CAT Rotary Track Drills QXR 920 Surface Drill System Maintenance Manual - PDF DOWNLOAD

BI620144

QXR MAINTENANCE MANUAL

BI620144

SERVICE MANUAL (08/03/25)

II

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 © 2008 Printed in Canada

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SERVICE MANUAL (08/03/25)

III

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SERVICE MANUAL (08/03/25)

IV

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)

V

Finding the Information…

Table of Contents (10217) 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

Carousel Assembly

4-03-001

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TABLE OF CONTENTS (08/03/25)

VI

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

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TABLE OF CONTENTS (08/03/25)

VII

8.0

Troubleshooting Guide

8.1

Mechanical System

8-01-001

8.2

Hydraulic System

8-02-001

8.3

Air System

8-03-001

8.4

Electrical System

8-04-001

Appendix Fire Suppression

A

Hydraulic Schematic

B

Air Schematic

C

Electrical General Arrangement

D

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1.0 INTRODUCTION (08/03/25)

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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 vicinity 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 or 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 boring location plans and 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

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.

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

2. Be completely familiar with 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 drill, water pump, and air supply.

4. Keep all non-essential personnel away from operator’s controls and 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 mast at any time.

9. Disconnect electrical power supply to 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 electrical panel door open.

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

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

1-01-004

Safety Instructions for Driving and Operating 1. Do not move 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 drill are in off positions before connecting 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 water hose for damage or leakage before starting the pump.

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

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

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

2. Disconnect electrical power source, mine air, and water supply before diagnosing or servicing drill.

Relieve pressures in hydraulic, pneumatic, and water systems prior to servicing.

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

4. High voltage systems (380V, 575V, 460V, etc) are to be serviced and diagnosed by qualified electrical personnel only.

5. Do not reconnect or repair loose or damaged wiring with electrical power connected to drill.

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

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

8. 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.

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

1-01-005

9. 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.

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

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

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

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

14. Clean grease fittings with clean cloth before greasing.

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

1-01-006

Warning and Caution 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

Decal is at control panel and valve controls.

•

Keep personnel away from mast when positioning.

•

Keep personnel away when performing mast set-up functions.

•

Do not stand under mast at any time.

Carousel •

Do not rotate carousel or mast unless arm unit is inside carousel.

Pinch point.

• Decal is at articulation point and at tramming valves.

Stay clear while operating.

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

1-01-007

Rotating Drive Hazard •

Stay clear while operating.

•

Do not operate without guard.

Decal is at rotating components and at compressor drive.

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.

Lifting Drill: Use designated lifting points.

•

Decal is on track frame.

Look for this decal on the track frame for designated lift points. There are lifting eyes attached to the track frame for the specific purpose of lifting the drill. Improper lifting of the equipment could cause serious personal injury and damage to the drill.

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

1-01-008

Fluid and Filter Notices: Fill with Hydraulic Fluid Only Decal is at hydraulic tank.

Fill with Rock Oil Only Decal is at rock oil tank.

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.

Perform this Safety Check before welding:

Disconnect electrical panel before doing any welding.

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

1-01-009

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 starting the engine.

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

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

Extinguishing Fires A Fire Suppression System is installed on the drill. In case of fire, do the following: 1. Shut down drill immediately.

2. Pull safety ring on actuator assembly mounted at drill control panel.

3. Push plunger at actuator assembly mounted at drill control panel.

4. Move away from drill and follow local fire safety procedures.

5. Do not restart drill until drill and fire suppression system are checked.

1-01-0010

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2.0 GENERAL MAINTENANCE (08/03/25)

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2.1 DRILL ASSEMBLY (08/03/25)

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

2-01-001

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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.

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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2.3 PM PROGRAM (08/03/25)

2-03-001

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: General Maintenance Charts:

Lubrication and inspection points

Fastener Torque Table:

Refer to this table when no specific rating is specified

Fluid Cross-over List:

Refer to the list for approved fluid types

PM Schedules:

Service forms for 250, 1000, and 2000 hours

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2.3 PM PROGRAM (08/03/25)

2-03-002

Fig 2.3.1 Lubrication Points

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2.3 PM PROGRAM (08/03/25)

2-03-003

2.3.1 Lubrication Because of the severe operating conditions normally encountered in drilling operations, lubrication is very important. A scheduled lubrication program is required to extend the drill’s service life using high quality lubricants. Keep the lubricants in sealable containers marked with their contents and store these according to fire regulations.

The lubrication points and intervals are shown in Fig. 2.3.1 to Fig 2.3.6.

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

Lubrication Types/ System Capacities Equipment

Lubrication

Capacities

Engine Oil

SAE 5W-30 – low temperature

2.5 gal (44 ℓ)

SAE 15W-40 – high temperatures Top Drive

Gear Oil 80W-90 – low temperature

2 qts (2 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)

2-03-004

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

Lubrication Cross-over Chart Fluid Type

Shell Oil

Esso (Mobil)

Petro-Canada

Mohawk

XD3 Extra 15W-40

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)

2-03-005

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

Please refer to section 6.4 for information on the rock drill grease lubrication system.

2.3.4 Lubrication Points and Intervals Refer to Fig 2.3.1 and the following table for 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

N/A

6

Air Swivel

Extreme Pressure Grease

250

Maintenance

7

Track Tension

Extreme Pressure Grease

250

Operator

8

Mast Boom Fittings

Extreme Pressure Grease

8

Operator

9

Cab Boom Fittings

Extreme Pressure Grease

8

Operator

10

Cylinder Pin

Extreme Pressure Grease

50

Operator

11

Intake Valve – Comp.

Extreme Pressure Grease

8

Operator

12

Osc. Pivot – Outside

Extreme Pressure Grease

8

Operator

13

Osc. Cylinder

Extreme Pressure Grease

8

Operator

14

Engine

Esso XD3 Extra 15W-40

8

Operator

15

Compressor

Esso XD3 Extra 10W

8

Operator

16

Osc. Pivot – Inside

Extreme Pressure Grease

8

Operator

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2.3 PM PROGRAM (08/03/25)

2-03-006

2.3.5 Centralized Machine Lubrication Your machine is equipped with a centralized machine lubrication system, consisting of centralized grease blocks and a greaser assembly (see Fig 2.3.7) to deliver the grease.

Refer to Fig 2.3.2 for centralized grease blocks location. See Fig 2.3.3 – Fig 2.3.6 for examples of centralized grease blocks.

Lubricate all points every 8 hours.

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

Fig 2.3.2 Centralized Grease Block Location

BI620144

2.3 PM PROGRAM (08/03/25)

Fig 2.3.3 Grease Block on Cab Boom

Fig 2.3.4 Grease Block on Frame

Fig 2.3.5 Grease Block on Mast Boom

2-03-007

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2.3 PM PROGRAM (08/03/25)

2-03-008

Fig 2.3.6 Grease Blocks on Mast Greaser Assembly Greaser with cable reel for greasing pins and bushings on body of QXR. It is mounted on the front of the drill beside the right track.

Fig 2.3.7 Greaser Assembly

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2.3 PM PROGRAM (08/03/25)

2-03-009

Fig 2.3.8 Drill Filtration

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2.3 PM PROGRAM (08/03/25)

2-03-0010

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

Key

Filter Type

Intervals

Service

250 Hours 250 Hours 250 Hours 250 Hours 250 Hours 2000 Hours

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance

250 Hours 250 Hours 250 Hours 250 Hours 8 Hours 250 Hours

Maintenance Maintenance Maintenance Maintenance Operator Maintenance

250 Hours 250 Hours

Maintenance Maintenance

250 Hours 250 Hours

Operator Operator

1000 Hours

Operator

2000 Hours

Operator

2000 Hours

Maintenance

CAT Engine 1 2 3 4 5 6

Air Filter – Primary Air Filter – Secondary Engine Oil Filter Fuel Filter Secondary Fuel Filter Coolant Element

Compressor 7 8 9 10 11

Air Filter – Primary Air Filter – Secondary Main Fluid Filter Moisture Separator Element Drain the moisture separator Oil Separator

Hydraulics 12 13

Hydraulic Pressure Filter Hydraulic Return Filter

Cab Pressurizer 14 15

Air Filter – Primary Air Filter – Secondary

Grease Injection 16

Moisture Separator Element

Air Conditioner 17

Clean or replace filter screens

Water Strainer 18

Clean or replace strainer

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2.3 PM PROGRAM (08/03/25)

2-03-0011

2.3.7 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.

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

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2.3 PM PROGRAM (08/03/25)

2-03-0012

2.3.8 Pipe Thread Grease Pump

2.3.8.1 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 30 psi Max 150 psi

Maximum Output Pressure:

7500 psi

Delivery Output:

0.55 cu.in. (8 ccm)/cycle

Fig 2.3.14 Pipe Thread Grease Pump

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2.3 PM PROGRAM (08/03/25)

2-03-0013

2.3.8.2 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.

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.

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2.3 PM PROGRAM (08/03/25)

2-03-0014

2.3.8.3 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.

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2.3 PM PROGRAM (08/03/25)

2-03-0015

2.3.9 Annual Maintenance of the Coolant Heater Your heater has been designed to operate with a minimum of maintenance. To ensure the efficient operation of your heater, an annual maintenance program is strongly recommended to be performed each year.

NOTE: A higher duty cycle may require a more frequent maintenance schedule i.e. 2 or 3 times each year.

Proper maintenance will result in the following benefits: •

Maximum heat transfer to the coolant

•

Minimum battery power draw

•

Long term cost savings

•

Increased reliability

Fig 2.3.15 Coolant Heater

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2.3 PM PROGRAM (08/03/25)

2-03-0016

1. Clean Heater Enclosure (refer to Fig 2.3.16) •

Remove the heater enclosure cover and blow out the compressor with compressed air.

•

Clean any accumulated debris or dust from the components.

•

Make sure the opening around the exhaust pipe is clear.

•

Visually inspect all the components for wear or damage.

WARNING! Do not pressure wash.

Fig 2.3.16 2. Check Exhaust System (refer to Fig 2.3.16) •

Check the exhaust system carefully.

•

Make sure the exhaust pipe is vented safely away from the vehicle cab.

•

Check the pipe for dents, restrictions, or severely corroded areas.

•

Replace the exhaust pipe and clamps, if necessary.

•

Ensure the exhaust pipe clamp is tight.

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2.3 PM PROGRAM (08/03/25)

2-03-0017

3. Check Heat Exchanger (refer to Fig 2.3.17) •

To maintain optimum heat output, clean any combustion deposits that may have accumulated on the heat exchanger fins.

•

Remove the fan end assembly and combustion tube to access the inside of the heat exchanger.

•

Ensure exhaust pipe is clean and free from restriction.

•

Use a wire brush to loosen deposits and a vacuum to suck them out.

Fig 2.3.17 4. Check Cooling System •

Check all heater hoses and connections for signs of leakage or damage.

•

Repair or replace as required.

NOTE: The coolant mix must be 50% Ethylene Glycol.

5. Check Batteries (refer to Fig 2.3.18) •

Check the condition of batteries and the power connections. The heater will not function properly with weak batteries or corroded connections.

Fig 2.3.18

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2.3 PM PROGRAM (08/03/25)

2-03-0018

6.Check Fuel System (refer to Fig 2.3.19) •

Check the fuel system for damaged fuel lines or leakage.

•

Make sure the clamps on the fuel lines are secure.

Fig 2.3.19 7. Check Fuel Filter (refer to Fig 2.3.20) •

Remove and inspect filter. Clean or replace as necessary.

Fig 2.3.20 8. Clean Nozzle (refer to Fig 2.3.21) •

To properly clean the nozzle, use a degreaser/cleaner or carburetor cleaner in a spray can. This will wash any dirt out and leave no residue. When using compressed air, blow into the nozzle orifice from the head end.

Fig 2.3.21

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2.3 PM PROGRAM (08/03/25)

2-03-0019

9. Compressor Air Filter ( refer to Fig 2.3.22) •

Replace inlet air filter annually or more often if dusty conditions are encountered.

Fig 2.3.22 10. Electrical System •

Check the internal and the external wire harnesses for damage. Replace if required.

11. Timer/Toggle Switch •

Check to see if either/or operates as required. Replace if necessary.

12. Operation Test •

Run the system for at least 15 minutes or until the heater cycles “OFF” and then “ON” again.

•

Alternate the thermostat for the sleeper heater (if connected) between the lowest and highest settings to ensure that the sleeper heater fan cycles “OFF” and “ON”.

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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, 11/8, 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

BI620144

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 SHC-624 or equal

Engine

See Caterpillar 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

Water pump

ESSO NUTO H46 or equal

Jib boom

Inspect:

Pulleys, pivot joint

Chain Feed

Inspect:

Pulleys, bushings, chain

Carousel

Inspect:

Wear liner, bearings, bushings

Filter Changes

Adjust:

Arm, clamp pressure

Hydraulic pressure filters

Replace, check bypass valve

Inspect:

Under top drive mounting plate

Hydraulic return filters

replace

Wear guide Sliders

Inspect:

Sliders and guide bars for wear

Air compressor filter

See section 6.2 Sullair Compressor

Adjust:

@ Top drive mounting plate

Engine Air Filter

See Caterpillar Manual

Inspect:

Clevises, pins

Miscellaneous

Inspect:

Cylinders, centralizer jaws

Control gauges

Top drive

Adjust:

Bearing pre-load

Top drive motors

Inspect:

Seals

Electrical by Qualified Electrician

Centralizer

Inspect:

Remove debris

Electrical panels:

Mast pivot shaft

Tighten:

4 - 1” dia. bolts

@ Carrier block Lower Mast

Inspect: for proper operation

Inspect wires, terminals, conduits, joysticks

The following filters will be required for this PM: Hydraulic Circuit

QTY

Description

Part Number

3

Hydraulic Pressure Filter

CX001670

Hydraulic pump

Inspect:

Seals, hoses, fittings

2

Hydraulic Return Filter

CP17218

Cylinders

Inspect:

Seals, rods

1

Engine Oil Filter

1R-0716

Air Circuit Air hoses

Inspect:

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Air hoses, fittings, hose safety devices

Caterpillar Engine

1

Primary Fuel Filter

1R0749

A/R

Primary Engine Air Filter

6I-2505

A/R

Primary Compressor Intake Air Filter

6I-2505

1

Compressor Oil Filter

CP17062-1

1

Moisture Separator Element Control Circuit

02250111-924

1

Moisture Separator Element – Accessory Circuit

CP18037-004

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector

N – See Note

BI620144

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

Test:

Brakes

Fluid Inspection Torque hubs

Gear Lube SAE 80W-90

Tramming motor

Inspect:

Seals

Hydraulic tank

ESSO NUTO H46 or equal

Torque hub

Inspect:

Seals

Compressor

MOBIL SHC-624 or equal

Engine

See Caterpillar 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 80W90

Jib boom

Inspect:

Pulleys, pivot joint

Water pump

ESSO NUTO H46 or equal

Chain Feed

Inspect:

Pulleys, bushings, chain

Carousel

Inspect:

Wear liner, bearings, bushings

Filter Changes

Adjust:

Arm, clamp pressure

Hydraulic pressure filters

Replace, check bypass valve

Inspect:

Under top drive mounting plate

Hydraulic return filters

replace

Wear guide Sliders

Inspect:

Sliders and guide bars for wear

Air compressor filter

See sect. 6.2 Sullair Compressor

Adjust:

@ Top drive mounting plate

Engine Air Filter

See Caterpillar Manual

Inspect:

Clevises, pins

Miscellaneous

Inspect:

Cylinders, centralizer jaws

Control gauges

Top drive

Adjust:

Bearing pre-load

Top drive motors

Inspect:

Seals

Electrical by Qualified Electrician

Centralizer

Inspect:

Remove debris

Electrical panels:

Mast pivot shaft

Tighten:

4 - 1” dia. bolts

The following filters will be required for this PM:

@ Carrier block Lower Mast

Hydraulic Circuit

Inspect: for proper operation

Inspect wires, terminals, conduits, joysticks

QTY

Description

Part Number

3

Hydraulic Pressure Filter

CX001670

Hydraulic pump

Inspect:

Seals, hoses, fittings

2

Hydraulic Return Filter

CP17218

Cylinders

Inspect:

Seals, rods

1

Engine Oil Filter

1R-0716

1

Primary Fuel Filter

1R0749

A/R

Primary Engine Air Filter

6I-2505

A/R

Primary Compressor Intake Air Filter

6I-2505

1

Compressor Oil Filter

CP17062-1

1

Moisture Separator Element Control Circuit

02250111-924

1

Moisture Separator Element – Accessory Circuit

CP18037-004

1

Secondary Fuel Filter

129-0373

Air Circuit Air hoses

Inspect:

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Air hoses, fittings, hose safety devices

Caterpillar Engine

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector

N – See Note

BI620144

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 Mast boom

Inspect:

Bushings, pins

Top drive

Gear Lube SAE 80W90

Water pump

ESSO NUTO H46 or equal

Mast connection

Inspect:

Bushings, pins

Compressor

Mobil SHC-624 or equal

Cab boom

Inspect:

Bushings, pins

Engine

See Caterpillar 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

Filter Changes

Adjust:

Arm, clamp pressure

Hydraulic pressure filters

Replace, check bypass valve

Inspect:

Under top drive mounting plate

Hydraulic return filters

replace

Inspect:

Sliders and guide bars for wear

Air compressor filter

See sect. 6.2 Sullair Compressor

Adjust:

@ Top drive mounting plate

Engine Air Filter

See Caterpillar Manual

Wear guide Sliders

@ Mast connection plate @ Carrier block

Miscellaneous

Chain tensioners

Inspect:

Springs and bushings

Control gauges

Lower Mast

Inspect:

Clevises, pins

Electrical by Qualified Electrician

Inspect:

Cylinders, centralizer jaws slip plate flats, drill table

Electrical panels:

Inspect:

Bearing pre-load

Top drive

Top drive motors

Inspect: for proper operation Inspect wires, terminals, conduits, joysticks

Adjust:

Bearing pre-load

The following filters will be required for this PM:

Torque:

Mtg. Plate bolts

QTY

Description

Part Number

Inspect:

Seals

3

Hydraulic Pressure Filter

CX001670 CP17218

Torque:

Motor Bolts

2

Hydraulic Return Filter

Centralizer

Inspect:

Remove debris

1

Engine Oil Filter

1R-0716

Mast pivot shaft

Tighten:

4 - 1” dia. bolts

1

Primary Fuel Filter

1R0749

A/R

Primary Engine Air Filter

6I-2505

A/R

Primary Compressor Intake Air Filter

6I-2505 CP17062-1

Hydraulic Circuit Hydraulic pump

Inspect:

Seals, hoses, fittings

1

Compressor Oil Filter

Cylinders

Inspect:

Seals, rods

1

Moisture Separator Element Control Circuit

02250111-924

Control valves

Inspect:

Seals

1

Moisture Separator Element – Accessory Circuit

CP18037-004

A/R

Secondary Engine Air Filter

6I-2506

A/R

Secondary Compressor Intake Air Filter

6I-2506

1

Receiver Tank Separator Element w/Gasket

CM77033-2KIT

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Caterpillar Engine

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector

N – See Note

BI620144

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

Inspect

Control valves

Inspect

Seals

Check

For proper installation

Inspect

Air hoses, fittings, hose safety devices

Track Assembly Track links

Link wear

Track rollers

Track roller

Air Circuit

Idler wheel

Idler wear

Air hoses

Drive sprocket Track tension

Sprocket wear Adjust

Drive Train Hydraulic brakes

Seals, rods

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 SHC-624 or equal

Chain Feed

Inspect

Pulleys, bushings, chain

Engine

See Caterpillar 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

Inspect

Sliders and guide bars for wear

Miscellaneous

Adjust

@ Top drive mounting plate

Control gauges

Mast

Sliders

Fluid Changes

Inspect: for proper operation

@ Mast connection plate @ Carrier block Chain tensioners

Inspect

Springs and bushings

Electrical by Qualified Electrician

Lower Mast

Inspect

Cylinders, centralizer jaws slip plate flats, drill table

Electrical panels:

Replace

Clevises, pins

The following filters will be required for this PM:

Top drive

Inspect

Bearing pre-load

QTY

Description

Part Number

Adjust

Bearing pre-load

3

Hydraulic Pressure Filter

CX001670

Torque

Mounting Plate bolts

2

Hydraulic Return Filter

CP17218

1

Engine Oil Filter

1R-0716

Top drive motors

Inspect wires, terminals, conduits, joysticks

Torque

Motor Bolts

1

Primary Fuel Filter

1R0749

Inspect

Seals

A/R

Primary Engine Air Filter

6I-2505

Centralizer

Inspect

Remove debris

A/R

Primary Compressor Intake Air Filter

6I-2505

Mast pivot shaft

Tighten

4 - 1” dia. bolts

1

Compressor Oil Filter

CP17062-1

1

Moisture Separator Element Control Circuit

02250111-924

1

Moisture Separator Element – Accessory Circuit

CP18037-004

A/R

Secondary Engine Air Filter

6I-2506

Hydraulic Circuit Hydraulic pump

Inspect

Seals, hoses, fittings

Inspect

Operating pressure

A/R

Secondary Compressor Intake Air Filter

6I-2506

Standby pressure

1

Receiver Tank Separator Element

CM77033-2KIT

Refer to manual sections or Appendix for:

Comments (Continue on reverse):

Caterpillar Engine

Add service code to boxes:

C – Completed

Sullair Drill Compressor

O – Okay not required

Tipton Dust Collector

N – See Note

BI620144

3.0 UNDERCARRIAGE (08/03/25)

BI620144

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.

Fig 3.1.1 Track Adjustment

BI620144

3.2 FINAL DRIVE (08/03/25)

3-02-001

3.2 Final Drive The information in this section is excerpted from Caterpillar Industrial Products, Inc. Support Literature Owner’s Manual and is applicable to your model of Final Drive.

Contents •

Parts Lists and drawings

•

Operation and Maintenance

•

Systems Operation

•

Testing and Adjusting

•

Disassembly and Assembly

Fig 3.2.1 Final Drive

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4.0 FEED ARRANGEMENT (08/03/25)

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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.

BI620144

4.1 MAST FEED SYSTEM (08/03/25)

Fig 4.1.1 Mast Feed System

4-01-002

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4.1 MAST FEED SYSTEM (08/03/25)

4-01-003

4.1.1 QXR Feed Chain Adjustment

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.

BI620144

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.

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

3. Back off locking nut.

4. Turn adjusting nut clockwise to tighten chain.

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

6. 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.

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

Fig 4.1.3 Top Chain Adjustment

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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.

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

3. Back off locking nut.

4. Turn adjusting nut clockwise to tighten chain.

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

6. 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.

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

Fig 4.1.4 Bottom Chain Adjustment

BI620144

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.

Fig 4.1.5 Wear Guides

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4.1 MAST FEED SYSTEM (08/03/25)

4-01-007

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.

Fig 4.1.6 Carrier Block

BI620144

4.1 MAST FEED SYSTEM (08/03/25)

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

Fig 4.1.7 Feed Chain Block

4-01-008

BI620144

4.1 MAST FEED SYSTEM (08/03/25)

4.1.5 Jib Boom Inspect Jib Boom every 250 hours.

Refer to Fig 4.1.8

Fig 4.1.8 Jib Boom

4-01-009

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4.1 MAST FEED SYSTEM (08/03/25)

4-01-0010

4.1.6 Lower Mast PM Tasks The lower mast assembly requires minimal servicing but the cylinders and clevis pins need to be inspected.

The slip plate flats (see Fig. 4.1.9) are exposed to heavy loads and tend to wear. Build up these spots by welding when considerable metal has worn off.

250 Hour Intervals:

1000 Hours Intervals:

2000 Hours Intervals:

•

Inspect cylinders and slip plate flats

•

Remove debris from centralizer tube

•

Inspect centralizer jaws

•

Inspect cylinder clevises and pins

•

Inspect centralizer jaws

•

Inspect drill table

•

Replace clevis pins

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4.1 MAST FEED SYSTEM (08/03/25)

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4.1.6.1 Overhaul procedure Servicing the mast feed 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. 4.1.9.

2. Inspect centralizer jaws and replace as required.

3. Inspect slip plate flats (See Fig. 4.1.9). Build them up with weld to original shape or replace them when required.

4. Overhaul the hydraulic cylinders as required. Note that the feed cylinder requires more frequent rebuilding than the double acting cylinders.

5. Reassemble the lower masts in reverse order.

Fig 4.1.9 Lower Mast

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4.2 TOP DRIVE (08/03/25)

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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 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:

6.0 qts. (5.6 l)

Weight:

780 lbs. (350 kg)

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4.2 TOP DRIVE (08/03/25)

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4.2.1 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 or manufacture it from an old drill pipe (See Fig. 4-2-1).

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 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.

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4.2.2 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.

4.2.3 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 4.2.10.

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 TOP DRIVE (08/03/25)

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4.2.3.1 Using the Right Equipment When working on a 6230 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 deg and securely holding it in the required position as shown in Fig 4.2.2 and Fig 4.2.3.

Fig 4.2.2 Stand

Fig 4.2.3 Stand

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4.2 TOP DRIVE (08/03/25)

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4.2.4 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.

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 the 4 of 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 part, replacing any worn components.

Fig 4.2.4 Disassembly

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4.2.5 Installation of Pinion Gears and Bearings 1. Install bearing cup and upper pinion bearings into gear housing top plate (see Fig 4.2.5).

Fig 4.2.5 Installation 2. Install lower pinion gear bearing into gear housing and install pinion gears (see Fig 4.2.6).

Fig 4.2.6 Installation

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4.2 TOP DRIVE (08/03/25)

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4.2.6 Driveshaft Assembly and Installation Begin assembly of the driveshaft in the upright position.

Refer to Fig 4.2.7 to Fig 4.2.22 1. Install the top spacer. Refer to Fig 4.2.7

Fig 4.2.7 2. Using a bearing warmer, heat one bearing cone to between 250-300°F (120-150°C) (refer to Fig 4.2.8).

Fig 4.2.8

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3. Install the heated bearing cone on the shaft (see Fig 4.2.9).

Fig 4.2.9 4. Install spacer on top of the bearing cone (see fig 4.2.10).

Fig 4.2.10

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5. Heat the wear sleeve between 350-375 deg F (180-190 deg C). See Fig 4.2.11 6. Install the heated wear sleeve on the shaft (see Fig 4.2.12).

NOTE: If the procedure for heating the bearings and wear sleeves is not followed they may freeze (seize) on the driveshaft. Care should be taken not to exceed a temperature of 375 deg F (190 deg C) when heating the wear sleeves.

Fig 4.2.11

Fig 4.2.12

7. After allowing the driveshaft to cool, invert it and install the bull gear (see Fig 4.2.13).

Fig 4.2.13

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8. Install the bottom spacer (see Fig 4.2.14).

Fig 4.2.14 9. Install the second bearing cone (see Fig 4.2.15).

Fig 4.2.15

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4.2 TOP DRIVE (08/03/25)

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10. Install the second wear sleeve (see Fig 4.2.16).

Fig 4.2.16 11. Install splined piston insert (see Fig 4.2.17 and Fig 4.2.18) checking alignment of air ports. Secure the insert with a ¼” x 1” grade 8 bolt, using 262 Loctite on the threads.

NOTE: The splined piston is available in different sizes depending on the application.

Fig 4.2.17

Fig 4.2.18

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4.2 TOP DRIVE (08/03/25)

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12. Lower the assembled driveshaft into the top drive housing to allow the bull gear to rest on the bottom. The use of a lifting device is necessary (see Fig 4.2.19, Fig 4.2.20, and Fig 4.2.21).

Fig 4.2.19

Fig 4.2.20

Fig 4.2.21

13. Install Gear housing gasket, coating both sides with Loctite High Tack (see Fig 4.2.22).

Fig 4.2.22 14. Position the gear housing top plate on the gear housing, insuring that it is fully seated before bolting. Tighten the 4 ¾” – 10UNC x 4” gr.8 bolts first in a crisscross manner, tightening in 3 steps to 375ft/lbs (512Nm).

15. Install the 6 of ½”– 13UNC x 4” gr.8 bolts tightening in three steps to 105 ft/lbs (143Nm).

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4.2 TOP DRIVE (08/03/25)

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4.2.7 Setting Bearing Preload 1. Rotate the top drive to the inverted position. Install the lower bearing cup onto the bottom bearing cone (see Fig 4.2.23), then install the bottom bearing cap.

Fig 4.2.23 2. Insert the bolts and slowly tighten to seat the bearing cup evenly; do not over tighten. Insert the splined piston into the splined piston insert and install a ¾” bolt in the piston (see Fig 4.2.24).

Fig 4.2.24 3. Rotate the top drive two full revolutions using the ¾” bolt installed on the splined piston; this will seat the bearing cup. Loosen the bolts on the bottom bearing cap and the retighten.

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4.2 TOP DRIVE (08/03/25)

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4. Use the torque wrench on the ¾” bolt installed on the splined piston to check the rolling torque; this is the correct way to measure preload on the bearings, of the driveshaft (see Fig 4.2.25). The correct rolling torque is 75-85ft/lbs (102-116 N/m).

Tightening of the bottom bearing cap bolts will increase the bearing preload and the rolling torque. Once the correct rolling torque is achieved, use feeler gauges to check the clearance between the bearing cap and the gear housing in three places. Use an average of these readings and subtract 0.005” (0.127mm).

Fig 4.2.25 5. Remove the bearing cap and insert the correct amount of shims under the cap (see Fig 4.2.26). Reinstall the cap and tighten the bolts to 375ft/lbs (512 Nm) dry torque.

Recheck the rolling torque and insure the proper torque value is obtained.

NOTE: Shims in the kit are either 0.005” (0.127mm) clear or 0.010” (0.254mm) white.

NOTE: Upon obtaining the correct preload, remove the retaining bolts and apply blue Loctite #243 to the threads. Reinstall and torque to 275 ft/lbs (375Nm) wet torque.

Fig 4.2.26

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4.2 TOP DRIVE (08/03/25)

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4.2.8 Installing Upper Seal and Housing 1. Remove the splined piston from the driveshaft. Install the bottom seal (see Fig 4.2.27). Lubricate the contact surface of the seal and wear sleeve of the driveshaft prior to installation.

Fig 4.2.27 2. Rotate the top drive to the vertical position. Install the 90deg ½” street elbow into the upper seal housing (see Fig 4.2.28). Coat the sealing surfaces of the top plate and upper seal housing gasket with Loctite High Track sealant.

Fig 4.2.28 3. Install the upper seal housing securing with 8 of 3/8”-13UNC x 2 ¼” gr.8 UNC bolts and lock washers. Torque to 60Nm dry torque.

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4.2 TOP DRIVE (08/03/25)

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4. Fill the gearbox with 85W140 gear oil, to the top (leave the upper seal out until gearbox is full to insure all the air escapes).

5. Coat the sealing surface of the upper seal and driveshaft, and install the seal. Then install both fill plugs.

6. Install the splined piston o-ring on the piston and lubricate. Insert the splined piston spring into the driveshaft (see Fig 4.2.29). Check for free movement of the piston when fully inserted.

Fig 4.2.29

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4.2 TOP DRIVE (08/03/25)

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4.2.9 Installing Air Swivel and Hydraulic Motors 1. Install swivel o-ring on the driveshaft and lubricate (see Fig 4.2.30).

Fig 4.2.30 2. Apply anti-seize to the threads of the swivel and install onto the driveshaft (see Fig 4.2.31), tightening by hand only.

NOTE: swivel in picture is left hand thread, RB30 is right hand thread.

When Top Drive is installed, follow proper tightening instructions, given in section 4.2.11.

Fig 4.2.31

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4.2 TOP DRIVE (08/03/25)

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3. Coat the hydraulic motor gaskets with Loctite High Tack sealer and place them on the gear housing. Install hydraulic motors and torque bolts ½”-13UNC x 2 ½” flange 12pt.

Gr.8 to 105 ft/lbs (143N/m) (see Fig 4.2.32).

Fig 4.2.32

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4.2 TOP DRIVE (08/03/25)

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4.2.10 Saver Sub 4.2.10.1 Removal 1. Lower the Top Drive to bottom of travel and support mast safely to remove the hydraulic motors.

2. Clean the top of the Top Drive to prevent debris from entering the Top Drive and cause premature wear.

NOTE: Left is looking from the rear of the drill, toward the mast.

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

4. Install the Top Drive-locking tools and secure each with four bolts. Refer to Fig 4.2.33 and Fig 4.2.34 CAUTION! After installation of the Top Drive locking tools, do not engage the drill’s rotation either forward or reverse, as damage to the Top Drive may occur.

Fig 4.2.33

Fig 4.2.34

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4.2 TOP DRIVE (08/03/25)

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5. Raise the Top Drive so the saver-sub is at the same height as the breakout cylinder.

6. Install the saver-sub breakout wrench 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

Fig 4.2.35 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.

Fig 4.2.36 8. After the joint is broken, remove the saver-sub retainer and wrench, and remove the saver-sub by hand.

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

2. Remove 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 breakout wrench onto saver sub then install the appropriate wrench holding tool.

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

Fig 4.2.37 7. Push high rotation torque button, Check gauge t ensure pressure of 2500 psi.

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

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

10. Remove breakout wench holding tool and breakout wrench.

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4.2 TOP DRIVE (08/03/25)

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4.2.11 Air Swivel 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

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

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

Support mast and top drive before loosening hydraulic components.

1. Lower the top drive to a comfortable working position to remove the Air Swivel, ensuring the Saver-Sub is not engaging the breakout bars on the slip plate.

2. Clean the top of the top drive to prevent debris from entering the top drive and cause premature wear.

WARNING! Ensure that the mine air supply is disconnected from the drill and that the air system does not contain any pressure, which could cause serious injury.

3. Remove the anti rotation bracket from the top drive mounting plate.

4. Remove the main air supply line and the splined piston airline from the Air Swivel.

Fig 4.2.38

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5. Install the Air Swivel wrench on the Air Swivel and connect the safety chain.

NOTE: The Air Swivel has left hand thread.

Fig 4.2.39

Fig 4.2.40

6. Start the drill and slowly apply reverse rotation to breakout the Air Swivel.

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

7. After the joint is broken remove the Air Swivel wrench and remove the Air Swivel by hand.

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.

4.2.11.2 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. Apply a liberal amount of Anti-Seize compound to the thread of the Air Swivel and lubricate the o-ring. Start the Air Swivel by hand into the drive shaft and continue to screw in the Air Swivel until the shoulders meet.

NOTE: The Air Swivel has left hand thread.

3. Install the Air Swivel wrench on the Air Swivel and connect the safety chain.

4. Adjust the rotation pressure to: 1000 lbs for underground unit, 1600 lbs for surface unit (QXR).

5. From the drilling panel, start the drill and with the rotation joystick slowly apply forward rotation to make up the Air Swivel.

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

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6. Remove the Air Swivel wrench.

7. Install the main air supply line and the splined piston airline from the Air Swivel.

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

9. Use breakout wrench and retainer to hold back saver sub while tightening air swivel.

Slowly apply forward rotation until wrench contacts mast.

Fig 4.2.41 10. Apply full forward rotation.

11. Adjust forward rotation pressure to 1400lbs (1600lbs for QXR) for drilling.

Fig 4.2.42

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4.2.11.3 Dismantling Air Swivel Refer to Fig 4.2.43, Fig 4.2.44, and Fig 4.2.45 1. Remove Nut at Top Of Air Swivel 2. Remove Bolts 3. Remove Air Housing Cap. 4. Remove Shim set.

5. Insert Punch through holes in bottom of housing and tap seal retainer and bearing assembly out.

6. Remove seal retainer and retaining ring.

7. Place wrench on flats and remove small tube.

8. Remove wear sleeve and bearings from large tube. Heat bearings and wear ring when removing to prevent scoring of the large tube

Fig 4.2.43

Fig 4.2.44

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4.2 TOP DRIVE (08/03/25)

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9. Remove the seal plug from the swivel housing.

NOTE: Seal plug has left hand thread.

10. Remove small rotary seal and inspect for wear.

11. Remove bearing and snap ring and inspect for wear.

Fig 4.2.45

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4.2 TOP DRIVE (08/03/25)

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4.2.11.4 Inspection of Parts 1. Inspect housing for wear, scoring, cracks, burrs, and thread condition. If any cracks are found, the housing must be replaced.

2. Inspect large tube for wear on the sealing area and the snap ring groove for damage.

If wear is present or snap ring groove is damaged, the large tube should be replaced.

3. Inspect small tube for wear on sealing area and thread damage.

4. Inspect wear sleeve for wear in the sealing area.

5. Inspect seal retainer for cracks and damage. Punch marks on the bottom from disassembly can be lightly buffed off. If any cracks are found, the retainer must be replaced.

6. Inspect housing cap for wear, and damage in the seal groove.

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

Fig 4.2.46

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4.2 TOP DRIVE (08/03/25)

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4.2.11.5 Assembly Procedure 1. Clean and inspect housing for scoring, cracks, and thread condition. Ensure hole for grease fitting is free of burrs that could possibly cut seals on installation. Repair as necessary. Lubricate and install small rotary seal.

Fig 4.2.47 2. Install seal plug with a small amount of blue Loctite on the threads, into the housing and torque to 150 ftlbs (203Nm) NOTE: the seal plug is left hand thread.

Fig 4.2.48

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3. Turn the housing over and install bearing with a light coat of anti-seize into the housing. Install snap-ring with a coating of anti-seize into the housing, be sure the snap-ring is properly inserted in the groove.

Fig 4.2.49 4. Place the large tube upside down on the bench. Using a suitable bearing warmer heat the wear sleeve to 200°F (93°C) and install on the large tube.

Fig 4.2.50

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5. Heat the bearings to 200°F (93°C).

Fig 4.2.51 6. Install the first bearing with the numbers down, install the bearing spacer, then install the second bearing with the numbers up.

Fig 4.2.52 NOTE: Be sure to install bearings with proper orientation. See diagram below.

Fig 4.2.53

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7. Install snap-ring into the groove on the large tube. Allow the large tube to cool.

Fig 4.2.54 8. Lubricate and install the O-ring into the groove on the small tube.

Fig 4.2.55 9. Install the small tube inside the large tube and tighten firmly.

Fig 4.2.56

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10. Install a 7/8” lock washer and 7/8” UNC nut onto the small tube.

Fig 4.2.57 11. Torque to 150 ftlbs (203Nm).

Fig 4.2.58 12. Install the large rotary seal into the seal retainer. Remove the o-ring from the rotary seal and install into the groove; carefully bend the inner part of the seal in a “U” shape and install into the groove NOTE: Only bend the seal as far as needed or it will be damaged.

Fig 5.2.59

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13. Install the back-up ring and CP16303-005 O-ring into the outer groove. Make sure that the back-up ring is closest to the bearing side of the retainer and that the concave side is facing the o-ring.

Fig 4.2.60 14. Lubricate the seals well and install the bearing retainer onto the large tube. Take care not to damage the seals.

15. Lubricate the inside of the housing and the seals on the seal carrier. Install the large tube assembly into the housing; make sure the seals are not cut during installation.

Using a soft faced hammer tap the large tube assembly into the housing keeping the bearings square to the housing, until it comes to rest firmly at the bottom.

Fig 4.2.61 NOTE: Do not install the housing seal at this time, as it will result in an improper rolling torque adjustment.

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16. Install the housing cap onto the housing. Do not put bolts in at this time. Using the shim kit, fit as many shims as will fit between the housing and the cap. Remove one (1) of the thinnest shims; this will be the starting point for setting the rolling torque.

17. Remove the housing cap and install the shims, reinstall the cap. Install four (4) equally spaced 3/8” x 1 ¾” UNC bolts and torque to 40 ftlbs (54 Nm). Using a beam or dial style torque wrench, check the rolling torque. The rolling torque must be 1015 ft-lbs (13.5 to 20 Nm). Add or remove shims as needed until the desired torque is reached.

Fig 4.2.62 18. Remove the housing cap and install the seal. Install the housing cap on the housing and install the two (2) seal retainers.

Fig 4.2.63

Fig 4.2.64

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19. Install eight (8) grade 8 3/8” x 1 ¾” UNC bolts with 3/8” lock washers and torque to 40 ftlbs (54 Nm).

Fig 4.2.65 20. Lube with extreme pressure grease until the housing is full.

Fig 4.2.66

Fig 4.2.67

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4.3 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 4.3.1 Pipe Alignment

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4.3 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 4.3.2 Carousel Inspection

4-03-002

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4.3 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 4.3.3 2000 Hour Inspection

4-03-003

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4.3 CAROUSEL ASSEMBLY (08/03/25)

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4.3.1 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 Fig 2.3.13 Torque Table.

4.3.1.1 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.

Fig 4.3.4 Pipe Clamp Adjustment

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4.3 CAROUSEL ASSEMBLY (08/03/25)

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

Fig 4.3.5 Lower Carousel Adjustment

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4.3 CAROUSEL ASSEMBLY (08/03/25)

Fig 4.3.6 Upper Carousel Adjustment

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5.0 HYDRAULIC SYSTEM (08/03/25)

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5.1 HYDRAULIC SYMBOLS (08/03/25)

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5.1 Hydraulic Symbols

Fig 5.1.1 Hydraulic Symbols

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5.2 HYDRAULIC CIRCUITS (08/03/25)

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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 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.

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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.:

CP17027-38

Rotation:

Left Hand

Capacity:

4.3 cin (71 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.:

CP17027-39

Rotation:

Right Hand

Capacity:

4.3 cin (71 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.:

CP17027-47

Rotation:

Left Hand

Capacity:

2.75 cin (45 cc) 21 gpm (78 l/min) @ 1800 rpm

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5.2 HYDRAULIC CIRCUITS (08/03/25)

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Pressure and Flow Settings

P-1 Pump Circuit

P-2 Pump Circuit

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

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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5.3 HYDRAULIC PUMP (08/03/25)

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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 of 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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5.3 HYDRAULIC PUMP (08/03/25)

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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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5.3 HYDRAULIC PUMP (08/03/25)

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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.

Fig 5.3.2 Hydraulic Pump

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5.3 HYDRAULIC PUMP (08/03/25)

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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 HYDRAULIC PUMP (08/03/25)

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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.

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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5.3 HYDRAULIC PUMP (08/03/25)

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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 know volume while measuring the time and calculating the flow.

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5.3 HYDRAULIC PUMP (08/03/25)

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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 HYDRAULIC PUMP (08/03/25)

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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.

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 HYDRAULIC PUMP (08/03/25)

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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.

1. The retaining plate flexes and allows the slipper to loose contact with the swashplate. On the pressure side of the pumps rotation the slipper is once again brought to contact as the highpressure 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.

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

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. The pump will continue running until it completely destroys the swashplate.

Fig 5.3.5 Poor Suction Conditions

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5.3 HYDRAULIC PUMP (08/03/25)

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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 (ie. The pump outlet is unloaded to tank) excessive wear will occur in this area causing premature pump failure.

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5.3 HYDRAULIC PUMP (08/03/25)

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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 above.

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 (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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5.5 CONTROL VALVES (08/03/25)

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Controls

Valve Type

Flow Rating

Pressure Setting

Flow Setting

Feed Extension

On/Off

6.6 gpm (25 l)

Note 1

Wide open

Mast Swing Control

On/Off

6.6 gpm (25 l)

Note 1

Note 2

Mast Dump

On/Off

6.6 gpm (25 l)

Note 1

Note 2

Boom Swing

On/Off

6.6 gpm (25 l)

Note 1

Note 2

Boom Lift

On/Off

6.6 gpm (25 l)

Note 1

Note 2

Cab Tilt

On/Off

6.6 gpm (25 l)

Note 1

Note 2

Cab Swing

On/Off

6.6 gpm (25 l)

Note 1

Note 2

Oscillation

On/Off

6.6 gpm (25 l)

Note 1

Wide open

Winch

On/Off

10.2 gpm (40.0 l)

1500 psi (103 bar)

Note 2

Breakout

On/Off

6.6 gpm (25 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)

Note 1

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 CONTROL VALVES (08/03/25)

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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: Use tachometer when setting water pump motor.

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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5.5 CONTROL VALVES (08/03/25)

Fig 5.5.8 Pressure Reducing Valve

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5.6 MOTORIZED PULLDOWN AND HOLDBACK CONTROL (08/03/25)

5-06-001

5.6 Motorized Pulldown and Holdback Control Adjustment 5.6.1 Adjusting Pulldown – Maximum Pressure 1. Lower head to bottom of travel. Leave feed lever fully forward and increase pull down pressure to maximum (see service manual for pressure setting).

2. If pressure requires adjustment, loosen the socket head screw on the clamp ring (see Fig 1). Turn motor housing clockwise to increase pressure and counter clockwise to decrease pressure.

3. Adjust to maximum pressure by first decreasing until pressure drops then increasing until maximum value is reached.

4. Tighten cap screw on clamp ring to maintain setting.

5.6.2 Adjusting Holdback – Maximum Pressure 1. Raise head to top of travel. Increase holdback to maximum pressure (see service manual for pressure setting). Feed head down using maximum pressure. The feed should stop moving and the holdback pressure should be equivalent to pulldown.

2. If pressure requires adjustment, loosen the socket head screw on the clamp ring (see Fig 1). Turn motor housing clockwise to increase pressure and counter clockwise to decrease pressure.

3. Adjust to maximum pressure by first decreasing until pressure drops then increasing until maximum value is reached.

4. Tighten cap screw on clamp ring to maintain setting.

Fig 5.6.1

BI620144

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

BI620144

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: •

Pressure gauge that is suitable for the pressure involved.

•

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

•

Misc. hoses and fittings.

•

Hydraulic hand pump.

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.

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5.8 HYDRAULIC FILTRATION (08/03/25)

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.

5-08-001

BI620144

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

BI620144

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.

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

Notes:

1. Forward pressure: 1600 psi (110 bar), Reverse pressure: 2800 psi (193.5 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.

BI620144

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

5-09-002

BI620144

5.9 PROPORTIONAL VALVES (08/03/25)

5-09-003

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)

5-09-004

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

BI620144

6.0 DRILL AIR CIRCUIT (08/03/25)

BI620144

6.1 AIR SCHEMATIC (08/03/25)

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

6-01-001

BI620144

6.1 AIR SCHEMATIC (08/03/25)

6-01-002

Schematic Key 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

PART No. CP18015-10 CX000211 CP18038 CP18039 CP17017 CX000212 CP17054 CP17054-2 CP18037-002 CP18037-001 CP18016-5 CP18313-2A CX000545 CP18313-2 CP18115-2 CM16300-24 CM48024-350-38 CM48024-350-214 CM48024-350-180 CP18021 CP17068 CP18020-3 CP17020-1 CP18222-8 CP18322-1 CP18422-18 CP18422-18-1 CP18115-3 CP17074 CQ18422-300 CP19403 CP18025-1 CP18125 CP17013-12 CP17112-1 CM17012-1 CP48001-AR1 CP17120-1 CP47146 CM48024-350-093 CP18115-5 CP18147-1 CM17012-2 CP18020 CP18015-4 CP69004 CP17052-550 250031-852 CP18115-3 CM17071-6 CM77033-2KIT 02250111-923

DESCRIPTION Solenoid Valve Grease Injection Assembly 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 Assembly ½” Ball Valve Top Drive Assembly Air Hose, Top Dr.-Bulkhead Air Hose, Bulkhead-Bulkhead Air Hose, Bulkhead-Bulkhead Safety Tie Breather Needle Valve, Water Pump Gauge, Water 0-1000 psi Unloader Valve, Water Water Pump Assembly Water Filter (Coarse) Filter Element 1” Ball Valve Cap Fill Vent 2.5” Water Tank Sensor, Water Level Check Valve, ½” Inline Check Valve Ball Valve Valve, Actuator Actuator Bracket Valve, Line/Sump Gauge, Hyd Pressure 0-600 psi Check Valve Air Hose, Bulkhead-Drill Ball Valve 1 ½” Solenoid Valve Stub Shaft Needle Valve ¼” 3/8” Ball Valve Antifreeze Tank Safety Relief Valve Min. Pressure/Check Valve 1” Ball Valve Receiver Tank Assembly Filter Element w/Gasket Moisture Separator

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

02250111-924

Filter Element

A/R

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A/R 1

KEY 51 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 92 93

PART No. CP17053 048061 CP17186 CP18147-2 CP18006-2 CQ20100-27A CP17059 CP17058 047525 CP17146 02250116-974 CP69018 CP17057 047524 02250111-620 02250111-619 CP17062 CP17062-1 02250044-281 CX000544 CX000671 250041-069 02250051-747 409011 250025-294 046559 022033 02250055-528 CP41018-29 CP17070-8 CP18418 CP18418-1 CP18418-2 250024-942 02250126-832 02250111-630 02250111-629 CP18006-1 CP17086 CP18025-5 02250107-045 CP18025-1 CP18146 CM18318-1 CP18422-21 CP18422-21-1 740 48134 CP41028 048354 250022-728

DESCRIPTION Separator Restrict. Indicator Gauge, Sys Pressure 0-600 psi Flange, SAE 61 Step Up Coil, 24 VDC Gauge Radiator Assembly Muffler System Blowdown Valve Repair Kit Inline Check Valve Ball Valve Grease System Running Blowdown Valve Repair Kit Thermal Bypass Valve Element Main Fluid Filter Filter Element Oil Return Strainer Regulator, 100-400 psi ¼” 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 2.5” Flex Hose Screw Compressor 900/500 Air Filter Assembly 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 Check Valve 2-Way Solenoid Valve Water Trap Assembly Water Filter (Fine) Filter Element Lubrigun Alcohol Injector Radiator Tube Regulator Pressure Relief Valve

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

BI620144

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

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-002

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.

Fig 6.2.2 Compressor

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-003

Fig 6.2.3

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-004

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

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

Fig 6.2.4 Receiver Tank and Separator Elements

6-02-005

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-006

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 port. These ports are stamped on the thermal valve body indicating: 1. From tank 2. To cooler 3. From cooler 4. 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.

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.

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

Fig 6.2.5 Fluid Stop Valve

Fig 6.2.6 Main Compressor Fluid Filter

Fig 6.2.7 Entrance/Exit Ports

6-02-007

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-008

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.

6.2.8 Air Inlet System

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6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-009

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.

Esso Mobile Rarus SCH1024

1000hrs

Esso Mobile Rarus SCH1026

1000hrs

-40°C to +14°F -10°C to +40°C +14°F to +104°F Over +40°C Over +104°F

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.

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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

6-02-0010

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-0011

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)

6-02-0012

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

55

0-600 psi pressure gauge

500 psi Pressure Regulator

61

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

53

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

70

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

100

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

32

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.

Running Blowdown Valve

62

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

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-0013

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

85

Valve to manually unload compressor.

Air Filter

76

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

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-0014

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.

6.2.10 Butterfly Inlet Valve

BI620144

6.2 SULLAIR COMPRESSOR (08/03/25)

6-02-0015

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.

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.

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.

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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.

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.

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 Highpressure regulator now functions and opens, sending a signal opening the running blowdown and the inlet control cylinder, closing it to maintain 350 psi.

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.

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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Fig 6.2.16 Tram/Set-up Panel

Fig 6.2.17 Compressor Discharge

6-02-0022

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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 6.2.18 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).

Fig 6.2.18

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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 180psi. 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.

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 oring 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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Fig 6.2.38 Pressure Regulator

Fig 6.2.39

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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

6-02-0038

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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.

BI620144

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

6-02-0043 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/pressure regulator in the suction line and a relief valve mounted in the discharge line.

PM Tasks Visual inspections and changing the crankcase oil are routine maintenance procedures. The hydraulic motor requires lubrication of the drive coupling but no periodic servicing is required. Service instructions are not included because replacing the motor is more economical than overhauling.

250 Hour Intervals: Check pressure regulator/ strainer 1000 Hour Intervals: Change crankcase fluid 2000 Hour Intervals: Perform a pressure test

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

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:

425 psi (29.4 bar)

Speed:

225 rpm

Crankcase Capacity:

40 fl. oz. (1.2 L)

Lubricant Type:

Shell Tellus T 37 Hydraulic Oil

Weight:

32 lbs. (14.5 kg.)

Relief Valve:

425 psi (29.4 bar)

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6.3 WATER PUMP (08/03/25)

6-03-002

6.3.1 Pump Speed Adjustment The pump has a direct drive propelled by a hydraulic motor. Using a tachometer, set the motor speed to 225 rpm by adjusting the hydraulic flow at the control 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)

6-03-003

6.3.2 Dismantling of Valves Refer to Fig 6.3.1 WARNING! Disconnect electrical power, mine air, water supply, and relieve pressure in air receiver before servicing.

1. Remove fasteners (53, 55) securing discharge manifold (52) to crankcase (2).

2. Tap discharge manifold from backside with soft mallet to separate it from crankcase.

Repeat action until it breaks free from cylinders.

3. Valve assemblies will remain in manifold. With reverse pliers, remove valve seats (43). Valve (44), spring (45), and retainer (46) will then fall out when manifold is inverted.

6.3.3 Assembling of Valves Refer to Fig 6.3.1 1. Replace retainers (46) in manifold chambers.

2. Insert spring (45) into center of retainers (46).

3. Inspect valves (44) and valve seats (43) for wear, ridges, or pitting and replace as necessary.

4. Insert valve over spring with recessed (dish) towards discharge manifold.

5. Examine O-ring (42) and back-up ring (66); replace if worn. Lubricate O-rings to avoiding damaging them.

NOTE: First install O-ring in groove on seat (towards seating surface), then on backring.

6. Insert valve seats into manifold chambers.

7. Install manifold on pump and lubricate O-rings on cylinders. Be cautious when slipping manifold over cylinders to avoid damaging cylinder O-rings.

8. Install fasteners and torque to 217 in.-lbs (24.5 N m).

NOTE: Reinstall all original shims. When new manifold is used, re-shim pump.

CAUTION! When starting pump, check to see that there is no cylinder motion as this would cause premature failure of cylinder O-rings. Motion of center cylinder must be eliminated by adjustment described later.

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6.3 WATER PUMP (08/03/25)

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6.3.4 Dismantling the Pumping Section Refer to Fig 6.3.1 1. Remove discharge manifold as previously described.

2. Grasp cylinders (41) by hand and with up and down motion, pull cylinders from inlet manifold (31). Mark each cylinder to allow installation in original location.

3. Remove cotter pin (39), nut (38) and washer (37) from piston rod (21).

4. Remove retainer (36), spacer (35) and piston/cup assembly (34, 34A). Remove inlet valve (33).

6.3.5 Pump Assembly Refer to Fig 6.3.1 1. Examine surface of inlet valve (33) for pitting or scaling. Reverse valve, then sand inlet side of valve, using 240 grit emery cloth. Surface must be clean. Replace it if excessive wear is apparent. Slip it onto rod (21).

2. Examine seating surfaces on piston (34) and sand clean on flat surface using 240 grit emery cloth. Replace piston if extreme pitting or sharp edges are present.

3. Examine cup (34A) for wearing, cracking, or separating from piston and replace as required. Lubricate it before installing on piston.

NOTE: See parts manual for Cup Insert Tool. Lubricate tool before using.

Push cup (34A) over insert tool and square with all surfaces. Faulty cup installation causes premature cup failure. Lubricate piston (34) and slip on rod (21).

4. Replace piston spacer (35) and retainer (36) on rod (21).

5. Replace washer (37) and cotter pin (39). Install nut (38) and torque to 60 in.-lbs. (6.8 N m).

6. Examine cylinder walls for scoring or etching which would cause premature wear of cups. Replace them if worn.

7. Lubricate cylinder and replace O-ring and/or back-up ring if worn or damaged.

Carefully slip cylinder over rod end and push into inlet manifold. Make sure cylinders are installed in their original positions.

8. Position discharge manifold on pump, install fasteners and torque to 217 in.-lbs. (24.5 N m).

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6.3 WATER PUMP (08/03/25)

6-03-005

CAUTION! Cylinder motion will cause premature failure of O-ring and cylinder seals.

Check for cylinder motion immediately after the pump is started. If there is any motion noted in the center cylinder, switch it with one of the end cylinders and start the pump again. If there is motion noted in one of the end cylinders, correct it by removing one manifold shim, then install the lock washers and nuts. Torque to 10 ft.-lbs. (13.6 N m).

6.3.6 Removing Sleeves and Seals Refer to Fig 6.3.1 1. Remove discharge manifold (52) and piston assemblies as described previously.

2. Remove inlet manifold (31) containing seals.

3. Grasp sleeves (27), with pulling and twisting motion and remove sleeves from piston rod (21).

NOTE: Remove sleeve with pliers only if replacing worn sleeves, as using pliers would mark sleeves.

4. Remove seal retainer (29).

5. Remove O-rings (26) and back-up rings (28) on piston rod then check them for wear.

Replace them as required.

6.3.7 Installing Sleeves and Seals Refer to Fig 6.3.1 1. Lubricate new O-rings and slip them on piston rod. Install first O-ring in groove on piston rod. Position back-up ring against shoulder in front of first O-ring. Then install second O-ring. Exercise caution as you slip O-ring over threaded end of piston rod.

2. Examine sleeves (27) for scoring or etching and replace as required. Immerse sleeves in oil and carefully twist and push sleeve on rod (machined counter bore end first).

3. Install seal retainers (29).

4. Place inlet manifold (31) on pair of clearance blocks with crankcase side down and drive out old seals (30).

5. Invert inlet manifold with crankcase side up and install new seals. Lubricate circumference of seal and install Perm-A-Lube seal with Garder spring down.

6. Lubricate seal insert tool and slip it on piston rod end, position inlet manifold on pump and remove tool.

NOTE: Install original quantity of washers (48) on studs before installing inlet manifold (31).

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6.3 WATER PUMP (08/03/25)

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7. Reassemble piston and discharge manifold as described earlier.

6.3.8 Servicing the Crankcase Refer to Fig 6.3.1 1. While inlet manifold, sleeves and seal retainers are removed, examine crankcase seals for wear.

2. Check oil for water content.

3. Rotate crankshaft by hand. Rotation must be smooth.

4. Examine crankshaft oil seal (14) for cracking or leaking.

5. Consult your supplier if the crankcase requires servicing.

6. Reassemble in reverse order.

7. Add hydraulic fluid Shell Tellus T 37 or equivalent to level indicated on sight glass.

6.3.9 Pump Installation Install pump on drill and attach hoses. Check the crank case oil. Adjust pump speed and suction pressure regulator as outlined in beginning of this module.

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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)

6-04-002

Fig 6-4-1

Fig 6-4-2

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)

6-04-003

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 GREASE INJECTION (08/03/25)

6-04-004

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)

Fig 6.4.4 Adjusting Flow Rate

Fig 6.4.5 General Settings screen

6-04-005

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6.4 GREASE INJECTION (08/03/25)

6-04-006

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 in the PanelView under ‘LUBE SETTINGS’ in the general settings screen. See Fig 6.4.5 The timings can be entered by touching the screen in the appropriate area. (See red arrows on Fig 6.4.6) 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 Lube/Grease Settings screen

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7.0 ELECTRICAL (08/03/25)

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7.1 ELECTRICAL CIRCUITS (08/03/25)

7-01-001

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:

See electrical drawings

Motor Control:

120 volts, single phase

Valve Control:

24 volts, DC

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7.2 ELECTRICAL COMPONENTS (08/03/25)

7-02-001

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 Inspection

•

Clean and inspect electrical system

•

Lubricate electric motor bearings

•

Inspect dust boot on all joysticks

•

Test instrumentation lamps

•

Inspect seals on all panels

WARNING! Opening electrical panel exposes high voltage. Disconnect electrical power when servicing. Electrical circuits to be serviced by qualified electricians only.

CAUTION! Disconnect electrical power and isolate ground before arc welding.

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.

Control Panels Visually inspect the switches, gauges and controls on the drill control panel and the set-up/tramming panels. Replace worn joystick boots and contact blocks.

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

7-03-001

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7.4 TYPES OF VALVES (08/03/25

)

7-04-001

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 Hershman 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: •

Feed Extension

•

Air

•

Cab Swing

•

Mast Dump

•

Carousel Arm

•

Winch

•

Boom Lift

•

Jib Boom

•

Breakout

•

Cab Tilt

•

Mast Swing

•

Centralizer

•

Oscillation

•

Boom Swing

•

Diverter

•

Water Pump

•

Dust Collector

•

Carousel Clamp

•

Slip Control

Proportional valves with white/grey connectors are installed on the following applications: •

Tram control

•

Rotation control

•

Feed control

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)

7-06-001

7.6 Testing On/Off Valves When malfunctioning of the solenoid is suspected, perform the following test: 1. Remove Hershman 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 Hershman Connector

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7.7 PROPORTIONAL VALVES (08/03/25)

7-07-001

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 (feedback). 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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7.8 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 Hershman 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:

12 volts DC (100% of supply voltage).

pin 2:

3 volts DC (25% of supply voltage).

pin 1:

0 volts DC

pin 2:

0 volts DC

pin 1:

12 volts DC (100% of supply voltage).

pin 2:

9 volts DC (75% of supply voltage).

pin 1:

12 volts DC (100% of supply voltage).

pin 2:

9 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:

12 volts DC (100% of supply voltage).

pin 2:

3 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 PLC SYSTEM (08/03/25)

7-09-001

7.9 Accra-Feed PLC 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 SLC500 PLC ROTATION PRESSURE SWITCH •

Monitors forward rotation pressure (set 1200psi). See hydraulic schematic.

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7.9 ACCRA-FEED PLC SYSTEM (08/03/25)

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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. Proper cooling of the PLC is impossible if a layer of dust is deposited.

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 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 PLC 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.

BI620144

7.9 ACCRA-FEED PLC 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)

7-10-001

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 Start screen

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25)

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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.

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.

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7.10 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25)

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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 OPERATOR INTERFACE PANELVIEW 1000 (08/03/25)

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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.

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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8.0 TROUBLESHOOTING (08/03/25)

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8.0 TROUBLESHOOTING (08/03/25)

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8.0 Troubleshooting The Troubleshooting is divided into four types of systems; Mechanical, Hydraulic, Air, and Electrical.

Use the elimination process to investigate each system separately because some of the problems may originate in any one of the four systems. Refer to the troubleshooting guide, schematic layouts and service modules to diagnose the system.

Encouragement:

Notice unusual things - ask yourself questions.

Use the elimination process to find the problem.

Refer to Maintenance Sections to help you understand the system.

First Step - Perform the following preliminary inspection: Mechanical System: 1. Check for loose bolts.

2. Check for damaged components or misalignment.

3. Check for leaks and unusual sounds.

Hydraulics System: 1. Check for proper type and level of fluid.

2. Check for proper fluid pressure.

3. Check for correct rotation of pump.

4. Check that all manual and remote controls are operating.

5. Check that cylinders and motors operate in correct direction.

6. Check that shut-off valves are open.

Air System: 1. Check for leaks.

2. Check for proper air pressure.

3. Check that all manual and remote controls are operating.

4. Check that shut-off valves are open.

Electrical System: 1. Check that the phase reversal indicator is not lit.

2. Check for proper electrical connections.

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8.1 TROUBLESHOOTING MECHANICAL SYSTEMS (08/03/25)

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8.1 Troubleshooting Mechanical Systems Tramming does not move or move straight 01. Seized or clogged tracks. Clean and inspect tracks and rollers. Refer to Section 3.01.

02. Derailed tracks. Reinstall and set track tension.

03. Bolts sheared off at final drive.

04. Track tension too tight. Check for 3/8" (10 mm) track sag.

05. Defective tram motors. Check for excessive motor leakage. Disconnect case drain hose at motor. Service motor if flow is excessive.

06. Locked brakes.

•

Defective shuttle valve. Take pressure reading at bleed port in brake assemblies.

•

Defective seal in brake release piston. Replace as required.

•

Defective parts in brake assemblies. Replace as required.

07. Hydraulic system malfunction.

08. Defective tramming valve.

9. Malfunctioning torque hub.

•

Check oil level - most torque hub failure is due to dry running conditions. Inspect torque hub fluid for metal shavings. Dismantle unit if above conditions are present.

Tramming is too slow or lacks power 01. Seized or clogged tracks. Clean and inspect tracks and rollers.

02. Track tension too tight. Check for 3/8" (10 mm) track sag.

03. Defective tramming motor. Check for excessive motor leakage. Disconnect case drain hose at motor. Service motor if flow is excessive.

04. Brakes not releasing fully. Defective seal in brake release piston. Replace as required.

05. Incorrect pressure or flow setting at control valve.

06. Incorrect system pressure. Set system pressure to 2800 psi.

07. Defective control valve. Replace defective valve section.

Brakes are slipping 01. Worn friction disc or damaged springs.

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8.1 TROUBLESHOOTING MECHANICAL SYSTEMS (08/03/25)

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Excessive noise or vibration when tramming 01. Loose hardware in drive train.

02. Defective tram motors. Check for excessive motor leakage. Disconnect case drain hose at motor. Service motor if flow is excessive.

03. Defective brakes.

04. Defective torque hubs.

Mast swing does not rotate 01. Internal leakage in rotary actuator.

02. Improper system relief, valve pressure or flow setting at control valve.

03. Improper system or standby pressure setting at pump.

04. Defective control valve.

Mast rotates erratically or rotates after setting 01. Damaged counterbalance valves. Replace all four counterbalance valves at rotary actuator.

02. Improper pressure relief, valve pressure or flow setting at control valve.

03. Improper system or standby pressure setting at pump.

04. Defective control valve.

Mast rocks back and forth 01. Loose bolts at mast connection plate.

Hydraulic cylinders not operating 01. Defective remote valve controls. Operate manual valve on drill deck. If cylinders operate, test electrical and hydraulic circuits.

02. Defective control valve.

03. Disconnected cylinder clevis.

04. Defective cylinder. Check cylinder for damaged seals.

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8.1 TROUBLESHOOTING MECHANICAL SYSTEMS (08/03/25)

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Cylinder creep 01. Pin-hole leak in hydraulic hose.

02. Leaking load checks.

03. Internal cylinder leak.

04. Leaking control valve.

Centralizer does not retract 01. Centralizer brackets plugged with debris. Remove debris.

02. Cylinder clevis disconnected. Repair as required.

03. Pressure at centralizer valve set too low. Adjust pressure setting.

Oil leakage at stinger cylinder 01. Defective cylinder seals or scored cylinder rod.

Pulldown control does not function correctly 01. Incorrect setting or malfunctioning of pulldown valve.

02. Leaking or by-passing seals in feed cylinder.

03. Improper relief valve setting at drilling control valve.

Holdback control does not function correctly 01. Incorrect setting or malfunctioning of holdback valve.

02. Improper relief valve setting at drilling control valve.

03. Sequence valve out of adjustment. Adjust as required.

04. Leaking or by-passing seals in feed cylinder.

Top drive does not rotate, or rotation is slow or rough 01. One or both top drive motors defective. Inspect rotor set for leakage in top drive motors. Check for excessive heat in top drive motors. Heat source may be a flow restriction. Temperature over 200° F (93° C) may damage seals.

02. Misaligned or defective top drive assembly. Check bearing adjustment at top drive assembly. Check for damaged gears or bearings in top drive assembly.

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8.1 TROUBLESHOOTING MECHANICAL SYSTEMS (08/03/25)

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Splined piston in top drive does not retract 01. Damaged splined piston or weak spring in top drive. Dismantle unit and check splined piston for twist or burr that may interfere with spring’s action. Test string for proper compression force.

02. Check female splined in drill string. If damaged, repair it by filing or grinding.

Rotation and Feed joysticks produce uneven speeds in both directions 01. Solenoid Adjustment needs calibration. Refer to Solenoid Adjustment.

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8.2 TROUBLESHOOTING HYDRAULIC SYSTEMS (08/03/25)

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8.2 Troubleshooting Hydraulic Systems Fluid is hot 01. Open or leaking control valve.

02. Clogged aftercooler or insufficient cooling (if equipped with cooling option).

03. Incorrect pump or control valve settings.

04. Relief valve in control valve stuck open.

05. Excessive bypass in cylinders or hydraulic motors.

06. Defective components in hydraulic pump or excessive bypass.

System is noisy 01. Cavitation condition caused by leaking or clogged suction line or worn seals.

02. Leaking valve.

03. Standby pressure at pump set incorrectly.

04. Air entering hydraulic system. Check fittings and hoses on suction lines.

05. Damaged hydraulic pump.

Fluid quickly contaminates 01. Scratched cylinder rods. Check all cylinders and replace as required.

02. Damaged pump.

Fluid is foaming 01. Incorrect type or level of hydraulic fluid. Check for water contamination.

02. Air entering hydraulic system. Check fittings and hoses on suction lines.

Valve Solenoid Malfunction 01. Follow tests as outlined in Testing Valve Solenoids.

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8.2 TROUBLESHOOTING HYDRAULIC SYSTEMS (08/03/25)

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Insufficient pressure or flow 01. Operating pressure or standby pressure at hydraulic pump of adjustment.

02. Pressure relief, valve pressure or valve flow setting at control valve out of adjustment.

03. Check for load sense not operating.

04. Clogged suction strainer in hydraulic tank.

05. Defective pump. Check for internal leaks.

Pump is noisy or vibrates 01. Loose or defective pump coupling.

02. Defective hydraulic pump.

03. Defective pump control valve.

Pump does not run 01. Damaged pump coupling. Remove inspection plate on bell housing and inspect.

02. Poor electrical connection.

03. Defective pump motor. Test motor and controls.

Hydraulic motors or cylinders do not respond NOTE: when troubleshooting the control valves, perform the following tasks in order: 01. Check problems listed in mechanical system.

02. Check problems listed in electrical system.

03. Perform checks listed in this section.

Rotation and Feed joysticks produce uneven speeds in both directions 01. Solenoid Adjustment needs calibration. Refer to Solenoid Adjustment.

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8.3 TROUBLESHOOTING AIR SYSTEMS (08/03/25)

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8.3 Troubleshooting Air Systems NOTE: Refer also to section 6.2 Sullair Compressor Air pressure is zero or low 01. Check electrical circuit. Refer also to section 6.2 Sullair Compressor.

Water pump pressure is zero 01. Closed suction valve.

02. Defective water pump solenoid valve.

03. Defective water pump motor. Confirm that motor is turning.

04. Defective water pump or accessories - See “Water pump pressure is low”.

05. Defective relief valve in water pump circuit.

Water pump pressure is low 01. Partially closed suction valve.

02. Defective or clogged regulator/strainer. Inspect and clean it.

03. Incorrect speed of water pump motor. Adjust hydraulic flow to correct speed.

04. Defective water pump solenoid valve.

05. Defective relief valve in water pump circuit.

06. Clogged needle valve (water metering valve).

07. Malfunctioning water pump. Worn seals in water pump. Worn piston assembly due to inadequate water supply. Check strainer to confirm source problem.

Water pump runs extremely rough 01. Restricted or leaking inlet line.

02. Stuck discharge valve or damaged cup in water pump. Clean pump and replace parts.

03. Worn inlet seals. Replace inlet manifold seals.

Water pump leaking 01. Replace leaking seals and o-rings. Check for water in crankcase and excessive play in crankshaft. Overhauling the pump is recommended.

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8.3 TROUBLESHOOTING AIR SYSTEMS (08/03/25)

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Grease delivery is incorrect 01. Check for proper air supply pressure. Adjust air pressure regulator to 80 - 100 psi (5.5 – 6.9 bar).

02. Check for clogged or defective check valve in discharge line.

03. Check for clogged or defective grease injector, adjust volume. .

04. Air pressure regulator for rock grease pump is faulty. Check for worn O-rings, gaskets, valve stem and valve seat. Replace whole unit as required. Adjust air pressure regulator to 80 - 100 psi (5.5 – 6.9 bar).

05. Defective grease pump. If worn, replace piston, piston seat, and piston packing.

Replace pump tube if worn.

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8.4 TROUBLESHOOTING ELECTRICAL SYSTEMS (08/03/25)

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8.4 Troubleshooting Electrical Systems WARNING! Servicing electrical circuits is for qualified electrical personnel only.

Engine does not start 01. Check main breaker.

02. Check high voltage line to control transformer.

03. Check breakers and fuses in electrical panel.

Tram controls (joysticks only) are insensitive 01. Flow adjustment module set incorrectly. Refer to Tram Control Adjustment.

Hydraulic motors or cylinders not operating 01. Operate application manually using control valve lever. If working, test joystick, switch and valve solenoid. Refer to electrical diagrams.

02. Test valve solenoid as outlined.

Rotation and Feed joysticks produce uneven speeds in both directions 01. Solenoid Adjustment needs calibration. Refer to Solenoid Adjustment.

Valve Solenoid Malfunction 01. Follow tests as outlined in Testing Valve Solenoids.