Professional Documents
Culture Documents
ARIES MEGAMATIC
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
(204) 633-0678
III
Getting Familiar
There are 8 sections.
Service Info
IV
General Maintenance Drill Assembly Break-in Maintenance PM Program PM Schedules 2-01-001 2-02-001 2-03-001 2-04-001
3.0 3.1
Feed Arrangement Slide Arrangement Rotary Actuator Mast Feed System Lower Mast Top Drive Top Drive Motor Breakout Wrench Carousel Assembly 4-01-001 4-02-001 4-03-001 4-04-001 4-05-001 4-06-001 4-07-001 4-08-001
II
5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0 6.1 6.2 6.3 6.4 6.5
Hydraulic System Hydraulic Symbols Hydraulic Circuits Hydraulic Pump Hydraulic Cylinders Control Valves Hydraulic Filtration Miscellaneous Controls Oil Cooler Proportional Valves Drill Air Circuit Drill Air Circuit Water Pump Grease Injection Fire Suppression Screw Booster Compressor 6-01-001 6-02-001 6-03-001 6-04-001 6-05-001 5-01-001 5-02-001 5-03-001 5-04-001 5-05-001 5-06-001 5-07-001 5-08-001 5-09-001
Electrical Electrical Circuits Electrical Components Testing of Valve Solenoid Alignment Laser Accra-Feed PLC System 7-01-001 7-02-001 7-03-001 7-04-001 7-05-001
Troubleshooting Guide Troubleshooting Mechanical Systems Troubleshooting Hydraulic Systems Troubleshooting Air Systems Troubleshooting Electrical Systems 8-01-001 8-02-001 8-03-001 8-04-001
III
Appendix Ansul Fire Suppression, A-101 Ansul Fire Suppression Owners Manual Ansul Fire Suppression, Checkfire SC-N Instruction Manual for Hydrodynamic Cable Reels Hydraulic Schematic Air Schematic Electrical General Arrangement Cubex Tool Catalogue A B C D E F G H
1.0 INTRODUCTION
This symbol warns of possible danger. Proceed with caution.
Module Date (Year/Month/Day) Page Number
Updating of Manual Updated modules will be issued for revisions and corrections as required. Please keep your manuals updated.
1-01-001
If there are any questions concerning the safety of drilling on sites in the vicinity of overhead power lines, call your supervisor.
1-01-002
1-01-003
1-01-004
1-01-005
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. 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 the 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 a clean cloth before greasing.
1-01-006
Observe the following safety instructions on the decals shown below BEFORE operating the drill:
Mast Function Keep personnel away from the mast when positioning. Decal is at control panel and valve controls. Keep personnel away when performing mast set-up functions.
Rotating Drive Hazard Stay clear while operating. Decal is at rotating components. Decal is at compressor drive. Do not operate without guard.
1-01-007
Observe the following safety instructions on the decals shown below BEFORE servicing the drill:
Danger! Compressed Air! Relieve pressure from receiver before servicing. Decal is at booster air receiver/drain valve.
Danger! High Voltage! Access by qualified personnel only. Decal is at electrical panel.
Danger! Outriggers and mast stingers can cause serious crushing injury stand clear.
1-01-008
Disengage torque hubs for towing. Engage torque hubs to apply brakes.
1-01-009
Check that all pressurized air hoses are secured with hose connection safety devices.
Check that all controls are in the off position before connecting the power supply.
Check that all valves are in the off position before connecting the air system and power supply to the drill unit.
1-01-010
Joe
Doe
Please print.
Job Title
Zip
Be aware of the safety procedures when operating and servicing Drilling Equipment. 1. Safety symbols - Know the safety symbols. - Know the operating and maintenance procedures. 2. Compressed air system - Relieve the air pressure before servicing. - Check that all air hoses are secured with safety chains. - Keep away from hot compressor components. 3. Protective equipment - Wear safety glasses, ear protection, dust masks and proper clothing. - Check that all guards are in place. 4. Operating precautions - Keeps hands away from moving components. - Check that the path is clear before tramming. - Check that personnel is away from drill while tramming or positioning. - Check that the mine air supply hose and high voltage cable have free movement for tramming. - Engage the torque hubs to apply brakes and disengage them for towing. - Place the mast on T-rest before moving drill. 5. Fluid leakage - Wear protective gear when investigating hydraulic leaks. High pressure jet streams may cut skin and result in injuries. 6. Drilling - Use sufficient water to reduce inhaling of dust. - Be cautious when using the breakout wrench to avoid injury. 7. Equipment maintenance - Replace worn or damaged parts immediately. Well-maintained equipment is required for maximum personal safety. - Inspect the Ansul Fire Suppression System periodically if equipped with this option.
I fully understand these safety procedures and I will practice them to my best knowledge and ability.
Signature
Date
Th is pa g e le ft bl an k in te nt i
on al
ly
CUBEX Ltd.
1. Distributor
Distributors Claim No. Owner Page of Date
Claim No.
1218 Redonda St., Box 13, Grp 524, RR5, Winnipeg, Manitoba, Canada, R2C 2Z2
W-
2. Model
Serial No. Hour Meter Reading
3. Failure
Repair Date
Failure Description
Failure Cause
Approved Comments
Rejected
4. List
Qty.
Total Parts
5. Labour
Description of Repair
6.
I certify that the parts and labour claimed for repair were used as indicated and that failure did not appear to have resulted due to negligence, misuse, accident and that the equipment was not altered without written permission from Cubex.
Signature
Date
Th is pa g e le ft bl an k in te nt i
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2-01-001
CAUTION! Be familiar with the operating procedures before operating the drill.
2-01-002
2-02-001
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 (see Section 2.3). 3. Change the pressure filter and the return filter. 4. Check for hydraulic leaks. 5. Check the entire drill for unusual indications. 6. Change the crankcase oil in the water pump. Use hydraulic fluid. 7. Check the bearing pre-load on the top drive (see Section 4). 8. Open the control panel and inspect the wires, terminals, and conduits. WARNING! By Qualified Electricians Only! 9. Refer to the engine and compressor service manuals for any required maintenance. 10. Inspect the carousel for proper operation. 11. Perform a 250 Hour Inspection (see the PM Schedules).
2-02-002
2-03-001
2-03-002
Type N/A Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Esso NUTO 46 Rock Drill Grease Esso NUTO 46 SAE 80W-90 low temp; SAE 140 high temp Lithium Grease Mobil SHC-1024
1
Interval/Hrs N/A 8 hours 8 hours 250 hours 250 hours 250 hours 8 hours 8 hours 8 hours 8 hours 250 hours 50 hours 50 hours
Service By N/A Operator Operator Operator Operator Maintenance Operator Operator Operator Operator Electrical Operator Operator
Note 1 : Do not over-grease. Excessive grease may cause overheating. Note 2 : Refer to Maclean Carrier Manual for recommended lubrication.
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 drills 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. The recommended lubricants and system capacities are listed below. Substitute lubricants must meet these specifications. Mixing different types of gear lubrication should be avoided.
Equipment Top Drive Compressor Rock Grease Tank Hydraulic Tank Water Pump
Lubrication Gear Oil SAE 80W-90 / SAE 140 Mobil SCH 1024 Esso AROX NM 000 Esso NUTO 46 Esso NUTO 46
Capacities 6.3 qts (6 ) 35 gal (132.5 ) 8.4 gal (32 ) 66 gal (250 ) 40 fl. oz. (1.2 )
2-03-004
API Service CG-4 or CF-4 SAE 15W40 (for -15C to 50C) SAE 5W30 (for -30C to 30C) Engine Oil Spirax HD SAE 80W-90 Gear Oil Darina XLEP2 Grease Tellus T-37 NUTO 46 Harmony HVI-36 Mohawk HV132 UNIREX EP1 Precision EP2 N/A Mobil HD 80W-90 Gear Lube 80W-90 Gearlube GL5 80/90 HP
Compressor Oil
2-03-005
Rock-drill Oils
Manufacturer Texaco Exxon Mobil Gulf Sinclair D Cities Services 75A D-A Lubricant Co. 500 Non-Fluid Oil Corp. E.F. Houghton & Co. 370 Southwestern Petroleum SAE 50 Kendall Refining Co. Shell Oil Co. 72 Lubrication Engineers 6305 Imperial Oil Co. Rock- 50 Champlin Purrol Co Chevron Oil Co. Molub-Alloy RockDrill Oil 381 Grade 10 Vistac 30X Molub-Alloy RockDrill Oil 297 Grade 30 Vistac 220X Molub-Alloy Drill Oil 297 Grade 50 Tonna R Oil 27 Monolec 6301 Swepco SAE 10 A #89/NR Grade 10 1541 EPL Arox EP 45 Almo #1 Grade 30 1542 EPM Arox EP 65 Almo#3 Rock-Drill 63 Air Drill Oil B Neptune 50A Rock-Drill Lubricant A #59/NR Rock-Drill Oil 340 Swepco SAE 30 Kenoil 065EP Tonna R Oil 41 Monolec 6303 Tonna R Oil Monolec Air Drill Oil Neptune Rock-Drill 5 A #79/NR Rock-Drill Swepco Grade 50 1543 EPM Ster-Mar 90 Almo #5
2-03-006
Unit __________________________
Serial # _______________________
Date __________________________
Service Codes: Clean, wash Grease Lubrication Hinge pins Dump cylinder pins Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease
Inspect
Rotary actuator pivot pins Rotary actuator bearings Feed extension pins
Seals, oil, test Seals, oil Seals, oil Seals, oil, filters
Fluid Changes Top drive Gear Lube SAE 140 high temp 80W90 low temp
Feed Arrangement Slideover Feed cylinder Sliders Wear guides Lower Mast Top drive Top drive motors Breakout wrench Breakout vise Hydraulic Circuit Hydraulic pump Cylinders Inspect: Inspect: Seals, hoses, fittings Seals, rods Hoses, fittings Inspect: Inspect: Adjust: Inspect: Inspect: Adjust: Inspect: Inspect: Inspect: Cylinders Cylinder, bushing @ Top drive mounting plate Under top drive mounting plate Cylinders, centralizer jaws, remove debris Bearing pre-load Seals & clean assembly & clean assembly
Engine Oil
Filter Changes Hydraulic pressure filter Hydraulic return filter Compressor oil filter Mine Air Filters Control Circuit Filter Engine Oil Filter Engine Fuel Filter Replace, check by-pass valve Replace Replace Replace Replace Replace replace
Electrical by Qualified Electrician Air Circuit Inspect: Air hoses, fittings, hose safety devices Compressor Daily Check Receiver/Sump oil level Moisture separator check and clean Air inlet filter check and clean Electric motor bearings Lubricate: lithium grease
Note: Optional equipment is not listed. See the Table of Contents for any equipment not listed above.
Unit ________________________
Serial # _______________________
Clean, wash Air Circuit Inspect: Inspect: Seals, fluid, test Seals, oil Seals, oil Seals Oil and filter Grease Lubrication Hinge pins Dump cylinder pins Inspect: Inspect: Adjust: Torque Cylinders Counterbalance valves Gear rack Actuator bolts Trunnion mounts, cylinders Sliders and guide bars for wear @ Top drive mounting plate @ Mast connection plate Under top drive mounting plate Cylinders, centralizer jaws, slip plate flats, drill table, remove debris Top drive Bearings Mounting plate bolts Seals Motor bolts & clean assembly & clean assembly Filter Changes Hydraulic pressure filters Hydraulic return filters Compressor oil filter Air inlet filter Moisture separator element Replace, check bypass valve replace Replace Replace Replace Fluid Changes Top drive Hydraulic tank Water pump Compressor/sump tank Engine Oil Gear Lube SAE 140 high temp 80W90 low temp ESSO NUTO H46 or equal ESSO NUTO H46 or equal SCH 1024 Rotary actuator pivot pins Rotary actuator bearings Feed extension pins Air swivel top drive Air inlet valve Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Inspect and clean Air hoses, fittings, hose safety devices Grease pump seals Compressor daily check Air inlet filter check and clean Pressure regulator valves
Inspect: Inspect:
Top drive motors Breakout wrench Breakout vise Hydraulic Circuit Hydraulic pump Cylinders Control valves Fill Pump
Miscellaneous Control gauges Fire suppression (optional) Inspect: for proper operation Complete inspection
Electrical by Qualified Electrician Electrical panels: Electric motor bearings Note: Optional equipment is not listed. See the Table of Contents for any equipment not listed above. Add service code to boxes: Inspect wires, terminals, conduits, joysticks Lubricate with lithium grease C Completed O Okay not required N See Note Comments (Continue on reverse):
Unit __________________________
Serial # ________________________
Date __________________________
Service Codes: Clean, wash Air Circuit Inspect Water pump Seals Brake test Change oil and filter Change oil Oil and filters Intake filter Clean purifier To specs Grease Lubrication Hinge pins Dump cylinder pins Rotary actuator pivot pins Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Extreme Pressure Grease Compressor Air inlet filter Pressure regulator valves Grease pump Air hoses, fittings, hose safety devices Perform Perform Inspect Pressure test Clean strainer Pressure test Seals Daily check Check and clean Inspect and clean
Perform Perform Perform Perform Replace Perform Train bolts Feed Arrangement Slideover Inspect Replace Adjust Carrier Slideover Inspect Replace Torque Wear guides Rotary actuator Replace Inspect Adjust Torque Feed cylinder Replace Inspect Sliders Inspect Adjust Adjust Lower mast Replace Inspect Torque
Cylinders Pivot pin bushings, pins, keys, wear bushing Slideover Cylinder Slide bushings Bolts Under top drive plate Counterbalance valves Gear rack Actuator bolts Clevis pins Hydraulic by-pass, trunnion mounts, cylinders Guide bars for wear @ Top drive mounting plate @ Mast connection plate Clevises, pins Cylinders, centralizer jaws, slip plate flats, drill table, remove debris Top drive, adjust bearings Mounting plate bolts Seals Motor bolts & clean assembly
Rotary actuator bearings Feed extension pins Air swivel top drive Air inlet valve
Fluid Changes Top drive Hydraulic tank Water pump Compressor/sump tank Gear Lube SAE 140 high temp 80W90 low temp ESSO NUTO H46 or equal ESSO NUTO H46 or equal SCH 1024
Filter Changes Hydraulic pressure filters Hydraulic return filters Hydraulic oil fill filter Compressor oil filter Replace, check indicator Replace Replace Replace
Top drive Top drive motors Breakout wrench Hydraulic Circuit Hydraulic pump
Air inlet filter Moisture separator element Bearing fluid filter Miscellaneous Control gauges Fire suppression
Inspect Inspect
Seals, hoses, fittings Operating pressure and standby pressure Seal, rods Seals For proper operation Seals Add service code to boxes: C Completed, O Okay not required, N See Note Electrical by Qualified Electrician Electrical panel Electric motor bearings Inspect wires, terminals, conduits Lubricate: lithium grease
Note 1 applies to drills with narrow frames only. Brakes and tram motors are mounted to angle drive assembly. Comments (Continue on reverse):
3.0 UNDERCARRIAGE
3-01-001
PM Tasks
The carrier requires periodic maintenance and visual inspections to detect worn or damaged components. 50 Hour Intervals: 1000 Hour Intervals: Check powertrain tanks and refill. Refer to attached manuals for lubrication and detailed service instructions. Clean thoroughly and check powertrain components for leaks or wear indications. Refer to the carrier manuals while servicing transmission, axle, brakes, engine, etc.
WARNING! Block the carrier tires if parked on an incline. Stop the engine, apply brakes, and disconnect electrical power before servicing.
Technical Specifications:
Mercedes 904 Dana Spicer 32000 New Holland D65 Hydraulic Hydraulic
3-01-002
4-01-001
WARNING! Keep away from slideover arrangement while in operation. Support mast and slideover frame before removing any components or loosening hydraulic fittings.
4-01-002
4-01-003
4-01-004
4-02-001
Overhauling the rotary actuator is required when excessive leaking of hydraulic fluid is noticed. It includes replacing seals, O-rings, bearings, pistons, shims, and counterbalance valves. To perform this maintenance, the mast assembly must be removed. If possible, all major components in Section 4 should be overhauled at the same time to reduce labour time.
WARNING! Support full weight of mast before removing any components or loosening hydraulic fittings.
4-02-002
4-02-003
4-02-004
Equal distance
Alignment Rods
4-02-005
4-02-006
4-03-001
The telescopic cylinder is exposed to heavy operating loads as well as shock loads. Rebuild the feed cylinder as outlined in Section 5 Hydraulic System.
WARNING! Secure or support mast before removing any components or loosening hydraulic fittings.
4-03-002
See Note
4-03-003
4-03-004
4-03-005
4-03-006
4-04-001
4-04-002
4-05-001
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: Weight:
4-05-002
4-05-003
4-05-004
4-05-005
Top Drive
Stand
4-05-006
4-05-007
Bearing Cup
2. Install lower pinion gear bearing into gear housing and install pinion gears (see Fig 4.5.6).
Pinion Gear
Pinion Bearing
4-05-008
Fig 4.5.7
2. Using a bearing warmer, heat one bearing cone to between 250-300F (120-150C) (refer to Fig 4.5.8).
Fig 4.5.8
4-05-009
3. Install the heated bearing cone on the shaft (see Fig 4.5.9).
Fig 4.5.9
Fig 4.5.10
4-05-010
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 375F (190C) when heating the wear sleeves.
Fig 4.5.11
Fig 4.5.12
7. After allowing the driveshaft to cool, invert it and install the bull gear (see Fig 4.5.13).
Fig 4.5.13
4-05-011
Fig 4.5.14
Fig 4.5.15
4-05-012
Fig 4.5.16
11. Install splined piston insert (see Fig 4.5.17 and Fig 4.5.18) checking alignment of air ports. Secure the insert with a x 1 grade 8 bolt, using 262 Loctite on the threads. NOTE: The splined piston is available in different sizes depending on the application.
Align retaining hole to insure correct alignment of air ports. Install x1 grade 8 bolts and secure with blue Loctite 243.
Fig 4.5.17
Fig 4.5.18
4-05-013
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 4.5.19, Fig 4.5.20, and Fig 4.5.21).
Fig 4.5.19
Fig 4.5.20
Fig 4.5.21
13. Install Gear housing gasket, coating both sides with Loctite High Tack (see Fig 4.5.22).
Fig 4.5.22
14. Position the gear housing top plate on the gear housing, insuring that it is fully seated before bolting. Tighten the 4 10UNC x 4 gr.8 bolts first in a crisscross manner, tightening in 3 steps to 375 ft-lbs (512 N-m). 15. Install the 6 of 13UNC x 4 gr.8 bolts tightening in three steps to 105 ft-lbs (143 N-m).
4-05-014
Fig 4.5.23
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 bolt in the piston (see Fig 4.5.24).
Fig 4.5.24
3. Rotate the top drive two full revolutions using the bolt installed on the splined piston; this will seat the bearing cup. Loosen the bolts on the bottom bearing cap and the retighten.
4-05-015
4. Use the torque wrench on the 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 4.5.25). The correct rolling torque is 75-85 ft-lbs (102-116 Nm). 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 (0.127 mm).
Fig 4.5.25
5. Remove the bearing cap and insert the correct amount of shims under the cap (see Fig 4.5.26). Reinstall the cap and tighten the bolts to 375 ft-lbs (512 N-m) 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 (375 N-m) wet torque.
Fig 4.5.26
4-05-016
Fig 4.5.27
2. Rotate the top drive to the vertical position. Install the 90 street elbow into the upper seal housing (see Fig 4.5.28). Coat the sealing surfaces of the top plate and upper seal housing gasket with Loctite High Track sealant.
Fig 4.5.28
3. Install the upper seal housing securing with 8 of 3/8-13UNC x 2 gr.8 UNC bolts and lock washers. Torque to 60 N-m dry torque.
4-05-017
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 4.5.29). Check for free movement of the piston when fully inserted.
Fig 4.5.29
4-05-018
Fig 4.5.30
2. Apply anti-seize to the threads of the swivel and install onto the driveshaft (see Fig 4.5.31), 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 4.5.31
4-05-019
3. Coat the hydraulic motor gaskets with Loctite High Tack sealer and place them on the gear housing. Install hydraulic motors and torque bolts -13 UNC x 2 flange 12 pt. gr.8 to 105 ft-lbs (143 N-m) (see Fig 4.5.32).
Fig 4.5.32
4-05-020
Top Drive
Fig 4.5.33
Prevents the top drive driveshaft from turning during saver sub removal
Fig 4.5.34 5. Raise the top drive so the saver-sub is at the same height as the breakout cylinder.
4-05-021
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 4.5.35
Saver sub breakout wrench Breakout cylinder connected in extended position to allow movement for breaking saver sub
Fig 4.5.35
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 4.5.36
8. After the joint is broken, remove the saver-sub retainer and wrench, and remove the saver-sub by hand.
4-05-022
4.5.10.2 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 ftlbs. 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.
With wrench against the mast, apply 2500 psi forward rotation to tighten the saver sub to the shaft
Fig 4.5.37
7. Push high rotation torque button; check gauge to 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.
4-05-023
Fig 4.5.38
4-05-024
5. Install the air swivel wrench on the air swivel and connect the safety chain. NOTE: The air swivel has left hand thread.
Fig 4.5.39
Fig 4.5.40
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 driveshaft should be covered to prevent any debris from entering the top drive.
4-05-025
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. 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 4.5.41
10. Apply full forward rotation. 11. Adjust forward rotation pressure to 1400 lbs for drilling.
Fig 4.5.42
4-05-026
Fig 4.5.43
Fig 4.5.44
4-05-027
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 4.5.45
4-05-028
Step 4
Step 6
Step 2 Step 5
Step 1
Step 3
Fig 4.5.46
4-05-029
Fig 4.5.47
2. Install seal plug with a small amount of blue Loctite on the threads, into the housing, and torque to 150 ft-lbs (203 N-m). NOTE: The seal plug is left hand thread.
Fig 4.5.48
4-05-030
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 4.5.49
4. Place the large tube upside down on the bench. Using a suitable bearing warmer heat the wear sleeve to 200F (93C) and install on the large tube.
Fig 4.5.50
4-05-031
Fig 4.5.51
6. Install the first bearing with the numbers down, install the bearing spacer, then install the second bearing with the numbers up.
Fig 4.5.52 CAUTION! The orientation of the bearings is important. Position the bearings as shown in Fig 4.5.53 with the bearing numbers facing away from each other.
Bearing Numbers
Fig 4.5.53
4-05-032
7. Install snap-ring into the groove on the large tube. Allow the large tube to cool.
Fig 4.5.54
8. Lubricate and install the O-ring into the groove on the small tube.
Fig 4.5.55
9. Install the small tube inside the large tube and tighten firmly.
Fig 4.5.56
4-05-033
10. Install a 7/8 lock washer and 7/8 UNC nut onto the small tube.
Nut
Lockwasher
Fig 4.5.57
Fig 4.5.58
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.
Seal Retainer
Rotary Seal
Fig 4.5.59
4-05-034
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.
Backup Ring Rotary Seal O-ring
Fig 4.5.60
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.
Seal Retainer
Housing
Fig 4.5.61 NOTE: Do not install the housing seal at this time, as it will result in an improper rolling torque adjustment.
4-05-035
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 UNC bolts and torque to 40 ft-lbs (54 N-m). Using a beam or dial style torque wrench, check the rolling torque. The rolling torque must be 10 to 15 ft-lbs (13.5 to 20 N-m). Add or remove shims as needed until the desired torque is reached.
Fig 4.5.62
18. Remove the housing cap and install the seal. Install the housing cap on the housing and install the two (2) seal retainers.
Fig 4.5.63
Fig 4.5.64
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19. Install eight (8) grade 8 3/8 x 1 UNC bolts with 3/8 lock washers and torque to 40 ft-lbs (54 N-m).
Fig 4.5.65
20. Lube with extreme pressure grease until the housing is full.
Fig 4.5.66
Fig 4.5.67
4-06-001
CAUTION! Rebuilding the hydraulic pumps is recommended for qualified maintenance technicians only.
Motor Specifications: Top Drive Motor CP17014-6 Displacement: Continuous Pressure: Continuous Flow: Speed: Weight: 12.1 in3/rev (198 cm3/rev.) 2800 psi (193.5 bar) 20 gpm (76 l/min.) 0 - 349 rpm 36 lbs. (16.3 kg.)
4-06-002
4-06-003
4-06-004
9. Check rotor vane clearance as follows: Place the rotor set (8) and wear plate (9) on a flat surface then rotate the rotor as illustrated in Fig 4.6.2. Measure the clearance between the vane and rotor lobe. Replace the rotor set if the clearance is more than 0.005" (0.13 mm). If this motor is equipped with two sets of stators, repeat above procedure on other side. 10. Inspect drive link (10) for damaged splined. No noticeable lash should be apparent between mating spline parts. 11. Remove seal ring (4) from item 18. Remove thrust bearing (11) from coupling shaft (12) and inspect it for wear. 12. Remove coupling shaft (12) and check it for wear. Replace it if the two diameters show wear in excess of 0.020 (0.51 mm). 13. Remove inner thrust bearing (13) to inspect condition. Remove item 16 and item 17. Remove seal (20) using a seal puller. 14. Remove bearing (19) using a suitable bearing puller.
4-07-001
4-07-002
4-08-001
WARNING! Secure or support mast before inspecting or servicing drill. Drill pipe may move if pipe clamping pressure is set incorrectly.
4-08-002
Fig 4.8.1
Fig 4.8.1 A
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4-08-004
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.
1. Load drill pipe manually into drill table and tighten drill string
3. Release clamping pressure by turning upper and lower cylinder rods into clevises. You may have to open clamp for easy turning.
4. Adjust cylinder clevis until clamp grips drill pipe firmly. Open pipe clamp. Turn cylinder rods two complete revolutions out of clevises to adjust clamping pressure. Tighten lock nuts. Remove drill rod from drill table.
Fig 4.8.2 Pipe Clamp Adjustment You must also perform these adjustments when replacing carousel components. Tighten screws to torque values shown in Section 2.3.5 Torque Table.
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4. Loosen lock nuts and turn adjusting screws until drill rod aligns with saver sub. Adjustment is in Arc B. 6. Tighten both adjusting screws and lock nuts at clamp arm cylinder. 7. Operate carousel to check alignment.
4-08-006
5-01-001
Filter or strainer Variable Displacement Pump with One Direction Flow Fixed Displacement Pump Check Valve Ball Valve Pressure Relief Valve Shuttle Valve Internal Orifice Control Valve, 3-position, solenoid with spring return, manual lever control Flow Direction Reservoir Return Pilot Line Hydraulic Line
Fig 5.1.1 Hydraulic Symbols
5-01-002
5-02-001
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.
See Section 5.6 Hydraulic Filtration. Inspect system for leaks. 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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Fig 5.2.1 Hydraulic Schematic See the Appendix for a full-size schematic
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5-02-004
5-03-001
Principals of Operation
The displacement mechanism of this series of pumps operates via two stroking pistons (large and small) which adjust the position of the swashplate. The smaller of the two stroking pistons (1) works in conjunction with its spring (2) to always try to move the swashplate to maximum angle, and therefore the pump to maximum displacement. High pressure oil is continually routed from the outlet (pressure) port to the small stroking piston via the control oil drilling (3). Working in opposition to this on the opposite of the swashplate is the larger stroking piston (4). If pressurized fluid is routed to the larger stroking piston (4), it will exert a force to de-stroke the pump to a lower displacement value. Since piston (4) has a larger area than piston (1), the pump will de-stroke with pressure on both cylinders. It is therefore possible to control the pump displacement by changing the pressure applied to the larger of the two stroking pistons. All the pump controls work on the same principal of controlling the pressure on this large stroking piston (4) in order to vary the pumps displacement.
5-03-002
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. 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 at 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 loosened, 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 quiet, adjust the differential (standby) pressure setscrew clockwise until the pressure on the outlet of the pump is at the required standby pressure. Once you have set the pressure, lock the jam nut and replace the protective nut on the differential pressure adjustment.
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5. Next, set the compensator control adjustment to the recommended setting. 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.
Jam Nut
Protective Nuts
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5.3.2 Adjustments
5.3.2.1 System (Operating) Pressure Adjustment
The system pressure is set at the pumps control valve, mounted at the rear of the pump. 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) by turning the setscrew with a 4 mm allen key. Turn it counter-clockwise to reduce pressure. One turn creates a pressure change of approximately 725 psi (50 bar). 3. Reinstall the protective cap and torque to 15 ft-lbs (21 N-m).
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Restrictor Valve
Flow Meter
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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 71 cc 100 cc Table 5.3.B Acceptable Pump Flow 27.5 to 31 gpm 39 to 44 gpm
NOTE: For a case drain leakage test, it is recommended that you DO NOT use a flow meter. This is because piston pumps are very sensitive to case drain pressure. Using a flow meter in most cases causes a certain back pressure that could damage the pump. Instead, use the manual method of directing the case drain into a pail of known volume while measuring the time and calculating the flow.
5-03-007
Pump is bypassing.
Check the pumps condition. If the pump does not pass standards, replace. Check the load sense line for leakage at fitting, breakage, or an obstruction.
Pump is worn.
Check the acceptable pump performance as outlined in Section 5. Change pump out as necessary. 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.
Pump is noisy.
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2. Lubrication and hydrostatic balancing are lost here 3. Which causes slipper pad failure.
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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5-03-010
In order to avoid damage by either of these 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.
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5.3.5.5 Cavitation/Aeration
Cavitation results when air, which is typically entrained or dissolved in the hydraulic fluid, is allowed to expand because of a low-pressure situation. This occurs in pump inlets, which by nature have a low-pressure condition. The expanded gas bubbles at the inlet collapse with considerable force as the pumping chamber is exposed to system pressure. This collapsing action results in rapid energy losses in the form of heat and noise. This energy level is also high enough to cause serious damage to the lens plate and/or the cylinder barrel of the pump. Aeration is somewhat different than cavitation, however the resulting noise and damage to the pump is nearly identical. Aeration occurs when there are air bubbles present in the reservoir fluid at atmospheric pressure (typically caused by excessive foaming or vortexing at the pump inlet). These air bubbles are then drawn into the inlet line of the pump and ultimately cause of the same damage as described in cavitation.
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5-04-001
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: 1000 Hour Intervals: Wash and inspect cylinder rods, rod wipers Wash and inspect cylinder rods, rod wipers Inspect cylinder operation
NOTE: Washing cylinder rods extends seal life. The following tools are recommended for servicing the telescopic feed cylinders: CT47907-008: CT47907-007: CM47807-T1: Large Gland Nut Tool Small Gland Nut Tool Seal Installation Tool
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5-04-003
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5-05-001
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 (next page) for these settings. If additional parts need servicing, it may be more economical to replace the individual valve sections. 1000 Hour Intervals: 2000 Hour Intervals: Visual inspection Visual inspection. Operate controls to check for proper operation
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Flow Rating
17.2 gpm (65 l) 34.2 gpm (100 l) 26.4 gpm (100 l) 2.6 gpm (9.8 l) 2.6 gpm (9.8 l) 2.6 gpm (9.8 l)
Pressure Setting
Wide open (Note 1) Wide open Wide open Wide open Wide open
Flow Setting
Wide open Wide open Wide open Wide open Wide open Wide open
Flow Rating
10.6 gpm (40 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 2.6 gpm (9.8 l) 1.3 gpm (4.9 l) 6.6 gpm (25 l) 6.6 gpm (25 l) 2.6 gpm (9.8 l)
Pressure Setting
Wide open Wide open Wide open (Note 3) Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open
Flow Setting
(Note 2) Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open Wide open
NOTES:
1. Forward Pressure: 1400 psi (82.9 bar). Reverse Pressure: 2800 psi (193.5 bar). 2. Set flow to run water pump motor at 225 rpm using a tachometer. 3. Set pressure for port A and B to 1500 psi (103.4 bar).
3200 psi (221.1 bar) in all circuits, except the drilling valve
After installing hydraulic components and hoses, check that hydraulic actuators are operating in direction as indicated on controls.
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5.5.9 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 5.5.5. 2. Replace filter (7) and O-rings (8 and 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).
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5-05-009
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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5-06-001
PM Tasks
The pressure filter and return filter are cartridge type with serviceable indicators. The manual fill pump fills through the return oil filter. The electric fill filter has a cartridge type filter. 250 Hour Intervals: 1000 Hour Intervals: 2000 Hour Intervals: Change pressure filter and return filter Change hydraulic fluid Change fill filter Clean filter indicator on pressure filter
Filter Types:
Cartridge In-tank Manual pump fills through return oil filter Electric pump has internal filter
WARNING! Disconnect power supply and mine air before servicing drill. High pressure jet leaks may cause injury.
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5-06-003
Disconnect electrical power, mine air, water supply and relieve pressure in air receiver before servicing.
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5-06-005
5-06-006
5-07-001
5-07-002
Restriction Fittings Installed at both ports on the following valves: Optional Pipe Arm
Sequence Valve
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PM Tasks
1000 Hour Intervals: Clean and flush 1. Check for leaks. 2. Use a mild concentrate of a suitable heat exchanger cleaner. 3. Flush with clean water from the water outlet port.
CAUTION! Drain the water when exposed to freezing conditions. Note: You must turn on the cooling water before drilling.
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5-09-001
PM Tasks
Periodic maintenance is limited to external inspections. Overhauling the control valves includes replacing O-rings and seals, and setting the pressure and flow. See Section 5.9.1 Proportional Valve Settings for these specifications. If additional parts need servicing, it may be more economical to replace the individual valve sections. 1000 Hour Intervals: 2000 Hour Intervals: Visual inspection. Visual inspection. Operate controls to check for proper operation.
WARNING! After installing hydraulic components and hoses, check that hydraulic actuators are operating in direction as indicated on controls. CAUTION! Operating pressure in hydraulic pump must be set correctly before performing this adjustment. Improper Makeup & Breakout Speed may damage equipment or drill pipes.
All proportional valves are equipped with white/grey connectors. These instructions apply to proportional valves only.
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Notes:
1. Forward pressure: 1400 psi (96.5 bar), Reverse pressure: 2800 psi (193.5 bar). Reverse pressure is much higher than forward pressure to allow for breaking of tool joints.
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5-09-005
Fig 5.9.3
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6-01-001
PM Tasks
The air circuit requires limited maintenance but a schematic diagram is included for troubleshooting. 250 Hour Intervals: Inspect hose connection safety devices, all hoses
WARNING! Check that air hoses are in good condition and secured with hose connection safety devices. Disconnect electrical power, mine air, water supply, and relieve pressure in air receiver before servicing.
6-01-002
Fig 6.1.1 Air Schematic See the Appendix for a full-size schematic
6-02-001
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: 1000 Hour Intervals: 2000 Hour Intervals: 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: Volume: Discharge pressure: Speed: Crankcase Capacity: Lubricant Type: Weight: Pump Accessories: Relief Valve: Pressure Regulator: (Mine Water) 4 gpm (15 l/m) at 225 rpm 450 psi (31 bar) 225 rpm 40 fl. oz. (1.2 L) Esso NUTO 46 Hydraulic Oil 32 lbs. (14.5 kg.) 450 psi (31 bar) 50 psi (3.4 bar) Check pressure regulator/ strainer Change crankcase fluid Perform a pressure test
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6-02-003
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.
6-02-004
6-02-005
6-02-006
6-03-001
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 (1) periodically in order to avoid air trapped in the lines. Add grease every time the grease level drops below middle window sight. Every shift: 250 Hour Intervals: Check grease level in the tank (1), drain air filter (3), and check oil in air lubricator (4). Inspect system for leaks
The grease injection system settings are: - air pressure in the grease pump (2) by regulator (7). - cycle time (from 20 sec to 24 hr) controlled by the ERIS Panel or manual timer. - amount of grease injected in a cycle by adjusting the injector (6) to suit the drill hole size (see specifications below).
25:1 fixed setting 2.15 cu.in. (35.2 cc)/cycle 0.5 CFM per stroke
Operating Pressure:
Min Max
1000 psi 3500 psi 0.05 cu.in. (0.82 cc) 0.50 cu.in. (8.2 cc)
Output:
Min Max
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1 1. Solenoid Valve 2 2. Grease Injector 3. Air Lubricator 4 4. Air Filter 5. Regulator 5 3 6. Fill Cap 7. Breather Cap 8. Grease Tank 9. Grease Pump
6-03-003
Disconnect electrical power, mine air, water supply, and relieve pressure in air receiver before servicing.
6.3.3 Operation
The pre-determined lubrication cycle frequency is set by the operator using a manual timer. 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 sol valve 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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Adjustment Screw
Lock Nut
Bleed
Injector Body
2 4 6 8
1 3 5 7 9
Fig 6.3.4
Fig 6.3.5
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6-03-006
The selectors can be turned clockwise and counterclockwise to select the desired time scale or operating mode. Each selector has a snap mechanism that secures the selector at a given position. Set the selector at a position at which it is secured. Do not set it midway between two secure positions, or a malfunction could result from improper setting. Settings for ON-Start/OFF-Start If voltage is applied to terminal B1, or if terminals A1 and B1 are shorted, the operating mode is switched to ON-start mode. If these terminals are disconnected, the mode switches to OFF-start mode. The operating mode will not change if the state of the applied voltage changes during timer operation. Selection of Time Scale Refer to Fig 6.3.4 The time scale is selected by turning the ON-time scale selector and OFF-time scale selector. The time scales will appear in the following order in each time scale display window on the left of the selector: 0.1 s, 1 h, 0.1 h, 1 m, 1 s, 0.1 h, 0.1m, 1 s. Time Setting Use the ON-/OFF-time setting dials to set the ON-/OFF time. Locking/Unlocking Selectors and the Time Setting Dial Refer to Fig 6.3.5 The ON-/OFF-time setting dials and time scale selectors can be locked using the Y92S-38 Lock Key, a special pen-type tool that is sold separately. To lock the dials or selectors, insert the Lock Key in the keyhole to the lower right of the dial or selector and turn it clockwise until the dial or selector is completely covered with the red cover. To unlock, turn the Lock Key in the opposite direction. The timer settings for either grease or oil are as follows: Oil Grease 8 seconds on (ON-time set to 8, Time scale set to 1 s) 12 seconds on (ON-time set to 2, Time scale set to 0.1 m) 6 seconds off (OFF-time set to 6, Time scale set to 1 s) 24 seconds off (OFF-time set to 4, Time scale set to 0.1 m)
6-04-001
In Case of Fire
1. Shut down the drill and set the brakes immediately. 2. Pull the ring pin on the manual actuator and strike the red plunger button (see Fig 6.4.1). 3. Evacuate the vehicle. 4. Stand by with a hand portable fire extinguisher. Fig 6.4.1 Pull pin. Strike plunger. NOTE: Do not restart drill until drill has been repaired and fire suppression system has been recharged.
What to Expect
When an A-101 system discharges, there is considerable noise accompanied by clouds of dry chemical. While breathing foreign particles is not pleasant, the agent FORAY is non-toxic and exposure during a fire will not harm you.
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Checkfire SC-N Control Module
Manual Actuator
Detection Wire
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6-04-004
Sounder
Battery
Release
Delay
Reset
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6-04-006
Pressure Switch Circuit (Feedback) Activated Mode When this mode is actuated, the Alarm LED will pulse a minimum of 30 seconds at 4 pulses per second. The control module will then go into the postdischarge mode and the Alarm and Release LED will pulse at a rate of one pulse per 10 seconds. Release Trouble (Yellow) The yellow Release LED and the audio will pulse at a rate of once every 10 seconds when a trouble condition is detected in the release circuit. The control module will return to normal when the trouble condition is cleared. The Release trouble will also pulse after the system has completed a discharge cycle or a pressure switch feedback signal has been received. The trouble signal in this condition is used to indicate a recharge of the fire suppression system is necessary. A Release trouble under either of these conditions can only be cleared by resetting the control module. Detection Trouble (Yellow) The yellow Detection trouble LED and the audio pulse once every 10 seconds when the control module detects a trouble in the detection circuit. The control module will automatically return to normal when the trouble is cleared. Sounder (Audio) The sounder gives the audio indication for all alarm and trouble outputs. The sounder will pulse at the same rate as the visual corresponding LED> The sounder gives the audio indications of the various outputs. The sounder is rated at 85 Db at 10 feet. The pulse rates are as follows: Alarm Time Delay 1 2 pulses per second Alarm Time Delay 2 4 pulses per second Trouble 1 pulse per 10 seconds Loss of Power 1 pulse per 10 seconds Release Circuit Fired 4 pulses per second for 30 seconds, then 1 pulse per 10 seconds Low Battery 1 pulse per 10 seconds
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6-04-008
Manual Actuator
Automatic Actuation
Manual Actuator
Pressure Switch
Union Assembly
Nozzle
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6-04-010
6-04-011
9. Test the system and place into service by completing the steps listed under Functional Test pages 19 and 20 in the Checkfire SC-N Installation, Recharge, Inspection, and Maintenance Manual, located in Appendix C. 10. Record date of recharge on a tag or in permanent record file. Notify operating personnel that the system is back in place.
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18. Pull up the button on the dashboard actuator and insert the ring pin. 19. Remove the spent cartridge. 20. Screw a fully charged cartridge into the remote actuator, hand tighten. Verify the part number as in step 5. 21. Connect the actuation system hose at the cartridge receiver/actuator assembly, wrench tighten. 22. Attach a lead and wire seal to the ring pin and actuation button or lever. 23. Notify operating personnel that the fire suppression system is back in service and record the date of recharge.
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6-04-014
8. Secure the fill cap, hand tighten. 9. Disengage the bursting disc union. 10. Examine the bursting disc. If necessary, move the tank slightly to view the disc. The bursting disc should be properly seated with the washer side facing out (smooth side in) and should be undamaged (smooth, not scored or ruptured). 11. Engage the bursting disc union (wrench tighten). 12. Be sure the dry chemical tank is firmly mounted in its bracket. 13. Loosen the bolts that restrain the cartridge or remove the extinguisher cartridge guard assembly. 14. Inspect the expellant gas cartridge assembly for evidence of mechanical damage or corrosion. 15. Unscrew the cartridge from the pneumatic actuator/cartridge receiver and weigh it. Replace if its weight is not within ounce on A-101-10 models, ounce on the A-101-20/30 models of the weight stamped on the cartridge. 16. Inspect the threads on the cartridge and in the pneumatic actuator/cartridge receiver for nicks, burrs, cross-threading, or rough or feathered edges. 17. Check the pressure vent in the pneumatic actuator/cartridge receiver for obstruction. 18. Examine the cartridge receiver gasket for elasticity clean and coat lightly with a good grade of high heat resistant grease. 19. Return the cartridge pneumatic actuator/cartridge receiver. Hand tighten. 20. Check the hose, fittings, and nozzles for mechanical damage. 21. Check the nozzle openings - the slot should be closed (capped) with silicone grease or covered with a plastic blow-off cap. 22. Check the remote actuator - remove the cartridge and weigh it. Replace if its weight is not within ounce of the weight stamped on the cartridge. 23. Inspect the threads on the cartridge and in the actuator for nicks, burrs, crossthreading, or rough or feathered edges. 24. Check the pressure safety vent in the actuator body for obstruction. 25. Examine the actuator cartridge gasket for elasticity clean and coat lightly with a good grade of high heat resistant grease. 26. Pull the ring pin and operate the actuator button several times to check for free movement. 27. Seal the ring pin to the puncture lever with lead and wire seal. Return the cartridge to the remote actuator, hand tighten. 28. Record the date of maintenance.
6-04-015
6-04-016
6-05-001
PM Tasks
250 Hour Intervals: 1000 Hour Intervals: Complete 250 Hour Maintenance Schedule (Section 6.5.30) Complete 1000 Hour Maintenance Schedule (Section 6.5.30)
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Fig 6.5.1
Fig 6.5.2
6-05-003
Functional Description
The compressor unit supplied with this booster is a one stage positive displacement, high pressure, flood lubricated type rotary screw air compressor, utilizing mine-supplied compressed air to act as a primary stage. The compressor unit utilizes two rotors to compress the incoming mine air. A driven male rotor drives a female rotor and, as they turn, compressed air is drawn into the unit through the inlet system where it is trapped in the grooves of the rotors and forced around to the discharge side of the case, recompressing it to obtain a 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. By changing gear sets we are able to use the same air end to give us different capacity units. 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 manual 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: 1. As a coolant, it controls the rise of air temperature normally associated with the heat of compression. 2. It seals the leakage paths between the rotors as well as between the rotors and stator. 3. 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. Then the air flows to the service line and the fluid is directed through the cooling and lubricating system in preparation for reinjection.
6-05-004
Control Circuits
Oil Fill Inlet for Receiver Tank Control Circuit Air Filter
6-05-005
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 shutdown. From the discharge valve, the air/fluid mixture is directed to the sump. The sump has four basic functions: 1. It acts as a primary fluid separator. 2. It serves as the compressor fluid sump. 3. It houses the final fluid separator. 4. It 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 psi (2758 kPa) 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 high-pressure shutdown switch (set at 440 psi), which will shut the compressor unit down. A second protection for high discharge pressure utilizes a 550 psi pressure relief valve, which is located on the wet side of the separator and is vented to atmosphere. Also, a High Compressor Discharge Temperature Shut Down (set at 240F) and High Receiver Temperature Shut Down (set at 220F) will shut the compressor unit down if the temperature exceeds the normal operating range.
6-05-006
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 shut down. DO NOT OVERFILL. WARNING! DO NOT open the fluid filler cap when the compressor is pressurized. Shut down the compressor and bleed the sump to 0 psi before removing the cap. A hydraulically operated, 2-inch ball valve is used to open and close the discharge air when required.
6-05-007
Functional Description
The booster 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: A - From tank B - To cooler C - From cooler D - To compressor As previously stated, upon start-up the fluid temperature is cool and routing to the cooler is not required. The fluid first enters the thermal valve and then flows on to the compressor unit, bypassing the cooler. As the compressor continues to operate, the temperature of the fluid rises and Port A of the thermal valve begins to close. The closing of Port A forces a portion of the fluid through the fluid cooler. The cooler is a radiator type cooler that works in conjunction with the fan. The fan forces air through the cooler, removing the heat of compression from the fluid. From the cooler, the fluid is routed back to the thermal valve, entering at Port B. Before the temperature of the fluid becomes high enough that Port A is completely closed, cooled fluid at Port B is mixed with warmer fluid entering Port A. When the temperature of the fluid reaches 250F (121C), 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.
6-05-008
6-05-009
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 lubricating 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 120 psi) will shut the compressor unit down in the event of low or no oil pressure. Another shutdown, the Oil Stop Signal Pressure Switch (set at 90 psi) will shut the compressor unit down in the event of a lost signal pressure to the oil stop valve.
6-05-010
Ref. No. 1 2 3 4
2 3
Description Fixing Kit Air Filter Housing Air Filter (inside housing) Auto Drain Fitting
2 3
6-05-011
Functional Description
The compressor inlet system consists of one mine air filter, a water separator, gauges to monitor filter condition and mine air, shutdown systems for low mine air and air filter restrictions, 3 ball valve, compressor air inlet valve, and interconnecting piping to the compressor. The air filters are dry element type filters capable of cleaning extremely dirty air and are equipped with an auto water discharge system plus an auto drain valve. Reading pressure\differential between incoming air and discharge air on the filter housing monitors air filter condition (differential should not exceed 5 psi). The compressor unit is protected from damage, caused by low mine air supply, with a low mine air shutdown switch. In the event of low mine air (60 psi) the compressor unit will shutdown after a twenty second delay. Also incorporated is a low compressor inlet shut off which will shut the compressor unit down after a twenty second delay. This shutdown will monitor restricted airflow through the air filters (20 psi differential). Shutdown on low mine air will require diagnosing and repair of mine air supply. Shutdown on low compressor inlet pressure will require the change of air filter elements. It would be advisable to verify the presence of the correct mine air pressure before assuming that the filters need replacement. This could happen in the event that the low mine air shutdown switch malfunctioned or was incorrectly set. NOTE: When checking mine air pressure, it is necessary to do so while the compressor is in operation. Static air pressure can significantly drop while making air.
6-05-012
6-05-013
Key # 27 26
Purpose Vents the receiver/sump pressure to the atmosphere at compressor shutdown. Vents excess receiver/sump pressure to the atmosphere when the receiver/sump exceeds the desired pressure during unload functions. N.C. (normally closed) valve that controls opening and closing of the running blowdown. Used to maintain the system in low pressure mode. Opens a pressure line between the receiver/sump tank, inlet control valve, and running blowdown allowing the inlet to regulate air delivery and opening the running blowdown to discharge excess air to the atmosphere. Set at 410 psi.
86
24B
24A
Opens a pressure line between the receiver/sump tank and inlet control valve, allowing the inlet control valve to regulate air delivery according to demand. Set at 400 psi.
23
Used to change operational modes from high pressure to low pressure or vice-versa. The manual unloader valve is located with the compressor gauges and shutdown switches. N.C. valve that controls signal pressure to the Shutdown Blowdown Valve. During operation this valve is open, closing the shutdown blowdown valve allowing pressure to build.
20
6-05-014
6-05-015
Relieves air pressure from signal line circuit on shutdown. Used to relieve pressure when not required. It is also used to increase sensitivity of the circuit and bleed off any trapped moisture. Removes vaporized moisture, fluid, dirt, etc. in a filter medium where they are merged as droplets, which drop into the drain area. The drain is cleaned by opening a drain valve at the bottom of the canister. It is recommended that draining be done daily or even more frequently, under severe conditions. Indicator will read in the red zone indicating service of the separator element is required. Controls release of fluid during warm up. Cooler for removing heat from fluid generated by compression. Filters fluid prior to injection into the compressor. Cuts off flow of fluid to the compressor unit at compressor shutdown and allows flow of fluid to the compressor on start-up. Boosts the mine air. Used to close the inlet valve when the compressor unit is shut down and the mine air is left on. This prevents unwanted rollover of the compressor unit when not in use. Regulates the amount of air allowed to enter the unit. This regulation is determined by the amount of air being used at the service line. Cuts off the reverse flow of air/fluid mixture through the compressor discharge system at compressor shutdown. Contains a wire mesh filter to prevent contamination.
14
Separator Restriction Indicator Thermal Bypass Valve Oil Cooler Main Fluid Filter (Oil Filter) Oil Stop Valve
13 15 16 17 18
6 28A
Intake Valve
33
6-05-016
6-05-017
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. Maintains correct oil flow from scavenger line. Opens receiver/sump pressure to the atmosphere should pressure inside the receiver /sump tank exceed 575 psi. Located on wet side of tank. Acts as a fluid separator, sump, and air filter. 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. Monitors the fluid level in the receiver/sump. The sight glass is located on the side of the receiver/sump tank. The proper fluid level is halfway of the sight glass. DO NOT OVERFILL. Check the level when the compressor is shut down.
21 12
11 31
6-05-018
6-05-019
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 one stage hi pressure screw is designed to operate in one of two modes of operation, the lowpressure mode (approx. 200 psi) and the high-pressure mode (up to 410 psi). The Control System consists of an inlet control valve, running blow-down valve, shut down blow-down valve, shut down blow-down solenoid valve, low air pressure solenoid, manual selector, signal line bleed solenoid, orifice, signal line silencer and a blow-down silencer. Refer to Section 6.5.7 for a description of valves and functions. The position of the pressure selectors determines the pressure that the control system will respond to. The functional description of the control system is described in seven distinct phases of operation which (except for the start phase) apply to both high and low pressure modes. The inlet control valve is a normally closed valve. Signal pressure regulates the incoming air to control output flow of the compressor unit.
6-05-020
Low air pressure solenoid valve opens (normally closed)
Oil stop valve opens (normally closed) Signal line bleed solenoid closes (normally open)
Fig 6.5.19 Compressor Start Up Mode / Running Mode Low Air Pressure
6-05-021
6-05-022
Signal line bleed solenoid closes (normally open) Anti-rollover solenoid valve closes (normally open)
Fig 6.5.20 Compressor Start Up Mode / Running Mode Low Air Pressure
6-05-023
6-05-024
6-05-025
6-05-026
Running blowdown valve opens (normally closed) Shutdown blowdown valve closes (normally open)
Signal line bleed solenoid closes (normally open) Anti-rollover solenoid valve closes (normally open)
6-05-027
Shutdown blowdown valve opens and bleeds off the receiver tank.
Anti-rollover solenoid valve opens, sending a signal to the intake valve, closing it.
6-05-028
6-05-029
The PLC battery part # LS14250 should be replaced regularly to avoid loss of data. Please see the following page for instructions on replacing the battery. There are shutdowns incorporated in order to protect the unit and personnel from damage and / or injury. These shutdowns will shut the compressor unit down in the event that any of the systems operate out of their designed parameters. Also, whenever a shutdown is activated, a visual beacon (an indicator light to identify the system) and an audio alarm will be set off to notify the operator that there is a system problem. Low inlet pressure shutdown set at 60 psi. Low oil pressure set at 120 psi. High receiver pressure set at 440 psi - immediate shutdown. High discharge temperature set at 240F - immediate shutdown. High receiver temperature set at 220 F - immediate shutdown. Motor overload (located in the electrical panel) Phase reversal (located in the electrical panel) Mine air filter pressure differential switch set to 20 psi Separator filter pressure differential switch set to 10 psi Oil stop signal pressure switch set to 90 psi
6-05-030
When an alarm occurs, the horn will sound and a warning light on the indicator panel will light. The operator can push the Silence button to silence the horn. This action will also turn off the warning light if the alarm conditions have been cleared. If the warning light remains on after the silence button has been pushed, an error condition is still present. Investigate the error condition and correct any problems. Press the Lamp Test/Reset button. If the error condition has been cleared, the warning light will go off.
6-05-031
6-05-032
Air Inlet
Water Inlet
6-05-033
6.5.17.1 Start Up
1. Check that the pressure selector is in Load mode (see Fig 6.5.28). 2. Connect discharge to drill and install the hose connection safety device (adhere to site specific requirements) (see Fig 6.5.30). 3. Connect the mine air supply and install the hose connection safety device (adhere to site specific requirements). Then open the mine air valve (see Fig 6.5.30). 4. Ensure that discharge valve is closed. 5. Push start button. Unit will operate in low air mode for approximately 1 minute (see Fig 6.5.29). 6. Open discharge valve to drill. WARNING! When working on booster, ensure mine air connection is disconnected, the electrical power is disconnected, and the air receiver is completely drained.
6.5.17.2 Shutdown
1. Close discharge valve. 2. Push system stop button on main control panel (see Fig 6.5.29). CAUTION! Do not use emergency stop button for routine shutdown. 3. Unit will continue to run in low pressure mode for approximately 1 minute. 4. Close mine air supply once compressor has stopped. 5. Drain moisture from pre-filter.
6-05-034
Ref. No. 1 2 3
Fig 6.5.33
6-05-035
Set pressures to: Inlet signal pressure High air pressure 410 psi 410 psi
6-05-036
Fig 6.5.35
6-05-037
Fig 6.5.37
6-05-038
6-05-039
Lower spring ensures a constant contact/ground between the element and the tank.
Scavenger line to remove excess buildup between the separator and receiver tank.
The strap provides a direct connection to the separator element to carry the ground through the spring and retaining plate.
Fig 6.2.28
Fig 6.2.29
6-05-040
6-05-041
Fig 6.5.44
6-05-042
6-05-043
6-05-044
6.5.26 Pressure Regulator (Control Inlet Signal Pressure/High Air Pressure Regulator)
Maintenance on the regulator valves comprises of replacing the diaphragm and spring units inside of the regulator. When replacement is necessary, insure that the regulator is in the direction of flow as indicated on the body of the unit.
Fig 6.5.47 Pressure Regulator (Control Inlet Signal Pressure/High Air Pressure Regulator)
6-05-045
Fig 6.5.48
Fig 6.5.49
Fig 6.5.50
Fig 6.5.51
Fig 6.5.52
Fig 6.5.53
6-05-046
6-05-047
6-05-048
6-05-049
NOTE: If any of the following checks are No, DO NOT RUN UNIT. Pre-start Inspection Has the first air inlet filter been flushed? Has the auto drain on the second air inlet filter been checked? Is oil visible in receiver/sump tank glass? Is the compressor free from oil leaks? Are the oil cooler and fan clean? Are safety slings in place? Are the bull hoses in good condition? Has the mine air been blown down before connecting bull hose? Has the signal filter been drained? Has the safety relief valve on the receiver/sump tank been checked? 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: YES NO
YES
NO
psi
6-05-050
6-05-051
3. Replace oil filter element. 4. Check separator element. 5. Check and clean control line moisture separator element. 6. Check oil level. Top up if necessary and record amount added
8. Replace oil filter element. 9. Replace separator element. 10. Inspect and clean pressure regulator valves. 11. Replace control line moisture separator element. 12. Drain and clean receiver/sump tank. 13. Replace oil. Oil capacity of the receiver/sump tank is 35 US gallons (132 litres).
6-05-052
7.0 ELECTRICAL
WARNING! Servicing the Control Panel is for Qualified Electrical Technicians ONLY!
7-01-001
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 Section 8 Electrical Components in the Parts Manual
WARNING! Danger! The main control panel is high voltage. Confirm voltage before servicing. The maintenance procedures are for qualified electricians only.
Circuit Voltages:
7-01-002
7-01-003
7-01-004
7-01-005
To allow a technician to communicate with the ERIS console, there is a threaded plug in the top left corner of the panel. When this plug is removed, it reveals a USB connection. In order to communicate with the internal CPU in the ERIS panel without disassembling the console, what is needed is a USB keyboard. The keyboard can be plugged into the external USB port and the keyboard then can take over control of the computer. NOTE: It is recommended that a special keyboard and flashdrive should be used for this purpose that has been tested for compatibility to ensure reliable connectivity through the USB port. This is available through your local dealer under the following Cubex part numbers: CP000272 USB keyboard with pointing device and two USB ports. CP000271 512MB USB flashdrive.
7.1.2.1 Communication with the ERIS Console from the External USB Connection
The ERIS console must be powered up. 1. Plug the USB keyboard into the external USB port on the console. 2. If the console is in the control mode with the GUI (Graphical User Interface) showing on the monitor, hit Escape on the keyboard. This should bring the display to a Windows environment. At this point, the joysticks can be calibrated and/or new code (software) can be loaded.
7-01-006
Fig 7.1.4 This screen identifies that the A/D (analog to digital) Controller is communicating with the computer.
7-01-007
Fig 7.1.5 3. The buttons on the joysticks can then be checked for communication with the computer. Press each button in turn, one at a time. When pressing a button on the joystick, the corresponding button on the screen (see Fig 7.1.5) will light up. The light number 13 will show as being constantly on. This light represents the tilt switch that is built into the PCB (printed circuit board). If the ERIS panel is tilted, this light should go out. Fig 7.1.6 reflects the button numbering sequence the computer recognizes from the USB controller.
Fig 7.1.6
7-01-008
4. The visual graphics for testing the X (right to left) and Y (back and forth) axis of the joysticks is slightly different between right and left joystick. As shown in Screen 2, the left joystick is represented by cross hairs in a square. When the left joystick is moved in its extreme pattern (move the joystick in a complete circle, pushing it as far to the outside edge as possible), the cross hairs should touch the sides of the box. If it does not, the left joystick should be calibrated. The right joystick is then confirmed through the slide bar graph as shown in Screen 2. While moving the right joystick in its extreme pattern, the slide bars should touch the top and bottom of the graph. If it does not, then the joystick should be re-calibrated.
7-01-009
A Calibration Wizard window will appear (see Fig 7.1.8) and lead you through a series of steps to calibrate the joysticks. All instructions can be found at the top of the screen (see Fig 7.1.9 through Fig 7.1.13).
Fig 7.1.8 3. Grasping the left joystick, move it around in a circle as far as it will go. Then press any button on the joystick. Refer to Fig 7.1.9
Fig 7.1.9
7-01-0010
3. Next, verify the center point of the left joystick by leaving it centered and clicking next. See Fig 7.1.10
Fig 7.1.10 4. Moving onto the right joystick, the screens will change. Even though the screen will indicate Y Rotation, this is actually calibrating the X Axis of the right joystick. See Fig 7.1.11
Fig 7.1.11
7-01-0011
5. Even though the screen will indicate Z Rotation, this is actually calibrating the Y Axis of the right joystick. See Fig 7.1.12
Fig 7.1.12 6. The calibration of both right and left joysticks should now be complete. See Fig 7.1.13
Fig 7.1.13
7-01-0012
7-01-0013
Fig 7.1.14 3. There are two program groups inside the ERIS program group. Both have to be uninstalled. We will start by first uninstalling the LLMC program group. Move the mouse over the LLMC folder to expose its contents as shown in Fig 7.1.15.
Fig 7.1.15
7-01-0014
4. First click on the killswitch program (see Fig 7.1.15) to stop all background processes for the ERIS from running. Next, go to the LLMC program group again and click on the uninstall icon. Follow the prompts (see Fig 7.1.16 and Fig 7.1.17).
Fig 7.1.16
Fig 7.1.17 5. Click on the Close button (see Fig 7.1.17) to complete the uninstallation process. You will now be returned to the desktop.
7-01-0015
6. We will now uninstall the OCC application. Navigate to the OCC program group as shown in Fig 7.1.18.
Fig 7.1.18 7. Click on the uninstall icon and follow the prompts as shown in Fig 7.1.19 and Fig 7.1.20.
Fig 7.1.19
7-01-0016
Fig 7.1.20 Click on the Close button (see Fig 7.1.20) to complete the uninstallation process. You will now be returned to the desktop. The ERIS software is now completely removed from the computer. NOTE: Reboot the ERIS panel before proceeding to the next step.
Fig 7.1.21 NOTE: The text on this icon will be specific to your drill type i.e. Aries, Orion. 2. Double click on this icon. This one install program will re-install the OCC and LLMC. Follow the prompts as shown in Fig 7.1.22 through to Fig 7.1.32.
7-01-0017
Fig 7.1.22
Fig 7.1.23
7-01-0018
Fig 7.1.24
Fig 7.1.25
7-01-0019
Fig 7.1.26
Fig 7.1.27
7-01-0020
Fig 7.1.28
Fig 7.1.29
7-01-0021
Fig 7.1.30
Fig 7.1.31
7-01-0022
Fig 7.1.32
3. The new ERIS program is now fully installed. Reboot the ERIS panel and the ERIS interface will load automatically.
7-01-0023
Fig 7.1.33 Please refer to the electrical schematic for the corresponding wire orientation in the industrial plug in the rear of the ERIS console.
7-01-0024
Fig 7.1.34
7-01-0025
Fig 7.1.35 To test the output of the power supply, simply disconnect the 16 volt connector (black) and measure the voltage with a meter while the 24 volt is still connected. This will require the plug at the back of the panel to be hooked up to a 24 volt source.
7-01-0026
Fig 7.1.36
7-01-0027
Fig 7.1.37 5. Remove the power, Ethernet, and USB cables from the CPU shown in Fig 7.1.38.
Fig 7.1.38 The computer can now be removed from the enclosure.
7-01-0028
Fig 7.1.39
7-01-0029
7.1.7 Troubleshooting
Symptom System will not start Possible Cause Power switch and linkage not installed correctly Power supply is not charging battery or supplying power to the system System becomes sluggish or hangs up repeatedly CPU may be overheating Section Reference 7.1.7.3 7.1.7.1 Action Correct installation of power switch Test power supply and 24v connections Check if heatsink connector is working properly. Send computer back to factory for analysis and re-installation of operating system Check all wiring harnesses
7.1.7.4
n/a
USB connection or joystick harnesses have a short, break in wiring or become disconnected Joystick has wiring disconnect or short
Verify joystick functionality in windows control panel. Replace joystick if all connections are verified and it is still not working Verify wiring harnesses and connections. Verify settings in both windows network connections and RSLinx as per listed pages
7-01-0030
7-02-001
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.
7-02-002
7-02-003
7.2.2 Overloads
When replacing overloads, adjust them to the correct current settings but do not set them to Automatic Reset. Do not use higher rated fuses then the factory installed units.
7.2.4 Troubleshooting
Check the Troubleshooting Section to determine the problem source. The voltmeter and ammeter at the indicator panel (see Fig 7.2.2) are used to diagnose the system.
7-02-004
7-03-001
7-03-002
7-03-003
Proportional valves with white/grey connectors are installed on the following applications: Tram control Rotation control Feed control Mast Swing Mast Dump
7-03-004
7-03-005
7-03-006
pin 1: pin 2:
Conclusion:
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
7-04-001
7.4.2 Troubleshooting
Should the laser not turn on, use the following procedure: 1. Ensure the output from the PLC is functioning (that the light is on). If the light is not on, your problem is the output from the PLC. 2. If the light is on and the laser is still not working, check the wiring. 3. If the wiring is good and the laser is still not working, you need to replace the laser unit.
7-04-002
7-05-001
Hydraulic On/Off Valve This switches between manual operation of the holdback relief circuit and rotation pressure sensing holdback control circuit
When Accra-Feed is on, the Accra-Feed hydraulic valve connects ports 1 and 3 Holdback is now controlled by rotation pressure Manual operation of the holdback relief is not possible Pulldown control is still maintained
7-05-002
7-05-003
Causes - No feed power - No feed signal - Loose wiring - No PLC power - PLC on error mode
Corrective Action 6) Check the Feed joystick if it is away from the center. 7) Check O/10 for feed signal pot -if theres no signal-replace the AntiJam and Speed Adjustment Box. 8) See No. 3 If the problem still persists, call Cubex Technical Support.
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
9) 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. 10) Check for any loose wiring from controller to the rotational valve. 11) See No. 3 12) See No. 4 13) Check the terminals supplying the PLC or terminals I/5 and O/4. If the problem still persists, call Cubex Technical Support.
Slow rotational rpm in manual mode No response or rotation from the saver sub during Accra-Feed on.
- The Feed joystick is not all way up or down - No rotational power - No rotational signal - Loose wiring - No PLC power - PLC on error mode
See Prob. 9 14) Check the Rotation joystick if it is away from the center. 15) Check I/5 for rotational power; O/5 and O/6 for rotational signal pot-if theres no signal local or remote rotational pot. 16) See No. 3 If the problem still persists, call Cubex Technical Support.
7-05-004
Causes - Loose wiring - Defective pressure switch - Not set at 1,400 psi - PLC on error mode - No power supply
Corrective Action 17) Check the voltage supply on Hirschmann 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 I/2 for terminal connection. If the problem still persists, call Cubex Technical Support.
- Loose wiring - Defective anti-jam pot - PLC on error mode - No power supply - Fuse blown up
21) Check the voltage signal at O/9 varies from 12 to 18 vdc. 22) Check the Anti-Jam pot and rotate it, see if you can get voltage signal 12 to 18 vdc. If not replace with new Anti-Jam Speed adjustment box. 23) See No. 3 If the problem still persists, call Cubex Technical Support.
24) Check the voltage signal at O/3 for beacon alarm. 25) Check the power supply for beacon alarm. 26) If the beacon is defective - replace with the new one. 27) Check for the rotational pressure switch 28) Check the Anti-Jam and speed adjustment box. 29) Check the PLC if it on error mode. If the problem still persists, call Cubex Technical Support.
8.0 TROUBLESHOOTING
8-00-001
8.0 Troubleshooting
The Troubleshooting is divided into four types of systems; Mechanical, Hydraulic, Pneumatic 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. 2. Check that all manual and remote controls are operating. 3. 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.
8-00-002
8-01-001
8-01-002
Cylinder creep
01. Pin-hole leak in hydraulic hose. 02. Leaking load checks. 03. Internal cylinder leak. 04. Leaking control valve.
8-01-003
8-01-004
8-02-001
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 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.
8-02-002
8-03-001
8-03-002
8-04-001
8-04-002