUITS (08/03/25)

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7.1 Electrical Circuits Wiring Diagrams are located in Section 8 of the Parts Manual. The main Electrical General Arrangement is located in the back of this manual.

PM Tasks Preventative maintenance includes cleaning and inspecting of the electrical components.

Consult the Parts Manual for complete parts description. Label wires before dismantling any equipment.

Service Intervals: See the Preventative Maintenance Schedules in Section 2.4

WARNING! Danger! The main control panel is high voltage. Confirm voltage before servicing.

THE MAINTENANCE PROCEDURES ARE FOR QUALIFIED ELECTRICIANS ONLY.

Circuit Voltages:

Main Circuit:

24V

Valve Control:

24 volts, DC

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7.2 ELECTRICAL COMPONENTS (08/03/25)

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7.2 Electrical Components PM Tasks Clean and inspect the electrical components at the specified intervals. Replace damaged parts immediately to avoid down time.

250 Hour Intervals:

•

Clean and inspect electrical system

•

Inspect dust boot on all joysticks

•

Inspect seals on all panels

CAUTION! Isolate ground before arc welding.

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7.2.1 Electrical Panel WARNING! The following procedures are to be performed by qualified electricians only.

1. Push lamp test button at panel to check for defective bulbs. Replace as required.

2. Clean and inspect electrical panel. Check for loose connections.

3. Clean contacts with proper contact cleaner.

4. Replace any slightly damaged parts to avoid down-time. Inspect panel seals.

7.2.2 Control Panels Visually inspect the switches, gauges and controls on the drill control panel and the setup/tramming panels. Replace worn joystick boots and contact blocks.

7.2.3 Replacement Parts Check the Parts Manual for complete replacement components; if parts are not listed, contact the Cubex Parts Department.

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7.3 ON/OFF VALVE ACTIVATION (08/03/25)

7.3 On/Off Valve Activation

Fig 7.3.1 On/Off Valve Activation

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7.4 Types of Valves The circuit voltage in the setup and drilling panel is approximately 24 volts DC. The On/Off valves are equipped with black Hirschmann connectors and have a smaller solenoid than the proportional valves (See Fig 7.6.1 next page).

On/Off valves are used on the following applications: •

Cab Tilt

•

Carousel Arm

•

Breakout

•

Oscillation

•

Jib Boom

•

Centralizer

•

Slip Control

•

Cab Swing

•

Diverter

•

Air

•

Winch

•

Carousel Clamp

•

Dust Collector

Proportional valves with white/grey connectors are installed on the following applications: •

Tram control

•

Boom Lift

•

Rotation control

•

Water Pump

•

Feed control

•

Mast Dump Mast Swing

•

Feed Extension

•

Boom Swing

7.5 Testing of Valve Solenoids When troubleshooting control valves equipped with remote joysticks, the electrical circuit needs to be tested. There are no simple procedures to determine if the solenoids are defective.

Use the elimination process to check related components before replacing the valve solenoids.

Refer to the Troubleshooting Section before performing the following tests.

NOTE: The On/Off valves have different testing method than the proportional valves.

CAUTION! Eliminate all possible problems before replacing valve solenoids.

WARNING! Use proper start-up procedures when starting drill.

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7.6 TESTING ON/OFF VALVES (08/03/25)

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7.6 Testing On/Off Valves When malfunctioning of the solenoid is suspected, perform the following test: 1. Remove Hirschman connector and check voltage between pin 1 and pin GR (Fig 7.6.2). Zero voltage reading indicates faulty circuit or joystick. Refer to electrical circuits to troubleshoot the problem.

2. If voltage reading is approximately 24 volts, inspect and clean pins in connector and solenoid. Reinstall connector and operate valve. Replace solenoid if valve is not operating.

NOTE: Pin 3 is not used on the On/Off valves.

Fig 7.6.1 On/Off Valve

Fig 7.6.2 Hirschman Connector

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7.7 PROPORTIONAL VALVES (08/03/25)

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7.7 Proportional Valves The joystick sends an electrical signal to the PLC and the PLC sends the signal to the solenoid that responds to joystick’s position. This signal (set-point) is converted into a hydraulic pressure which moves the main spool.

Inside the transducer (C), the position of the main spool is converted to an electrical signal (feed-back). This signal is registered by the electronics.

The variation between the set-point and feed-back signals activates the four miniature valves in the solenoid (see Fig 7.7.1). These miniature valves move the main spool to adjust to the changes set by the joystick.

Fig 7.7.1 Proportional Valve

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7.7 PROPORTIONAL VALVES (08/03/25)

7-07-002

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7.8 FAULT MONITORING SYSTEM (08/03/25)

7-08-001

7.8 Fault Monitoring System The proportional valves are equipped with a fault monitoring system, located in the solenoid, to stop the hydraulic flow in the event of uncontrollable spool movements or positions. It produces a fast and operator-independent reaction to stop the current to the solenoid, causing the main spool to return to the neutral position. The indicator light on the solenoid near the connector changes from green to red when the fault monitoring system is activated.

The fault monitoring system is activated by the following problems: 1. If the set-point voltage is less than 10% or more than 90% of the supply. A short circuit in the wiring harness to the joystick would create a lower set-point voltage.

2. If the feed-back signal from the position transducer corresponds to a main spool travel beyond the set-point signal of 15%. A stuck main spool would not move to neutral position when the operator slows the operation.

NOTE: The monitoring system reacts only to faults of more than 500 ms durations. It continues to interrupt until the problem is repaired, even after restarting the drill.

7.8.1 Testing Proportional Valves Remove the Hirschman connector and check the voltage between the pins to pin GR (See Fig 7.6.2).

NOTE: The joystick must be in full up, down or dead center position when checking voltage at pin 1 & 2.

Supply voltage is 24 volts. Actual voltage may vary slightly.

Joystick in forward position (See Fig 7.8.1):

Joystick in neutral (See Fig 7.8.1):

Joystick in backward position (See Fig 7.8.1):

Joystick in left position (See Fig 7.8.1):

pin 1:

24 volts DC (100% of supply voltage).

pin 2:

6 volts DC (25% of supply voltage).

pin 1:

0 volts DC

pin 2:

0 volts DC

pin 1:

24 volts DC (100% of supply voltage).

pin 2:

18 volts DC (75% of supply voltage).

pin 1:

24 volts DC (100% of supply voltage).

pin 2:

18 volts DC (75% of supply voltage).

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7.8 FAULT MONITORING SYSTEM (08/03/25)

Joystick in right position (See Fig 7.8.1):

Conclusion:

7-08-002

pin 1:

24 volts DC (100% of supply voltage).

pin 2:

6 volts DC (25% of supply voltage).

If readings match above test, replace the solenoid If readings do not match, check the following: •

Joystick not travelling to full position

•

Faulty joystick

•

Faulty wiring

•

Improper voltage

Fig 7.8.1

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25)

7-09-001

7.9 Accra-Feed Control System Cubex Limited, one of Canada’s leading mining equipment manufacturers, introduces another innovation in drilling technology called the Accra-Feed System (AFS). Controlled by a programmable logic controller (PLC) that provides significant productivity gains through improved hole accuracy and increased drill bit life. The Accra-Feed system can consistently deliver hole accuracy of less than one (1) percent deviation in holes over 30 meters long.

7.9.1 Accra-Feed Operation During Accra-Feed operation, the forward rotation pressure and holdback relief circuit are combined together, if the drill bit binds in the hole, the rotation pressure will increase in turn, so will the holdback pressure. This will relieve weight on bit, as rotation pressure decreases, so will the holdback and feed will return to the pre-set rate (feed potentiometer).

Should forward rotation pressure exceed 1200psi, the pressure switch will close, sending a signal to the PLC which signals the anti-jam circuit to retract the feed cylinder for two (2) seconds. How far the feed cylinder travels in two (2) seconds is controlled by the anti-jam potentiometer. If forward rotation drops below 1200psi, feed will resume.

If not, the PLC will again signal the anti-jam circuit. This is a continuous cycle of five (5) attempts. After that, the feed cylinder will retract and stop. Rotation will be maintained and a beacon or alarm will sound (optional).

7.9.2 Accra-Feed Components VMM (Vansco Multiplexing Module) ROTATION PRESSURE SWITCH •

Monitors forward rotation pressure (set 1200psi). See hydraulic schematic.

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7.9.3 PLC Operation When Accra-Feed is on, 24V is fed to PLC382, VMM8, Output 9 that energizes the hydraulic valve to enable the rotation and holdback circuit. Feed and rotation signals from respective potentiometers will be sent to the corresponding proportional valves. PLC422, VMM9, Input 11is the rotation pressure switch and will see 24V on a hydraulic pressure of 1200psi. If this happens, the signal of the anti-jam potentiometers will be sent to the feed proportional valve until the pressure drops below 1200psi for more than two (2) seconds.

Rotation Pressure Switch

PLC422, VMM9, Input 11

Accra-Feed Valve

PLC382, VMM8, Output 9

Feed Proportional Valve

Consists of:

•

Feed Power

PLC262, VMM5, Output 4

•

Feed Signal

PLC262, VMM5, Output 5

Rotation Proportional Valve

Consists of:

•

Rotation Power

PLC262, VMM5, Output 9

•

Rotation Signal

PLC262, VMM5, Output 10

Accra-Feed is set On/Off by pressing Accra-Feed button on the right joystick.

Pulldown is controlled by joystick and holdback is controlled by rotation pressure.

7.9.4 Maintenance of PLC in Accra-Feed System 1. Periodically, inspect the tightness of the terminal’s screws. They become loose over a period of time.

2. Ensure that components are free of dust and contaminants.

3. Corrosion may take place in some environments (e.g. mining environment).

Check periodically for corrosion of connecting terminals. Printed circuit board and connector may become corroded internally.

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7.9.5 Troubleshooting Guide Symptoms

Causes

Corrective Action

No response or movement from the Top Drive while moving the Feed Joystick-in manual mode

- The Feed joystick not all way up or down.

Call Electrician to troubleshoot the following causes:

- Loose wiring on terminals of control panel.

1) Check the terminal voltage signal of Feed Joystick-voltage power should be 24 vdc and feed signal 6-18 vdc. If none of this condition-replace the joystick.

- Loose wiring in pins and sockets - Loose wiring on the terminals of PLC - Power supply is OFF - PLC on error mode - PLC is OFF

2) Check for any loose wiring from controller to the feed valve.

3) Check the voltage on Hirschmann Connector. For pin 1 =24 vdc, pin 2 = 618 vdc.

4) If the PLC is on error mode, reset the error or the power.

5) Check for Power LED. If not, consult schematic for power wires.

If the problem still persists, call Cubex Technical Support.

Slow Feed Travel up or down - in manual mode

- The Feed joystick is not all way up or down

See no. 1

No response or movement from the Top Drive during Accra-Feed ON

- No feed power

6) Check the Feed Joystick if it is away from the center.

- No feed signal - No PLC power

7) Check PLC262, VMM5 Output 5 -if there’s no signal-replace the Anti-Jam and Speed Adjustment Box.

- PLC on error mode

8) See no.3

- Loose wiring

9) Check Feed Power – PLC262, VMM5 Output 4.

If the problem still persists, call Cubex Technical Support.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25)

No response or rotation from the saver sub while moving the Rotation Joystick-in manual mode

- no rotational power - no rotational signal - loose wiring - PLC on error mode - No power supply

7-09-004

10) Check the terminal voltage signal of rotational Joystick -voltage power should be 24 vdc and rotational signal 6-18 vdc. If none of this condition replace the joystick.

11) Check for any loose wiring from controller to the rotational valve.

12) See no.3 13) See no.4 If the problem still persists, call Cubex Technical Support.

Slow rotational rpm - in manual mode

The Feed joystick is not all way up or down

See no. 10

No response or rotation from the saver sub during accra-feed ON.

- No Rotational power

14) Check the Rotation Joystick - if it is away from the center.

- No Rotational signal - Loose wiring - No PLC power - PLC on error Mode

15) Check PLC262, VMM5, Output 9 for rotational power; PLC262, VMM5, Output 10 for Rotational signal pot-if there’s no signal local or remote rotational pot.

16) See no.3 If the problem still persists, call Cubex Technical Support.

Rotational pressure switch won’t work.

- loose wiring - defective pressure switch - not set at 1,400 psi - PLC on error mode - No Power Supply

17) Check the voltage supply on Herschmann connector between pin 1 and 3.

18) Check the Forward Rotation torque adjustment pressure if it is below 1,400 psi (normal factory setting is at 1,600 psi).

19) Check the pressure Switch, if it is defective – replace with a new one.

20) Check PLC422, VMM9, Input 11 for terminal connection.

If the problem still persists, call Cubex Technical Support.

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7.9 ACCRA-FEED CONTROL SYSTEM (08/03/25)

Anti-Jam is not working when Accra- Feed is On.

-----

Beacon alarm is not working.

- loose wiring

21) Check the high pressure switch PLC382, VMM8, Input 6.

If the problem still persists, call Cubex Technical Support.

- defective light - PLC on error mode - No Power supply

Accra-Feed System is not working properly.

7-09-005

See the previous causes

22) Check the voltage signal at PLC422, VMM9, Output 4 for beacon alarm.

23) Check the power supply for Beacon Alarm.

24) If the beacon is defective - replace them with the new one.

25) Check for the Rotational pressure switch.

26) Check if the PLC is on error mode.

If the problem still persists, call Cubex Technical Support.

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25)

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7.10 Operator Interface PanelView 1000 7.10.1 Maintenance of PanelView Terminal 1. Use ethyl alcohol (ethanol) on a cotton gauge pad or soft cloth to clean the touch screen. This is more efficient than isopropyl (which leaves a slight residue upon first application), and more safe than methyl ethyl ketone (MEK) which may discolor the screen on repeated applications.

2. Use 50% solution of alcohol (ethanol or isopropyl) in water on a cotton gauge pad or soft cloth to clean the enclosure.

3. Change intensity of the screen, as needed, from the start screen.

7.10.1 Main screen

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7.10.2 Troubleshooting PanelView Terminal PanelView is a color touch screen and it is mounted inside the cab. This terminal has 24VDC power supply. The following table lists the most common messages that can occur on a PanelView terminal.

Message

Cause

What To Do

Application is corrupted.

The application file has become corrupted (checksum failure) or invalid data was read from it.

Try downloading the file again.

Application file is not compatible.

The application file requires a later version of Firmware.

Install the correct version of Firmware.

Error erasing memory card.

The memory card could be faulty.

Try reformatting the memory card using the “format destination” button in the memory card transfer application screen. If this does not work, replace the memory card.

Error writing to memory.

The memory card could be faulty.

Try reformatting the memory card using the “format destination” button in the memory card transfer application screen. If this does not work, replace the memory card.

The transfer failed.

Application file corrupt.

File transfer failed.

Try downloading the file again.

Invalid file I/O.

An error has occurred accessing the memory card. The card could be faulty.

Try reformatting the memory card using the “format destination” button in the memory card transfer application screen. If this does not work, replace the memory card.

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Memory card containing application file has been ejected. Current application file has been de-selected.

The current application is on the PCMCIA card and the card is ejected.

Replace the card and re-select the application.

Memory card format failed. Please try again.

The memory card could be faulty.

Try reformatting the memory card using the “format destination” button in the memory card transfer application screen. If this does not work, replace the memory card.

Time/Date received from PLC is invalid.

The value of one or more of the Time and Date from PLC tag is not valid.

Check that the PLC program is sending valid values to the terminal.

No memory card in the socket. Please replace card and try again.

There is no memory card in the socket.

Insert a compatible memory card in the sockt and try your action again.

“PLC communication lost” message in the PanelView display.

Cable problem.

Check the termination and cable pin assignments.

Rack assignments in the PLC and terminal do not match.

Make sure the rack assignments in the PLC match the terminal.

Terminating resistor not installed properly.

Install the terminating resistor at both ends of the link: •

150 Ω ½ watt resistor for 57.6 or 115.2 kbaud.

•

82Ω ½ watt resistor for 230 kbaud.

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7.10.3 Alarm Messages on the Terminal The drill has a number of shutdown conditions in order to protect the drill from any unexpected damages. The terminal is programmed to display various functions of the drill, as well as alarm conditions that may shutdown the drill if the conditions exceed the preset values. The alarm screen is shown in Fig 7.10.2.

Example – the applicable error will be outlined in red

Reset button Error button outlined in red

Fig 7.10.2 Alarm screen Refer to the operator's manual for details on the display screens and their functions.

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7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

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7.11 QXR Canbus Electrical System Your Cubex equipment is manufactured utilizing Canbus J1939 Multiplexing technology to provide the machine with superior operating characteristics enhancing performance and minimizing downtime of the unit.

Compared to conventional wiring utilizing relays the Canbus system offers reduced maintenance, reduced space requirements, fewer connections, more options and fewer reliability issues.

Multiplexing is used to combine multiple signals into a single complex signal to be transmitted over a shared single medium. After transmission the complex signal is then restored to its original constituent signals.

OEM’s are implementing multiplexed electrical systems because it reduces fuses and relays, minimizes wiring costs and complexity, simplifies troubleshooting and provides unparalleled reliability. Multiplexing also facilitates software configurable interlocks.

7.11.1 Components 7.11.1.1 Cab Control Panel

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7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7.11.1.2 Rear Control Panel

7.11.1.3 PanelView

7-11-002

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7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7.11.1.4 Joysticks

7.11.1.5 Mast Sensor Junction Box

7-11-003

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7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7.11.1.6 Carousel Junction Box

7.11.1.7 10-Channel Low-Pass Filter Module

7-11-004

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7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

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7.11.2 Canbus Components 7.11.2.1 Vansco Multiplexing Module (VMM) 1210 Multiplexing Module Multiplexing technology allows manufacturers to reduce cost while increasing flexibility in design and improving diagnostic capability.

Features Economical and Rugged VMMs were designed and built for the on-highway and off-highway industry by experienced professionals. This system is compliant to SAE J1455 and J1113 Environmental Standards.

“Plug and Play” Modules allows users to install a new module without having to resort to laptop computers or other external devices. Very little training is required to diagnose and replace a module.

Large I/O Count reduces the number of modules per vehicle, reducing system cost. The high capacity self-limiting outputs eliminate the need for breakers and fuses and can be used in parallel for higher current requirements.

Single Part Number System reduces inventory costs and simplifies diagnostic and repair work.

User Friendly Software uses a ladder logic format in a Windows™ environment. This allows for easy initial programming, easy software/vehicle configuration changes, and simple diagnostics.

Improved Connectivity with other parts of the electrical system on the vehicle. The VMM System uses industry standard SAE J1939 CAN-based architecture for easy connectivity to other standard devices.

Simple Diagnostics with indicator lights on each module and intuitive diagnostic software in your PC, the VMM System reduces the time required to find and repair system faults, thereby reducing downtime.

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7.11.2.2 Pocket Gateway Module (PGM) The Vansco Pocket Gateway Module is a general-purpose data protocol converter that can receive, translate, and transmit information over J1708 and J1939 protocols. The PGM has two J1939 ports and one J1708 port for connection to the most common automobile networks. Additionally, the PGM has an RS-232 interface for connection to on-board computers or laptops for diagnostics/reprogramming.

Features Network Link provides data connection between the drive train network and chassis networks while providing isolation between the networks. The PGM will pass through information that is required by a second network and block all other traffic.

Data Link Adapter (DLA) The PGM provides PC interface to drive train network and other data networks through the built-in RS-232 port. The PGM will pass real-time data through the serial port for performing diagnostics.

Upgradeable Flash based application can be reprogrammed through the serial port without disassembly.

Programmable general purpose platform can be programmed with custom applications for use as a Master Controller/Gateway/Router/Bridge in any CAN/J1939/J1708 system.

Rugged Enclosed in a rugged plastic housing for protection from drops and chemical spills.

Operates over the industrial temperature range.

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7.11.3 Operation The VMM1210 is a programmable logic controller (PLC) for applications with steady state voltages less than 32V. It has 12 inputs and 10 outputs as well as a CAN/J1939 communication port and an RS232 programming port. The VMM1210 performs the following tasks:

Receives Digital/Analog/Frequency Inputs: The VMM1210 has 8 digital inputs capable of reading either active high or active low type inputs. In addition, it has 4 inputs capable of reading analog voltages, frequency values or digital active low type inputs.

Activates Outputs: The VMM 1210 has 8 high current (10A max) high side outputs. In addition it has two low current (3A max) outputs capable of driving either high side or low side loads and can also be arranged in an H-Bridge configuration. Outputs can drive any type of load including lights, relays, solenoids, fans, etc.

Monitor Outputs: The VMM1210 monitors its 10 outputs continuously for fault information. Faults include short circuits (to ground or power), over currents and open load. The VMM1210 allows systems to reduce the number of fuses by allowing the outputs to protect themselves electronically. In the event of a fault the VMM1210 will disable the output(s) that are faulted. The automatic recovery of faulted states can be turned on or off (for safety reasons). As well, if turned on, the automatic fault retry can be adjusted to suit a variety of safety related situations. Open load detection allows for the detection of open (burnt out) loads, this detection can be turned on or off and can also be modified to check only at power up of the system or continuously.

Over current levels can be adjusted in one amp increments anywhere from 1A to 12A to allow the system to react more like various fuse types.

Communicate Input/Output State Information: In order to multiplex, the VMM1210 must be able to communicate its information to other CAN/J1939 messages representing the states of its inputs and outputs and other ladder logic based equipment. These messages are broadcast type and can be read by and acted on by any other module connected to the same CAN/J1939 network.

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Processes Ladder Logic Ladder logic is a graphical representation of standard logic (AND, OR, NOT, etc). The VNN1210 processes ladder logic written using the Vansco Multiplex Module Software Package (VMMS). The ladder logic defines which inputs or arrangement of inputs turns on which outputs on the module. The inputs and outputs in the ladder logic can be from one or more modules connected together in a system via the CAN/J1939 network.

The VMM1210 is connected to various types of inputs and loads to allow the transmission of input and output state information to other areas of the vehicle as shown below. In addition, the VMM1210 can be liked via a Vansco Pocket Gateway Module (PGM) allowing it to remain isolated from the drive train network and to communicate with devices on other networks such as J1708. The following figure shows the arrangement of VMM1210’s and the CAN/J1939 network in a typical vehicle application.

In a typical arrangement, the VMM1210’s are place at various locations in the equipment (front, rear, top, and bottom) and all are linked via the CAN/J1939 twisted pair shielded cable. This arrangement allows the modules to act as multiplexors in that they all receive inputs and drive outputs in their respective zones, but also communicate that input/output state information to all others in the system. This has the effect of reducing long runs of wiring from front to rear or top to bottom in equipment since all input/output information is available on the CAN/J1939 network.

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7.11.4 VMM 1210 Hardware and Software 7.11.4.1 Hardware The VMM 1210 Hardware consists of the following: •

Infineon C167 microcontroller, 256KB Flash, 64KB SRAM

•

8 General purpose digital inputs (programmable as active high or low and as power control inputs)

•

4 Programmable inputs (programmable as analog, digital or frequency)

•

5 Dedicated address inputs

•

8 General purpose high side drivers (10A per output rating, programmable PWM with programmable base frequency)

•

2 General purpose high side/low side outputs (programmable as high side or low side or as an H-Bridge)

•

2 High current bus bar inputs (supplies power to high side drivers)

•

1 Logic power input

•

1 CAN/J1939 Network Port

•

1 Pseudo – RS232 Programming Port

General Purpose Inputs Inputs 1 to 8 on the VMM 1210 are general purpose digital inputs. These inputs can be programmed as active high or active low and as power control inputs using the VMM Software package.

Programmable Inputs Inputs 9, 10, 11 and 12 on the VMM1210 are programmable inputs. These inputs can be programmed as analog, digital or frequency type inputs.

Address Inputs There are 5 dedicated address inputs. These inputs are used to set the system address on the module such that it is unique among all other modules in the system.

General Purpose High Side Outputs Outputs 1 to 8 on the VMM1210 are general purpose, high current high side outputs.

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General Purpose Low Side Outputs Outputs 9 and 10 on the VMM1210 are general purpose, low current, programmable high or low side outputs.

Power Connections There are two main power connections, the high current bus bar battery power inputs and the low current logic power input. The bus bar inputs are separated into two connectors of two wires each. Bus bar current flow greater than 20A requires two wires in the connector, less than 20A only requires one wire in the connector. To maintain product moisture sealing, if both wires are not populated, the spare location should be populated with a plug.

There is one main low current logic power connection (power and ground wire) which is required as the main power source for the VMM1210 circuitry. This draws low current (<500mA) and should be connected to a power location with little voltage drop. This allows the VMM to take advantage of its full voltage range as well as prevent analog shifts due to ground level shifts.

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7.11.4.2 VMM 1210 Software The VMM 1210 has three pieces of software on board during normal operation. These are: •

Boot Code

•

Application Code

•

Ladder Logic

Boot Code The boot code acts as a base operating system for the VMM1210. It provides the ability to download other applications (such as ladder logic or application code) to the VMM1210 via the CAN/J1939 port. Boot code is downloaded to the product at the factory and is typically not upgradable by the end customer.

Application Code The application code acts as the second level operating system for the VMM1210. It provided the I/O scanning functions, the I/O state transmission functions, the plug and play functions and the ladder logic processing functions. Application code is upgradable by the customer and can be downloaded to VMM1210’s via the VMM Software package through the CAN/1939 network.

Ladder Logic The ladder logic is the main program for the VMM1210 which allows the VMM1210 to perform tasks based on the user requirements. Ladder logic is written using the VMM Software package; a powerful, user-friendly, windows-based application. Ladder logic is drawn on the graphical user interface and compiled, that is, converted into a format readable by the VMM1210.

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7.11.4.3 Updating the VMM1210 Software The VMM1210 software can be updated with the use of the VMM Software package. The software package provides the means to update Application Code as well as Ladder Logic.

This update is done through the CAN/J1939 network using either a Vansco Data Link Adapter (DLA) or PGM to link the PC to the CAN/1939 network.

To update software, go the TOOLS menu and select DOWNLOAD LOGIC, DOWNLOAD APPLICATION or DOWNLOAD PCM APPLICATION (see Section 7.11.4.4) NOTE: the software must be setup with a key that provides permissions to download any or all of these items. For keys or for more information on keys, please contact Cubex or their local reps.

7.11.4.4 PC Software Installation The VMM software application is all that is required to generate and download ladder logic applications, diagnose electrical system problems and start using the VMM1210. The software is available through Cubex or their local reps.

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7.11.5 Functions 7.11.5.1 QXR Input/Output List – Cab Control Panel – VMM1 PLC22 Inputs

Outputs

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Drill Light Cab Boom

2

J1-2A

Engine Start

2

J1-3D

Drill Light Cab Top

3

J1-2C

Emergency Stop Cab

3

J2-1C

HID Drill Light Mast Bottom

4

J1-2F

Drill Light

4

J2-3C

HID Tram Light Forward

5

J1-3B

Tram Light

5

J1-3F

HID Tram Light Reverse

6

J1-3E

Horn

6

J1-1C

HID Drill Light Mast Top

7

J2-1E

Cab Pressurizer

7

J1-1D

Tram Strobe Light

8

J2-1B

Spare

8

J1-1F

Work Strobe Light

9

J2-2B

Spare

9

J2-3D

Horn

10

J2-2D

Spare

10

J2-1D

Spare

11

J2-2C

Spare

12

J2-2E

Spare

7.11.5.2 QXR Input/Output List – Cab Control Panel – VMM2 PLC62 Inputs

Outputs

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Master Power

2

J1-2A

Pendant Start

2

J1-3D

Wiper Drill Window

3

J1-2C

Breakout Wrench In

3

J2-1C

Spare

4

J1-2F

Breakout Wrench Out

4

J2-3C

Wiper Tram Window

5

J1-3B

Winch In Slow

5

J1-3F

Wiper Top Window

6

J1-3E

Winch In Fast

6

J1-1C

Spare

7

J2-1E

Winch Out Slow

7

J1-1D

Chair Heater

8

J2-1B

Winch Out Fast

8

J1-1F

Floor Heater

9

J2-2B

Floor Heater On

9

J2-3D

Cab Pressurizer

10

J2-2D

Door Safety Bar

10

J2-1D

Dome Light

11

J2-2C

Throttle Supply

12

J2-2E

Throttle Position

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7.11.5.3 QXR Input/Output List – Cab Control Panel VMM3 PLC102 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Air Conditioning 1

2

J1-2A

Spare

2

J1-3D

Air Conditioning 2

3

J1-2C

Spare

3

J2-1C

Air Conditioning 3

4

J1-2F

Spare

4

J2-3C

Gauge Power

5

J1-3B

Spare

5

J1-3F

Gauge On

6

J1-3E

Spare

6

J1-1C

Computer Power

7

J2-1E

Spare

7

J1-1D

Computer On

8

J2-1B

Spare

8

J1-1F

12V Power Supply

9

J2-2B

Spare

9

J2-3D

Gauge Lights

10

J2-2D

Spare

10

J2-1D

Cab Sight Power

11

J2-2C

Spare

12

J2-2E

Spare

7.11.5.4 QXR Input/Output List – Rear Control Panel VMM4 PLC222 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Power Emergency Stop

2

J1-2A

Engine Start

2

J1-3D

Water Trap Heater

3

J1-2C

Compressor Low Oil Pressure

3

J2-1C

Engine Start

4

J1-2F

Compressor High Interstage Temp

4

J2-3C

Low Air (180 psi)

5

J1-3B

Compressor High Discharge Temp

5

J1-3F

High Air (350 psi)

6

J1-3E

Engine Power Unswitched

6

J1-1C

Fan Flow Control

7

J2-1E

Engine Power Unswitched 2

7

J1-1D

Compressor Inlet Open

8

J2-1B

Engine Power Switched

8

J1-1F

Compressor Inlet Close

9

J2-2B

Emergency Mode Enable

9

J2-3D

Tram Speed High

10

J2-2D

Spare

10

J2-1D

Engine Shutdown

11

J2-2C

Spare

12

J2-2E

Spare

BI620146

7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7-11-015

7.11.5.5 QXR Input/Output List – Rear Control Panel VMM5 PLC262 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Feed Power

2

J1-2A

Spare

2

J1-3D

Feed Signal

3

J1-2C

Spare

3

J2-1C

Right Tram Power

4

J1-2F

Spare

4

J2-3C

Left Tram Power

5

J1-3B

Spare

5

J1-3F

Left Tram Signal

6

J1-3E

Spare

6

J1-1C

Right Tram Signal

7

J2-1E

Spare

7

J1-1D

Water Pump Power

8

J2-1B

Spare

8

J1-1F

Water Pump Signal

9

J2-2B

Spare

9

J2-3D

Rotation Power

10

J2-1D

Rotation Signal

10

J2-2D

Spare

11

J2-2C

Spare

12

J2-2E

Spare

7.11.5.6 QXR Input/Output List – Rear Control Panel VMM6 PLC302 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Drill Air On

2

J1-2A

Emergency Stop Tram Step

2

J1-3D

Drill Air Off

3

J1-2C

Emergency Stop Mast Rest

3

J2-1C

Mast Swing Power

4

J1-2F

Fire Suppression Pressure Switch

4

J2-3C

Feed Extension Power

5

J1-3B

Safety Relay

5

J1-3F

Feed Extension Signal

6

J1-3E

Spare

6

J1-1C

Mast Swing Signal

7

J2-1E

Spare

7

J1-1D

Boom Swing Power

8

J2-1B

Spare

8

J1-1F

Boom Swing Signal

9

J2-2B

Spare

9

J2-3D

Mast Dump Power

10

J2-2D

Spare

10

J2-1D

Mast Dump Signal

11

J2-2C

Spare

12

J2-2E

Spare

BI620146

7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7-11-016

7.11.5.7 QXR Input/Output List – Rear Control Panel VMM7 PLC342 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Boom Lift Power

2

J1-2A

Oscillation Up

2

J1-3D

Boom Lift Signal

3

J1-2C

Oscillation Down

3

J2-1C

Oscillation Down

4

J1-2F

Oscillation Left

4

J2-3C

Cab Tilt Down

5

J1-3B

Oscillation Right

5

J1-3F

Cab Tilt Up

6

J1-3E

Oscillation Front

6

J1-1C

Oscillation Up

7

J2-1E

Horn

7

J1-1D

Right Track Power

8

J2-1B

Spare

8

J1-1F

Right Track Signal

9

J2-2B

Spare

9

J2-3D

Cab Swing Right

10

J2-2D

Spare

10

J2-1D

Cab Swing Left

11

J2-2C

Spare

12

J2-2E

Spare

7.11.5.8 QXR Input/Output List – Rear Control Panel VMM8 PLC382 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Pulldown Relief

2

J1-2A

Hydraulic Oil Low Level

2

J1-3D

Holdback Relief

3

J1-2C

Hydraulic Oil High Temp

3

J2-1C

Splined Piston

4

J1-2F

Engine Air Filter Indicator

4

J2-3C

Reverse Drilling

5

J1-3B

Compressor Air Filter Indicator

5

J1-3F

High Rotation Torque

6

J1-3E

Rotation High Pressure

6

J1-1C

Thread Greaser

7

J2-1E

Spare

7

J1-1D

Chassis Greaser

8

J2-1B

Spare

8

J1-1F

Air Flush

9

J2-2B

Feed Flow Channel A

9

J2-3D

Accra-Feed

10

J2-2D

Feed Flow Channel B

10

J2-1D

Hammer Lubrication

11

J2-2C

Rotation Flow Channel A

12

J2-2E

Rotation Flow Channel B

BI620146

7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7-11-017

7.11.5.9 QXR Input/Output List – Rear Control Panel VMM9 PLC422 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

HID Tram Light Forward

2

J1-2A

VMM Power Mast

2

J1-3D

HID Tram Light Reverse

3

J1-2C

Unswitched Power Mast

3

J2-1C

Back-up Alarm

4

J1-2F

Switched Power Mast

4

J2-3C

Rear Strobe Light

5

J1-3B

Spare

5

J1-3F

Level Sensor Power

6

J1-3E

Spare

6

J1-1C

Flow Transducer Power

7

J2-1E

Low Water Level Alarm

7

J1-1D

Tram Light Mast Rest

8

J2-1B

Low Water Level Shut Off

8

J1-1F

Tram Light Left Rear

9

J2-2B

Pulldown Pressure

9

J2-3D

Pressure Transducer Power

10

J2-1D

Spare

10

J2-2D

Holdback Pressure

11

J2-2C

Rotation Pressure

12

J2-2E

Drill Air Pressure

7.11.5.10 QXR Input/Output List – Mast Valve Junction Box VMM10 PLC482 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Winch Out

2

J1-2A

Spare

2

J1-3D

Winch In

3

J1-2C

Spare

3

J2-1C

Centralizer In

4

J1-2F

Spare

4

J2-3C

Breakout Wrench Out

5

J1-3B

Spare

5

J1-3F

Breakout Wrench In

6

J1-3E

Spare

6

J1-1C

Centralizer Out

7

J2-1E

Spare

7

J1-1D

Diverter Down

8

J2-1B

Spare

8

J1-1F

Diverter Up

9

J2-2B

Spare

9

J2-3D

Slips Out

10

J2-2D

Spare

10

J2-1D

Slips In

11

J2-2C

Spare

12

J2-2E

Spare

BI620146

7.11 QXR CANBUS ELECTRICAL SYSTEM (08/03/25)

7-11-018

7.11.5.11 QXR Input/Output List – Mast Valve Junction Box VMM11 PLC522 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Carousel Arm In

2

J1-2A

Arm Out

2

J1-3D

Carousel Arm Out

3

J1-2C

Cable Safety Switch

3

J2-1C

Spare

4

J1-2F

Spare

4

J2-3C

Carousel Clamp Close

5

J1-3B

Spare

5

J1-3F

Carousel Clamp Open

6

J1-3E

Spare

6

J1-1C

Spare

7

J2-1E

Spare

7

J1-1D

Winch High Speed

8

J2-1B

Spare

8

J1-1F

Sensor Supply

9

J2-2B

Spare

9

J2-3D

Carousel Rotate In

10

J2-2D

Spare

10

J2-1D

Carousel Rotate Out

11

J2-2C

Spare

12

J2-2E

Spare

7.11.5.12 QXR Input/Output List – Mast Sensor Junction Box VMM12 PLC582 Input

Output

Input #

Pin #

Function

Input #

Pin #

Function

1

J1-1E

Master Power

1

J1-3C

Stage Sensor Power

2

J1-2A

Stage 1

2

J1-3D

Laser Sensor Power

3

J1-2C

Stage 2

3

J2-1C

Drill Light Makeup & Breakout

4

J1-2F

Spare

4

J2-3C

Spare

5

J1-3B

Spare

5

J1-3F

Spare

6

J1-3E

Spare

6

J1-1C

Spare

7

J2-1E

Spare

7

J1-1D

Spare

8

J2-1B

Spare

8

J1-1F

Spare

9

J2-2B

Spare

9

J2-3D

Spare

10

J2-2D

Spare

10

J2-1D

Spare

11

J2-2C

Spare

12

J2-2E

Spare

BI620146

8.0 TROUBLESHOOTING (08/03/25)

8.0 TROUBLESHOOTING

Clean Tools and Equipment!

BI620146

BI620146

8.1 TROUBLESHOOTING THE TRAM DRIVE (08/03/25)

8-01-001

8.0 Troubleshooting If the performance is lacking, action must be taken to correct any problems. The operator is expected to be able to repair minor problems that are within his/her responsibilities. Any problem beyond that must be repaired by certified maintenance people.

This section is intended for the use of the operator and a more detailed Troubleshooting Guide can be found in the Maintenance Manual.

It is the operator's responsibility to report any apparent problems to the maintenance personnel.

8.1 Troubleshooting the Tram Drive Crawler Does Not Run but Tramming Motors Are Operating Check for sheared off bolts at the final drive sprocket.

Check for mud build up at the crawler tracks.

Check if the tracks are off the front idler. Loosen the track and move it back onto the wheel. Adjust tracks to proper tension.

Check for frozen tracks and thaw the ice as required.

Crawler Does Not Move and Tramming Motor Does Not Run Check items 1, 2, and 3 as above.

Check for damaged parts in the tram drive and the final drive gearbox.

Check if tram motor is running.

Crawler Does Not Tram Straight Check if both torque hubs are engaged.

Perform Checks as outlined in "Crawler does not move".

BI620146

8.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (08/03/25)

8-02-001

8.2 Troubleshooting the Hydraulic System Pump Does Not Deliver Oil Check for proper fluid level and appropriate oil viscosity in hydraulic reservoir. In extreme cold conditions, it may be necessary to heat the oil.

Check for proper pump rotation as marked on coupling guard.

Check for flow restriction by inspecting the suction line, strainer, and reservoir.

Check for air leaks at pump intake. Oil level must be above bottom of sight glass.

Check for sheared off pump drive shaft.

Check pump load sense line for oil flow. Test each function separately.

Pump is Running Hot Check for any function stuck open.

Cavitation or Pump Noise Check for air leaks at the pump intake or shaft packing. Pour oil on joints and around drive shaft then listen for change in operation.

Check for proper oil viscosity.

Insufficient Pressure Check for proper oil level in reservoir.

Slow Rotation at Top Drive Check for low pump delivery (see "Pump Does Not Deliver Oil").

Check for malfunctioning of hydraulic motor.

No Rotation at Top Drive Assembly Check for hydraulic motor malfunctioning.

Check for damaged gears or bearing.

Check for pump flow (see "Pump Does Not Deliver Oil").

BI620146

8.2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (08/03/25)

Slow or No Feed Check for low pump delivery (see "Pump Does Not Deliver Oil").

Check for oil insufficient pressure.

Check pulldown relief valve for high setting. Pulldown pressure must be approximately 100 psi (6.9 bar) higher than holdback pressure.

Check for high setting of holdback relief valve.

Check for internal leaks in feed cylinder.

Check for binding in top drive mounting plate.

Mast Does Not Rotate Check for restrictions in set up control valve by removing hoses.

Check for collapsed hydraulic hose to actuator.

Check main pressure in hydraulic pump.

Actuator Allows Mast to Move After Being Set Check for bypassing of directional control valve. Inspect the valve spool.

Check for damaged counterbalance valve cartridge.

8-02-002

BI620146

8.3 TROUBLESHOOTING THE WATER INJECTION PUMP (08/03/25)

8-03-001

8.3 Troubleshooting the Water Injection Pump Discharge Pressure is Too Low Check for restrictions in suction line or relief valve.

Check for incorrect valve adjustment or damaged relief valve.

Check for low pump speed. Pump should run at 12 l/min proportionally.

Cavitation Problems Cavitation occurs in the pump when the cylinders do not fill completely with water during the suction stroke. This condition creates a pressure pulsation, which may damage the pump and equipment if not repaired immediately.

Check for proper diameter of water supply line. This line must be the same or larger than pump suction plumbing.

Check for air leaking into the suction system by tightening fittings and inspecting hoses.

Check for weak or worn plunger packing. Partially worn plunger packing may draw air on the suction stroke but these may not leak during the discharge stroke, creating a similar condition as in cavitation.

No Water Discharge Check for restrictions in the suction line.

Check if suction line valve is closed.

Excessive Pump Noise Check for loose suction line connection.

Check for over speeding of pump. Reduce the flow to the hydraulic motor by adjusting the flow control valve.

BI620146

8.4 TROUBLESHOOTING THE AIR DRIVEN OIL INJECTION PUMP (08/03/25)

8-04-001

8.4 Troubleshooting the Air Driven Oil Injection Pump Air Motor Does Not Operate Check for restrictions in the air supply line.

Air Seepage from Air Exhaust While Pump is Not Working Check for leaking inlet valve.

Loss of Pressure, Volume, or Continuous Operation of Pump when Not in Normal Use Check for foreign particles on the piston seat or on the ball of the foot valve.

Check for damaged piston or foot valve.

Check for scorn pump tube wall and replace if required.

Excessive Amount of Air in Lubricant or Excessive Amount of Lubricant in Air Check air leakage at gland packing, gland gasket, O-ring and U-cup packing.

NOTE: Some lubricant in the exhaust air is required.

8.5 Troubleshooting the Air Driven Grease Injection Air Motor Does Not Operate Check for restrictions in the air supply line.

Check air pressure on regulator.

Grease Is Not Delivered to the Drilling Air Line Check if grease level is low.

Check for grease output from vent when open. Prime the line if air is trapped.

Check for grease injection from the injector. Prime and adjust if required.

BI620146

8.6 TROUBLESHOOTING THE AIR DELIVERY SYSTEM (08/03/25)

8-06-001

8.6 Troubleshooting the Air Delivery System Air Pressure Builds too Slowly Check for leaks in air line.

Check for restrictions in the air filter or inlet.

Compressor Shuts Down with Air Demand Present Clean compressor fluid cooler and check for poor ventilation.

Check fluid level, add fluid.

Check compressor fluid, change fluid.

Check temperature-regulating valve.

Check for a short or open circuit in discharge temperature switch. Change if discharge temperature switch is malfunctioning.

Compressor Does Not Build-Up Full Discharge Pressure Check for leaks in air line or open valves.

Check for restrictions in the air filter or inlet. Check the filter indicator and change element if required.

Adjust pressure regulator and replace if necessary.

Compressor Unloading with an Excessive Pressure Build-Up Readjust pressure-regulating valve.

Check for cracks in unloader line.

Check inlet valve.

Check for worn seals or unloader plunger.

Excessive Compressor Fluid Consumption Check return line; clean orifice and strainer.

Check and replace separator element if necessary.

Check all pipes, connections, and components in lubrication system.

BI620146

8.6 TROUBLESHOOTING THE AIR DELIVERY SYSTEM (08/03/25)

Compressor Overheating Clean fluid cooler core.

Change thermostat element in thermal valve.

Clean fluid cooler tubes.

Check and fill sump fluid.

Clean orifice and strainer in plugged Return line.

8-06-002

BI620146

8.7 TROUBLESHOOTING THE HAMMER (08/03/25)

8-07-001

8.7 Troubleshooting the Hammer Tool Does Not Start Check for correct assembly of tool.

Check if piston is binding in the piston case or against the valves. Remove all burrs, gall marks, and scratches.

Check for damaged check valves springs. Clean rust, burrs, and scratches from valve dart.

Check for broken foot valve assembly.

Tool Stops Operating Check for "collared" or "bridged" hole. Lift the drill assembly off the bottom of the hole, then clean the hole with water injection.

Check for damaged parts such as piston case, pistons, driver sub, and drill bit.

Polish galled spots and replace parts as required. Insure that the piston slides freely inside the piston case.

Check for clogged air passages in the drill bit.

Check for obstructions in the drill pipe, air hoses and top drive.

Operating Pressure is Lower than Specifications Check if correct type of choke is installed.

Check for wear of choke. Install a smaller choke to bypass less air. If wear is excessive, replace any worn parts.

Check for restrictions in the air delivery system.

Low Penetration Rate Check for dull drill bit.

Check for broken or missing carbides in bit. Before using a new bit, clean out the drilling hole.

Check for excessive back pressure in the drill hole. Remove any collaring around the hole, then flush the hole with the drill's water injection.

BI620146

8.7 TROUBLESHOOTING THE HAMMER (08/03/25)

Galling of Internal Parts Check for proper lubrication and adjust the oil injection rate.

Check for uneven lubrication. Repair injection pump if required.

Check for foreign material inside of tool.

Check for warpage in the piston case.

8-07-002

BI620146

8.8 TROUBLESHOOTING THE DRILL BIT (08/03/25)

8-08-001

8.8 Troubleshooting the Drill Bit Abrasive Wear Check for worn carbides in bit. Use the proper rotation speed and drill weight to suit the drilling conditions.

Loss of Carbides in Bit Check the bit for loss of carbides. If any are missing and no damage is apparent, it indicates that the piston was striking the bit while the bit was not in full contact with the rock formation. This force tends to loosen the inserts. This condition may occur when the bit encounters broken or loose formation.

To avoid these conditions, control the drill to minimize these heavy blows when the bit is not in full contact.

Bit Breakage and Carbide Failure Check for hairline cracks and breakage around the buttons in the bit. Gauge buttons are most prone to such failures. This condition may be due to excessive weight on bit, improper rotation speed, or a lack of sharpening the bit.

Inspect the bit face periodically and sharpen the bits when required.

Carbide Breakage Breakage may occur due to the following: A piece of carbide may have been left in the socket when a new bit was installed.

The carbide may have been pinched while being pushed into an undersized carbide hole.

The bit may have been pushed through a bent drill hole casing.

Excessive use between recommended sharpening periods.

NOTE: Drilling in hard formation requires more frequent sharpening.

BI620146

8.8 TROUBLESHOOTING THE DRILL BIT (08/03/25)

8-08-002

Uneven Wear Conditions Uneven wear conditions may be due to the following: Check for uneven wear spots at the gauge row buttons.

The drill bit may remove the rock chips too slowly. Increase the air volume to avoid this condition.

Check for a bent drill rod and replace as required, then check the machine set-up.

Check for bit erosion just above the gauge buttons.

This creates spiraling into the rock and poor hole cleaning. Adjusting the rotation speed and frequent hole cleaning may help but the bit should be replaced at this time.

Check for excessive button wear or breakage indicating dry drilling conditions. The buttons may overheat due to extreme weight on the bit or due to improper rotation speeds.

Increase the water injection and adjust the drilling speed to avoid these problems.

Check for powdery cuttings, which indicate that the bit requires sharpening.

Check for squealing of bit during drilling. The bit steel at gauge may be rubbing.

Grind any projections or deformations on the bit steel. Cutting relief slots in the bit skirt may also be helpful.

Check for shank failure due to insufficient drill weight, uneven drill feed or excessive operating pressure.

Operate the drill at the proper air pressure and maintain a steady down pull on the bit to prevent shock loading.

BI620146

8.9 TROUBLESHOOTING THE DEPTH LASER (08/03/25)

8-09-001

8.9 Troubleshooting Depth Laser Laser appears not working. No red light is coming out of aperture.

Possible causes: Power supply could be disrupted.

Power supply wiring polarity is not in right order.

Laser unit burnt out. Short condition, Nearby Arc-welding performed, Reversepolarity power introduced, water short-condition in junction box …etc.

Solution suggestion: The unit requires 24VDC power supply.

Red wire must be connected to Positive, and Green wire must be connected to Negative.

Replace the laser unit.

Laser appears working; red light is pulsing in even intervals, no output signal.

Possible causes: Short condition cable.

Analog output wiring is reversed.

Laser beam is not reaching/reading the target correctly.

Solution suggestion: All four connecting wires must be free of insulation damage and in no contact between them.

White wire is Analog positive output; Black wire is Analog ground output.

Laser beam must be able to reach the target surface throughout the entire travel. If laser bounces of any surface at any time, the readings would be incorrect or zero output (Error condition for analog output) appears. Target surface cannot be reflective or polished surface.

BI620146

8.9 TROUBLESHOOTING THE DEPTH LASER (08/03/25)

8-09-002

Laser appears working, red light is pulsing but in un-even intervals Possible causes: Laser beam is not reaching/reading the target correctly.

Loose or missing target.

Solution suggestion: Laser beam must be able to reach the target surface throughout the entire travel. If laser bounces of any surface at any time, the readings would be incorrect or zero output (Error condition for analog output) appears. Target surface cannot be reflective or polished surface.

Target must be “visible” to the laser beam at all the time. Surface of the target might need re-painting. (Satin/flat finish spray paint in neutral colors are recommended such as primer gray, primer yellow, primer red).If used in location where direct sun light is present, olive green (Military) color is recommended.

Loose target plate creates undesirable readings.

General notes: Check for the condition of the protective lens. The glass must be free of cracks, dirt, grease and other obstructions. Order and replace lens if required.

To test and inspect the functionality of the TERRA DP-1 laser sensor, you must have the ANALOG output wires disconnected at the sensor closest mast junction box.

First make sure that laser light is hitting the target and flashing evenly. Use digital meter instrument to measure the 4-20 mA signal direct from the disconnected wires. Some digital meters cannot measure this way. If so, connect the wires back to the PLC input and install the meter leads between the Black signal wire and the PLC signal input wire.